RaycoWylie i4000 User manual

Instruction Manual
i4000
Excavator Rated Capacity Limiter and Range
Limiting System
Copyright © 2019
RaycoWylie Systems
All rights reserved.
Wylie Systems
(Rayco Technology Group)
201 Prospect Avenue
Suite 106 - box 159
Hagerstown, MD 21742
USA
Tel: [phone]
Fax: [phone]
Rayco Electronic Systems
(Rayco Technology Group)
2440 Dalton Avenue
Ste-Foy, Qc
CANADA
G1P 3X1
Tel: [phone]
Fax: [phone]
Wylie Systems
(Rayco Technology Group)
Drury Lane
St-Leonards on Sea, East Sussex
ENGLAND
TN38 9BA
Tel: [phone]
Fax: [phone]
55M4000UBE00-A
Rev: MLF April 2019

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i4000 RCL For Excavator Instruction Manual
55M4000UBE00-A
The purpose of this manual is to provide the customer with the operating procedures
essential for the promotion of proper machine operation for its intended use. The
importance of proper usage cannot be overstressed. All information in this manual
should be read and understood before any attempt is made to operate the machine.
Since the manufacturer has no direct control over machine application and operation,
conformance with good safety practice in this area is the responsibility of the user and
his operating personnel.
All procedures herein are based on the use of the system under proper operating
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of the equipment are strictly forbidden without written approval from RaycoWylie
Systems.
The i4000 RaycoWylie Systems Excavator Information Center must be regarded
only as an aid to the operator. When the parameters are set correctly, the indicator
will warn the excavator operator of an approaching overload condition that could cause
damage to equipment, property, and/or injury to the operator or site workers in the
vicinity of the excavator and its load.
This system must never be used, under any circumstances, as a substitute for the good
judgment of a excavator operator when carrying out approved excavator-operating
procedures. Responsibility for the safe operation of the excavator lies with the excavator
operator. The indicator equipment will not necessarily prevent excavator damage due
to overloading and related causes if not set properly.
Before operating a excavator equipped with a RaycoWylie system RCI, the
operator must carefully read the information in both this manual and the excavator
manufacturer operator’s manual. He must also be aware of all the federal, state and
local safety standard and regulations applicable to his job. Correct functioning of the
system depends upon routine daily inspection.
Any suspected faults or apparent damage should be immediately reported to the
responsible authority before using the excavator.

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i4000 RCL For Excavator Instruction Manual
55M4000UBE00-A
Since the personnel’s safety and the appropriate use of the machinery
are a priority, different symbols are used in this manual to highlight
important points.
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represents. Each time you see one of these symbols in this manual, the
operator’s safety or the machinery’s integrity are concerned.
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NOTE: PROVIDES INFORMATION WHICH CAN BE OF
SPECIAL INTEREST.
DANGER: INDICATES A POTENTIALLY DANGEROUS
SITUATION WHICH, IF NOT AVOIDED, COULD RESULT
IN A PERSON’S DEATH OR IN SIGNIFICANT DAMAGE
TO THE MACHINERY.
ATTENTION: INDICATES A POTENTIALLY DANGEROUS
SITUATION WHICH, IF NOT AVOIDED, COULD RESULT
IN MINOR OR MODERATE DAMAGES. IT CAN BE USED
TO WARN ABOUT UNSAFE PRACTICES.
IMPORTANT: INDICATES A SITUATION WHICH COULD
DAMAGE THE MACHINERY.

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i4000 RCL For Excavator Instruction Manual
55M4000UBE00-A
CONTENTS
Warning page3
1 - GENERAL DESCRIPTION OF THE SYSTEM page 9
1.1 Introduction page 9
1.2 Operator skill page 9
1.3 Usefulness of the i4000 system page 9
1.4 Description of the i4000 system page 10
1.4.1 Audible alarm page 11
1.4.2 Visual alarm page 11
1.5 Location and description of typical components page 12
1.6 Overall scheme page 13
1.7 Technical information page 14
2 - DETAILED DESCRIPTION OF THE DISPLAY UNIT page 15
2.1 Overview of the display unit page 15
2.2 Description of operation keys page 16
2.3 Duty selection tab page 17
2.4 Lifting tab page 18
2.5 Range limiting tab (optional) page 18
2.6 Tools tab page 19
3 - INSTALLATION AND CALIBRATION page 23
4 - OPERATING INSTRUCTIONS page 25
4.1 Safety recommendations page 25
4.2 Residual risks page 26
4.3 Power-up page 27
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4.4.2 Selecting the measuring unit page 29
4.4.3 Selecting the language page 30
4.4.4 Selecting the night light intensity page 31
4.4.5 Adjust system data and time page 32
4.5 Duty selection page 33

55M4000UBE00-A
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i4000 RCL For Excavator Instruction Manual
CONTENTS
5 - RATED CAPACITY LIMITER page 35
5.1 Enabling/Disabling the lifting mode page 35
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6 - RANGE LIMITING SYSTEM page 37
6.1 Enabling/Disabling the range limiting mode page 38
6.2 Height limit page 39
6.3Slewlimit page40
6.4 Slew and variable height page 41
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6.6 Slew and variable radius limit page 45
7- DIAGNOSTIC AND MAINTENANCE page 47
7.1 Diagnostic menu page 47
7.2 Angle and Length sensor page 49
7.3Loadsensor page50
7.4 Slew sensor (Option of the range limiting device) page 51
7.5 Relay board page 52
7.6 Software information page 53
7.6.1 System data page 53
7.6.2 Load data page 54
7.6.3 Correction load page 54
7.7 Detected addresses page 55
7.8 Error messages page 55
7.8.1 Internal peripherals page 55
7.8.2 External peripherals page 56
8 - INSPECTIONS AND MAINTENANCE page 59
8.1 Frequent inspections page 59
8.2 Periodic inspections page 59
8.3 Checking the displayed load page 60
8.4 Maintenance page 61
8.5 Maintenance procedure page 62
8.6 Adjustments and repairs page 63

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i4000 RCL For Excavator Instruction Manual
55M4000UBE00-A
-1-
General description of the system
1.2 Operator skill
1.3 Usefulness of the i4000 system
The i4000 system shall prevent the excavator from supporting a load outside
the limits of the permitted radius and outside the loads shown and described on
the rated capacity chart or the permissible working load of the ropes when set
and operated correctly.
This manual contains information regarding the operation, troubleshooting, and
maintenance procedures of the i4000 system. Please make sure you respect the
safety rules currently in force in the country where you are using the i4000 system,
in order to reduce the risk of injuries or of damages to the machinery. Please
consider each safety directive mentioned in this manual when using the i4000
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maintenance.
1.1 Introduction
The i4000 system shall be operated only by personnel without limitations in the
physical abilities of the upper limbs and no visual or hearing impairment, who
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and fully understood the instructions in this manual. Operator requirements
shall include: demonstrating the ability to read, write, comprehend, use
arithmetic, read and understand the load / capacity charts in the language of the
excavator manufacturer’s operating instruction materials. Maintenance of the
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55M4000UBE00-A
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i4000 RCL For Excavator Instruction Manual
1.4 Description of the i4000 system
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of the excavator. This version measures the boom cylinder pressure, the boom
angle and the stick angle to indicate safe or critical conditions, while performing
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slew angle to provide some extra information to the operator. All the sensors are
linked through a single CAN bus (Controlled Area Network).
The pressure sensors provides electrical signals that are proportional to the actual
pressure in the hydraulic boom cylinder system of the excavator. Inclinometers
provides a signal that is proportional to the boom and stick angles. The radius and
the load are calculated from these signals with the dimensional excavator data pre
programmed in the i4000 system.
During operation the load lifted by the excavator is calculated from the measured
boom cylinder pressure and is automatically compared with corresponding data
related to the maximum permissible excavator loading. (Load charts)
The actual load is expressed as a percentage of the permitted load (% SWL). If this
percentage exceeds a preset value, alarms and safety functions are activated. The
values of the hook load, the permissible load (SWL), the lifting point height and
the radius are displayed in a digital form on a graphic liquid crystal display (LCD).
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slew angle will also be available. The required duty charts are stored in a non-
volatile memory and FDQRQO\EHPRGLÀHGZLWKWKHDSSURYDORIWKHH[FDYDWRU
manufacturer.
The calculated machine parameters and calibration data are stored in an additional
non-volatile memory. The calibration of the system is performed only with the use
of known loads, boom angles, and other pre-determined data.