4 IFlex Operator Manual - ATF 80-4

IK 350 / 1368
Operator’s Console Contents
for FA 043 /ATF 80-4 General Information
Important Notes
System Description
Programming
Checks before start-up
Service and Maintenance
Troubleshooting
Appendix
Operator’s Manual
Issue 4/2006 Rev. C
This document has the order no.

50 350 19 1368 e (ATF 80-4)
Operator’s Manual IK 350 / 1365 (FAUN ATF 80-4)
TABLE OF CONTENTS
1. General information 3
2. Important notes 4
3. System description 5
3.1 System functions 7
3.2 Control console 7
3.3 Indicators and control elements 8
3.4 Data display (normal operation) 16
3.4.1 Description of status symbols 17
3.4.2 Switch over for multi function field 17
3.5 Data display (illustration for counterweight assembly) 18
3.6 Data display (telescoping and bolting display) 19
4. Programming 20
4.1 Programming the required mode 21
4.2 Setting the rope fall arrangement 23
4.3 Contrast setting, data display 25
4.4 Language selection 26
4.5 Speed preselection for master controller 27
4.6 Limitations of geometry 28
4.6.1 Limitation of the slewing angle 29
4.6.2 Limitation of the boom head height 30
4.6.3 Limitation of the boom angle 31
4.6.4 Limitation of radius 32
5. Checks before start-up 33

5.1 Operation 35
6. Service and maintenance 36

6.1 Info menu 37
6.2 Service menu 38
7. Troubleshooting 39
7.1 General information 39
7.2 Error messages (E ##) 39
7.3 Error messages (S ####) 44
Appendix 45
© 2006 PAT GmbH · D-76275 Ettlingen · Hertzstr. 32 - 34 · ++49 (0) 7243 709-0 · fax ++49 (0) 7243 709-222 · Email: [email protected] 2
50 350 19 1368e_Rev C (ATF 80-4).doc / 2006-04-24 / Rev. C / rk.
General Information / Important Notes
1. GENERAL INFORMATION
The PAT Load Moment Indicator (LMI) and control system iFLEX5 has been designed to provide the
crane operator with the essential information required to enable the machine to be used within its de-
sign parameters. Using various sensing devices, the Load Moment Indicator monitors various crane
functions and provides the operator with a continuous reading of the crane's capacity. The readings
continuously change as the crane moves through the motions needed to make the lift.
If non permitted conditions are approached, the Load Moment Indicator will warn the operator by
sounding an audible alarm, lighting a warning light and locking out those functions that may aggravate
the crane's condition.
The PAT iFLEX5 system provides a graphical user surface whose functionality and layout is deter-
mined by the crane manufacturer. The selection of the programmed functions is essentially simplified
by the use of symbols.
The Load Moment Indicator and Control system consists of an iFLEX5 system consisting of two units,
an operator’s console IK 1368 CAN and different sensors for the acquisition of measuring values.
The contents of this Manual is subject to alterations. PAT can accept no warranty for this material, including any related
warranty with respect to marketability and suitability for particular purposes. PAT can accept no warranty for errors in the
content of this Manual, nor for direct or indirect damage caused in connection with the provision and the use of this Manual.
This manual is protected by copyright. All rights reserved. This Manual may not be copied, either in full or in part, reproduced
or translated into another language without the prior written authorization by PAT.
General Information / Important Notes
2. IMPORTANT NOTES
The LMI is an operating aid to warn the crane operator of an imminent overload or proximity of the
hook block to the boom head, in order to avoid possible damage to property or personal injury.
The system cannot be, and is not intended to be, a substitute for good judgement or experience on
the part of the crane operator, or for the application of recognised, safe working methods when using
cranes.
ATTENTION
The crane operator is not released from his obligation to operate the crane safely. He must
ensure that he fully understands and follows the notes and instructions displayed.
Before beginning work with the crane, the crane operator must carefully read and
understand the entire Manual to ensure that he is aware of the operation and limitations of
the LMI.
Proper functioning depends on due daily inspection and compliance with the operating
instructions listed in this Manual. Please read section 5 of this Manual.
The LMI can only offer the crane operator help if it is correctly adjusted, and the correct
load chart and the correct operating code have been selected for the particular rig
arrangement. To avoid damage to property and serious or even fatal injuries to persons, it
is essential to ensure that the LMI is correctly adjusted before beginning crane work.
This system could be equipped with an external key-operated switch which is located on
the side of the housing of the central unit. This key-actuated switch bridges (overrides) the
control lever's shut-off function by the LMI. This switch may only be actuated in
emergencies by authorized personnel. Non-compliance with these instructions may lead to
damage to property and serious or even fatal injuries to persons.
System description
3. SYSTEM DESCRIPTION
The Load Moment Indicator and Control system for the FA 043 / ATF 80-4 consists of an iFLEX5 sys-
tem consisting of two central units, an operator’s console IK 1368 CAN and different sensors for the
acquisition of measuring values.
System description
The system works according to the principle of variance comparison. The actual value which is
obtained by pressure measurement, is compared with the set values stored in the central data
memory, and evaluated by the microprocessor. When the limit values are reached, an overload
warning signal is triggered on the display and control console. At the same time, any crane
movements that could increase the load are disabled.
The crane-related data specified by the manufacture, such as load charts, boom weights, centres of
gravity and dimensions, are stored in memory chips in the central data memory. These data form the
reference values for calculating the operating states.
In some cases, the system function is controlled by automatic components such as boom length and
angle transmitters, and in other cases by manual devices, such as keys on the display and control
console.
The boom angle and the boom length are detected by a length-angle transmitter mounted on the
boom. The crane load is measured using pressure sensors mounted on the piston and rod sides of
the boom elevation cylinder.
System description
3.1 System functions
After the system is switched ON, it starts with an automatic test run of the LMI system, the displays
and control elements as well as of the acoustic alarm.
During the test run, the start screen is displayed:
After the system has passed through the system test without errors, the crane data display
appears.
In case of malfunction, an appropriate error code "E##" appears on the data display (1). (In this
context, refer also to chapter 7.)
3.2 Control console
The console has two functions:

• Inputs into the LMI system by the crane operator (operation modes, numbers of rope falls)
• Indication of important data and information
• Information for service purpose
The control console is located in the crane cabin in the crane operator's field of vision. To improve
identification of the displays and control elements, these are backlit during operation. The console
comprises various control elements as well as a multifunctional LC display; these are described in
detail in chapter 3.3
Operation
3.3 Indicators and control elements
Fig. 1 shows the indicator and control elements of the DS 350 /1368 console. The numbers in the
figure correspond to the numbers in the following functional description for each element.
Fig. 1
1 Data display 10 "increase contrast" tip switch
2 Utilization indicator (bargraf) 11 "decrease contrast" tip switch
3 Function keys F1...F5 12 "Alarm off" tip switch
4 "LMI override" warning lamp 13 "Information" tip switch
5 "A2B override" warning lamp 14 Numerical keypad
6 "A2B " warning lamp 15 "Operation mode" tip switch
7 Pre-warning lamp (load moment) 16 "Geometrical limits" tip switch
8 Overload lamp (load moment) 17 "Tara" tip switch
9 Contrast sensor 18 special functions tip switch
Operation
(1) Data display
The data display (1) is a backlit graphic LC display which shows, depending on the operating state,
the required information, such as load values, geometric and crane data, symbols etc. During night
work, the indication appears inverted to prevent dazzling the crane operator.
Examples for possible indications:
Set-up menu (operation mode) Normal operation display Programming slewing angle
Service menu analog inputs II Tele control indicator Contrast setting menu
A detailed description of the symbols and indicators is given in chapters 3.4, 3.5, 3.6 and 6. of this
manual.
Operation
(2) Utilization bar graph
This utilization bar graph display indicates how much of the

loader‘s rated capacity is being used. (utilization)
As the rated capacity of the loader changes as it is moved through
its various motions, the utilization display will constantly change as
well.
The bar graph is marked with different colors:
• green: and safe section (0%...90% of rated cap.)
• yellow: prewarning section (90%...100% of rated cap.)
• red: overload section (>100% of safe working load)
(3) Function keys F1...F5
These keys can be used to select certain functions from among

menu symbols with selection options. The symbols above the keys
identify the function in question.
The meaning of the various symbols is shown in chapters 3.4 to
3.6 and in chapter 6.
(4) "LMI override" warning lamp
This red warning lamp goes on if the LMI shut-off feature has been
bridged manually.
(5) "Anti-Two Block switch (A2B) override" warning lamp
This red warning lamp goes on if the hoist limit switch shut-off
feature has been bridged manually.
Operation
(6) "A2B" warning lamp
This red warning lamp goes on if the contacts of the hoist limit
switch open, i.e. a hoist limit state has occurred. The acoustical
alarm sounds, while crane movements increasing the load
moment are stopped.
NOTE
A hoist limit state occurs if the hook block touches the boom
head. In this case, there is a risk of the winch rope breaking and
the load falling. The cause of the hoist limit state may be that the
load has been drawn against the boom head or that the boom
has been extended or lowered without the corresponding length
of winch rope having been unwound.
(7) "Pre-warning load moment" warning lamp
This yellow pre-warning lamp goes on if the load of the crane

amounts to more than 90 % of the rated lifting capacity in question,
thus indicating an imminent overload situation.
(The warning light will flash, if the upper main boom angle limit is
exceeded (if operation mode is "on rubbers")
ATTENTION
This means that the crane operator is only allowed to continue

crane work with extreme caution!
Operation
(8) "Overload" warning lamp
This red overload warning lamp informs the crane operator that an
overload condition has occurred.
It goes on when the load imposed on the crane has reached 100
% of the maximum lifting capacity which is admissible for the
current operating state. The acoustical alarm will sound. At the
same time, the crane movements increasing the load moment are
stopped.
(9) Sensor "display contrast"
Dependent to the surrounding light conditions this sensor controls

the brightness of the LC display and the buttons.
(10-11) "Contrast setting" tip switchs
With this buttons the display contrast can be adjusted according to

the environmental light conditions. By pressing both buttons simul-
taneousely the preset contrast is set. The contrast setting also can
set via the contrast setting menu (chapter 4.3)
(12) "Horn off" key
Operation of this push-button serves to briefly suppress the

acoustical alarm (soonest after 5 s alarm duration). The alarm
sounds again, if the reason for which the alarm has been triggered
is still present.
(13) "Info" key
This key selects system

information menu (refer to
chapter 6.1)
Operation
(14) Numerical keypad
These numerical keys are used for numerical inputs.
The keys and have no function !
(15) "Select" key (SEL)
The key "SEL" is used to call up the set-up menu for setting the
mode codes, the number of rope. Upon actuation, the hoist limit
switch warning lamp (7) and the overload warning lamp (8) go on,
and the LMI shut-off feature is activated.
The correct setting of the LMI for the rig arrangement in

question is extremely important for correct functioning of
the system and the crane. Thus, mode codes and the
number of rope falls may only be set by crane operators
who are absolutely familiar with load charts, utilization and
operation of the system.
The procedure for entering the mode code, the number of rope falls and the speed preselection for
the master controllers is described in chapter 4.
Operation
(16) "Limits" key (LIM)
Key used to program limitations of geometry.

(refer to chapter 4.5)
(17) "Tare" key (TARE)
The "TARE" key serves to issue the net load to the actual load
indicator "ACT" (refer to chapter 3.4). The net load is the actual
load less load lifting equipment and hook block. The "TARE" key
must be pushed before hoisting operation is commenced.
After the key has been actuated, it lights up and the actual load
indication is set to zero (tared). After the load has been lifted, the
net load (payload) appears in the actual load indicator.
As soon as the working radius is changed (due to changes of the
angle or radius), the indicator displays again the actual load, and
the taring function is finished.
NOTE
The actual load comprises the hook block, the winch rope
and all load handling devices. The net load is the load
currently fixed to the hook, without load handling device.
Incorrect indications may be due to ambient influences,
e.g. the wind acting on a boom or the load.
(18) "Control" key (CTRL)
The "CTRL" key serves to select the special functions. The

following special functions can be selected:
• Display contrast setting (see chapter 4.3).
Operation
Acoustical alarm (without illustration)
The acoustical alarm sounds in the following cases:

System test, overload condition, approaching a hoist limit state (if
hoist limit switch function is detected by the LMI), malfunction of
LMI system, and in case of operating errors detected by the
system.
The acoustical alarm can be suppressed briefly via the key (12)
"Alarm switch" soonest after 5 s alarm duration. The alarm sounds
again, if the reason for which the alarm has been triggered is still
present.
Operation
3.4 Data display (normal operation)
level 1 to next level Tele control set operation mode select Multi- tare
(shown here): function display
level 2: ---
to next level pre-select unit Geschwindigkeit start menu geomet-
Meisterschalter rical limitation
level 3:
back to level 1 select language valve control Service menu: Info: CAN -Bus
Operation
3.4.1 Description of status symbols
auxiliary winch selected tele correction
LMI error tele stop
control error node 2 tele position reached
control error node 3 slewing angle limitation active
bus errorr hight limitation active
slewing brake radius limitation active
reeving boom angle limitation active
Anti two blick switch upper structure locked
ID-sensor error speed preselect active
locking sensor error
3.4.2 Switch-over for multi-function field
With function key (first level) the content of the multi-function filed can be scolled:
1 2 3 4
telescoping wind speed wind speed in control jib length jib angle
length in km/h m/s pressure P1
1
only with corresponding software configuration, otherwise step will jumped over
2
appears automatically, if the pre-programmed wind speed limit is exceeded. The value flashes and the alarm sounds simultaneously.
3
only with existing jib extension, otherwise step will jumped over
4
only with existing jib extension, otherwise step will jumped over
Operation
3.5 Data display (illustration for counterweight assembly)
Operation
3.6 Data display (telescoping and bolting display)
Programming
4. PROGRAMMING
After switching ON the system, the operating parameters must first be entered according to the actual
rig arrangement of the crane. Here, it is essential that the crane operator's entries are made correctly!
This procedure consists of two parts:

• Programming the LMI according to the crane's rig arrangement, using the correct operating code
for the selected load chart (refer to chapter 4.1).
• Input of the rope fall arrangement (rope reeving) according to the actual number of rope falls used
(refer to chapter 4.2).
Wrong input into the LMI of the operating code and the number of rope falls used can result
in material damage and/or in serious, even fatal injury to persons.
The correct input of the operating code and the number of rope falls is essential for proper
functioning of the system and the crane.
Consequently, these entries may only be performed by crane operators who are absolutely
familiar with load charts and the application and control of the LMI.
Programming
4.1 Programming the required mode
Any modification of the crane structure requires a setup of the LMI system by input of a corresponding
operation mode code. The setup procedure can only be started during normal operation display.
During the programming procedure, the system interrupts crane movements temporarily. Moreover, the warning lamps (7) and (8) go on.
Call of function: By actuating key or with function key
Enter operation code
return to normal display
Cursor automatically moves to the first digit. The input can be carried out
via numerical keypad (14) or with function keys.
Set cursor to the left by one digit
Set cursor to the right by one digit
decrease marked value
increase marked value
Confirm input
When changing the operation mode, the succeeding acknowledgement

menu is displayed
Programming
In this menu the operator has to confirm the inputs again.

Check indicated inputs before confirmation !
NO, inputs are invalid.
YES, inputs are valid
After confirmation the input of the operation mode is terminated

and the normal display appears.
Programming
4.2 Setting the rope fall arrangement
Any modification of the number of falls (reevings) requires a setup of the LMI system by input of a
corresponding reeving number. The setup procedure can only be started during normal operation
display.
During the programming procedure, the system interrupts crane movements temporarily. Moreover, the warning lamps (7) and (8) go on.
Call of function: By actuating key or with function key
input reeving
return no normal display
Cursor automatically moves to the first digit. The input can be carried out
via numerical keypad (14) or with function keys.
Set cursor to the left by one digit
Set cursor to the right by one digit
decrease marked value
increase marked value
Finish input
When changing the operation mode, the succeeding acknowledgement

menu is displayed:
Programming
In this menu the operator has to confirm the inputs again.

Check indicated reeving number before confirmation !
NO, inputs are invalid.
YES, inputs are valid
After confirmation the input of the reeving is terminated and the

normal display appears.
Programming
4.3 Contrast setting, data display
This function can be used to adjust the display contrast optimally according to the light conditions.
The setting remains stored and thus need not be performed every time the system is started up.
Actuate "CTRL" key.
A pattern enabling optimum contrast tuning appears on the display.

If necessary, set contrast via the function keys as follows:
more contrast
less contrast
Actuate the key to save the settings and to terminate the function.
Note: The contrast directly can be adjusted via key (10) and (11)
Programming
4.4 Select language
The system features a function which allows language selection for the display menus.
Call function: by actuating key (normal display, layer 3)
Select desired language with function buttons.

By pressing function button F5 you can switch over the display layer to se-
lect other available languages.
Programming
4.5 Speed preselection for master controller
By actuating the function key (normal display, layer 2) the speed preselction menu for the mas-
ter controllers is called up:
speed preselection for main hoist
speed preselection for auxiliary hoist
speed preselection for luffing cylinder (luffing up and down)
During the programming procedure, the system interrupts crane movements temporarily. Moreover, the warning lamps (7)
and (8) go on.If a value was changed, the following symbol appears on the operating menu screen: .
Activate bar to the right of the one being edited.

Increase marked value by 1 %.
Decrease marked value by 1 %.
* Switch over to quick seeting option*
Confirm input. (Values will be stored)
* actuate 1x:
Increase marked value by 10 %.

Decrease marked value by 10 %.
* actuate 2x:
set marked value to 100%

set marked value to 20%
Programming
4.6 Limitations of geometry
• The LMI system comprises programmed limit entries for the operating range of the crane. Programming
easily is facilitated by interactive step-by-step guidance.
• The functions can be used individually or combined. Symbols will mark active limitations.
• If a programmed limit is exceeded,
⇒ the system shuts off the crane moving, which was caused by exceeding the limit.
⇒ this triggers visual indication (blinking symbol)
The types of limitation are indicated by the following symbols:
type of limit overview symbol status symbols

(with indication of active limits) continous display: limit active
blinking display: limit exceeded
Slewing angle (⇒ refer to chapter 4.6.1)

limitation
Height limitation (⇒ refer to chapter 4.6.2)
Boom angle (⇒ refer to chapter 4.6.3)

limitation
Radius limitation (⇒ refer to chapter 4.6.4)
Programming
4.6.1 Limitation of the slewing angle
Programmable function for limitation of the left and/or right slewing angle.
Actuate LMI key. Overview screen appears.
Ã for programming: select function "slewing angle limitation"

Ã back
Ã Store actual slewing angle position as left limit.

Ã Store actual slewing angle position as right limit.
Ã back
Ã Switch on/off slewing angle limitation.

When limitation is switched on, the limit value and the respective status symbol appears. The sym-
bol will blink, if one limit value is reached or exceeded. (Note: The left / right limit can switched on /
off only together! )
Ã back
Programming
4.6.2 Limitation of the boom head height
Programmed function for limitation of the boom head height.
Ã for programming: select function "limitation of boom head hight"

Ã back
Ã Store actual boom head hight as maximum.

Ã back
Ã Switch on/off boom head hight limitation.

bol will blink, if the limit value is reached or exceeded.
Ã back
Programming
4.6.3 Limitation of boom angle
Programmable function to limit the smallest and/or the biggest boom radius.
Ã for programming: select function "limitation of boom anglet"

Ã back
Ã Store actual boom angle position as maximum limit.

Ã Store actual boom angle position as minimum limit.
Ã back
Ã Switch on/off maximum boom angle limitation.

bol will blink, if one limit value is reached or exceeded.
Ã Switch on/off minimum boom angle limitation.
Ã back
Programming
4.6.4 Limitation of radius
Programmable function to limit the smallest and/or the biggest boom radius.
Ã for programming: select function "limitation of boom radius"

Ã back
Ã Store actual boom radius as minimum limit.

Ã Store actual boom radius as maximum limit.
Ã back
Ã Switch on/off minimum boom radius limitation.

Ã Switch on/off maximum boom radius limitation.
Ã back
5. CHECKS BEFORE START-UP
Before crane work is commenced, the following electrical connections must be checked to ensure that
the LMI system is correctly wired for the current crane rig arrangement.
• Cranes with main hoisting gear only

If the crane is working with the main boom, i.e. without boom extension or fly jib, no additional
connections are required. However, it is important to ensure that the hoist limit switch weight is
correctly mounted on the main boom winch rope. With an even number of rope falls, the hoist limit
switch weight is mounted at the "dead end" of the winch rope. With an odd number of rope falls, the
hoist limit switch weight is mounted at the rope fall with the lowest working speed.
If the crane is working with a main boom extension or fly jib, the connecting cable must be installed
between the distributor plugbox on the fly jib and the distributor plugbox on the main boom. The
weight of the hoist limit switch of the main boom must be removed and then mounted on the hoist limit
switch of the boom extension or of the fly jib.
If the hoist limit switch weight is not repositioned, the hoist limit switch system cannot work
properly. During work with the boom extension / fly jib, no weights should be mounted on
the hoist limit switch of the main boom.
• Cranes with main and auxiliary hoisting gear

If the main boom extension or fly jib is not used, the override plug must be inserted into the distributor
plugbox on the main boom and the hoist limit switch weight must be mounted on the main boom.
If the crane is working with a main boom extension or a fly jib, the connecting cable must be installed
between the distributor plugbox on the boom extension or the fly jib and the distributor plugbox on the
main boom. Moreover, weights must be mounted to the hoist limit switch of the main boom and the
boom extension or the fly jib.
If the boom extension or the fly jib is in working position, and if the main boom is not equipped with a
winch rope, then the weight of the hoist limit switch must be removed from the main boom in order to
eliminate any risk to persons or damage to the equipment.
After the electrical cable connections have been checked for the rig arrangement in question, the
following inspections must also be carried out:
1. Check all cable connections to the system components for damage.
2. Check the hoist limit switches and hoist limit switch weights for ease of movement.
3. Check the spring-loaded cable drum for ease of running, drum pre-tension and correct cable
winding.
4. Check the mechanical and the electrical installation of the load cells on the fly jib (if fitted).
The checks described below must be carried out carefully in order to prevent damage to the
crane and injury to persons. The correct function of the LMI system depends on successful
completion of these checks before work is started. If the crane operator cannot see the
hook block while approaching the pulley head, he must instruct an assistant (slinger) to
help him. The crane operator must be ready to stop the crane immediately if the LMI system
does not work correctly, that is, if the red warning lamps do not light up, the acoustic alarm
does not sound and crane movements, such as hoisting, telescopic extension and lowering
cannot be disabled.
Check the hoist limit switch warning lamp and the acoustic alarm as follows:
1. Manually lift the weight attached to the hoist limit switch. As soon as the weight is lifted, the
acoustic alarm should sound and the Hoist limit switch warning lamp should light up.
2. Use the main hoisting gear to pull the hook block slowly against the hoist limit switch weight. As
soon as the hook block starts lifting the weight, the acoustic alarm should be actuated, the hoist
limit switch warning lamp should light up and the main hoisting gear should be switched off. Lower
the hook block slightly in order to terminate this state.
3. Lower the main boom slowly using the boom elevation in order to bring about a possible hoist limit
state. As soon as the hook block starts lifting the weight, the acoustic alarm should sound, the
hoist limit switch warning lamp should light up and the boom elevation should be switched off.
Lower the hook block slightly in order to terminate this state.
4. Slowly extend the telescopic boom in order to bring about a possible hoist limit state. As soon as
the hook block starts lifting the weight, the acoustic alarm should sound, the hoist limit switch
warning lamp should light up and the telescoping function should be switched off. Lower the hook
block slightly in order to terminate this state.
If the warning lamp and the acoustic alarm do not function as described, and if the crane
movements are not disabled, the system is not working properly. The fault must be
eliminated before work is started.
5. If the crane is fitted with a main boom extension or a fly jib, the test must be repeated for the hoist
limit switch of the boom extension / fly jib.
6. Check whether the displayed main boom length corresponds to the actual length.
7. Check whether the displayed angle of the main boom corresponds to the actual angle.
8. Check whether the displayed working radius of the crane corresponds to the actual working radius.
9. Check the load display by lifting a known weight. The accuracy of the load display must be within
the given tolerance.
5.1 Operation
After being set correctly, the LMI is ready to operate. The crane operator must therefore be familiar
with all the control elements of the LMI and enter the correct commands before the crane can start
work. All settings must be tested by lifting a known weight and comparing this with the information
displayed by the LMI.
The figures in the load chart contain the weight of the hook block, the load securing ropes and other
load lifting devices. This combined weight must be deducted from the figures in the load chart in order
to determine the net load to be lifted.
If any of the displays shows a discrepancy between the values displayed and the actual
values, please contact your local PAT Service Centre for repair of your system or to have
calibration of the LMI tested.
Contacts: www.hirschmann-ac.de
Any modification of the crane structure or changes to the crane require subsequent testing
of the LMI's calibration.
Service and maintenance
6. SERVICE AND MAINTENANCE
Maintenance of the Automatic Safe Load Indicator (LMI) comprises the inspection of the following:
1. Wiring connecting the various parts of the system. If a cable is damaged, it must be replaced
immediately.
2. The insulation of the length transmitter rope or the hoist limit switch cable and of the cable guides.
If the insulation is worn, or the cables guides damaged, these parts should be replaced.
3. Inspection of the hoist limit switch for ease of movement.
4. Inspection of the cable drum for sufficient pre-tension.
5. Inspection of the pressure sensors on the boom elevation cylinders and connection hoses for oil
leaks.
Staff who have not been specially trained may only eliminate the faults listed in the error
table, but must not replace any defective mechanical parts or cables.
6.1 Info menu
The system comprises a menu structure which shows typical system information
Call up function:: By actuating key
return to normal display
6.2 Service menu
The system comprises a menu structure which shows information for service purpose
During the service function, the system interrupts crane movements temporarily. Moreover, the warning lamps (7) and (8) go on.
Call up function: By actuating key

(normal menu / layer 3)
call up in- /outputs node 2
Switch to info master controller, left
return to main menu
for further information to operate the service menus refer to

appendix „description of menu structure“
Troubleshooting
7. TROUBLESHOOTING
7.1 General information
In the event of a malfunction or operator error detected by the system, a code "E xx" (LMI error) or "S
xxxx" (control error) appears on the data display (1), thus specifying the reason for the malfunction.
Error LMI system:
Error control system: or
The error codes listed in the error table explain the various errors that can occur in the LMI system.
Faults in the LMI system caused by exceeding the predefined ranges or through operator error
caused by the crane operator can normally be remedied by the crane operator himself. Faults in the
microprocessor system may only be remedied by factory-trained after-sales service staff. In this
case, please contact the PAT after-sales service.
7.2 Error messages LMI system (E ##)
System programm: refer to page "revision history" in this manual
Error Code Error Cause Elimination

E01 Fallen below radius • Fallen below the minimum • Luff down the boom to a
range or angle range radius or gone past the radius or angle specified in
exceeded maximum angle specified in the load chart.
the respective load chart
due to luffing up the boom
too far
E02 Radius range ex- • Gone past the maximum • Luff up the boom to a radius
ceeded or fallen be- radius or fallen below the or angle specified in the load
low angle range minimum angle specified in chart.
the respective load chart
due to luffing down the
boom too far
Troubleshooting

E04 Operating mode not • A non existing operating Set the correct operating mode
acknowledged or not mode has been selected for the operating state in ques-
available tion
E05 Prohibited length • Boom has been extended • Extend/retract boom to the
range either too far or not far correct length
enough, e.g. if it is prohib-
ited to go beyond a certain
maximum boom length or
with load curves for jibs
where the main boom has to
be extended to a certain
length
• Length sensor adjustment • Retract boom. Check the
has changed, e.g. the cable prestress of the cable reel
slid off the length sensor (cable must be taut). Open
reel. the length sensor and care-
fully turn the length sensor
pot counterclockwise until
the detent by means of a
screw driver
• Clutch between length sen- • Replace the complete clutch
sor pot and drive is defective including drive wheel and
adjust length sensor pot as
described above
E11 Fallen below lower • Length potentiometer is • Replace length potentiome-
limit value for measur- defective ter
ing channel "length
main boom"
• Electronic component in the • Replace sensor unit
measuring channel is defec-
tive
E12 Fallen below the lower • Pressure transducer is de- • Replace pressure trans-
limit value in the fective. ducer
measuring channel
"pressure piston side"

measuring channel is defec-
tive.
E13 Fallen below lower • refer to E12 • refer to E12
limit value in the
measuring channel
"pressure rod side"
E15 Fallen below lower • Angle potentiometer • Replace angle sensor

limit value in measur- defective
ing channel "angle
main boom"
Troubleshooting

measuring channel defec-
tive.
E21 Upper limit value in • refer to E11 • refer to E11
measuring channel
"main boom length"
has been exceeded.
measuring channel
"pressure piston side"
has been exceeded
measuring channel
"pressure rod side"
has been exceeded.
measuring channel
"main boom angle"
has been exceeded.
E37 Error in the logical • System program file is • Upload valid system
program flow defective software
• Flash-EPROM defective • Replace central unit

E38 System program and • The system program in the • Upload valid system pro-
crane data file do not LMI does not match to the gram file or the valid crane
match. programming in the crane data file
data file
E39 System program and • The system program in the • Upload valid system pro-
load chart file do not LMI and the programming in gram file or the valid load
match the load chart file do not chart file
match.
E3A crane data file and • The crane type in the crane • Upload crane data pro-
load chart file do not data file and the program- gramming with the same
match ming in the load chart file do crane type in the crane data
not match. file and the load chart file
E43 Error in the write/read • Write/read memory (RAM) • Replace central unit
memory, (RAM) or central unit defective.
E47 Error in the monitored • The CRC sign of the moni- • Restart the LMI
write/ read memory. tored write/read memory is
wrong
The CRC verification
of the monitored • The buffer battery is • Replace buffer battery on
write/read memory decharged (< 2V at 1kOhm). the central unit.
provides an incoher-
ent result
• Central unit defective. • Replace central unit
Troubleshooting

E51 Error in the crane • No valid data in the crane • Upload valid crane data file
data file data file.

E52 Error in load chart file. • No valid data in the load • Upload valid load chart file
chart file

E56 Error in crane data • No valid data in the crane • Restore or upload valid
file. data file during calibration. crane data file

E57 Error in serial crane • Calibration data file does not • Upload calibration data file
data file. contain valid data.

E61 Error in the CAN bus • CAN Bus cable between the • Check the connection be-
data transfer for all central unit and the sensor tween the central unit and
CAN units unit defective or not con- the sensor units
nected.
• Can bus port in the central • Replace the central unit
unit defective
• Short circuit in a CAN Bus • Replace Can Bus cable
cable
E64 Error in the can bus • Cable between the central • Check the cable to the sen-
data transfer of the unit and the sensor unit de- sor unit
length/angle sensor fective.
unit
• Can bus port in the central • Replace the central unit
unit defective
• Can bus port in the sensor • Replace the sensor unit
unit is defective
• Sensor unit is defective • Replace the sensor unit
E65 Error in the can bus • The analog values of the • Replace the sensor unit
length/angle sensor sensor unit are invalid
unit
E84 Wrong rigging condi- • The selected rigging condi- • Select another rigging condi-
tion. tion is not contained in the tion
crane data file.
• Check the programming in
the crane data file.
E85 Error in the radius • The computed radius is too • Check the programming in
determination small (negative deflection) the crane data file.
Troubleshooting

E87 Error in length • Measurement total length • Check length measurement
measurement. defective main boom length (refer to
E21)
The telescope • Wrong telepercentage from • Check length measurement
combination telecontrol tele cylinder (refer to E21)
determined does not
correspond to the • Tolerance in DGA 11.1.4 too • increase tolerance
length measurement. close
EAB short-circuit in A2B • short-circuit in A2B • replace A2B switch
switch switch module
• short-circuit in A2B • replace cable
cable
EAC Interruption in A2B • Interruption in A2B • replace A2B switch
switch switch module
• Interruption in A2B • replace cable
cable
EB0 Rope layer different • Rope length not calibrated • Carry out online function ‘5’,
between calculation • Invalid digital inputs • Turn off layer check with
and dig inputs digital inputs
EDB Overload recorder – • parameter programming • re-setup overload recorder
parameter failure deleted (serial EEPROM or • if failure appears sporadi-
battery buffered RAM) cally: press "Horn off" button
EDC Overload recorder – • operation time limit excee- • reset system

watchdog triggered ded • connect terminal and read
out messages
EDD battery low voltage • battery test: low voltage • exchange battery and set
time again
• if failure appears sporadi-
cally: press "Horn off" button
EDE Overload recorder – • another task busy with wri- Reset system to reset error
data record was not ting data record indication
written
EDF Overload recorder – • maximum storing capacity Reset system or LMI over-
flash block full exceeded load active / start with new
flash block
EFD Failure LMI watchdog • function which needs more Message removes automa-
time extension than 0.5 s is active i.e. write tically after a few seconds
Flash PROM
Note:
Should an error message be displayed which is not included in the above list, please contact your local PAT
After-Sales Service.
Troubleshooting
7.3 Error Codes, Control (S####)
Error code Error Elimination

S2/S3
01xx • Check wiring if required repair
Master controller defective
or exchange master controller
1E left y-direction
1F left y-direction, contacts hang
20 left x-direction
21 left x-direction, contacts hang
22 right y-direction
23 right y-direction, contacts hang
24 right x-direction
25 right x-direction, contacts hang
Note:
Should an error message be displayed which is not included in the above list, please contact your local PAT
After-Sales Service.
Appendix: Description of menu structure
Description of menu structure
Display Description of function keys
no function key
1: language selection: german

2: language selection: english
3: language selection: dutch
4: language selection: french
5: switch over to layer 2 for selection of other languages
F1 (5): language selection: spanish

F2 (6): language selection: italian
F3 (7): language selection: russian
F4:
F5: back to layer 1
1: switch to layer 2
2: switch to telescope menu
3: select operating mode / reeving
4: select content of multi symbol field
5: tare function
2: select unit meter / feet
3: call up master controller menu
4: select geometrical limitation
5:
2: call up language selection menu
3: call up telecope control menu
4: call up service menus
5: call up bus info menu
1: switch to info for bus symbols

2:
3:
4:
5: return to LMI screen
1:
2:
3:
4:
5: return to bus menu
1: digital inputs Node2 Basis

2: digital inputs Node3 Basis
3: analog inputs Node 4
4: switch to master controller left
1: digital inputs Node2 extension

2: digital outputs Node2 Basic
3: analog inputs Node2 Basic / extension
4: analog outputs Node2 Basic / extension
5: return to service menu
1: digital inputs Node2 Basic

2: digital outputs Node2 extension

3:

2: digital outputs Node2 extension
4:

3: frei
4: alalog outputs Node3 Basic
1:
3: analog inputs Node3 Basic
4: analog outputs Node3 Basic

2:
4: analog outputs Node3 Basic

4:
1:
2:
3:
4:
1:
2:
3:
4: switch to master controller, right
1: switch to master controller, right

2:
3:
4:
1:
2: switch to control telescope
3:
4:
5: return to LMI menu
1: switch to control hoist 2

3: switch to control slewing gear
4: switch to control luffing gear



4: switch to control luffing gear 2

1:
2: input operating code
3: input number of falls (reeving)
4:
1: Set cursor to the left by one digit

2: Set cursor to the right by one digit
3: decrease marked value
4: increase marked value
5: Finish input / return to last menu
1: confirm input
2: frei
3: frei
4: frei
5: discard inputs
1: select radius limitation menu

2: select hight limitation menu
3: select boom angle limitation menu
4: select slewing angle limitation menu
1: Activate bar to the right of the one being edited

2: Increase marked value by 1 %.
3: Decrease marked value by 1 %.
4: Switch over to quick seeting option (next layer)

2: Increase marked value by 10 %.
3: Decrease marked value by 10 %.
4: switch to next layer

2: set marked value to 100%
3: set marked value to 20%
4: switch to next layer
1: switch on/off left radius limit

2: set left radius as left limit
3: set right radius as right limit
4: switch on/off right radius limit
5: return to limit selection menu
1: switch on/off hight limit

2: set actual hight as hight limit point
3:
4:
1: switch on/off left slewing angle limits

2: set left slewing angle as left limit
3: set right slewing angle as right limit
4:
1: switch on/off left boom angle limit

2: set left boom angle as left limit
3: set right boom angle as right limit
4: switch on/off right boom angle limit
Annex: Important notes for crane operators and crane operating companies
INSTRUCTIONS 1 Shut-off values for boom cranes with variable load ratings
depending on variable working radius
The crane shut-off values are determined by us based on the load charts and design drawings specified by the
crane manufacturer.
These theoretical shut-off values must be checked by means of tests on the crane with weighed test loads for all
modes and at least with the following rig arrangements, depending on the crane design.
• Cranes with fixed boom length in operation:
Smallest, medium and largest radius for shortest, medium and longest boom length, as well as shortest,
medium and longest fly jibs for these boom lengths.
• Cranes with boom length variable in operation:

Smallest, medium and largest radius for each length increment as well as for all fly jibs.
INSTRUCTIONS 2 Important notes for the crane operator
The LMI is an operating aid to warn the crane operator of an imminent overload or of the hook block
approaching the boom head, in order to avoid possible damage to property or personal injury.
This system cannot be, and is not intended to be, a substitute for good judgement or experience on the part of
the crane operator, or for the application of recognised, safe working methods when using cranes. The crane
operator is not released from his obligation to operate the crane safely. He must ensure that he fully
understands and follows the notes and instructions displayed. Before beginning work with the crane, the crane
operator must carefully read and understand the entire Manual to ensure that he is aware of the operation of the
LMI and the crane. Proper functioning depends on due daily inspection of the system and compliance with the
operating instructions listed in this Manual.
The system can only offer the crane operator help if the LMI is correctly adjusted, and the correct load chart and
the correct operating code have been entered for the particular rig arrangement. To avoid damage to property
and serious or even fatal injuries to persons, it is essential to ensure that the LMI is correctly adjusted before
beginning crane work.
This system could be equipped with a key-operated switch which is located in the
microprocessor central unit. This key-operated switch overrides the LMI's shut-off feature.
The switch may only be actuated in emergencies by authorized personnel. Non-compliance
with these instructions may lead to damage to property and serious or even fatal injuries to
persons.
INSTRUCTIONS 3 Important notes for the crane operating company

In the Federal Republic of Germany, the design of overload safety devices for cranes is subject to the directives
of VDI standard 3570 (VDI = Verein Deutscher Ingenieure - Association of German Engineers). The significance
and the limitations of overload safety devices are also pointed out in this directive.
"In the operation of cranes, overload safety devices are intended to prevent accidents and risks to persons,
property, the load and the crane as far as possible as a result of overloading. The crane operating company and
the crane operator must remember that an overload safety device cannot detect all hazards in good time, and
that a malfunction is possible through influences that are not apparent. For this reason, you cannot be released
from your obligation to exercise due care and from your responsibility for complying with the operating
regulations and the load limits of the crane. Overload safety devices must not be used for standard operation.
They should only react in emergencies. The load rating of the hoisting equipment must not be reduced by an
overload safety device."
VDMA Instruction Sheet for Overload Safety Devices (Automatic Safe Load Indicators)
for Boom Cranes
According to § 24 of the UVV (provisions for the prevention of accidents) "Boom cranes", the boom crane delivered to you is
equipped with an overload safety device (automatic safe load indicator) which switches off the crane's hoisting gear and the
boom retracting mechanism when the admissible load moment is exceeded. In order to enable discharging after the
overload safety device has reacted, it must still be possible to perform a contrary movement. This means, for example, that it
must still be possible to lower the load after the hoisting gear has been switched OFF.
An overload safety device (automatic safe load indicator) is installed to prevent crane use for lifting of loads which endanger
its stability. Thus, the overload safety device (automatic safe load indicator) is an emergency switch which, in case of crane
overloads, shuts off all movements which might increase the load moment, and thus prevents possible damage or accidents.
In order to enable the overload safety device to fulfil its functions as a safety unit, please pay attention to the following
instructions:
1. Overload safety devices (automatic safe load indicators) must not be used for switching off the hoisting gear or the boom
retracting mechanism during normal operation. The crane operator has to make sure in all cases before such work that
the lifting capacity is not exceeded by the load to be lifted. Loads which exceed the lifting capacity of the crane must not
be lifted in spite of the fact that the overload safety device is installed. This device must not be used for weighing
purposes, and the crane must not be charged with loads exceeding the individually highest admissible load.
2. Tearing off fixed loads is only admissible if the crane manufacturer has agreed to it, and only with cranes which are
specially equipped for this purpose. During such operations, the overload safety device (automatic safe load indicator)
must not be used as load measuring equipment for normal operation.
3. The overload safety device installed in the crane must be serviced at regular intervals and checked for safe operation
before crane work. According to § 35 of the UVV (Provisions for the Prevention of Accidents) "Boom cranes", crane
maintenance work also comprises regular inspections of the overload safety device.
4. In general, the overload safety device is not automatically adjusted to the different modes of operation of the crane.
Therefore the crane operator is obliged to adjust the overload safety device to a different range of lifting capacities or
load moments, when the mode of operation of the crane is altered. To this effect, the operating instructions of the
manufacturer of the installed overload safety device must be complied with. Safe operation of the machine and crane
work free of accidents depend to a large extent on careful compliance with these instructions. An incorrectly set overload
safety device, e.g. a device which is set to a high load moment while the outriggers are retracted, is considerably more
dangerous than a crane without an overload safety device, as it conveys a feeling of safety to the driver, which is in fact
not justified, and which may cause serious accidents.
5. The overload safety device (automatic safe load indicator) installed must be adjusted by the crane driver to the different
ranges of lifting capacities or load moments, when the crane is adjusted to different modes of operation, such as:
a) when the outriggers are extended or retracted (switching over to the high or low load moment)
b) when the boom length is changed by:
- manual extending and retracting (telescoping)
- mounting or dismounting intermediate elements;
c) when the crane is swung or slewed into the range of the higher or lower stability moment (switching over to the high
or low load moment)
d) when changing over to a different lifting capacity range by fitting multiple rope falls to the hoisting gear or the boom
retracting mechanism.
6. Please note positively that the overload safety device cannot become effective, i.e. the drive assembly cannot be
switched off quickly enough when the crane is operated incorrectly. In this case, accidents cannot be precluded
completely in spite of the overload safety device being installed. This applies particularly to the following cases:
- the hook or the load lifting equipment is fixed underneath the load;
- excessive time-lag forces are effective;
- loads are dropped into the rope;
- the load is pulled diagonally;
- moving the crane in an area with significant ground slope;
- subsiding subsoil;
- wind load.
7. If an equipment for switching off or overriding the overload safety device (automatic safe load indicator) is installed, it
may only be used if particular precautions have been taken, and in the presence of the crane supervisors, e.g. during
crane inspections and during the operations intended by the crane manufacturer.
Careful compliance with the provisions comprised in this instruction sheet and in the operating manual
of the crane manufacturer is a prerequisite to safe operation of the overload safety device (overload
disconnect unit).
Should you have any doubts, please consult the manufacturer's Operating Manual. If it does not provide
sufficient information, it will be necessary to contact the company in question.
Unauthorized tampering with the overload safety device's mechanical components will rule out all
warranty claims.
Issued by: VDMA Fachgemeinschaft für Hebezeuge und Fördermittel

im Verein Deutscher Maschinenbau-Anstalten e.V.
Düsseldorf-Oberkassel
INSTRUCTIONS 4 Notes on Electromagnetic Compatibility (EMC) in electronic

systems taking account of the effect of electromagnetic fields
Electromagnetic fields are having an increasing effect on electronic systems and may lead to malfunctions; to
avoid these, we have listed preventive measures in the following, according to the latest state of technology:
1. The preventive measures proceed primarily from the basic idea that the electronic circuits should be
shielded from irradiated high frequencies by a closed, low-resistance protective skin against high-frequency
interference.
− All components are equipped with metallic outer housings with earthing option;
− only cables with a braided screen are used. The screen must generously cover all connectors and must
be of high conductivity;
− coupling of the crane earth and the electronics earth in one single point of the system only.
2. The general precautions listed under Section 1 cannot assure complete protection against electromagnetic
fields in all cases, however, since the size and type of effect depend on local conditions.
Examples of such influencing factors are:

− particularly unfavourable arrangement of the aerials in relation to the system,
− very high transmission power,
− consistent compliance with measures of Section 1 not possible due to local conditions,
− long cables,
− coupling of interference into the supply leads.
In unfavourable conditions, one has no choice but to take experimental measures on site, in addition to the
preventive measures, while taking account of the principles mentioned in Section 1, for example:
• fitting filters or short-circuiting the interference frequencies using capacitors;

• establishing or separating earth connections;
• using a guarded shield system.
INSTRUCTIONS 5 Notes on industrial safety when repairing display and control

consoles
Caution: Liquid crystal displays contain liquid chemical substances in the display.
Particular caution and care are therefore necessary:
• when operating equipment containing liquid crystal displays

• during storage and transport (risk of breakage !)
• when disposing of unusable or excess liquid crystal displays
Broken Displays !
Possible sources of danger are chemical effects in the event of skin contact with broken
liquid crystal displays. In the event of contact, wash the affected skin areas thoroughly with
soap. Be particularly careful with open wounds !
INSTRUCTIONS 6 Installation instructions for display and control consoles without

closed metallic housing
To avoid radio interference, high-frequency devices and equipment coming under general approval
requirements published by the Federal Minister for Post and Telecommunications in his Official Gazette No.
163/1984 as Decree No. 1045/1984 and No. 1046/1984 must comply with the limit values and conditions laid
down there.
For display and control consoles without closed metallic housing (dashboard installation version), the conductor
screen must therefore be mounted on the dashboard directly in front of the console by means of a bare cable
clip.
Revision History
Revision History
Version Date Modifications Name

Rev. A 2004-11-11 Issue according to german manual Rev. A (2004-09-15) Konopka
for FAUN FA-035 / ATF 110
Console software: KFIT V 1.0 (6.09.2004)
Rev. B 2005-10-07 addendum error code table E87 to EAC, EDB to EFD Konopka
System programm: LFIT V 1.0 (17.01.2005)
Rev. C 2006-04-24 Identical manual as for ATF 110 / FA 035 Konopka
but pictorial modifications for ATF 80-4 / FA 043
Console software: V 2.12 (13.01.2006)
Id-No. 32 24 02 12 - 020

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IK 350 / 1368

Operator’s Console Contents

for FA 043 /ATF 80-4 General Information

Checks before start-up

Service and Maintenance

Issue 4/2006 Rev. C

This document has the order no.

5. Checks before start-up 33

6. Service and maintenance 36

3.1 System functions

3.2 Control console

The console has two functions:

3.3 Indicators and control elements

(1) Data display

(2) Utilization bar graph

This utilization bar graph display indicates how much of the

(3) Function keys F1...F5

These keys can be used to select certain functions from among

(4) "LMI override" warning lamp

(5) "Anti-Two Block switch (A2B) override" warning lamp

(6) "A2B" warning lamp

(7) "Pre-warning load moment" warning lamp

This yellow pre-warning lamp goes on if the load of the crane

This means that the crane operator is only allowed to continue

(8) "Overload" warning lamp

(9) Sensor "display contrast"

Dependent to the surrounding light conditions this sensor controls

(10-11) "Contrast setting" tip switchs

With this buttons the display contrast can be adjusted according to

(12) "Horn off" key

Operation of this push-button serves to briefly suppress the

(13) "Info" key

This key selects system

(14) Numerical keypad

These numerical keys are used for numerical inputs.

The keys and have no function !

(15) "Select" key (SEL)

The correct setting of the LMI for the rig arrangement in

(16) "Limits" key (LIM)

Key used to program limitations of geometry.

(17) "Tare" key (TARE)

(18) "Control" key (CTRL)

The "CTRL" key serves to select the special functions. The

Acoustical alarm (without illustration)

The acoustical alarm sounds in the following cases:

3.4 Data display (normal operation)

3.4.1 Description of status symbols

auxiliary winch selected tele correction

LMI error tele stop

control error node 2 tele position reached

control error node 3 slewing angle limitation active

bus errorr hight limitation active

slewing brake radius limitation active

reeving boom angle limitation active

Anti two blick switch upper structure locked

ID-sensor error speed preselect active

locking sensor error

3.4.2 Switch-over for multi-function field

3.5 Data display (illustration for counterweight assembly)