LIEBHERR Diagnostics LICCON 2
Operating instructions BAL-No.: 99904-01-02 Pages: 75
Werk-Number Date
The operating manual is part of the crane! It must always be available within reach! The traffic regulations and those for crane operation must be observed!
Liebherr-Werk Ehingen GmbH Postfach 1361 D-89582 Ehingen / Donau : +49 (0) 7391 502–0 Fax: +49 (0) 7391 502–3399 :
[email protected] www.liebherr.com
1
Foreword General This crane has been built according to the present level of technology and recognized safety technical regulations. Despite that, dangers to body and life for the user and/or third persons or damage to the crane and /or other material assets can occur. This crane may only be used in flawless technical condition and according to its mission as well as with constant awareness of safety and dangers. Any problems, which could affect safety must be fixed immediately. Modifications on the crane may only be made with written approval by Liebherr-Werk Ehingen GmbH. Warning notes The following terms that are used in these operating instructions DANGER, WARNING, CAUTION and NOTICE are intended to point out certain important rules of conduct to all persons who work with the crane. Warn-
Signal word
Explanation
DANGER
Designates a dangerous situation which will lead to death or serious injury if it is not prevented.
WARNING
Designates a dangerous situation, which can lead to death or serious injury if it is not prevented.
CAUTION
Designates a dangerous situation, which can lead to slight or medium-grade injury if it is not prevented.
NOTICE
Designates a dangerous situation, which can lead to property damage if it
ing signs
is not prevented.
Further notes The term Note used in this operating instructions is intended to point out useful information and tips to all persons who work with the crane. Sym-
Signal word
Explanation
Note
Designates useful information and tips.
bol
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Operating instructions These operating instructions are intended to put you in a position to operate the crane safely and utilize the reliable usage options that it provides. The instructions also provide information about the function of important components and systems. Certain expressions are used in these operating instructions. In order to avoid misunderstandings, the same expressions should always be used. These operating instructions have been translated to be best of one’s knowledge. Liebherr-Werk Ehingen GmbH assumes no liability for translation errors. The German version of the operating instructions is solely applicable for factual accuracy. If you find any errors or if any misunderstandings arise when reading these operating instructions, please contact Liebherr-Werk Ehingen GmbH immediately. DANGER Risk of fatal accidents if crane is not operated correctly! Incorrect operation of the crane can result in death or serious injury! Only authorized and trained expert personnel are permitted to work on the crane! The operating instructions and on-site regulations and specifications (such as accident prevention regulations) must be followed. Using these operating instructions: – makes it easier to become familiar with the crane – avoids problems due to improper operation Observing these operating instructions: – increases reliability in use – extends the service life of your crane – reduces repair costs and downtime Always keep these operating instructions handy in the driver's or crane cab. The operating instructions belong with the crane! Only operate the crane if you are well familiarized with the equipment, and always follow these operating instructions. Note If you have received additional information from us relating to the crane, such as technical information bulletins, instructions and / or supplements to the operating instructions, then this information must also be observed and kept with the operating instructions. If there is anything in the operating instructions or the individual chapters that you do not understand, please contact us before starting the relevant work. The information and illustrations contained in these operating instructions may not be copied or distributed, nor used for competitive purposes. All rights are expressly reserved in accordance with copyright laws. All accident prevention guidelines, operating instructions, etc. are based on destined use of the crane. Destined use The destined use of the crane consists solely in vertical lifting and lowering of free and non-adhered loads, whose weight and center of gravity are known. To do so, a hook or hook block approved by Liebherr must be reeved on the hoist rope and it may only be operated within the permissible crane configurations. Driving with the crane, with or without an attached load is only permissible if a corresponding driving or load chart is available. The crane configurations intended for it and the safety conditions must be observed according to the corresponding operating instructions. Any other use or any other exceeding utilization is not destined use. Part of destined use is also adherence of required safety regulations, conditions, preconditions, crane configurations and working steps as noted in the crane documentation (operating instructions, load chart, job planer). The manufacturer is not liable for damages, which are caused by non-destined use or improper use of the crane. Any associated risk it is carried solely by the owner, the operator and the user of the crane.
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0.01 Foreword
Non-destined use Non -destined use is: – Working outside the permissible crane configurations according to the load chart – Working outside the permissible projection radii and slewing ranges according to the load chart – Selecting load values, which do not correspond to the actual crane configuration – Selecting LMB-Codes, which do not match the actual crane configuration – Working with bypassed load moment limiter or bypassed hoist limit switch – Increasing the projection radius of the lifted load after a LMB shut off, for example by diagonally pulling the load – Using the support pressure display as a safety function against tipping over – Using equipment or attachment parts which are not approved for the crane – Using the crane at sports and recreational events, especially for 'Bungee' jumps – Driving on a public road in non-permissible driving condition (axle load, dimension) – Driving with the equipment in place in a non-permissible driving condition – Pushing, pulling or lifting loads with the leveling regulation, the sliding beams or the support cylinders – Pushing, pulling or lifting loads by actuating the slewing gear, the luffing gear or the telescoping gear – Ripping stuck objects loose with the crane – Utilizing the crane for a longer period of time for material handling tasks – Releasing the crane suddenly (grapple or dumping operation) – Putting the crane into service when the weight of the load, which is suspended load on the crane, is changed, for example by filling a container suspended on the load hook The crane may not be used for: – attaching a stuck load for which the weight and center of gravity are not known and which has been released first, for example with a cutting torch – letting persons drive along outside the driver's cab – transporting personnel in the crane cab while driving – transporting personnel with the lifting equipment and on the load – transporting personnel with containers (cherry pickers), if no written approval of the corresponding job safety board has been issued – transporting loads on the chassis – two hook operation without auxiliary equipment – extended material handling operation The operating instructions must be read and used by all persons who are involved in use, operation, assembly and maintenance of the crane. Safety equipment Special attention must be paid to the safety equipment built into the crane. The functionality of the safety equipment must be monitored at all times. The crane must not be operated if the safety equipment is not working or not working correctly. Note Your motto must always be Safety first! The crane has been built in accordance with the applicable crane operation and driving regulations and has been approved by the relevant authorities. Attachment and spare parts
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DANGER Danger to life if original attachment parts are not used! If the crane is operated with attachment parts, which are not original, then the crane can fail and cause fatal accidents! Crane components can be damaged! Operate the crane only with original attachment parts! Crane operation with attachment parts, which do not belong to the crane is prohibited! DANGER The crane permit and the manufacturer's warranty will become void! If originally installed parts are modified, manipulated or replaced (e.g. removal of parts, installation of non-original parts), both the crane permit as well as the manufacturer's warranty will become void. Do not modify original parts! Do not remove original parts! Always use Liebherr original spare parts! Definition of directional data Forward driving means driving with the driver’s cab on the front. Reverse driving means driving with the tail lights of the chassis on the front. Front, rear, right, left on the crane refer to the condition, that the driver’s cab and the boom point in the same direction. Front is always in direction of the driver’s cab. Front, rear, right, left in the driver’s cab refer to the crane chassis. The driver’s cab is always in the front. Front, rear, right, left in the crane operator’s cab refer to the superstructure. Front is always in direction of the boom. Customer request Customer-specific equipment is marked with *.
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Contents
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Contents
Contents
20.00 Diagnostics
9
20.01 Overview Bus system 1 Overview Bus system 20.05 Error recognition - LICCON computer system 1 Error recognition - LICCON computer system 20.09 Test system Bluetooth™ Terminal (BTT) 1 Error determination on the Test system of the BTT 20.10 Test system
10 11 14 15 24 25 32
1 The BSE test system
33
2 Areas of the BSE test system
37
3 Error determination
57
20.15 Remote diagnostics
64
1 Remote diagnostics* 20.20 Diagnostics – disk brake pads 1 Diagnostics – disk brake pads*
Index
65 72 73
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20.00 Diagnostics
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20.01 Overview Bus system
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20.01 Overview Bus system
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1 Overview Bus system Note The main bus system overview (see illustration opposite) provides an insight into its structure, the modules used and their connection to the LIEBHERR system bus (LSB). The opposite illustration should only be viewed as an example! Depending on design, crane type, size and equipment of your crane, the LIEBHERR System Bus shown in the opposite illustrations differs from the LSB overviews of your crane. The detailed data for your crane is documented in the crane related LSB overviews in this chapter. Explanation of terms: BSE: BSE-Master (operating/display and control unit) MPC: Motorola-Power-PC DSP0: Digital Signal Processor 0 • DSP0 comprises: • LSB1 (LSBA) • LSB2 (LSBB) • LSB3 (LSBC) • LSB4 (LSBD) DSP1: Digital Signal Processor 1 • DSP1 comprises: • LSB5 (LSBE) • LSB6 (LSBF) • LSB7 (LSBG) • LSB8 (LSBH) I/O module: Input/output module UEA: Universal input/output module LSB: LIEBHERR system bus (LSB1, ... , LSBn). Data transmission between the individual modules using a three-wire bus. CAN: Controller area network (differential data transmission via 2 conductors) UW: Chassis OW: Superstructure
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20.01 Overview Bus system
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Explanation of terms (contd.): AM: Active master switch BK: Operating and control unit BT: Bluetooth™-Basis station DI: Dual inductive sensor DK: Pressure sensors DR: Turn sensor HO: Hoist limit switch IA: Inductive sensor (analog) ID: Inductive sensor (digital) IP: Inductive sensor / analog and position LG: Length sensors MS: Master switch NG: Inclination sensor PG: Pedal sensor SD: Spindle turn sensor SV: Headlight adjustment drive TE: Touch display UE: UEA module WD: Winch turn sensor WG: Angle sensors ZM: Pull test bracket
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20.05 Error recognition - LICCON computer system
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1 Error recognition - LICCON computer system 1.1
General Note The monitor illustrations in this chapter are only examples. Please note that all illustrations in this chapter are only examples and might not exactly match your crane. Faults or errors occurring in one or more modules will be displayed at the system level of the BSE test system (chapter 20.10). The error stack of the BSE test system may be used to display the error description of error(s) which have occurred. See chapter 20.10.
1.2
Locating and rectifying errors The crane operator can use the error diagnostics to immediately identify any errors that may have occurred. The error can in many cases be quickly located and rectified using the error description from the “BSE test system”. If the LICCON-Error-Code displays an error: Consult the section “Error determination” (chapter 20.10) of the BSE test system. If the monitor display is defective: Consult the section “Monitor errors”. Note Consult LIEBHERR Service. If the assistance of LIEBHERR Service is required, please always provide the following information: – Crane type – Crane number – Complete error number and any error message displayed on the monitor – Application conditions of crane – Action during which the error occurs – Frequency of error If the crane operator cannot rectify the error himself: Consult LIEBHERR Service.
1.3
LICCON-Error-Code (LEC) The LICCON-Error-Code describes two possible error classes: – System errors – Operating errors The error code is displayed in the superstructure (error determination display of “BSE test system”). In addition, all errors are listed in a separate error list (error text, cause, remedy). The structure of the error code is based primarily on a 6 digit error number as well as the given error class description.
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20.05 Error recognition - LICCON computer system
Error code: ±X. 12 34 56 Element
Description
±
Active / inactive error
X.
Error class “B ” / “E ” (operating error, system error)
12
Device (module generating the error)
34
Error path (source of error)
56
Type of error
There are two different error classes: – Operating errors “B ”: are indicated if the machine is operated incorrectly (keypad unit, ignition switch, ....). – System errors “E ”: (internal errors in I/O modules, applications, LSB errors ....). NOTICE Deleting errors in the error stack! When the ignition is turned off, all error messages (active and inactive) are deleted in the error stacks. Be careful when turning the ignition off.
1.4
Monitor errors Monitor errors: – Could indicate a defective monitor when switching on the control system. – Could stem from a shortage in monitor supply voltage (in this case the monitor stays dark). The light-emitting diode (LED) located at the bottom right of the monitor will indicate whether the monitor supply voltage (24 V) is present. Note After starting the LICCON computer system, the yellow LED on the LICCON Monitor will light for approx. 1 s and the LICCON computer system is booted.
1.4.1
Locating and rectifying monitor errors Possible monitor errors and their causes are listed below.
Error
Possible cause
Monitor remains dark after switching on - LED
No supply voltage
does not light up Possible error remedy: Check voltage supply.
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Error
Possible cause
No picture on monitor
Monitor has turned off the screen at ambient temperatures of lees than -20 °C and more than 70 °C Supply to monitor is unplugged or defective Monitor is defective
Possible rectification of error (follow given order for error remedy): Preheat or cool the cab. Check the supply voltage (V) on the monitor connection plug (nominal value: 18 V - 6 V, nominal: 24 V). Error
Possible cause
Monitor displays one of the following errors after
Individual monitor components (display, keypad,
turn on:
keyed switch) defective
- Monitor horn does not work - Sealed keypad defective - Brightness control defective - Keyed switch defective - Symbol elements incorrect or missing Inform LIEBHERR Service and have the defective monitor replaced by a new or fully-functional replacement monitor.
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20.05 Error recognition - LICCON computer system
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PCMCIA memory card If a five line error message “appears” at the upper edge of the start screen after booting the LICCON computer system, fig. 2, then the PCMCIA memory card is probably not “inserted” properly. Note Consult LIEBHERR Service.
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Error in the digital signal processors (DSP0 and DSP1) In case of a DSP control software error, the monitor will display a “test picture” when the LICCON computer system boots, fig. 3, and two touch displays in the control unit consoles will “permanently” display the “start screen”, fig. 4. Note Consult LIEBHERR Service.
1.7
UIO module errors UIO module errors are either indicated by the “BSE test system” at system level, or by a “LEC” and corresponding error description on the error determination screen. If the red LED on the front plate of the UIO module (connector side) is not lit, this might indicate there is no bus connection to/with the UIO module and that the UIO module is faulty. Note Consult LIEBHERR Service.
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LED error code and status display on I/O modules Note The LED display bar on the front plate of each I/O module indicates the error code and status, fig. 5. Inputs and constant current sources 1 SPI bus 2 CAN bus 3 Power supply 4 Inputs, outputs, LSB bus 5 LED Color
Module
Error /
Meaning
status
15
red
HW-Watchdog
Error
static
blinking
No error (LED 50% bright)
Intermittent error
operating status 14
red
13
HW error
Error
Change I/O module
-
yellow HW error
Status
Output stage defective
-
12
yellow HW error
Status
Initialization1
-
11
yellow HW error
Status
Appl.-/driver watchdog
Illegal Interrupt
10
green
-
-
-
-
9
green
-
-
-
-
8
green
-
-
-
-
7
red
LSB1 driver
Error
Persistent error on LSB1
Intermittent interruption on LSB1
6
yellow LSB1 driver
Status
LSB 1 bus off
Download via LSB1
5
red
Error
Persistent error on LSB2
Intermittent interruption on
LSB2 driver
LSB2 4
yellow LSB2 driver
Status
LSB2 bus off
Download via LSB2
3
red
Error
Persistent error on CAN
Intermittent interruption on
CAN driver
CAN 2
1
yellow CAN driver
red
SSC driver
Status
Error
All stations missing on
One/several stations miss-
CAN
ing on CAN
Persistent error on SSC
Intermittent interruption on SSC
0 1
20.05
yellow SSC driver
Status
-
-
Error in: Register, RAM, ROM, output stage watchdog, firmware, crane configuration file
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20.09 Test system Bluetooth™ Terminal (BTT)
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1 Error determination on the Test system of the BTT Error messages are created by erroneous functions. A distinction is made here between operating errors and system errors: – System errors 1.1 – Operating errors 1.2
1.1
Starting the test system Start the test system by pressing the function key F10 from “kilometer and operating hours”, “incline display”, “menu overview” and “engine control - chassis” programs. Press the function key F10. Result: – The test system is started, see fig. 2.
1.2
LICCON-Error-Code (LEC) The error code is displayed on the BTT display (error determination display in the “test system”). In addition, all errors are listed in a separate error list (error text, cause, remedy). The structure of the error code is based primarily on a 6 digit error number as well as the given error class description. Error code: ±X: F1 7E 11 Element
Description
±
Active / inactive error
X:
Error class “B ” / “E ” (operating error, system error)
F1
Device (module generating the error)
7E
Error path (source of error)
11
Type of error
There are two different error classes: – Operating errors “B ”: are indicated if the machine is operated incorrectly (keypad unit, ignition switch, ....). – System errors “E ”: (internal errors in I/O modules, applications, LSB errors ....). • System errors can still be subdivided into: • Active system errors Errors which are present continuously (Example: cable break, sensor defective, etc.). Marked with a “+” • Inactive system errors Errors which only occur momentarily (Example: loose contact, temporary sensor failure, etc.). Marked with a “-” NOTICE Deleting errors in the error stack! When the ignition is turned off, all error messages (active and inactive) are deleted in the error stacks. Be careful when turning the ignition off.
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20.09 Test system Bluetooth™ Terminal (BTT)
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Error stack All errors are displayed together with their error number and stored and documented in the error stack. – If only active system errors are present in the error stack it is not possible to store any additional system errors in the error stack. – If the error stack is filled with active system errors, a system error will be overwritten if an operating error occurs. – If an error is still present or the cause of error has not been rectified, a new active error message will be generated and displayed if the error occurs again, i.e. with a new date and time. CAUTION Deleting errors in the error stack! When the ignition is turned off, all error messages (active and inactive) are deleted in the error stacks. Be careful when turning the ignition off.
1.3.1
Determining errors from “kilometer and operating hours”, “incline display”, “menu overview” and “engine control - chassis” program Procedure If a system or operating error is present, then an error message appears on the function key F10, for example E, see fig. 3. Press the function key F10. Result: – The test system is called up, see fig. 4. Press the function key F3. Result: – The option “Total system” is shown, see fig. 5. Press the function key F3. Result: – The error determination screen for the entire system incl. all active operating and system errors is displayed, see fig. 6.
Note By pressing the function key F2, the error determination view is paged by one side. By pressing the function key F3, the error stack is read in again.
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20.09 Test system Bluetooth™ Terminal (BTT)
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Press the function key F1. Result: – The assignment of the function key F2 and the function key F3 changes, see fig. 7.
Note By pressing the function key F2, all errors in the entire system are deleted. By pressing the function key F3, the error parameters are superimposed. Press the function key F3. Result: – Selecting the function “Parameter ON/OFF” expands the error description of each error by the parameter line, see fig. 8. – In addition to the parameters, the “inactive” errors are also displayed.
Note Operating errors are shown with a delay in the error determination screen - as long as the error control is active. Severe operating errors are shown immediately in the error determination screen. With the function key F4, one gets into the high level menu or back to the “Menu overview” program.
1.3.2
Error information The information of an error as well as the date when the error occurred is distributed to 3 lines. When calling up the sub function PARAMETER ON with the function key F3, the error text is expanded by the parameters. In addition, all inactive errors “-” are shown, see fig. 8. Line 1:
Line 2:
Type of error
Error text
±B: = operating error
Documentary description
±E: = system error
of the error
Time/error frequency When error last occurred/how often error has occurred
Line 3:
Date When the error last occurred
Line 4:1
Error-specific data in hexadecimal form
5:1
Error-specific data in hexadecimal form
Line 1
20.09
When function “PARAMETER ON” is selected
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20.09 Test system Bluetooth™ Terminal (BTT)
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Changing the language Procedure The language of the menu texts in the test system can be changed as follows: Ensure that the following preconditions are met: – The start view of the test system is shown on the display of the BTT, see fig. 9. Press the function key F1. Result: – The cursor jumps down by one line, see fig. 10. Press the function key F3. Result: – The overview is shown in the text languages menu available, see fig. 11. Move the curser to the desired language via the function key F1 or function key F2. Press the function key F3. Result: – The menu texts are shown now in the selected language.
Note With the function key F4, one gets into the high level menu or back to the “Menu overview” program.
20.09
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20.10 Test system
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1 The BSE test system The BSE test system is a diagnostic tool used to localize and rectify system errors. Note The monitor illustrations in this section are only examples. The error codes and values shown in the monitor illustrations and the corresponding error descriptions might not exactly match the crane. Please note that all illustrations in this chapter are only examples and might not exactly match your crane.
1.1
Starting the BSE Test system Start the BSE test system from the “crane operation” program by pressing the “i” P8 key on the LICCON monitor. DANGER Risk of accident! In the BSE test system the LICCON monitor is solely used for test system functions. There are no warnings that the crane is being operated at its limits. Operate the crane with particular caution! Press program key “i” P8. Result: – The BSE test system starts up.
1.2
Changing the language settings The BSE test system language settings are modified by pressing special function keys E1 and special function keys E2. There is a choice of seven languages. Note The set language is indicated by a blue border around the national flag and by the text shown underneath in the corresponding language. Press the special function key E1. Result: – The blue selection square moves to the left . Press the special function key E2. Result: – The blue selection square moves to the right.
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Service levels The BSE test system is structured into three service levels. Note The current service level is shown at the upper right edge of the header on the BSE test system. In service level 0 the header is empty. It should be noted that service level 0 is automatically selected when the crane driver presses program key “i P8 ” to start the BSE test system. No daily code is required for service level 0. Note It is not possible to manipulate system- or safety-relevant parameters/functions using service level 0. The safety-relevant parameters/functions in service levels 1 and 2 are protected against access by unauthorized personnel.
Accessing the service levels Level
Authorization
Enter CODE
0
Crane driver
no
1
Assembly personnel
yes
2
Specialists
yes
In service level 0 the crane driver is authorized to: – Change the language settings. – Display a system overview showing all modules and sensors in the BSE test system. – Display errors in the error stack. – Delete individual errors in the error stack. – Delete all errors in the error stack. – Update the display of errors in the error stack. – Display the clock settings. – Display/retrieve screen shots.
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2 Areas of the BSE test system The BSE test system monitor is divided into three areas: – Header 1 – Display area of the test system 2 – Function key line 3
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Header The BSE test system header 1 shows the implemented crane software as well as the crane number for your crane. 1.1 Version number 1.2 Crane identifier 1.3 Crane number
1.4 Program counter 1.5 Current “Muli” status 1.6 Release date
20.10
• refers to the test system software • with crane type number • crane number of the software on the PCMCIA memory card • Note: The crane numbers of the monitor and software stored on the PCMCIA memory card must be identical. • the program counter will be counted up if the crane configuration is changed • displays the current Muli-status on the PCMCIA memory card • displays the release date for the current software
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Display area of the test system The following information is shown on the start screen of the BSE test system display area 2. 2.1 Time zone 2.2 Current time 2.3 Current date 2.4 Available languages
2.4.1 Flag 2.4.2 Set language 2.5 Crane number
2.6 Visualization software 2.7 IP address 2.8 Current brightness setting of the LICCON monitor
20.10
• Example: “MET” • “Middle European Time” • refers to the displayed time zone 2.1 • refers to the displayed time zone 2.1 • the desired language is selected with the special function key E1 and the special function key E2 Note: Also refer to section “Changing the language settings”. • the set language is indicated by a blue border around the corresponding flag • set language in text form • crane number of monitor • Note: The crane numbers of the monitor and software stored on the PCMCIA memory card must be identical. • visualization software version • IP address of the computer • manually adjustable in 7 stages (see chapter 4.02)
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The function key line The function key line 3 consists of function keys F1 to F8. The function keys are assigned to various functions which are shown in the “black fields” above the function keys. Not all the function keys on the LICCON monitor have to be assigned to a function. Press the function key to start the application or access the relevant menu. F1 SYSTEM
F2 ERROR
F3 CLOCK
F4 SCREEN SHOTS
• To access the system level. A clear and hierarchical overview of the modules is displayed. • The connected LSB stations and their status are also displayed. Note: See section System. • accessing errors in the error vault Note: See section Error. • to access the clock settings Note: Service level 0 is not authorized to change the clock settings. To modify the clock settings, use the daily code to switch to service level 1. Note: See section Clock. • Creates SCREEN SHOTS (maximum 10), which are stored in nonvolatile memory on a PCMCIA card. They may be accessed and displayed in the display area of the test system 2 by pressing function key F4. Note: See section SCREEN SHOTS.
F5 not used F6 SERVICE LEVEL
• call up the daily code entry Note: See section SERVICE LEVEL.
F7 not used F8 not used
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LIEBHERR
43
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B105052
44
LIEBHERR
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20.10 Test system
2.3.1
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Function key System “F1” Press function key F1 on the BSE test system start screen, illustration 3, to access the “system level”, illustration 4. The system level uses a hierarchical structure with the MPC at the top and the DSP´s arranged underneath in parallel. Each DSP is subordinate to four LSB buses. Note The system level provides the crane driver with a quick overview of any current system errors or faults. If a daily code is not entered (service level 0), it is only possible to use the cursor (function keys F1 – F4) to select modules or stations. A supplementary text 1 for the selected module or station is displayed above the function key line. All modules, LSB´s and stations at system level are color-coded. Each color has a certain significance. In addition to color-coding, each station may be displayed as a static or flashing icon. Note The state of a particular module, LSB or individual station may be determined by its color and whether the station is static or flashing.
Identification of modules, LSB´s, bus participants Color
static
green
X
Participant is OK
blue
X
Optional participant is missing
yellow
X
Error in error stack
red
X
Participant is faulty
Description
red
X
Required participant is missing
red1)
X
Incorrect participant type
1)
20.10
blinking
only the type identifier blinks, for example: DK (the type digits are not displayed in this case)
LIEBHERR
45
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20.10 Test system
B105053
46
LIEBHERR
20.10
20.10 Test system
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Hardware error A short-circuit between LSB and ground, or between LSB and a 24 V bus circuit, represents a hardware error. Consequently all bus participants will become faulty. Note All participants on the faulty bus circuit are displayed “blinking red”. Error determination Proceed according to the following sequence to determine the hardware error: – Pull the faulty LSB bus plugs (for example: LSBE/LSB5) from the corresponding circuit board (-A411). Note: On the LICCON monitor all LSB participants connected to the faulty LSB bus will continue to blink red after the plug connectors are detached. – Check the power supply 24 V (green LED) 2. Note: The green LED 2 lights up when the power is connected. – Check data transfer (red LED) 3.
LSB circuit board
LED function
Data transfer OK
the red LED 3 lights up or flickers at a high frequency
Data transfer faulty
red LED 3 blinks
Short-circuit of data line
red LED 3 is off
Note Replace the circuit board if data transfer errors occur on an LSB bus. If no problem is shown by the LED’s, check the sensors and lines.
20.10
LIEBHERR
47
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20.10 Test system
B105054
48
LIEBHERR
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20.10 Test system
2.3.2
027370-00
Function key Error “F2” Press function key F2 on the BSE test system start screen, illustration 6, to access the “error determination” for the whole system, see illustration 7. Pressing function key F2 will initiate the read out and display of active errors in the display area of the BSE test system. Note The following message will appear in the display area if no error is found in the whole system: “Hurray! NO ERROR!” Function key line on error determination screen See illustration 7. F1 Update
F2 CURSOR F3 CURSOR F4 Page by page SCROLLING
F5 Delete ERROR
F6 Delete ALL ERRORS
F7 PARAMETER ON / OFF
F8 BACK
20.10
• All active errors can be reloaded – for example if they were deleted – by pressing function key F1. • Active errors will be re-displayed together with the current date. • Move cursor “down” by one error. • Move cursor “up” by one error. • Press function key F4 to scroll between the error pages. • The current error page is displayed at the upper edge of the display area. Example: Page 1 of 4 is displayed as 1/4 1. • Deletes selected error. • Pressing function key F5 will delete the error where the cursor is positioned. • Deletes all errors in the selected error stack. Note: All errors in all modules will be deleted when selecting the whole system. • Show/hide inactive errors and error specific parameters. Note: The error description for active(+)/inactive(-) errors is extended from 2 to 3 lines. The third line displays error-specific parameters and the date when the error occurred. • Back to the BSE start screen.
LIEBHERR
49
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20.10 Test system
B105055
50
LIEBHERR
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2.3.3
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Function key Clock “F3” Press function key F3 on the BSE test system start screen, illustration 8, to access the clock settings menu, illustration 9. Note The clock settings cannot be modified if a daily code is not entered (service level 0). Service level 0 only provides “read-only access”. Function key line in clock settings menu See illustration 9. F1 CURSOR F2 CURSOR
• Move cursor “down” by one time zone. • Move cursor “up” by one time zone.
F3 not used F4 not used F5 not used F6 not used F7 not used F8 BACK
20.10
• Back to the BSE start screen.
LIEBHERR
51
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B105056
52
LIEBHERR
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2.3.4
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Function key Screen Shots “F4” Press function key F4 on the BSE test system start screen, illustration 10, to access the “screen shot” display, illustration 11. “Screen shots” are snapshots of the monitor display. This option allows the crane driver to record error conditions on the LICCON computer system (“freeze”) for reloading at a later date. Note Pressing function key F4 displays the first saved “screen shot” on the local LICCON monitor. To avoid confusion between “screen shots” and the original display, a text message is shown for approx. 2 s after the “screen shot” is displayed. This text message will appear in the middle of the “screen shot” and contains the number, date and time when the “screen shot” was created. Use special function key E1 and special function key E2 to switch between the individual “screen shots”. Creating “screen shots” Screen shots may be created from any of the programs in the LICCON computer system. To create a “screen shot”, press and hold down the “SHIFT” and “.” keys in the required program and then press the “P” key. A double beep is emitted if the screen shot was successful. Note A maximum of 10 consecutive screen shots can be made. Each additional screen shot will overwrite the oldest. Function key line in “Screen Shots” menu Note To return to the BSE start screen, press one of the function keys F1 to F8.
20.10
LIEBHERR
53
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B105057
54
LIEBHERR
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2.3.5
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Function key Service Level “F6” Press function key F6 on the BSE test system start screen, illustration 12, to enter the daily code, illustration 13. Note The daily code should only be entered by authorized persons, see section “Service Levels”. Function key line in “Service Level” menu Note To return to the BSE start screen, press one of the function keys F1 to F8.
20.10
LIEBHERR
55
B198252
56
LIEBHERR
20.10
20.10
027370-00
3 Error determination Malfunctions in the LICCON computer system generate error messages. A distinction is made here between operating errors and system errors. System errors can still be subdivided into: – Active system errors Errors which are present continuously (Example: cable break, sensor defective, etc.). Marked with a “+” – Inactive system errors Errors which only occur momentarily (Example: loose contact, temporary sensor failure, etc.) Marked with a “-” Note Should an error occur during crane operation, the error type (operating or system error) and error path are shown red in the “horn” icon on the function key line. If multiple errors occur, the error type and “faulty” module having the highest priority is displayed.
20.10
LIEBHERR
57
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B198250
58
LIEBHERR
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3.1
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Error stack Each BSE test system module (for example: MPC, DSP0, ...) has a memory for up to 15 errors. All errors are displayed together with their error number and stored and documented in the relevant error stack. – If the error stack of one module is full (15 errors), inactive errors will be overwritten by new active errors. – If only active system errors are present in the error stack it is not possible to store any additional system errors in the error stack. – If the error stack is filled with active system errors, a system error will be overwritten if an operating error occurs. – If an error is still present or the cause of error has not been rectified, a new active error message will be generated and displayed if the error occurs again, i.e. with a new date and time. CAUTION Deleting errors in the error stack! When the ignition is turned off, all error messages (active and inactive) are deleted in the error stacks. Be careful when turning the ignition off.
3.1.1
Determining errors from the Operation, Telescoping, Configuration, Support programs Procedure If a system error or operating error occurs, an error message will appear in the “Horn” icon above function key F8, for example B:DSP0. Press the function key F8. Result: – Acoustic signal is turned off. Press function key F8 again. Result: – The error determination screen of the BSE test system is called up. – The error in the faulty module is displayed in the error determination screen.
20.10
LIEBHERR
59
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B198250
60
LIEBHERR
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3.1.2
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Accessing the BSE test system Procedure Press program key “i” P8. Result: – The BSE test system program has been accessed. Press the function key “ERROR” F2. Result: – The error determination screen for the whole system incl. all active operating and system errors is displayed. Press function key “Parameter ON/OFF” F7. Result: – Selecting the function “Parameter ON/OFF” expands the error description of each error by the parameter line. – In addition to the parameters, the “inactive” errors are also displayed, see fig.
3.1.3
Error information The error information is split into 2 lines. When calling up the sub function PARAMETER ON with the function key F7, the error text is expanded by the parameters. The third line displays the error-specific data and date of occurrence. In addition, all inactive errors “-” are shown. Line 1:
Type of error
± LEC (LICCON-Error-Code)
Module generating the error
Line 2:
B! = operating error
+ = active error
(MPC, DSP0,
E! = system error
- = inactive error1
DSP1, LSB1, .......)
Time/error frequency
Type of error
When error last occurred/how
Documentary description of error
often error has occurred Line 3 :1 Date 1
20.10
Error-specific data in hexadecimal form
When function “PARAMETER ON” is selected
LIEBHERR
61
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B198251
62
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3.1.4
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Error stack empty If there no active errors in the whole system and the module-specific error stack are empty, the following message is displayed on the error determination screen of the BSE test system: “Hurray! NO ERROR!” Note The message “Hurray! NO ERROR!” also appears when there are inactive errors in the error stacks of the whole system or specific modules. Press function key F7 (Parameter ON/OFF) to display the inactive errors on the error determination screen.
20.10
LIEBHERR
63
026292-00
20.15 Remote diagnostics
B198266
64
LIEBHERR
20.15
20.15 Remote diagnostics
026292-00
1 Remote diagnostics* LWE remote diagnostics allows LIEBHERR cranes to be serviced remotely in the event of an error. The remote diagnostics module (GSM module) must be connected to the LICCON computer system of the crane. Once the connection between the crane and service point has been established, the data is transferred from the “REMOTE DIAGNOSTICS SYSTEMS” to the computer located at either LIEBHERR customer service or at one of the LIEBHERR service points. Worldwide remote diagnostics coverage is possible if the LIEBHERR customer service or LIEBHERR service point is provided with full access to the crane's functions. In addition to the “GSM connection”, a telephone connection must also be established with the LIEBHERR customer service or LIEBHERR service point to facilitate communication with the crane driver and issue instructions as required. Always ensure that the instructions given by the LIEBHERR customer service or LIEBHERR service point are followed precisely.
1.1
LWE remote diagnostics module 1 GSM module 1.1 Status LED 2 3 4 5 6 7 72
1.2
• The standard GSM module is equipped with a SIM card. • The GSM module has a dual-colour LED which will light/flash in the appropriate colour depending on the status
Tri-band antenna Antenna cable Holder Permanent magnet Cable WL634 Power supply 24 V Socket 24 V
Activating the remote diagnostics module or remote diagnostics device DANGER Risk of accident! Remote diagnostics should only be used by authorised persons. Several following conditions must be fulfilled to ensure trouble-free remote diagnostics and call setup to the GSM module. Note The WL634 cable was already fastened to the crane in the factory works and connected to the COM3 port at the rear of the monitor and the GSM module. The power supply of the GSM module must be plugged into the 24 V roof panel socket 72 when the “REMOTE DIAGNOSTICS SYSTEMS” is switched off.
20.15
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65
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20.15 Remote diagnostics
B198266
66
LIEBHERR
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20.15 Remote diagnostics
026292-00
Ensure that: – the power supply of the GSM module 7 is plugged into the 24 V roof panel socket 72. – the telephone number of the data service is known – the PIN code request of the SIM-card is deactivated The SIM-card offers three different telephone services, each of which has its own telephone number: – Voice – Fax – Data Note Deactivate PIN-Code request! A standard mobile telephone is required to deactivate the PIN-code request. Insert the SIM-card into this mobile telephone and switch off or deactivate the PIN code request. The factory-fitted SIM-card in the GSM module will expire after a period of two years. The inserted SIM-card could suddenly also stop functioning. Note In this case order a new SIM-card. When ordering a new SIM-card, send the following information to the provider to ensure you receive a system-compatible SIM-card. This is the only way of ensuring that the remote diagnostics will continue to function correctly. The “new” SIM-card must have the following characteristics. Required SIM-card characteristics: – Voice-data card – CSD and voice transmission – the Siemens MC45 GSM module (modem) will be used
Telephone number of the data service (crane
___________________________
operator): (please enter telephone number here) Call the appropriate LIEBHERR customer service point (CS-point) by mobile telephone. Inform the customer service employee of the new telephone number for the data service. The CS point calls the “crane” using the telephone number of the data service. The Status LED 1.1 on the GSM module 1 will flicker to indicate the call setup to the crane driver, illustration 1.
20.15
LIEBHERR
67
026292-00
20.15 Remote diagnostics
B198266
68
LIEBHERR
20.15
20.15 Remote diagnostics
1.3
026292-00
Carrying out a remote diagnostics Once the connection is successfully established, the LIEBHERR customer service employee can access the crane's “REMOTE DIAGNOSTICS SYSTEM” using the GSM connection between his PC and the GSM module. Note Access to the “REMOTE DIAGNOSTICS SYSTEM” by LIEBHERR-customer service occurs in the “background”. This is not noticed by the crane driver. DANGER Increased danger of accidents! The crane driver continues to have unrestricted use of all crane functions and operating screens during the complete remote diagnostics procedure. Permanent telephone contact must be maintained with the LIEBHERR customer service employee during the whole of the remote diagnostics. Execute all crane movements with the utmost care, lowest possible acceleration and minimum speed. If necessary consult the LIEBHERR customer service employee. Follow all instructions given by the customer service employee.
1.4
Identifying errors The remote diagnostics system can only identify static, electrical errors which are sampled using a timebase greater than 2 seconds. If an error only appears sporadically when working with the crane: Leave the crane switched on. Result: – LIEBHERR customer service can call the crane using the remote diagnostics system in order to locate the error. Troubleshooting Data connection with the crane cannot be established? The data connection has failed. Check the interface settings using the BSE configuration tool, see next section.
20.15
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69
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20.15 Remote diagnostics
B198267
70
LIEBHERR
20.15
20.15 Remote diagnostics
1.5
026292-00
Switching the interface using the BSE configuration tool The COM3 interface must be configured in the BSE configuration tool in order to permit remote diagnostics. The COM3 interface is usually preconfigured when the crane is shipped from the factory. Note If a remote diagnostics connection cannot be established, check the interface settings in the BSE configuration tool and if necessary change it to COM3. Procedure Switch on the ignition to access the BSE configuration tool. Turn the ignition switch to position 0. Result: – the crane engine is switched off – the LICCON computer system is shut down Press and hold down function keys “F2” and “F3” , then turn ignition switch to “position 1”. Result: – the BSE configuration tool starts up If the Ethernet interface has been configured, illustration 2: Press function key “F1” . Result: – the interface is switched to COM3 If the COM3 interface has been configured, illustration 3: Press function key “F8” . Result: – the BSE configuration tool is quit and the LICCON computer system boots
20.15
LIEBHERR
71
026274-00
20.20 Diagnostics – disk brake pads
B197975
72
LIEBHERR
20.20
20.20 Diagnostics – disk brake pads
026274-00
1 Diagnostics – disk brake pads* If the warning light 204 on the display unit light up, it is a sign that at least one brake pad on the crane is worn and has reached the wear limit.
1.1
Finding the worn disk brake pad You can find the worn brake pad via the diagnostics plug -X98 70 – which is in the center console. Make sure that the cover of the center console is open: – Make sure that the diagnostics plug -X98 70 is easily accessible – Prepare the multimeter for diagnostics Note Carry out the diagnostics for each brake pad individually. Connect the multimeter for the diagnostics according to the wiring diagram. The current determined with the multimeter provides information if the inspected brake pad is OK or if the brake pad is worn, or an electrical problem is present in the diagnostics circuit. During the diagnostics of the disk brake pads, always check all brake pads.
Diagnostics – disk brake pads
20.20
Signal
Description
24 V
Brake pad OK.
0V
Brake pad worn and / or electrical problem in diagnostics circuit
LIEBHERR
73
74
LIEBHERR
Index L
A Activating the remote diagnostics module or remote diagn 65 Areas of the BSE test system 37
C Carrying out a remote diagnostics 69 Changing the language settings 33
M Monitor errors 16
D
O
Diagnostics 9 Diagnostics – disk brake pads 72 Diagnostics – disk brake pads* 73 Display area of the test system 41
Overview Bus system 10 Overview Bus system 11
P
E
PCMCIA memory card 19
Error determination 57 Error determination on the Test system of the BTT 25 Error in the digital signal processors (DSP0 and DSP1) 21 Error recognition - LICCON computer system 14 Error recognition - LICCON computer system 15 Error stack 27, 59
F Finding the worn disk brake pad 73
G General 15
H Header 39
I Identifying errors 69 Index 75
LED error code and status display on I/O modules 23 LICCON-Error-Code (LEC) 15, 25 Locating and rectifying errors 15 LWE remote diagnostics module 65
R Remote diagnostics 64 Remote diagnostics* 65
S Service levels 35 Starting the BSE Test system 33 Starting the test system 25 Switching the interface using the BSE configuration tool 71
T Test system Bluetooth™ Terminal (BTT) 24 Test system 32 The BSE test system 33 The function key line 43
U UIO module errors 21
LIEBHERR
75
