55m4500ebe00e PDF

55M4500EBE00E Rev B
i4500 Crane Information Center

Rated Capacity Indicator for Lattice Cranes
with Load Sensor on Hoisting Rope
(Europe)
Instruction Manual
Ref: VH oct 2013
Copyright © 2013
RaycoWylie Systems
All rights reserved.
This page has been intentionally left blank
55M4500EBE00E RevB
The purpose of this manual is to provide the customer with the operating procedures
essential for the promotion of proper machine operation for its intended use. The
importance of proper usage cannot be overstressed. All information in this manual
should be read and understood before any attempt is made to operate the machine.
Since the manufacturer has no direct control over machine application and operation,
conformance with good safety practice in this area is the responsibility of the user
and of the operating personnel.
All procedures herein are based on the use of the system under proper operating
conditions, with no deviations from the original design. Alteration and/or
modification of the equipment are strictly forbidden without written approval from
RaycoWylie Systems.
The i4500 RaycoWylie Systems Crane Information Center must be regarded only
as an aid to the operator. When the parameters are set correctly, the indicator will
warn the crane operator of an approaching overload condition that could damage
the equipment, property, and/or cause injury to the operator or people working near
the crane and its load.
This system must never be used, under any circumstances, as a substitute for the
good judgment of a crane operator when carrying out approved crane-operating
procedures. The crane operator is responsible for the safe operation of the crane. The
indicator equipment will not necessarily prevent crane damage due to overloading
and related causes if not set properly.
Before operating a crane equipped with a RaycoWylie system RCI, the operator
must carefully read the information in both this manual and the crane manufacturer
operator’s manual. He must also be aware of all the federal, state and local safety
standards and regulations applicable to his job. Correct functioning of the system
depends upon routine daily inspection. Any suspected faults or apparent damage
should be immediately reported to the responsible authority before using the crane.
i4500 Lattice Boom Crane 5 Instruction Manual

55M4500EBE00E RevB
RaycoWylie Systems
Contents of EC Declaration of Conformity
The Manufacturer: Rayco Electronic System Authorised Representative:
2440 Av Dalton Wylie Systems
Québec, PQ, Canada Drury Lane
G1P 3X1 East Sussex, United Kingdom
TN38 9BA
In accordance with the 2006/42/EC The Machinery Directive

following Directives: 2004/108/EC The Electromagnetic Compatibility Directive
Hereby declare that: Product type: Rated Capacity Limiter/Indicator

Configured for total moment or hoist load sensing
for Lattice or Telescopic boom cranes
Model: i4500
Model number: 66D4500xxxxx
Is in conformity with the EN 13000 Cranes – Mobile Cranes

applicable requirements of EN 12077-2 Cranes Safety, limiting and indicating devices
the following harmonized EN 61000-6-2 Electromagnetic compatibility - immunity
standards: EN 61000-6-4 Electromagnetic compatibility - emission
Authorized person to Peter Southerden, Drury Lane, East Sussex, United Kingdom
compile Technical File:
For and on behalf of Wylie Systems, a division of

RaycoWylie Systems:
September 2012
ISO9001:2008 FM 33972
The product is manufactured in more than one country and all European Union import duties and taxes have been paid in
the United Kingdom.
www.raycowylie.com

55M4500EBE00E RevB
Since safety of personnel and proper use of the machine is of primary

concern, different symbols are used throughout this manual to
emphasize certain areas.
The following definitions indicate the level of hazard when these

symbols appear throughout this manual. Whenever one of these
symbols appears in this manual, personnel safety is a concern. Please
take the time to read and understand these definitions!
DANGER: INDICATES A POTENTIALLY HAZARDOUS

SITUATION WHICH, IF NOT AVOIDED, COULD RESULT
IN DEATH OR SERIOUS MACHINE DAMAGE.
CAUTION: INDICATES A POTENTIALLY HAZARDOUS

SITUATION WHICH, IF NOT AVOIDED, MAY RESULT IN
MINOR OR MODERATE INJURY AND MINOR MACHINE
DAMAGE. IT MAY ALSO BE USED TO WARN AGAINST
UNSAFE PRACTICES.
IMPORTANT: INDICATES A SITUATION THAT MAY

CAUSE MACHINE DAMAGE.
NOTE: PROVIDES INFORMATION THAT MAY BE OF

SPECIAL INTEREST.

55M4500EBE00E RevB
TABLE OF CONTENTS
EC Declaration of Conformity page 5

Warning page 7
1- GENERAL DESCRIPTION OF THE SYSTEM page 13

1.1 Introduction page 13
1.2 Personnel Qualification page 13
1.3 Intended Use of the i4500 System page 13
1.4 Brief Description of the i4500 System page 14
1.4.1
Audible Alarm page 15
1.4.2
Visual Alarms page 15
1.5 Location & Description of Typical Components page 18
1.6 Block Diagram page 19
1.7 Technical Data page 20

2- DETAILLED DESCRIPTION OF THE DISPLAY UNIT page 21
2.1 Main Display (Default Screen) page 21
2.2 Display Box Overview page 22
2.3 Operating Buttons Description page 23
2.4 Main Modes page 25
2.5 Warning Lights and Indicators Location page 26
2.6 Warning Lights and Indicators Description page 27
3- INSTALLATION AND CALIBRATION page 31
4- OPERATING INSTRUCTIONS page 31

4.1 Safety Instructions page 31
4.2 Residual Risks page 32
4.3 Power On page 33
4.4 System Configuration page 34
4.4.1
Duty Selection page 34
4.4.2 Working with Main Boom, 1 or 2 Hoists page 35
4.4.3
Working with Jib, 1 Hoist page 39
4.4.4 Working with Main Boom or Jib page 43

55M4500EBE00E RevB
TABLE OF CONTENTS
4.4.5 System Configuration Information Screen page 49

4.4.6 System Setup Configuration Mode page 50
4.4.6.1 Unit Selection page 51
4.4.6.2 Language Selection page 52
4.4.6.3 Date and Time Settings page 52
4.4.6.4 Night/Day Light Mode page 53
4.4.6.5 Backlight Mode page 54
4.4.6.6 Set and Remove Tare page 55
4.4.7- Bypass/Rigging Mode page 56
4.4.7.1 Rigging Mode (Maintenance and Rigging) page 56
4.4.7.2 Accessing Rigging Mode page 57
4.4.7.3 Bypass page 57
4.4.7.4 A2B Condition Override (Bypass) page 58

4.5 Bridging page 58
4.5.1 Bridging Device page 58
4.5.1.1 Bridging Interface page 59
4.5.1.2 Bridging and Range Limiting Interface page 60
4.6 Operational Limits page 61

4.6.1 Accessing the Operational Limits Setting Mode page 62
4.6.2 Limit Value Adjustments page 63
4.6.3 Enable/ Disable a Limit page 64
4.7 Range Limiting Options page 65

4.7.1 Accessing Range Limiting Mode page 67
4.7.2 Height Limit page 68
4.7.3 Free Zone page 69
4.7.4 Variable Height Limit page 70
4.7.5 Variable Radius Limit page 72
55M4500EBE00E RevB
TABLE OF CONTENTS
5-DIAGNOSTIC & TROUBLESHOOTING page 75

5.1 Diagnostic Menu page 75
5.2 Angle Sensor page 77
5.3 Load Sensor page 77
5.4 Relays page 79
5.5 Slew Sensors (Range Limiting Options) page 80
5.6 Detected Addresses page 80
5.7 Error Messages page 81
5.7.1
Internal Peripherals page 81
5.7.2
External Peripherals page 83
5.7.2.1 Angle, length and A2B Interface Errors page 83
5.7.2.2 Load Interface Errors page 84
5.7.2.3 Relay and Digital Input Interface Errors page 84
5.7.2.4 Generic Interface Errors page 85
5.7.2.5 Rotation Interface Errors page 86
6- INSPECTION AND MAINTENANCE page 87

6.1 Performance Check page 87
6.2 Maintenance page 89
6.3 Maintenance Procedure page 90
6.4 Adjustments and Repairs page 91

55M4500EBE00E RevB
-1-
General Description of the System
1.1 Introduction
This manual contains Operation, Troubleshooting and Maintenance information
for the i4500 system. When using the i4500 system, always observe the safety rules
and regulations applicable in the country where you operate the crane to reduce
the risk of injury or damage to the equipment. Each safety instruction throughout
this manual must be taken into consideration when using the i4500 system. The
information contained in this manual will enable qualified personnel to properly
operate the system and do the maintenance efficiently.
1.2 Qualifications
The i4500 system shall be only operated by personnel who have no limitations in
the physical abilities of the upper limbs and no visual or hearing impairment. The
personnel must have completed all operator trainee qualification requirements
and have read and fully understood the instructions in this manual. Operator
requirements include: demonstrating the ability to read, write and use arithmetic.
He must also be able to read and understand the load / capacity charts in the
language used in the crane manufacturer’s operating instruction materials.
Maintenance of the system is intended only for fully qualified and trained personnel..
1.3 Intended Use

The i4500 system is intended to provide a valuable aid to the crane operator by
indicating all relevant parameters typically shown on the duty chart of the crane.
The i4500 system shall prevent the crane from supporting a load outside the
loads shown and described on the rated capacity chart when set, calibrated and
operated correctly.

55M4500EBE00E RevB
1.4 Brief Description of the i4500 System
The i4500 “Rated Capacity Indicator” is a computerized crane monitoring system

designed to help the operator to safely operate the crane and to respect the
maximum load authorized by the crane manufacturer.
The indicator automatically monitors the load lifted by the crane and constantly
compares it with the maximum load allowed for each position.
The display of the system allows the operator to see continuous information related
to the actual load lifted by the crane. It also warns the operator when he approaches
the limit or goes over the capacity of the crane.
The system has sensors installed on the machine in order to measure or verify:
-The boom angle

-The hook load
-The two-block condition (A2B)
The system takes this information to check overload conditions and to measure
the operating radius and the crane capacity. A slew sensor (optional) can also be
installed to measure the boom position (on 360 degrees) and give extra information
to the operator. The display is located inside the operator’s cab to provide an easy
access to the information. All the sensors are linked through a CAN bus network
(Controlled Area Network).
The actual load is expressed as a percentage of the permitted load (maximum load
or safe working load - % SWL). If this percentage exceeds a preset value, alarms
and safety functions are activated. The required crane duty charts are stored in
a non-volatile memory and can only be modified with the approval of the crane
manufacturer. The calculated crane parameters and calibration data are stored in
an additional non-volatile memory.

55M4500EBE00E RevB
1.4.1 Audible Alarm
An intermittent buzzer located in the i4500 system display warns the

crane operator to take specific course of actions at the approach of the
rated capacity. The threshold of the approach alarm has been fixed at
95% of the rated capacity. The buzzer will sound in a continuous way when the
rated capacity is reached or exceeded (≥ 100%). Personnel in the danger zone are
warned by an external buzzer so that they can get out danger when the rated
capacity limiter is activated or overridden.
The crane operator will also be warned by the audible alarm when an operational
limit is activated and reached.
If you are wearing ear protection safety devices

or music earphones during crane operations, make
sure that they will not impair your ability to hear
the audible warning signals of the i4500 system.
1.4.2 Visual Alarms
The display of the i4500 system has been equipped with up to 3 warning lights to
warn the operator and signal for a specific course of action.
A yellow light will blink along with the audible alarm when the load reaches the
threshold point of the approach alarm (at 95% of the rated capacity).
A red light will illuminate when the rated capacity has been reached or exceeded.
WARNING
LIGHT
GREEN YELLOW RED

55M4500EBE00E RevB
1.4.2 Visual Alarms (cont’d)
External visual alarms are also provided with the external audible alarm to
warn the personnel in the danger zone so that they can be aware of the danger
when the rated capacity limiter is activated or overridden. Note that depending
on system configuration, your system may be equipped with one or with
three external lights. See tables 1 and 2 for external visual alarm operation.

I4500 system with three warning lights
Internal alarms External alarms
Green Yellow Red External

Event
Light Light Light Buzzer
No event Off Off Off Off On Off Off Off

Approach
to SWL Blinking Off Off Intermittent Off On Off Off
(Alarm 1)
Overload
On On Off Continuous Off Off On On
(Alarm 2)
Motion Cut
On On On Continuous Off Off On On
(Alarm 3)
Duty not
On On On Continuous Off Off On On
calibrated
Bypass
On On Off Continuous Off On On On
Overload
Bypass
Off Off Off Off Off On On On
A2B
Bridging Switch
Off Off Off Off Off On Off Off
Activated
A2B
Off Off On Continuous Off Off On On
(Normal Mode)
A2B
X X X Continuous Off On On On
(Calibration mode)
A2B
Off Off Off Off Off On On On
(Rigging Mode)
Calibration mode X X X Off Off On Off Off
Approach
Off Off Off Intermittent Off On Off Off
(Range Limiting)
Limit reached
Off Off Off Continuous Off Off On On
(Range limiting)
Rigging Mode Off Off Off Off Off On Off Off
Table 1

55M4500EBE00E RevB
1.4.2 Visual Alarms (cont’d)
I4500 system with 1 external warning light
Internal Alarms External Alarms
Red External
Event
Light Buzzer
No event Off Off Off Off Off Off

Approach
to SWL Blinking Off Off Intermittent Off Off
(Alarm 1)
Overload
On On Off Continuous On On
(Alarm 2)
Motion Cut
On On On Continuous On On
(Alarme 3)
Duty
On On On Continuous On On
Not calibrated
Bypass
On On Off Continuous On On
Overlaod
Bypass
Off Off Off Off On On
A2B
Bridging
Off Off Off Off Off Off
Switch
A2B
Off Off On Continuous On On
Normal Mode
A2B
X X X Continuous On On
Calibration Mode
A2B
Off Off Off Off On On
Rigging Mode
Calibration
X X X Off Off Off
Mode
Approach (Range
Off Off Off Intermittent Off Off
Limiting)
Limit reached
Off Off Off Continuous On On
(Range Limiting)
Rigging Mode Off Off Off Off Off Off
Table 2

55M4500EBE00E RevB
1.5 Location and Description of Typical Components
5
4
1
2
1) i4500 display box: It is also the central processing unit (CPU) of the
i4500 system. Its principal features are a CANBUS communication
interface and a graphical LCD screen.
2) Central I/O interface: This relay interface module is connected to

individual external I/O devices to be controlled or monitored by the i4500
system.
3) Load sensors: The load sensor is used to calculate the load on hook.
It is a dynamometer installed on the hosting rope
4) Anti-two block: the anti-two block is used make sure the block does not
hit the tip of the boom (optional).
5) Wind speed sensor: Shows wind speed value on the display (optional).

55M4500EBE00E RevB
1.6 Block Diagram of the i4500 Communication Link

Network
i4500 System
block diagram
Hydraulic
ECU
controller
CAN CAN
CAN 2.0B
SECONDARY
BUS
Optional
BORE SIDE ROD SIDE

PRESSURE PRESSURE
SENSOR SENSOR
A2B SWITCHLENGTH
i4500 Display
Angle I/O
TFT Display
CABLE REEL I/O
CAN 2 All in 1 USB INTERFACE CANbus
Integrated LOAD CELL
control unit INTERFACE
Video
IN CAN 1
Keypad CAN CAN
PRIMARY RCI CAN 2.0B

SAFETY
CRITICAL BUS
CAN CAN CAN

CANbus CANbus
INTERFACE INTERFACE
CANbus RELAY CONTROLLER
I/O I/O
I/O
Slew Sensor Anemometer
Optional
EXTERNAL
BRIDGING RLD KEY LOCKOUT VISUAL AND
KEY SWITCH SWITCH RELAY AUDIBLE
ALARM

55M4500EBE00E RevB
1.7 Technical Data
Accuracy: In accordance with SAE J159 or EN13000: 2010

Operating temperature: -20 ºC to + 70 ºC
Supply voltage: 9 to 32 VDC (maximum rating)
Display size: Available in:
4.3’’ LCD Screen
Display sealing: IP67

Memory capacity: 10,000 load/radius curves
CANbus sensors / interface: Default quantity Maximal quantity

- Load or pressure sensors 2 6
- Angle, Length sensors 1 5
- Relay output 5 32
- Digital inputs 4 16
- Provision for other sensors
Peripheral communication port RS-232

55M4500EBE00E RevB
-2-
Detailed Description of the Display Unit
2.1 Main Display (Default Screen)
DUTY NUMBER PARTS OF

LINE
WARNING
ALARMS
BOOM HOOK LOAD

LENGTH
MAX. SAFE
WORKING
M= MAIN LOAD
BOOM
A= AUX.
BOOM
PERCENTAGE
OF SAFE
WORKING LOAD
BOOM ANGLE OPERATING SLEW ANGLE* BOOM TIP

RADIUS HEIGHT
The parameter showing the boom height should be used only as a guide,
NOT as an indication that the crane would or would not pass under a
structure of which we precisely know the height.
*You can see the slew angle indicator (middle of the screen) only
when the range limiting option is installed on the machine.

55M4500EBE00E RevB
2.2 Display Box Overview
GRAPHIC INTERNAL WARNING LIGHTS

DISPLAY BUZZER (THREE COLORS)
MULTIFUNCTION BAR GRAPH MULTIFUNCTION

KEYS KEYS
FUNCTION DESCRIPTION
MULTIFUNCTION BUTTONS
Each of these buttons allows you to select and/or execute the indicated function
displayed on the screen in any given window.This way the task performed by a
given multifunction button will vary depending on the menu or window.
GRAPHIC DISPLAY
This menu driven communication interface allows access to the various menus
and options to control the i4500 unit system.
WARNING LIGHT
When operating within normal conditions the green LED warning light turns
on. The yellow warning light turns on to indicate that a set operating limit is
being approached. The red warning light turns on to warn the operator that an
abnormal condition has occurred.

55M4500EBE00E RevB
2.3 Operating Buttons Description
MODE BUTTON
Enables you to select the operation mode. Select this
button to choose one of these main operating modes:
-Limit Mode
-Diagnostic Mode
-Config. Mode
-Calibration Mode (protected by a password)
-Info Mode
-Error Mode
-Night Mode
DUTY BUTTON
Choose this button to access the menu for the
selection of the duty number. Select this button to
enable the selection of crane parameters such as the
boom length, the head type and the counterweight,
(if available).
UP BUTTON
Select this button to scroll up through menu options or to
increase adjustable values.
DOWN BUTTON
Select this button to scroll down through menu options
or to decrease adjustable values.
ESCAPE BUTTON
Select Escape button to exit a menu or any
programming window without saving any changes and
to go back to the previous screen.
Select repeatedly to return to the main screen.

55M4500EBE00E RevB
2.3 Operating Buttons Description (Cont’d)
BYPASS/RIGGING BUTTON
Select this button to enable the Rigging Mode option or
to bypass. (See section 4.4.7).
CLOSE WINDOW BUTTON

Select the close window button to close a menu window
and go to back to the main screen.
PARTS OF LINE BUTTON

Select this button to quickly access the parts of line menu
for the selection of the number of parts of line currently
in use.
SELECT BUTTON
Select this button to choose a highlighted item in any
given menu and to accept new values into the system.
ESCAPE BUTTON
It allows you to exit any programming window menu
without saving any changes and go back to the
previous screen.
INFO BUTTON
Select this button to access all the information regarding
the current crane configuration. Press it to access the
operating system’s information.
QUICK DUTY CHANGE BUTTON

Use the Quick Duty Change Button to alternatively
select whether lifting the load with the main boom or
the auxiliary jib.

55M4500EBE00E RevB
2.4 Main Modes
LIMIT MODE WITHOUT

LIMIT MODE WITH ROTATION ROTATION
OR
*optional
CONFIG. MODE
MAIN MODE
INFO MODE
ERROR MODE
DIAGNOSTIC
MODE
CALIBRATION
MODE
NIGHT MODE

55M4500EBE00E RevB
2.5 Warning Lights and Indicators Location
OVERLOAD LOCKOUT
APPROACH WARNING WARNING (RED WARNING
(YELLOW LIGHT) LIGHT) (RED LIGHT)
WARNING ALARM
ICONS
GREEN YELLOW RED

NORMAL APPROACHING OVERLOAD
LIMIT OR CONDITION
OVERLOAD OR LIMIT
REACHED
WARNING LIGHT
SYSTEM ERROR TWO-BLOCK

INDICATOR CONDITION
INDICATOR

55M4500EBE00E RevB
2.6 Warning Lights and Indicators Detailed Description
The approach warning light (yellow) turns on when the

hook load is between 90% and 99.9% of the rated capacity
(adjustable value). This comes with an audible warning
device that is fitted inside the display unit. This light will
also turn on if you are approaching within the calibrated
approaching distance (feet, meters or degrees) of a
predetermined limit set in the limits setting mode.
Operate with caution !

The crane is working near its maximum
load capacity.
The overload warning light (red) turns on at or above 100%

(adjustable value) of the rated capacity. This light will also
turn on if you are reaching a predetermined limit (set in
the limits setting menu).
The crane maximum capacity has

been reached or exceeded.
The lockout warning light (red) turns on at or above 100.1%

(adjustable value) of the rated capacity. Booming down
and hoisting up functions are usually blocked. The exact
operation is specific to the crane model.
The crane has exceeded safe operational

ratings and is now in an unsafe condition.
Hoisting up and booming down functions
will be stopped if a motion cut solenoid is
connected to the system.

55M4500EBE00E RevB

(cont’d)
The rope limit indicator appears on the i4500 screen to

indicate that the maximum load is limited by the rated
strength and the number of parts of line of the hoist
rope. Increase the number of parts of line between the
sheave on the boom tip and the block and change the
number of parts of line on the i4500 system to make
this indicator disappear and to reduce a rope limit.
The Two-Block condition indicator appears on the

i4500 display when such a condition is detected by
the system. This may block the hoist function and the
booming down depending on crane model and/or on the
options fitted on the machine.
HEIGHT One of these indicators (or many of them)

appear in the top-left corner of the i4500
screen when at least one operational limit is
active on the system. This is not a warning!
It is just there to remind you that an angle,
radius or height limit has been set in the limits
setting mode.
ANGLE RADIUS
If you are approaching a predetermined maximum or

minimum angle limit, one these indicators will appear
on the screen, the yellow approach warning light will
blink and the internal buzzer will sound on and off.
ANGLE ANGLE
MIN. MAX.
If you have reached a predetermined maximum or

minimum angle limit, one these indicators will appear
on the screen, the red overload warning red light will
be activated and the buzzer will sound continuously.
ANGLE ANGLE
MIN. MAX.

55M4500EBE00E RevB

(cont’d)
If you are approaching a predetermined maximum height limit, this

indicator will appear on the screen, the yellow approach warning
light will blink and the internal buzzer will sound on and off.
If you have reached a predetermined maximum height limit, this

indicator will appear on the screen, the red overload warning light
will turn on and the buzzer will sound continuously.
If you are approaching a predetermined maximum radius limit, this

indicator will appear on the screen, the yellow approach warning
light will blink and the internal buzzer will sound on and off.
If you have reached a predetermined maximum radius limit, this

indicator will appear on the screen, the overload warning light will
turn on and the buzzer will sound continuously.
The zones where the system will warn the operator that a preset limit is being
approached can be changed as required. These values are defined during the
tests performed by the technician during the calibration of the system.
Limits values are not active when the electric power is first applied to the i4500
and they are automatically disabled if electric power is removed.
Reaching an operator’s preset limit (set in the Limits Setting Mode) will not
result in crane lockout.

55M4500EBE00E RevB
-3-
Installation and Calibration
Installation of the i4500 system shall be done by a qualified technician. Furthermore,

calibration of the i4500 system must be done by a RaycoWylie certified technician.
The RaycoWylie technician will do a complete and structured verification of the
whole system before beginning the calibration of the system.
Failure to properly calibrate the system can result in overloading the crane.
This can cause machine breakage or tipping that could result in serious
injury or death. Always refer to a RaycoWylie certified technician to
calibrate your system.
Installation and calibration manuals are available upon

request at RaycoWylie. Please note that the installation and
calibration instructions have intentionally not been included
in this instruction manual.
-4-
Operating Instructions
4.1 Safety Instructions

When operating the i4500 system, always respect the safety rules and
regulations applicable in the country where you operate the crane to reduce
the risk of injury or damage to the equipment. Read the following safety
instructions before attempting to operate this system.
1. The i4500 Rated Capacity Indicator must be properly set up according to

the working site and to the configuration of the crane. A wrong set-up can
cause the i4500 indicator system to show unreliable information which
may cause hazardous conditions such as an overload.
2. The i4500 system is only an aid to the operator. Responsibility for the
safe operation of the crane lies with the crane operator. The i4500 system
will not necessarily prevent crane damage due to overloading and/or other
related causes.
55M4500EBE00E RevB
4.1 Safety Instructions (Cont’d)
3. Proper functioning of the equipment depends upon proper daily

inspection and conformity to the operating instructions described in
this manual.
4. During normal operation, the rated capacity of a crane should not

be exceeded. The overload indication should not be used as a normal
operating feature.
5. The crane should always be operated smoothly and at a safe speed.
6. In order to have a proper rated capacity and radius, the system must be
properly configured. Failure to properly configure the system can result in
machine breakage or tipping which could lead to serious injury or death.
7. The operator must verify the crane configurations and number of parts of
line for each available hoist every time he/she enters the crane and every
time the crane is rigged.
Note: Each hoist has its own configuration set-up kept in memory and the
configuration and number of parts of line will change simply by changing
the hoist from main to auxiliary.
Improper configuration of the i4500 system may also cause a

‘‘Zero Capacity’’ if no chart is found to match the configuration set
by the operator.
4.2 Residual Risks
In spite of the application of all relevant safety regulations and the imple-
mentation of safety devices, certain residual risks cannot be avoided:
• Risks caused by no indication of malfunction of the output relays avoiding

lockout to operate in overload conditions, causing machine breakage or tipping
that could result in injury or death.

55M4500EBE00E RevB
4.2 Residual Risks (Cont’d)

• The system gives no indication if there are power lines in the crane working
area, causing the risk of operating the crane near power lines that could
result in injury or death.
• The system gives no indication whether the outriggers have been fully extended.
It can cause machine breakage or tipping that could result in injury or death.
• The system gives no indication of the crane level. It can cause

machine breakage or tipping that could result in injury or death.
• The system gives no indication of poor ground stability. It can cause machine
breakage or tipping that could result in injury or death.
4.3 Power On
When the i4500 system is powered on, it performs a self-test during which it
verifies with the installed sensors the communication on the CAN bus network. It
loads in its user memory all the informations stored in its read-only memory. The
RaycoWylie logo is shown on the screen. When the test is over and the random
access memory is loaded, the red warning light turns on and the controls of the
cranes are blocked if there is an electrical or hydraulical lockout. The i4500 system
then shows the duty selection menu.
The crane operator must confirm that the duty given by the system is the one he
really wants to use or he must choose another one among the duties shown. Once
his choice is made, he must press the Select button and the system goes to the
normal operating mode.

55M4500EBE00E RevB
4.4 System Configuration
4.4.1 Duty Selection
Carefully read and understand these instructions before selecting a duty

number. Selecting the wrong duty number can result in overloading of the
crane risking machine breakage or tipping that could result in serious injury
or death. Never select a duty number if you have any doubts, instead seek
the advice of a qualified technician. Make sure that the duty number displayed
in the normal mode screen matches the current configuration of the machine.
Use the Duty button to select all the crane configuration details such
as the length of the main boom, the length of the jib, the counterweight,
the outriggers-/crawlers/tires, the hoists etc. Afterwards this duty is
associated to a corresponding duty number by the system.
If you need assistance, contact RaycoWylie with the technical file number of
your system.
The current duty number associated by the i4500 system figures in the upper left
corner of the display screen by default and additional configuration information
can be seen by pressing the Info button (see fig.1)
Duty Number
Duty
Button
Info
Button
Figure 1

55M4500EBE00E RevB
4.4.1 Duty Selection (Cont’d)
We need to provide the i4500 system with the proper information by answer-
ing a series of questions in order to choose the proper duty that matches your
crane configuration.
1. Select the Duty button.
2. Answer each question by selecting the right

information and press the Select (Enter)
button to accept new values into the system and
go to the next question.
4.4.2 Working with Main Boom Only (1 or 2 Hoists)
1. Select the Duty button.
2. Use the Up or Down buttons to select the length

or of the main boom among the choices on the list.
3. Choose the Select button to accept new value

or into the system or press the Escape button to
return to the main operating screen.

55M4500EBE00E RevB
4.4.2 Working with the Main Boom, 1 ou 2 Hoists (Cont’d)
4. Use the Up or Down buttons to select the main

or
boom among the choices on the list.
5. Press the Select button to confirm your choice

or or press the Escape button to go back to the
previous screen.
This menu only appears if

the system was set up with
two hoists. Go to the next
menu if your machine has
only one hoist.
6. Now select the hoist. H1 = Hoist 1 (main) or

or
H2 = Hoist 2 (auxiliairy). Use the Up or Down
buttons to select the right value among the choices
on the list.
7. Press the Select button to confirm your choice,

or
accept new value in the system and go to the next
parameter or press on the Escape button to go
back to the previous screen.

55M4500EBE00E RevB
8. Now enter the number of parts of line for the main

or
block. Use the Up or Down button to enter the
value of the first digit.
9. Use the Select button to underline the second

digit.
10. Use the Up or Down button to select the

or required value.
11. Use the Select button to enter the new value

or or press on the Escape button to go back to the
previous screen.
If there is only one choice

on this list, this menu
will not appear and the
system will go on to the
next menu.
12. Use the Up or Down buttons to select the position

or
of the outriggers among the list.

55M4500EBE00E RevB
13. Press the Select button to accept the new value

or in the system or press on the Escape button to
go back to the previous screen.
Once the duty selection is over, the i4500 automatically returns to the main screen
(normal operating mode). You can use the «Info» button to see at a glance the
configuration of the crane.
You might have to answer extra questions according to

your crane and its load chart, or for example if you have a
counterweight that you need to configure. Keep answering
the questions until you see the main screen.
Figure 2a
Info button

55M4500EBE00E RevB
4.4.3 Working with Jib, One Hoist
The menus in the sections

4.4.3 and 4.4.4 will not be
available if your crane has
no jib.
1.Press the Select button..
2. Use the Up or Down button to select the main

or boom length from the list.

main screen.
4. Use the Up or Down button to select the jib

or
configuration from the list.

main screen.

55M4500EBE00E RevB
4.4.3 Working with Jib, One Hoist (Cont’d)
6. Specify that you want to use the jib to lift the

or
load. Use the Up or Down button to highlight
the configuration of the jib you chose at point 4.
7. Press the Select button to accept new value in

or
the system and to go to the next parameter or
press the Escape button to go back to the main
screen.
This menu will not

appear if your crane
has only one hoist.
8. Press the X button to answer “NO” to the following

question: Is a block rigged on the main boom ?

55M4500EBE00E RevB
This menu will not

appear if your crane
has only one hoist.
9. You now have to select the hoist currently in use.

or
H1= Hoist 1 (Main) or H2= Hoist 2 (auxiliary)
Use the Up or Down button to select the right
value (usually H2 for the jib) from the list.
10. Press the Select button to accept this new value

or in the system or press the Escape button to go
back to the main screen
11. Now enter the number of parts of line used

or
between the jib block and the head sheave. Use the
Up or Down button to enter the first digit.
12. Press the Select button to highlight the

second digit.

55M4500EBE00E RevB
13. Use the Up or Down button to select the desired

or value.
14. Press the Select button to accept this new value in

or the system or press the Escape button to go back
to the main screen.
This menu will not appear

and the system will go on
to the next menu if there
is only one choice on this
list.
15.Use the Up or Down button to select the outriggers

or
position from the list.
16. Press the Select button to accept this new value

or in the system or press the Escape button to go
back to the main screen.
Once the selection of the configuration is over, the system automatically goes back
to the main screen (normal operating mode). You can use the Info button to see at
a glance the configuration of the crane.
You may have to answer extra

questions according to your
crane and its load chart, or
for example if you have a counter-
weight that you need to configure.
Keep answering the questions until you
see the main screen.
Figure 2b

55M4500EBE00E RevB
4.4.4 Working with the Main Boom or Jib
This configuration is
only possible if the
crane is equipped with
two hoists
1. Press the Select button.
2. Use the Up or Down button to select the main

or boom length from the list..

main screen.
4. Use the Up or Down button to select the jib

or
configuration from the list.

main screen.

55M4500EBE00E RevB
4.4.4 Working with the Main Boom or Jib (Cont’d)
6. Specify if you want to use the jib or the main

or
boom to lift the load. Use the Up or Down
button to highlight the configuration needed to
lift the load.
7. Press the Select button to enter the new value

or
in the system and to go to the next parameter
or press the Escape button to go to the
previous screen.
8. Press the Select button (the check mark) to

answer “YES” to the following question: Is there
a block rigged on the main boom ? This question
will appear on the screen if you have decided to
lift the load with the jib at step # 6. If you have
decided to lift the load with the main boom, the
following question will appear: Is there a block on
the attachment? You need to answer “YES” in
both cases.
55M4500EBE00E RevB
According to your choice

at step # 6, the system will
either start by the main
hoist or by the auxiliary
hoist.
9. You now have to select the hoist used on the jib

or
(usually H2) from the list. Use the Up or Down
button to select the good value among the choices
on the list.
10. Press Select button to accept the new value in

or the system or press the Escape button to go back
to the previous screen.
11.Now enter the number of parts of line used

or
between the block of the jib and the head sheave.
Use the Up or Down button to enter the first digit.
12. Press the Select button to highlight the

second digit.

55M4500EBE00E RevB

or
value.

previous screen.
15. You now have to select the hoist used on the main
or
boom (usually H1). Use the Up or Down button to
select the right value from the list.
16. Press Select button to accept the new value in the

or
system and go to the next parameter or press the
Escape button to return to the previous screen
17. Now enter the number of parts of line for the main
or block. Use the Up or Down button to enter the
first digit.

55M4500EBE00E RevB
18. Press the Select button to highlight the second

digit.

or value.
20. Press the Select button to accept the new value or

or press the Escape button to go back to the previous
screen.
If there in only one choice

on this list, this menu
will not appear and the
system will go on to the
next menu.
21. Use the Up or Down button to select the outriggers

or
position from the list.

or in the system or press the Escape button to
return to the previous screen
Once the selection of the configuration is over, the system automatically goes back
to the main screen (normal operating mode). You can use the Info button to see at
a glance the configuration of the crane.
You might have to answer extra questions according to

your crane and its load chart, or for example if you have a
counterweight that you need to configure. Keep answering
the questions until you see the main screen.

55M4500EBE00E RevB
Press this button to choose to

whether lift the load with the main
boom or with the jib.
Quick Duty Change Button

55M4500EBE00E RevB
4.4.5 System Configuration Information Screen
Simply pressing the Info button is a convenient way to verify the current
configuration of your crane. You can check at a glance the settings for many
parameters such as the outriggers state, the boom selection, the jib selection etc.
If all the data under the chart info screen is correct and if you had previously set
the correct hoist and parts of line number, then your system should be configured
correctly. You can also access the info mode by pressing the Mode button
(see steps below).
Press the Info button to display the current crane

configuration.
Press the Escape button to return to the main screen.
Or
1) Select the Mode button.
2) Use the Up / Down buttons to highlight Info Mode
3) Press the Select button to confirm your choice and

enter the info menu screen.
Chart Info Screen

55M4500EBE00E RevB
4.4.5 System Configuration Information Screen (Cont’d)
Once your system is properly configured, the

i4500 Rated Capacity Indicator is ready to use.
The info screen is different for each crane model. The representation shown
in this manual may not be identical to the chart info screen shown on
your system.
4.4.6 System Setup Configuration Mode
Choose the
Configuration.
Mode
(Config. Mode)
Config. Mode Selection Menu
Various display parameters can be configured by the operator. These

parameters are grouped in the system config. mode menu and they include:
1- Unit selection
2- Set tare
3- Language
4- Date and time
5- Backlight

55M4500EBE00E RevB
4.4.6 System Setup Configuration Mode (Cont’d)
Repeat these steps to modify any of the system setup options. You must
first access the system’s configuration mode:
1) Press the Mode button.
2) Scroll down with the Down button to highlight the

config. mode line
3) Press the Select button to confirm your choice and

access the config. mode menu.
4.4.6.1 Unit Selection
It is possible to choose among 6 measurement units combinations.

Each length and load measure will be displayed on the main display
To set the units proceed as follow:
1. Repeat steps 1 to 3 of the system setup configuration mode section

(see above, section 4.4.6)
2. Select the line “Units”.
3. Use the Up or Down button to highlight the desired unit

combination
4. Press the Select button to select the desired unit combination.

55M4500EBE00E RevB
4.4.6.2 Language Selection
The text on the i4500 can be displayed in many languages. The languages
available can vary depending on the software version.
To set the language, proceed as follows:
1. Repeat steps 1 to 3 of the system setup configuration mode section (see

section 4.4.6 on page 51)
2. Select the Language menu
3. Use the Up or Down buttons to highlight the desired language.
4. Press the Select button to confirm your choice.
4.4.6.3 Date and time setting
This sub menu allows you to adjust the date and time in the system. This is an
important step for the data recorder.

55M4500EBE00E RevB
4.4.6.3 Date and time setting (cont’d)
To set the date and the time, proceed as follows:
1. Repeat steps 1 to 3 of the system configuration section

(see section 4.4.6 on page 51).
2. Select the Date and Time menu.
4. The adjust clock window should appear on the screen.
Month
Day
Year
Scroll up or down with the Up or Down buttons to select
the desired month value.
5. Press the Select button to accept this new value into the system.
6. Repeat procedure to adjust the day and the year. Press the Select button to
confirm your choice.
7. To adjust the clock, scroll up or down with the Up or Down buttons to select
the desired hour value. Repeat procedure to enter the minutes.
8. Choose the Select button to save changes and go back to main menu.
4.4.6.4 Night / Day light mode
This menu allows access to the screen brightness pre-sets. Select a setting that
matches prevailing lighting conditions. Please note that the screen brightness
level for the night mode is set in the backlight menu (see backlight mode on the
following page).

55M4500EBE00E RevB
4.4.6.4 Night / Day light mode (cont’d)
To set the backlight mode, proceed as follow:
1. Press the Mode button..
2. Scroll down with the Down button to highlight the Night or Day mode
3. Press the Select button to change the backlight mode (to switch from day light
mode to night light mode or vice versa ).
4.4.6.5 Backlight Mode
You can modify the screen brightness levels (of the night mode) to help you read
the screen under various lighting conditions.
To adjust the display brightness, proceed as follow:
1. Repeat steps from 1 to 3 of the system setup option section (see section 4.4.6
on page 51 of this manual)
2. Select the backlight menu.
3. The «night level» window should appear on the screen. The «day» level is at
100 % (maximum brightness). For the «night» level, a 30 % to 60 % backlight
is suggested.
4. Use the Up or Down buttons to select the hundreds. Press the Select button.
5. Repeat the procedure to set the other digits.

55M4500EBE00E RevB
4.4.6.6 Set and Remove Tare Mode
Select the Tare Mode option to display the actual load on hook during a lifting
operation This mode is used to remove the weight of the block, hook and hoisting
rope. This way it only shows on the screen the weight of the lifted load.
To set the tare mode, proceed as follow:
1. Press the Mode button.
2. Scroll down with the Down button to highlight the config. mode
line.
3. Press the Select button to enter menu.
4. Scroll down with the Down button to highlight the Set Tare line.
5. Press the Select button to enable the Tare feature.
6. Repeat these steps to remove tare and to go back to normal mode.
The tare indicator appears on

the screen when some weight
have been removed on the load
displayed.

55M4500EBE00E RevB
4.4.7 Bypass/Rigging
Warning! When in rigging mode, the motion cut and

overload alarms are disabled. In this condition, the crane
is not fully protected by the i4500, therefore it’s absolutely
essential to follow the crane manufacturer’s advice
regarding lifting the block, the rotation or the use of the
outriggers.
The Bypass/Rigging button is used to access the Rigging Mode,

to override an Overload Condition or to override an A2B
condition. In the case of an emergency the operator can override
the system (lockout) by pressing the Bypass / Rigging button.
The Bypass/Rigging button must be released and pushed again
after 10 seconds.
4.4.7.1 Rigging Mode (Maintenance / Erection Mode)
It is often necessary to go outside the “safety zone”for which the crane manufacturer
provides ratings when stowing or erecting the machine For example, the boom
stowed position may be outside the maximum load radius or minimum boom angle
specified on any load chart.
For this reason, the i4500 provides a Maintenance/ Erection mode where the
boom may be lowered to the horizontal position without having the external alarm
continuously sounding or the motion cut operating.
It is important to note the following points when the rigging mode is

activated:
• There are no lockouts
• The A2B switch is still monitored but will not active the lockout system.
• No audible alarms.
• The yellow light is on.
• The speed of the movements is not limited .
• A flashing rigging message is shown on the display.
• The rigging mode can only be accessed when the SWL is zero..

55M4500EBE00E RevB
4.4.7.2 Accessing Rigging Mode
When the boom is positioned outside the maximum radius of operation or under the
minimum angle specified in the capacity load charts, the capacity drops to zero.(0).
At this point when pressing

the Bypass/Rigging button
the system automatically
enters in rigging mode and an
override message flashes on the
system display.
The rigging mode is automatically exited when the SWL is greater than
zero (0) or the system is powered off.
4.4.7.3 Override lockout system (Bypass)
When overriding the motion cut during

an overload condition, the speeds of the
movements are limited to 15% (25%
on some machines) of the permissible
working speed for the corresponding
load case. The external alarm and the
external yellow and red warning lights
are activated. Also, the override message
flashes on the display.
The overload condition can be overridden when:
• The load is above 100% SWL and

• The load is below 110% SWL and
• A valid duty is selected and the capacity is greater than 0; and
• There are no faulty sensors.
The override is automatically cancelled when:
• The load exceeds 110% SWL or • There is a faulty sensor; or

• The load is below 100% SWL or • At engine stop or
• The bypass button is pressed a second • An A2B condition occurs or
time or • The RCI/LMI resets.
• The control levers are in neutral position
for more than 10s. or

55M4500EBE00E RevB
4.4.7.4 A2B Condition Override (Bypass)
An A2B condition can be overridden when:
• The system is in rigging mode and

• There is an A2B condition (A2B)
• The A2B override is automatically cancelled when:
• - The bypass button is released; or

• - The A2B condition is cleared; or
• - The Rigging mode is exited.
4.5 Bridging
4.5.1 Bridging device
When the bridging device is activated the crane is no longer protected by

the i4500 system. Therefore, it is absolutely essential to obey the crane
manufacturer’s advice regarding crane operations.
A bridging device is an embedded electronic mechanism designed to be used in

case of system component failure or in case of emergency. This safety feature can
be accessed through a two-position momentary key switch. A Reset Button and a
Status Led are also provided. (See fig. on section 4.4.8 on page 51).
A bridging device may be provided if it’s located outside of the crane operator’s cab
and it’s under lock and key and it resets automatically at engine stop not later than
30 min.
Upon activation of the bridging device, the speed of all movements increasing the
loading condition is fixed at 15% max (25% in some machines) of the permissible
working speed for the corresponding load case.
Furthermore, when the bridging device is enabled, the external alarm and the
external warning red light are activated. An override message flashes on the
system display.

55M4500EBE00E RevB
4.5.1 Bridging device (cont’d)
The bridging is activated when:
• The momentary switch is turned to the “Indicator override” position.
The bridging is cancelled when:
• The reset button is pressed or

• The engine stops or
• The bridging is active for more than 30 min.
This added safety feature is available as an option.
4.5.1.1 Bridging interface
The Bridging interface is a device designed to activate the bridging feature.
OVERRIDE
KEY SWITCH
RESET
BUTTON
Bridging Interface
55M4500EBE00E RevB
4.5.1.2 Bridging and Range Limiting Interface
If your i4500 system has the Range Limiting option, the bridging device is
included in the Range limiting interface. The left section of the front panel
is dedicated for the bridging device and the right section is dedicated for the
range limiting option. See section 4.7 of this manual for the Range Limiting
Option.
RESET OVERRIDE RANGE LIMITING

KEY SWITCH KEY SWITCH
(OPTION)
Bridging and Range Limiting Interface

55M4500EBE00E RevB
4.6 Operational Limits
Carefully read and understand these instructions before setting the

operational limits. Setting the wrong operational limits can result in
accidentally running into obstacles which could lead to serious injury
or death.
In the operational limits setting mode, the operator can set and activate/
deactivate the following four (4) operational limits in addition to those
automatically provided by the i4500 system.
Here are the limits
1) The minimum boom angle limit
2) The maximum boom angle limit
3) The maximum boom tip height limit
4) The maximum operating radius limit.
Important: Please note that if your machine is

equipped with the range limiting option, the
operational limits setting mode will not be available
for selection (refer to section 4.6 of this manual for
more details on the range limiting device).

55M4500EBE00E RevB
4.6.1 Accessing the Operational Limits Setting Mode
2. The line «Limit Mode» should be highlighted by default.

ou If it is not the case, use the Up or Down buttons to
highlight this line.
3. Choose the Select button to confirm your choice and

access the operational limits mode.
Limit setting menu

55M4500EBE00E RevB
4.6.2 Limit Value Adjustment
1. Repeat steps 1 to 3 in the accessing the operational

limits setting mode section (see section 4.5.1 on page 59).
or 2. Use the Up and Down buttons to highlight the limit

setting you want to edit.
3. Press Select button to confirm your choice. The cursor

will automatically go to the next column.
or 4. Press the Up and Down buttons to select the desired

value for this particular limit.
5. Press Select button to confirm the selected value.
6. Press Escape button to return to the norma

operating mode.

55M4500EBE00E RevB
4.6.3 Enable / Disable a limit
Limit status
On/Off
1. Repeat steps 1 to 3 in the accessing the operational

limits setting mode section (see section 4.5.1 on page
59).
2. Press many times the Down button until the first

line of the limit state column (column On/Off) is
highlighted (see picture at the bottom of the page).
or 3. Use the Up or Down buttons to highlight the current

state (ON or OFF) of the limit you want to activate or
desactivate.
4. Press Select button to toggle between the ON and OFF
state of this limit.
5. Press the Escape button to return to the normal

operating mode.
Maximum angle limit enabled Maximum angle limit disabled
When the value of a given operational limit is changed (see section 4.5.2), the
modified limit is automatically activated.

55M4500EBE00E RevB
4.7 Range Limiting Option
Carefully read and understand these instructions before

setting an operational range limit. Setting the wrong
operational range limit can result in accidentally running
into obstacles which could lead to serious injury or death.
Crane travel is prohibited when range limiting is activated.
The limits must be reprogrammed everytime the crane

is moved
RaycoWylie recognizes that operating cranes near power

lines or equipment is an extremely hazardous practice
that requires extra precautions. To avoid the risk of
being electrocuted, it is therefore essential to operate
the crane outside the minimum clearances allowed in such
a way that there is no possibility of the crane, load line
or load becoming a conductive path to electricity. The
crane shall not be used to handle material stored under
electrical power lines unless any combination of boom, load,
load line, or machine cannot enter the prohibited zone.
The range limiting option provided by the i4500 system
shall not be used to delimit the prohibited zone. Refer
to federal, state, local safety standards and regulations
applicable in your country regarding operating cranes
near power lines.

55M4500EBE00E RevB
4.7 Range Limiting Option (Cont’d)
Shows which zone is programmed
Height Limit
Free Zone (two walls)
Varialbe height limit
Variable radius limit

A red icon indicates
that a limit has
been reached.
Menu options :
When there is a range limiting option and a slew sensor installed on the crane,
the i4500 automatically selects the range limiting mode as the only possible
choice. In this case, the following “limit mode” menu options are offered:
• Height limit
• Free zone
• Variable height limit
• Variable radius limit

55M4500EBE00E RevB
4.7.1 Accessing Range Limiting Mode
2. The «Limit Mode» line should be highlighted by default.
If it’s not the case, use the Up or Down button to
highlight the line.

or
3. Press the Select button to confirm your choice and to
access the range limiting mode.
Range Limiting Mode Screen

55M4500EBE00E RevB
4.7.2 Height Limit
The height limit is a limit on the

maximum height of the tip of the boom
or jib. We can also say that it is a height
limit with a 360° degrees fixed height .
1. Repeat steps 1 to 3 in the accessing

range limiting mode section (see
section 4.6.1 on p. 64).
2. The line «Height limit» is

highlighted by default. If it is not
the case, use the Up or Down
buttons to highlight it.
3. Press the Select button to confirm

your choice.
4. Boom up to the desired boom tip height limit.
5. Press Select button to confirm the maximum height of the boom tip. As you
release Select button, a 10-second countdown will allow you to boom down
before your programmed height limit becomes active.
Height limit
programmed
Height limit
reached

55M4500EBE00E RevB
4.7.3 Free Zone

VIEW FROM TOP
The free zone is a zone without First wall
height limits. It is limited by side
walls. The boom can’t go beyond
these walls.
1. Repeat steps 1 to 3 in the accessing

range limiting mode section (see
section 4.6.1 on p. 64)
2. Press the Down button to highlight

«Free Zone» and press the Select
button to confirm your choice.
3. Rotate the crane to the first limit position (first wall). Second wall
4. Press the Select button to confirm the position of the first wall.
5. Rotate the crane to the second limit position (second wall).
6. Press the Select button to confirm the position of the second wall.
7. As you release select button, a 10 seconds countdown will allow you to rotate
the crane between the two walls before your programmed free zone limit
becomes active.

55M4500EBE00E RevB
4.7.3 Free Zone (Cont’d)
Programmed
free zone
Right wall
reached
Left wall
reached
4.7.4 Variable Height Limit
A variable height limit is a height limit

which varies according to the boom
position on rotation (variable height
limit). According to the obstacle, we
can need a limit at a certain height at
a specific place and at another height
somewhere else.
1. Repeat steps 1 to 3 in the accessing range limiting mode section (see section
4.6.1 on p. 64).
2. Press the Down button to highlight the variable height limit line.
4. Rotate the crane towards the first limit position (first wall).
5. Press Select button to confirm the position of the first wall.

55M4500EBE00E RevB
4.7.4 Variable height limit (cont’d)
6. Rotate the crane towards the second limit position (second wall) with the boom
tip always at the maximum height permitted by the surrounding environment.
7. Press Select button to confirm the position of the second wall.
8. As you release Select button, a 10-second countdown will allow you to return
between the two walls and boom down below the height limit before your pro-
grammed variable height limit becomes active.
Variable
height limit
programmed
Right wall
reached
Left wall
reached
Height limit
reached

55M4500EBE00E RevB
4.7.5 Variable Radius Limit
A variable radius limit is a radius

limit which varies according to
the boom position on rotation.
Acroding to the obstacle, we can
need a radius limit at a specific
place and another radius limit
somewhere else.
1. Repeat steps 1 to 3 in the accessing range limiting mode section (see section
4.6.1 on p. 64).
2. Use the Down button to highlight the variable radius limit line
3. Press Select button to confirm your choice.
4. Rotate the crane to the first limit position (first wall).

5. Press Select button to confirm that this will be the position of the first wall..
6. Rotate the crane towards the second limit position (second wall) with the
boom always at the maximum radius permitted by the surrounding environ-
ment. Note that you can change the maximum radius during this operation.

55M4500EBE00E RevB
4.7.5 Variable Radius Limit (Cont’d)
7. Press the Select button to confirm the position of this second wall
8. As you release the Select button, a 10 seconds countdown will allow you to
return between the two walls and boom up below the allowed radius limit
before your programmed variable radius limit becomes active.
Variable
radius limit
programmed
Right wall
reached
Left wall
reached
Radius limit
reached

55M4500EBE00E RevB
-5-
Diagnostic & Troubleshooting
Warning! Troubleshooting shall be performed by a qualified

technician or by an operator assisted by a RaycoWylie
Service technician
This section provides technical troubleshooting support. It will answer the most
frequently asked questions that repair personnel may have when installing,
repairing or performing maintenance on the i4500 system.
5.1 Diagnostic Menu
A diagnostic menu provides information on the status of the system and on the
state of all connected sensors.
To access the diagnostic menu:
Press the Mode button
Use the Up or Down button to highlight the diagnostic option.

or
Press the Select button to enter the diagnostic menu.
By pressing the Select button, each line of the diagnostic menu gives access
to another page. Each page applies to one type of sensor or one particular type
of information.
Press the Escape button to return to the previous menu or to exit the
diagnostic mode

55M4500EBE00E RevB
5.1 Diagnostic Mode (cont’d)
This is the typical displayed information in the diagnostic menu:
Value State of the

transmitted connection with
by sensor sensor
Some applications have more than one angle or length sensor.
The first angle sensor displayed is the one installed closer to the main boom base.
For sensors, the second column gives the value of the parameter calculated by the
interface connected to the CanBus network and the third column gives the state of
the sensor connection to the CanBus network.
Concerning the A2B, it is its activation status that is displayed.
If the interface is not a sensor, such as the relay interface, and therefore does not
return a specific value, no value is displayed in the second column, however, the
state of connection to the CanBus network is given in the third column

55M4500EBE00E RevB
5.2 Angle Sensor
Press the Select button when «Angle 1» is highlighted to see the software
version of the angle sensor and it’s calibration state. The displayed
information will look like this:
The second line indicates the software

version of the angle/length sensor and also
its creation date.
The following values will allow the

RaycoWylie technician to diagnose a
problem coming fron the sensor.
If the angle sensor is not functioning properly, note these values and give them to
a RaycoWylie technician.
Press the Escape button to return to the main screen of the

diagnostic mode.
5.3 Load Sensor
To see the software version of the load sensor and its calibration state, press the
Select button when Load 1 is highlighted.

55M4500EBE00E RevB
5.3 Load Sensor (Cont’d)
The displayed information will look similar to this:
The basic criteria for a proper fucntionning of the load sensor are: the
scale value must be smaller than 1,0. Dr+ must be close to 5,00 volts (DC).
Press the Escape button to go back to the main screen of the

diagnostic mode.

55M4500EBE00E RevB
5.4 Relays
The information displayed for relay cards is divided into two screens. The first
screen is mainly about the state of the relays and digital outputs (Hdout).
It indicates the status of each individual relays and whether the relay coil is
energized or not. The second screen shows the state of the 16 digital inputs
(Hdin) and it indicates whether the input is active or not. Up to 4 relay cards can
be installed.
In the diagnostic menu,

press the Select button
when Relay Board 1 is
highlighted.
The system shows the first screen of the relay card diagnostic. It will look like this::
The second line indicates

the name and the software
version of the relay
interface. It also shows its
creation date.
By pressing the Down button, you get access to the Input block. The
displayed information will look like this:
Press the Escape button to go back to the main screen of the diagnostic
mode.

55M4500EBE00E RevB
5.5 Slew Sensors (Range Limiting Option)
In the diagnostic menu, press

the Select button when the
line «Rotation relative encoder»
is highlighted.
The displayed information will look similar to this:
The second line indicates the software

version of the rotation interface and it’s
creation date.
These values will allow the RaycoWylie

technician to diagnose a problem
coming from the slew sensor.
The information shown here may differ depending

on the slew sensor used.
5.6 Detected addresses
This menu of the diagnostic menu provides the addresses of the different sensors
on the CAN network detected by the i4500 system. Even if a sensor stops
communicating, addresses remain in memory as long as the system is on.

55M4500EBE00E RevB
5.7 Error messages
During start up and other operation processes, the

i4500 system analyses all interactions between internal
peripherals (memories, controllers, extension cards, etc.)
and external peripherals (various interfaces connected to
SYSTEM
the Canbus network). An error message will appear on the
ERROR
main screen if an error is detected.
INDICATOR
5.7.1 Internal Peripherals

If you have any questions or need technical assistance, please contact our technical
service department at RaycoWylie.
Error Messages Execution process Cause of error

Calibration’s data memory is When starting system, there There is a problem with
defective, or is a verification (writing/ the flash memory on the
Operator’s data memory is reading) of the whole flash engine board located in the
defective, or memory on the engine board i4500 display
Load chart data memory is Contact the technical service
defective, or department at RaycoWylie.
Data Logger memory is
defective
RAM memory is defective When starting system, there There is a problem with
is a verification (writing/ the RAM memory on the
reading) of the RAM engine board located in the
memory on the engine display
Board. Contact the technical service
department at RaycoWylie
Clock is defective The system regularly verifies 1) Verify if the battery on the
if the seconds are moving. If mother board in the display is
time does not change, then well inserted.
there is a problem 2) The clock chip is defective
on the mother board
Low battery The system detected that The lithium battery is out.
the lithium battery is low. Replace the battery on the
Because of this, the clock mother board
may stop or lose precision.

55M4500EBE00E RevB
5.7.1 Internal Peripherals (Cont’d)
Error Message Execution Process Cause of Error

•Canbus 1 is defective, or The CanBus controller There is a problem with
Canbus 2 is defective. verification the CANbus controller on the
Mother Board,
Not calibrated No calibration has been 1) Verify if the load chart

found for the selected duty. corresponding to the crane
has been calibrated.
2) Does the load chart depend
on rotation?
3) Does the load chart depend
on DIN inputs?
No 2nd duty found The load chart must be The Angle/Radius option
programmed in order to must be activated during the
compare two charts. One of compilation of the load chart
them is based on the angle
and the other one is based
on the radius. The smallest
value will be selected.
No Parameter The crane dimensions must CL3, CL4 and CL7 values
be correctly entered in the should never be at zero.
system otherwise the load
value will be non existant or
wrong.

55M4500EBE00E RevB
5.7.2 External Peripherals
5.7.2.1 Angle, Length and A2B Interface Errors

The i4500 system can support up to 5 angle interfaces. Activation of every angle
sensor is done in the calibration menu section ‘‘Enable/Disable I/O’’.

Angle sensor X is defective The angle sensor value in 1) The accelerometer or the
volts is not valid (1 volt to 4 12 bits converter is
volts). defective.
Angle x is in Pre-calibration. Indicates that angle card is in 1) In normal operation mode,

pre-calibration mode. the “Cal” jumper must be
taken out from the circuit
board.
2) Verify that the calibration
value of the
accelerometer is valid.
• Lost communication with The i4500 system has not 1) The angle interface is
angle X received data from angle defective,
interface If ‘‘time out’’ 2) The cable that links the
delay is reached, then a interface to the canbus
communication error is network is defective.
displayed.
Angle X is not calibrated Angle sensor is not calibrated.
Angle X Dr+ is defective The 5 volts reference voltage 1) The angle interfacet
is not valid (if < 4.5 volts or board is defective.
5.5 volts).

55M4500EBE00E RevB
5.7.2.2 Load Interface Errors
The i4500 system can support up to 4 load interfaces. Activation of every load
sensor is done in the calibration menu section ‘‘Enable/Disable I/O’’.

Load X is out of range The angle sensor value in bits 1)The amplifier or converter
is not valid 12 bits is broken
(if < 150 or > 3935). 2) The cable that links the
interface to the canbus
network is broken.
Load X is not calibrated Load sensor X is not calibrated
Load X Dr+ is defective The 5 volts reference voltage The load interface is broken.
is not valid (if < 4.5volts or >
5.5 volts).
Lost communication with The i4500 system has not 1) The load interface is
Load X received a valid message from defective,
the load interface on time. 2) The cable that links the
interface to the canbus net
work is broken
5.7.2.3 Relay and Digital Input Interface Errors
The i4500 system can support up to 4 interface cards and digital input.
Activation of every relay interface is done in the calibration menu section “I/O
activate/deactivate”

Lost communication with i4500 system does not receive 1) The relay interface is
Relay board X data from relay interface. If defective,
“time out” delay is reached, 2) The cable that links the
then a communication error is interface to the canbus
displayed. network is broken.
There is no automatic test for the relay contacts on the relay circuit
board. Therefore, there may not be a warning if a relay becomes
defective. The operator should test the lockout system periodically.

55M4500EBE00E RevB
5.7.2.4 Generic Interface Errors
The i4500 system can support up to 4 generic interfaces. Each one can support a
wind speed sensor, an inclination level sensor and an absolute rotation encoder .
Activation of every generic card is done in the calibration menu section ‘‘Enable/
Disable I/O’’.

Lost communication with The i4500 system does not 1) The generic interface is
generic card X receive data from generic broken
interface. If “time out” delay is 2) The cable that links the
reached, then a communication interface to the canbus network
error is displayed
is defective.
Cant X on generic X Waiting for a valid value of the 1) The X axis of the
Cant X from the interface inclinometer is not calibrated
2) A wire between the cable
that links the interface to the
canbus network is cut.
Cant Y on generic X Waiting for a valid value of the 1) The generic interface is
Cant Y from the interface broken.
2) A wire between the cable
that links the interface to the
canbus network is cut.
AIN 1 on generic X Waiting for a valid value of the 1) The AIN 1 input of the
AIN 1 input from the interface generic interface is not
calibrated
2) A wire is cut between the
sensor connected to AIN 1
input and the interface
AIN 2 on generic X Waiting for a valid value of the The AIN 2 input of the
AIN 2 input from the interface generic interface is not
calibrated
2) A wire is cut between the
sensor connected to AIN 2
input and the interface
Absolute rotation encoder Waiting for a valid signal from Absolute encoder is defective.
the absolute interface
Rotation encoder’s 0 ref The proximity switch has been Rotation encoder is defective.
detected when encoder did not
receive a pulse
Generic Dr + The 5 volts reference voltage The generic card is
is not valid (if < 4.5 volts or > defective
5.5 volts).

55M4500EBE00E RevB
5.7.2.5 Rotation Interface Errors
a) Relative rotation
The i4500 system can support only one (1) rotation interface. There are two
different kinds of slew sensors: a relative one and an absolute one. Activation of
rotation interface is done in the calibration menu section ‘‘Enable/Disable I/O’’.

Rotation encoder’s cable A GND wire indicates that Replace cable between
the cable between the encoder encoder and rotation interface.
and the rotation interface is
not cut. If the cable breaks,
the rotation interface will send
an error message to the i4500
system.
Rotation encoder’s ratio No ratio has been detected.. No ratio has been entered
or calibrated in the system.
Rotation encoder’s prox. Proximity sensor is not 1) The proximity sensor is
switch. detected at the configured defective.
position.
Lost communication with The i4500 system does not 1) The Rotation interface is
rotation encoder receive anything from the defective.
rotation interface If the 2) The Can Bus network
“timeout” delay is reached, cable is broken.
then a communication error is
displayed
b) Absolute rotation: (a generic card is used for this type of interface)

Rotation encoder’s ratioRatio is not programmed. No ratio has been entered or
calibrated in the system
Lost communication with The i4500 system does not 1) The Rotation interface is
rotation encoder receive anything from the defective,
rotation interface. If “time- 2) The Can Bus network
out” delay is reached, then cable is broken.
a communication error is
displayed.

55M4500EBE00E RevB
-6-
Inspection & Maintenance

6.1 Performance check
These notes are intended as a general guide for inspecting the performance of a properly
functioning system. Refer to the calibration guide for tests and checks that should be
carried out in the event of parts being replaced or after an incident or major overload.
Daily
Automatic test. At switch on, the Witness that all warning lights and sounders
system will perform a self test and function correctly and then return to normal.
alarm check before settling into
the normal working mode.
Configuration check. Check the Parts of line are set correctly.
Check the Duty number (machine configuration) is
set correctly.
Check the status of the Tare function is as required.
Check the units of measure displayed are set as
required.
Hook weight check. Check that the displayed weight of the hook is
normal. It may be necessary to check this at more
than one radius depending on the method of load
measurement employed.
Radius/Angle check Check that the displayed values for radius and
angle are normal.
SWL check Check that the displayed value for SWL matches
the machine load table for the current configuration
and radius (or angle).
A2B check (optional) If the machine is fitted with an over hoist (A2B)
switch, slowly raise the empty hook until the A2B
weight is supported by the hook, check the A2B
warning is given. Be careful not to raise the hook
into the boom tip in the event of a failure of the A2B
system.
At any time
While not conducting a lifting operation, press the top left and top right buttons
simultaneously (1+5) to witness the warning lights and sounders function correctly. This
effectively reboots the main system and performs the automatic start up checks referred
to above, note that the configuration setting may need to be reconfirmed before the system
returns to normal working.
55M4500EBE00E RevB
Every 12 months
Perform a complete periodical test and record the results in the service records of the
machine. Testing personnel must be familiar with both the machine and the i4500 system
together with any special features incorporated.
Position and level the machine, where possible rig enough parts of line to just be capable
of lifting the maximum SWL for the condition being tested. Ensure the i4500 settings are
correct for the configuration of the machine ie Parts of line and Duty number (boom length,
outrigger condition, counterweight etc.). Be sure to respect the relevant load chart and
never lift a load in excess of the published limits or at a position for which there is no Safe
Working Load published.
A minimum of two, certified test weights are required to check the accuracy of the load
indication. The first should be equal to the SWL at or near the minimum radius for the test
configuration and the second should be equal to the SWL at or near the maximum radius.
Slowly lift the large test weight at a safe radius, measure the actual radius of the suspended
load and note the i4500 display readings for load and radius. With the load suspended just
clear of the ground, boom down to the measured radius at which the test load is equal to
the SWL for the machine and stop, maintain a minimum clearance between the load and
ground by hoisting as required. Note that the approach warning alarm should be active at
this point. Lower the load to the ground to complete this test.
Repeat this procedure using the small test weight.
For load tables where boom angle determines the SWL rather than radius, measure the
actual boom angle and note the indicated boom angle value for each of these tests.
Accuracy of load The displayed load should be within the tolerance band set by
indication local standards, in general this means +/-5% in Europe and
+0% to +10% elsewhere but check local requirements.
Accuracy of The displayed radius should be within the tolerance band
radius indication set by local standards, in general this means +0% to +10% of
measured radius but check local requirements.
Accuracy of angle The displayed angle should be within the tolerance band set by
indication local standards, in general this means +0° to -2° of measured
angle but check local requirements.

55M4500EBE00E RevB
6.2 Maintenance
Replacement parts and original parts must be obtained

from RaycoWylie unless approved and authorized as an
equivalent by a RaycoWylie technician.
Preventive Maintenance
• Your i4500 system has been designed to operate over long periods of time with
minimum maintenance. However, continuous satisfactory operation depends
upon system’s care and cleaning.
Important: Do not use pressure steam on the i4500 display

box, junction boxes, angle sensors, load cells or on any
connectors. This could result in moisture in the connectors
and can cause eventual sensor failure.
• To clean the surface of the display, use mild soap (or mild window cleaners)
and a clean soft cloth.
Important: If condensation appears in the screen of the

display unit, open the cover in a dry place and let it air
dry for a day.
• Replace all cables showing cut or damage. Make sure the connector contacts
are not too corroded.
• Replace A2B switch if the plunger shows excessive corrosion.
To keep the i4500’s display waterproof, make sure the back cover is
tightened following an X pattern.
Your i4500 system requires no additional lubrication.

55M4500EBE00E RevB
6.3 Maintenance Procedure
Before starting repairs or adjustments on a crane,

you should take the following precautions.
• Place the crane where it won’t get in the way of other equipment or operations
in the area.
• Block all controls and ensure all operating features are secured from
inadvertent motion.
• Make sure the starting means are inoperative.
• Lower the boom to the ground, if possible, or otherwise secure against

dropping
• Lower the block to the ground or otherwise secure against dropping
• Release hydraulic pressure from all hydraulic circuits before loosening or

removing hydraulic components
• “Warning” or “Out of Order” signs shall be placed on the crane controls and be
removed only by authorized personnel.
• After adjustments and repairs have been made, the crane shall not be used until
all safety devices are reactivated and trapped air removed from the hydraulic
system. The instructions for the removal of air from hydraulic circuits should
be provided by the crane manufacturer.

55M4500EBE00E RevB
6.4 Adjustments and repairs
• Any hazardous conditions noticed during the inspection shall be corrected

before you start using the crane.
Important: Adjustments and repairs shall be done only by

qualified personnel..
Any adjustment shall meet RaycoWylie’s specified tolerances in order to maintain

the correct functioning of all components.
• Please contact our service department at RaycoWylie if you need replacement
parts for maintenance and repairs on our equipments.
If you have any questions or need technical assistance, please contact

our Technical Service Department at RaycoWylie quoting the
information found on the serial number label of your i4500 system.

55M4500EBE00E RevB
Notes


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55M4500EBE00E Rev B

i4500 Crane Information Center

i4500 Lattice Boom Crane 5 Instruction Manual

In accordance with the 2006/42/EC The Machinery Directive

Hereby declare that: Product type: Rated Capacity Limiter/Indicator

Is in conformity with the EN 13000 Cranes – Mobile Cranes

For and on behalf of Wylie Systems, a division of

i4500 Lattice Boom Crane 6 Instruction Manual

Since safety of personnel and proper use of the machine is of primary

The following definitions indicate the level of hazard when these

DANGER: INDICATES A POTENTIALLY HAZARDOUS

CAUTION: INDICATES A POTENTIALLY HAZARDOUS

IMPORTANT: INDICATES A SITUATION THAT MAY

NOTE: PROVIDES INFORMATION THAT MAY BE OF

i4500 Lattice Boom Crane 7 Instruction Manual

EC Declaration of Conformity page 5

1- GENERAL DESCRIPTION OF THE SYSTEM page 13

3- INSTALLATION AND CALIBRATION page 31

4- OPERATING INSTRUCTIONS page 31

i4500 Lattice Boom Crane 8 Instruction Manual

4.4.5 System Configuration Information Screen page 49

4.6 Operational Limits page 61

4.7 Range Limiting Options page 65

5-DIAGNOSTIC & TROUBLESHOOTING page 75

6- INSPECTION AND MAINTENANCE page 87

i4500 Lattice Boom Crane 10 Instruction Manual

General Description of the System

1.3 Intended Use

i4500 Lattice Boom Crane 13 Instruction Manual

1.4 Brief Description of the i4500 System

The i4500 “Rated Capacity Indicator” is a computerized crane monitoring system

-The boom angle

i4500 Lattice Boom Crane 14 Instruction Manual

1.4.1 Audible Alarm

An intermittent buzzer located in the i4500 system display warns the

If you are wearing ear protection safety devices

1.4.2 Visual Alarms

GREEN YELLOW RED

i4500 Lattice Boom Crane 15 Instruction Manual

1.4.2 Visual Alarms (cont’d)

I4500 system with three warning lights

Internal alarms External alarms

Green Yellow Red External

No event Off Off Off Off On Off Off Off

Rigging Mode Off Off Off Off Off On Off Off

i4500 Lattice Boom Crane 16 Instruction Manual

1.4.2 Visual Alarms (cont’d)

I4500 system with 1 external warning light

Internal Alarms External Alarms

No event Off Off Off Off Off Off

Rigging Mode Off Off Off Off Off Off

i4500 Lattice Boom Crane 17 Instruction Manual

1.5 Location and Description of Typical Components

2) Central I/O interface: This relay interface module is connected to

i4500 Lattice Boom Crane 18 Instruction Manual

1.6 Block Diagram of the i4500 Communication Link

BORE SIDE ROD SIDE

PRIMARY RCI CAN 2.0B

CAN CAN CAN