Flex 5 Operator

OPERATOR’S MANUAL

XCMG
iFLEX E5 IK2001

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Load Moment Indicator for Telescopic Crane iFLEX E5

NOTICE

SkyAzúl makes no warranty of any kind with regard to this material, including, but not
limited to, the implied warranties of merchantability and/or its fitness for a particular
purpose.

SkyAzúl will not be liable for errors contained in this manual or for incidental or
consequential damages in connection with the furnishing, performance, or use of this
manual. This document contains proprietary information, which is protected by copyright,
and all rights are reserved.

No part of this document may be photocopied, reproduced, or translated to another
language without the prior written consent of SkyAzúl.

SkyAzúl reserves proprietary rights to all drawings, photos and the data contained therein.
The drawings, photos and data are confidential and cannot be used or reproduced without
the written consent of SkyAzúl. The drawings and/or photos are subject to technical
modification without prior notice.

All information in this document is subject to change without notice.

SkyAzúl, Inc.

16 Walnut Street
Middletown, MD 21769
Fax [phone]

[e-mail]

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Load Moment Indicator for Telescopic Crane iFLEX E5

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Load Moment Indicator for Telescopic Crane iFLEX E5

Table of Contents

1. GENERAL INFORMATION................................................................................................................ 1

2. IMPORTANT NOTES................................................................................................ ........................... 2

3. COMPONENTS OF LMI SYSTEM .................................................................................................... 4

3.1 IFLEXE5/1 CONTROLLER ............................................................................................................... 5

3.2 IFLEX E5/4 CONTROLLER .............................................................................................................. 5

3.3 IFLEX C3 CONTROLLER ................................................................................................ ................. 6

3.4 ISCOUT EXPERT 2001 CONSOLE ..................................................................................................... 7

3.5 DAVS PRESSURE TRANSDUCER ....................................................................................................... 7

3.5.1 Technical Data .......................................................................................................................... 8

3.5.2 Installation ................................................................................................................................ 8

3.6 LWG321/322 LENGTH/ANGLE SENSOR .......................................................................................... 8

3.6.1 Technical Data .......................................................................................................................... 9

3.6.2 Installation ................................................................................................................................ 9

3.7 LG105 LENGTH SENSOR................................................................................................................. 10

3.8 ANEMOMETER ................................................................................................................................ 10

3.9 ANTI-TWO BLOCK SWITCH ............................................................................................................. 11

3.9.1 Technical Data ......................................................................................................................... 11

3.9.2 Installation ............................................................................................................................... 11

4． OPERATION AND DISPLAY INTERFACE ................................................................................ 12

4.1 STATUS DISPLAY ICON .................................................................................................................... 13

4.2 LCD DISPLAY AREA (VALUES ARE NOT REAL) ............................................................................... 15

4.3 FUNCTION KEY SYMBOLS .............................................................................................................. 18

4.4 FUNCTION KEYS ............................................................................................................................. 18

5． OPERATING METHOD (ONLY FOR EXAMPLE) .................................................................... 19

5.1 OM AND REEVING SETUP ............................................................................................................... 20

5.1.1 Set OM & Reeving by numerical codes ................................................................................. 21

5.1.2 Graphical OM Selection ......................................................................................................... 22

5.3 MAINTENANCE OM ........................................................................................................................ 25

5.4 LMI OVERRIDE ............................................................................................................................... 27

5.5 TELESCOPIC BOOM STATUS MONITORING .................................................................................... 28

5.6 SYSTEM SETUP ................................................................................................................................ 29

5.6.1 Joystick Sensitivity Setup ....................................................................................................... 29

5.6.2 Telescoping Cylinder Length Sensor Calibration .................................................................. 30

5.6.3 Display Brightness Adjustment and Time Setting ................................................................. 32

5.7 SYSTEM INFORMATION ................................................................................................................... 33

5.7.1 LMI System and Control System Error Code Search ........................................................... 33

5.7.2 Load Chart Search ................................................................................................................. 35

5.7.3 Port Information Search ........................................................................................................ 36

5.7.4 CAN-bus Status Overview ...................................................................................................... 37

5.8 VIRTUAL WALL SETTING ................................................................................................................ 37

6. PRE-OPERATING CHECK ............................................................................................................... 40

7. ROUTINE MAINTENANCE & ADJUSTMENT METHODS ........................................................ 42

7.1 MAINTENANCE ITEMS .................................................................................................................... 42

7.2 LENGTH SENSOR ADJUSTMENT...................................................................................................... 42

7.3 ANGLE SENSOR ADJUSTMENT ........................................................................................................ 43

8. TROUBLESHOOTING ...................................................................................................................... 45

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Load Moment Indicator for Telescopic Crane iFLEX E5

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Load Moment Indicator for Telescopic Crane iFLEX E5

1. GENERAL INFORMATION

The load moment indicator iFLEX E5 and control system (hereinafter referred to as LMI) are applicable
to the telescopic boom crane, lattice boom crane, all- terrain crane and other types of cranes.

The iFLEX E5 LMI can provide the crane operator with essential information required to operate the
crane within its design parameters. Using different sensors, LMI can provide the crane operator with
information on real time basis regarding boom length, boom angle, working height, working radius, rated
load and actual weight being lifted by the crane

The system operates on the principle of reference/real comparison. The boom angle and length is
measured by length/angle sensor that is mounted on the boom. Length measuring cable is also used for
the signal transmission of A2B switch. The crane load is measured by pressure transducers attached to the
luffing cylinder. The real value, resulting from all the sensors measurement is compared with the
reference data, stored in the controller. If non-permitted conditions are approached, the LMI will warn the
operator by audible alarm, warning light and at the same time, some dangerous movements such as lifting,
extending boom and luffing down will be stopped with the help of the crane control system.

This manual only gives guide for the LMI operation. Please refer to the Crane Operator’s Manual
provided by the crane manufacturer for detailed operating procedures of the crane.

Conformity of Standard:

GB12602-2009
EN13000-2010

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2. IMPORTANT NOTES

The LMI control system is an operational aid that warns a crane operator of approaching overload
conditions and of over-hoist conditions that could cause damage to equipment and personnel.

The device is not, and shall not, be a substitute for good operator judgment, experience and use of
accepted safe machine operating procedures.

The responsibility for safe operation shall remain with the crane operator who shall ensure that all
warnings and instructions supplied are fully understood and observed, Prior to operating the crane ,the
operator must carefully and thoroughly read and understand the information in this manual to ensure that
he knows the operation and limitations of the LMI.

The LMI can only protect overload of the crane in boom vertical range without crane overturn resulted
from non-vertical lifting, ground inclination, derailed wheel etc. Therefore, the operators should not
neglect the crane safety management and operation regulation even if the crane is equipped with LIM.

CAUTION

CAUTION

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The LMI can only work correctly after all adjustments have been properly set. To prevent material
damage and serious or even fatal accidents, operating mode, reeving and limit data have to be properly
set up before operating the crane.

If there is any change in the crane’s configuration data, the LMI needs to be re-calibrated.

Make sure to disconnect the power supply of the LMI from the crane before applying any welding work
on the crane body or booms. The pulse may cause damage to the electrical and electronics parts.
Hirschmann shall not be liable for any damage caused by this.

Make sure to disconnect the power supply of the LMI during thunderstorm weather. Hirschmann shall not
be liable for any damage caused by lightning.

This system can be equipped with an external key-operated switch located in the crane operator's cab.
This key-operated switch overrides control lever function switch-off by the LMI or by the hoist limit
switch system.
This switch may only be used during emergency situations, and even then only by authorized personnel.
Failure to observe these instructions could result in damage to property and severe or even fatal injuries to
personnel.

If the LMI in use fails or is not properly functioning, please do stop the operation of the crane, and
contact the service of Hirschmann or crane manufacturer. Hirschmann does not assume any responsibility
for undesirable consequences resulted from the continued operation!

WARNING

WARNING

WARNING

DANGER

DANGER

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3. COMPONENTS of LMI SYSTEM

Components of LMI System

Generally, the LMI and control system consists of

1. iFLEX E5/1 controller

2. iFLEX E5/4 controller

3. iFLEX C3 controller,

4. iSCOUT expert 2001 console,

5. LG105 length sensor,

6. DAVS pressure sensor

7. LWG322/321 length-angle sensor

8. HES anti-two block switch

9. Anemometer,

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3.1 iFLEXE5/1 Controller

The iFLEX E5/1 consists of a base board and an extention board and can offer more than 100
inputs and outputs which in turn allow processing functions on sensors and actuators.

The integrated CAN bus interfaces allow integration of intelligent sensors and actuators with
CANopen and also support SAE J1939.

-High integrated 32-bit microcontroller

-Integrated floating point unit (FPU)

-Real-time multi-tasking operating system

-Programmable according to IEC 61131-3 and C

-Supports SAE J1939

-Real-time clock

-SRAM, battery-buffered

-Temperature range -30℃ up to +75℃

Technical data:
CPU: 32 Bit RISC-processor 48MHz
Memory: 8 MB Flash (16 MB optional)
Protection class: IP67
Communication: 1×CANopen2.0B, 1×SAE J1939
Interface: 2×RS232, 1×RS485
Operating voltage: 10V～30VDC
Operating temperature: -30℃～+70℃ Storage temperature： -40℃～+85℃

3.2 iFLEX E5/4 Controller

iFLEXE5/4 controller is a 32 digit industrial control PLC system, high-performance, high-precision
and low-consumption, which meets the required safety standards under harsh environment.

-High integrated 32-bit microcontroller

-Integrated floating point unit (FPU)

-Real-time multi-tasking operating system

-Programmable according to IEC 61131-3 and C

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-Real-time clock

-SRAM, battery-buffered

-Temperature range -30℃ up to +75℃

Technical data：

CPU: 32BitRISC-processor 48MHz
Memory: 8MB Flash (16MB optional)
Protection class: IP65
Communication: 1×CANopen2.0B
Interface: 1×RS232, 1×RS485
Operating voltage: 10V～30VDC
Operating temperature: -30℃～+75℃ Storage temperature： -40℃～+85℃

3.3 iFLEX C3 Controller

The iFLEX C3 is a programmable controller and the ideal solution for small to medium sized
applications. By means of the flexible configuration of the inputs and outputs these controls can be
adapted to any application on crane. The CANopen interface allows the set up of a decentralized
network. The iFLEX C3 is programmable with CoDeSys or C.

-Compliance with standards of CE and EMC

-Sturdy design and high resistance to shock and vibration

-An extended temperature range -40° C up to +85°C

-High protection against humidity, powder, water and saline fog

-Flexible I/O configuration and scalable by external I/O MODULE

-Supports SAE J1939

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Technical data：

CPU: 16Bit or 32Bit
Protection class: IP65
Communication: 1×CANopen+1×RS485
Interface: 1×RS232
Operating voltage: 10V～36VDC
Analog input: 4～20 mA, 0～5V
Operating temperature: -40℃～+85℃
Storage temperature: -55℃～+120℃

3.4 iSCOUT expert 2001 Console

The iSCOUT expert 2001 colored LCD console, equipped with BestVIEW adaptive display technology
can show all the operational data that the operators are concerned.

Technical data:

Installation: in-dash/on-dash
Housing: metal
Protection class: front panel IP65，back panel IP65/IP20
Operating voltage: 10V～36VDC
Operating temperature: -20℃～+70℃
Storage temperature: -35℃～+80℃
Display resolution: VGA (640×480)
Dimension: 10.4 inch (diagonal), color 256 colors
Interface: 1×CANopen2.0B, RS232+RS485

3.5 DAVS Pressure Transducer

DAVS pressure transducers can measure dynamic pressure of liquid and gases under rough operating
environment. Measuring precision can be maintained even during continuous operation at extremely
dynamic pressure. The pressure transducer matches with a pressure connector with standard G1/4 thread
or other hydraulic connection pin.

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3.5.1 Technical Data

Operating voltage: 8～32VDC
Output signal: current 4-20mA

Operating temperature:-40℃～+85℃

Storage temperature: -40℃～+100℃
Protection class: IP67
Life expectancy: 〉10million cycles
Hysteresis tolerance: 〈±0.1%FS max.

DAVS Dimension

3.5.2 Installation

Hydraulic sensor is connected to the oil cylinder to check its continuous change of pressure.
Please note the allocated location of hydraulic piping and balance valve or hydraulic single-directional
value when installing the pressure transducer. Through thread connection (such as the following photo),
screw the pressure transducer in the hydraulic piping or seat of the balance valves or hydraulic valves.
Add the appropriate seal to the connection face to prevent oil leakage. Make sure the installation position
is safe, agreeable and easy for cable connecting.
Make sure the pressure sensor and hydraulic adaptor are tightly connected. The tightening moment of
G1/4 connector is 20Nm.

Pressure Transducer Installation Photo Connector Pin Allocation

3.6 LWG321/322 Length/Angle Sensor

LWG series Length/Angle sensor is used to precisely measure angle and length of the telescopic boom.

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3.6.1 Technical Data

Operating voltage: 15～30VDC
Operating temperature: -25℃～+75℃
Storage temperature: -40℃～+80℃
Protection class: IP65
Linearity tolerance: 〈±0.2°
Resolution: 〈±0.1°
Hysteresis tolerance: 〈±0.1°

LWG321 Length/Angle Dimension

3.6.2 Installation

The length and angle sensor shall be correctly installed so as to prevent possible cable breaking and other
failures.
During daily operation, the operator shall check that the surrounding obstacles will not get in touch with
the sensor and the measuring cable.

A

Guiding
rack

Length/angle
sensor

Measuring
cable

Guiding
wheel A

Angle α

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3.7 LG105 Length sensor

LG 105 length sensor can precisely measure the telescopic length and has the same working principle
with the LWG sensors.
It is fixed inside the bottom of the main boom and above the pivot of the telescopic cylinder to measure
the cylinder stroke.

Operating voltage: 15～30VDC
Operating temperature: -25℃～+75℃
Storage temperature: -40℃～+80℃
Protection class: IP65
Linearity tolerance: 〈±0.2°
Resolution: 〈±0.1°
Hysteresis tolerance: 〈±0.1°
Measure range: 0～15m

LG105 Length Sensor Dimensions

3.8 Anemometer

The anemometer is suitable for measuring wind speed in the open field for cranes and is generally
installed on the front end of the boom. It is not affected by the changes of boom angle and can guarantee
the wind cup parallel to the ground all the time. It mainly consists of wind cup, housing, bracket and cable.
(Refer to the illustration below)

Technical data:

Operating voltage: 10V-30VDC
Output signal: 4-20mA
Measure range effective: 0-40m/s
Resolution: 0.1m/s
Max. strength: for wind speed of 80m/s (max.30 min)

Wind cup

Installation bracket

Housing

Cable

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3.9 Anti-Two Block Switch

Anti-Two Block Switch (A2B) is compactly designed, of agreeable appearance and easy for installation.
Quality switch inside the cast aluminum shell assures a safe and liable limit position and avoid
over-hoisting. The glue sealed housing keeps the internal component away from the influence of
temperature, humidity, etc.

3.9.1 Technical Data

Operating voltage: 15～30V
Operating temperature: -25℃～+70℃
Storage temperature: -40℃～ +70℃
Protection class: IP67
Life expectancy: ＞5×106 times
Housing: cast aluminium

Weight: 1.2kg

A2B Outline Dimension

3.9.2 Installation

The switch should be installed inside boom head which one end of the hoist wire rope is fixed to. Stick
the hammer in one end of the hoist wire rope and connect the hammer with the switch by the wire rope of
required length and specification. At the same time, correctly connect the end of measuring cable which is
for transmitting the A2B signals and cable end of the A2B switch using waterproof connector to assure its
working stability.

Installation Photo Anti-Two Block Switch

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4． OPERATION AND DISPLAY INTERFACE

① Status display area (refer to 4.1）
② LCD display area （refer to 4.2）
③ Function keys area（key symbols shows in this line，for the definition of the 8 function keys from F1—F8 ,

please refer to 4.3 ）

④ Function keys.

1

2

3

4

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4.1 Status Display Icon

A. Error code icon

Operators can learn of the failure cause according to the error code

B.Reeving icon

Current reeving

C.OM code icon

Current OM code

D. CANBUS icon

CAN communication between the console and controller has error.

E.A2B switch warning icon

This red symbol lights up when the lifting limit switch open, i.e. a lifting limit has
been reached. The audio alarm sounds and any load moment-increasing crane
movements are immediately switched off.

F.Load moment pre-warning icon

This yellow symbol lights up when the crane load exceeds 90 % of the rated safe
working load and an overload situation is approaching.

G.Overload icon

This red symbol lights up when the crane load has reached 100% of the maximum
safe working load for the current operating situation and indicates to the crane
operator that an overload situation has occurred.

The audio alarm is sounded. Any load moment-increasing crane movements are
immediately switched off.

H.Time display icon

Display current local time

The crane operator can learn of the crane operating status from the status icons on top of the
console screen. Before the operation, operators shall fully understand the meaning of the
following icons and accordingly make correct judgment.

CAUTION

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I. Virtual wall- angle setup status icon

This yellow symbol lights up when the main boom angle approaches the upper
limit;

This yellow symbol lights up when the main boom angle approaches the lower
limit;

This red symbol lights up when the main boom angle exceeds the upper limit and
any angle-increase movement is cut off.

This red symbol lights up when the main boom angle exceeds the lower limit and
any angle-decrease movement is cut off.

Angle limit setup function has been set.

J. Virtual wall- work height setup status icon

This yellow symbol lights up when the work height approaches the maximum
height;

Work height limit setup function is called up.
This red symbol lights up when the work height exceeds the upper limit and any

height-increase movement is cut off.

K．Virtual wall- work radius setup status icon

This yellow symbol lights up when the work radius approaches the minimum
limitation;

This yellow symbol lights up when the work radius approaches the maximum
limitation;

Work radius limit setup function has been set.
This red symbol lights up when the work radius exceeds the lower limit and any

work radius-decrease movement is cut off.
This red symbol lights up when the work radius exceeds the upper limit and any

work radius -increase movement is cut off.

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4.2 LCD Display Area (values are not real)

The ISCOUT EXPERT 2001 console VGA (640×480）can display all the operational data. The Bestview
patented technology can help to provide clear and visual graphic display either under sunlight or in dark
night.
Main display (The following illustration is made based on a fixed job OM):

Main Display Fixed Jib OM

⑴ Error code and operating mode

When the system is not working correctly, the
error codes, causes and solutions will be
displayed in this area.

Definition of the displayed symbols ：

1. Counterweight

2. Outrigger span

3. Slight control setup display

4. Gradienter ：X-Y. (Optional)

1. Work Area

2. Slewing angle

1

2 4 3

1

2

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⑵Crane operating geometrical data

1. Installing angle of fixed jib (angle position
shown on the left picture is just for
indication, the actual angle is between
main boom extension line and the fixed jib)

2. Operating height

3. Main boom angle

4. Radius

5. Fixed jib length

6. Main boom length

⑶Load moment status bar and percentage display

1. Load moment status bar

2. Load moment percentage
value

The load moment percentage status bar indicates the relationship between the actual load moment and the
rated load moment during the crane operation and the load percentage value is subject to the relationship
changes.

Green zone：safe range （load moment percentage0-90%）
Yellow zone：pre-warning range （load moment percentage 90-100%）

Red zone：over-load warning range （load moment percentage exceeding100%）
Load moment percentage value corresponds to the ratio of actual load moment and rated load moment
indicated by the load moment status bar.

1. Actual load

2. Permissible max. load under
current OM

3. Current wind speed

1

2

4 3 6

5

The installing angle of fixed jib on the display is just for indication. The actual angle is the one

between the main boom extension line and the fixed jib.

CAUTION

1

2

1 2 3

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⑷ Telescopic boom section combination

1. Left cylinder pin locked (green)

2. Left cylinder pin unlocked

3. Right cylinder pin unlocked

4. Right cylinder pin locked (green)

5. Boom pin locked

6. Boom pin unlocked

7. Small hydraulic pump status

8. Current telescoping process (cylinder travel line dimension)

9. Telescopic boom combination code

10. Current extending boom section No. (the above picture. shows the 2nd boom is extending out)

11. Current extending boom percentage (cylinder travel line percentage)

12. Extending percentage of the current boom (the above picture. shows current telescopic percentage of
T2 boom is 46%)

⑸ Other parameter

Data below will only appear at the main display of crane type QAY240 and QAY260.

1. Temperature of cooling
liquid

2. Engine oil pressure

3. Engine speed

When the small pump begins working, the green light icon will flash to warn the operators.

1 2 4 3 6 5 7

10 9 8

11

12

CAUTION

1 2 3

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4.3 Function Key Symbols

Definition of the function key symbol

F1：OM and reeving setup key symbol（refer to section 5.1）

F2：Telescopic boom section combination selection key symbol (refer to section 5.2)

F3：LMI override activated key symbol（refer to section 5.4）

F4：Boom telescoping key symbol, to enter into the boom extending or retracting
movement monitor display.（refer to section 5.5）

F5：System setup key symbol（refer to section 5.6）

F6：System information key symbol（refer to section 5.7）

F7：Virtual wall setup key symbol（refer to section 5.8）

F8：“Alarm off” key symbol
The alarm sound can be silenced by pressing this function key.

4.4 Function Keys

There are totally 8 function keys from F1 to F8. Each of the keys has its function and is easy for
operation.

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5． OPERATING METHOD (only for example)

When controller and console of the iFLEX5 system is powered on, the data initialization automatically
starts. This progress cannot be directly observed, but a welcoming display (Logo display) will appear at
the console to present the manufacturer and the initializing status as below:

LOGO Display

During the initializing process, the console will keep alarming; press F5 to stop the alarming sound. If the
system communication is defective, the prompt “initialization fails” will appear at the Logo display. After
checking the cable connection of all parts and solve the problem, the console will return to normal
working.

No matter the console initialization is successful or not, the system will enter into the main
interface. But if initialization fails, it may take longer time to enter into the main interface from
the LOGO display for about 20s.

CAUTION

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5.1 OM and Reeving Setup

Since the working conditions of the crane are different, the LMI data is categorized by several OMs and
represented by OM codes. Before operating the crane, set the LMI OM code to match the actual OM of
the crane; meanwhile the reeving of the LMI shall also be set to match the actual reevinging of the crane.

After finishing the initialization, system will enter into OM confirm interface:

➢ If OM code already exists for the last operation, system will enter into the following interface:

OM Confirm interface 1
After entering into the interface, first check if the current OM is identical to the previous ones. If they are,
press to confirm and enter into the main interface. Press to reset the current OM and
reeving.

➢ If the OM code read out by the console is displayed as error after initializtion, system will give out

warning message and indicate E04 as shown in the interface below:

Prior to the operation of the crane, the OM and reeving must be correctly set by the qualified crane
operators. The mistakes in setting up the OM and reeving may cause serious or fatal results.

WARNING

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OM Confirm Interface 2
Press to reset OM and reeving (refer to OM & reeving setting).

5.1.1 Set OM & Reeving by numerical codes

1. Current OM code;

2. At OM & reeving setup
interface， press F1 to input
numbers and set OM code,
then press F8 to return;

3. At OM & reeving setup
interface, press F3 to set
reeving, then press F8 to
return.

1

2

3

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5.1.2 Graphical OM Selection

At OM & reeving setup interface, press F5 to select graphical OM：

4. Graphical OM setup —
select OM type

5. Graphical OM setup —
select fixed jib length

6. Graphical OM setup —

select fixed jib angle

7. Graphical OM setup —

select balance weight

8. Graphical OM setup —

select outrigger span

Definition of function keys at OM selection interface：

F1：Scroll up

F2：Scroll down

F3：Scroll back

F6：Alarm stop

F8：Confirm

Some of the items from 4 to 8 are not selectable. The system may take the selection by default if
there is only 1 option. For example, if a crane has only a full outrigger, the system automatically
select the full outrigger by default and the semi outrigger cannot be selected.

4

5

6

8

7

CAUTION

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5.2 Telescopic Boom Combination Selection

Prior to operating the crane, the crane operator must set the right boom combination according to actual
needs.

At main interface, press F2 to enter into boom combination interface. The system
has two selection methods: by pressing key and inputting numbers.

➢ Select telescopic boom combination by pressing key

No.： Boom combination Code No., boom

combinations can be selected by
scrolling the keys or by inputting the
numbers

Tn： The percentage of the n section boom

to be extended. For example, the No.
2 combination indicates the 3rd boom
section is to be extended by 4%
while all the other sections not to be
extended.

Leng： Boom length. After selecting the

boom combination, the length is
given by the system.

Press scroll up and scroll down to
select combination code No. and
press F8 to confirm.

➢ Select telescopic boom combination by Code No.

Press F6 and input numbers to select boom
combination Code No. ；

It’s important to set the correct boom combination by qualified and experienced crane operator

Telescopic constitute

Leng

WARNING

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➢ Select telescopic mode

Press F7 to select telescoping mode:
Auto or Manual
Auto: after the system finishes
extending or retracting as per the
boom combination ， it will
automatically lock the boom pin.
Manual: after the system finishes
stretching and retracting as per the
telescopic combination，the operator
needs to lock the boom pin manually
(for detail, please refer to crane
manual)

F1：Cancel
F7：Confirm

After selecting the boom combination and mode, the system will prompt to confirm the selection. Press
F1 to cancel the selection, or F7 to confirm the selection.

When the operator finishes the selection of boom combination, the system will automatically enter into
telescopic mode selection. After the operator chooses and confirm Auto or Manual Mode, the system
will enter into the main interface.

CAUTION

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5.3 Maintenance OM

The maintenance OM setup method as follow:

1. Press at the main interface to enter into OM setup interface:

Main Interface

Prior to any operation under Maintenance OM, it’s a must to read and fully understand the related

instructions provided at the Crane Operation and Maintenance Manual (Manufacturer’s
Specifications).
All operations have to be carefully carried out while strictly following the related instructions in the
Crane Operation and Maintenance Manual (Manufacturer’s Specifications)
Maintenance OM can only be used for the case of repairing the boom. It works as a special over-ride
switch. It’s strictly prohibited to lift load under Maintenance OM or to select this OM under normal
lifting.
Maintenance OM is not designed for normal lifting. Under this OM, the LMI will NOT meet the
requirements raised by GB12602-2009 (Lifting appliances-safety devices against overloading).
The operator must operate the crane with great caution. The LMI under the maintenance OM will
NOT give out indication when the crane is overloaded or to alarm the operator if the crane is NOT
safe. For further instructions, please contact the crane manufacturer.

WARNING

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2. At the OM setup interface, select maintenance OM and set correct counterweight, outtrigger etc.
strictly follow the load chart provided by crane manufacturer for this OM.

OM Setup Interface

3. Boom combination selection for maintenance OM: select the correct boom combination strictly follow
the maintenance OM load chart provided by the crane manufacturer.

Boom Combination Interface

Only when the boom is being telescoped to the correct combination and the cylinder pins and boom pin(s)
are being securely locked, it’s allowed to carry out boom maintenance.

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5.4 LMI override

For some emergency cases, when the LMI has to be by-passed during lifting, the operator can press the
“over-ride” key to temporarily de-activate the LMI.

At main interface, press F3 to enter into LMI override interface. The LMI
override interface is password protected (the default password is 1)

LMI Override Interface

At LMI override interface, press to activate LMI override and the boom telescoping and
luffing limit is override.

The console displays warning icon and sends audio warning to remind operator with
utmost care.

After press once again or press to exit LMI override interface, LMI function

The over-ride of LMI can only be used for emergency, with great caution. When the over-ride of
LMI is activated, the crane is no longer protected by the LMI. Under such circumstances, the
crane is under the danger of A2B tip-over or overload situation.

WARNING

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Load Moment Indicator for Telescopic Crane iFLEX E5

returns to normal.

5.5 Telescopic Boom Status Monitoring

After sucessful selection of the boom length combination, it is required to adjust the current boom
combination to be same with the target combination.During the adjustment, the operator can monitor the
boom status on the display.

At main interface, press F4 to enter into telescopic boom status monitoring
interface:

Telescopic Boom Status Monitoring Interface

The telescopic boom status monitoring interface actually is an enlarged picture of the telescopic boom at
the main interface to convenient the operator for better observation.

① From left to right：left cylinder pin locked, left cylinder pin unlocked, right cylinder pin unlocked,

right cylinder pin locked, boom pin locked, boom pin unlockid and small hydraulic pump status;

② Current telescoping boom section: when the underside of a section turns green, it indicates this

section is being extended or retracted;

③ From left to right: which section of the boom is being extended, boom combination code No, and

extending percentage for the boom；

④ Actual extending percentage of each boom；

⑤ The current working data of the crane.

1

2

3 5 4

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5.6 System Setup

At main interface, press F5 to enter into system setup interface：

F1：Key – Joystick sensitivity setup

F2：Key – telescoping cylinder length sensor calibration

F3：Key - Chinese-English display language interchange

F4：Key – Metric and imperial system interchange;

F5：Key – Adjust console brightness

F6：Key – Adjust time

F7：Key – joystick selection, press this key to select between analog joystick and

CAN joystick.

5.6.1 Joystick Sensitivity Setup

Joystick sensativity is mainly to adjust the joystick’s sensativity to the movementss of the crane.

At the system setup interface, press F1 to enter into joystick sensativity setup interface, then manually
select to set or auto-adjust the sensativity.

F1：Key – enter into manual selection interface;
F3：Key – enter into auto-adjustment interface.

Press F1 to enter into manual selection interface of the system sensativity:

Low-speed mode
Medium low-speed mode
Medium high-speed mode

High-speed mode

Select by pressing F1 and F2.

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Load Moment Indicator for Telescopic Crane iFLEX E5

5.6.2 Telescoping Cylinder Length Sensor Calibration

At system setup interface, press F2 to enter into telescoping cylinder length sensor calibration interface:

T
e
l
e
scoping Cylinder Length Sensor Calibration Interface

F1：Key – confirm the 2nd section of the boom to extend 0%

F2：Key – confirm the 2nd section of the boom to extend 46%

F3；Key – confirm the 2nd section of the boom to extend 92%

F4：Key – confirm the 2nd section of the boom to extend 100%

F5：Key – confirm the 6 section of the boom to strech 0%

F6：Key – final confirmation of the setup

F7：Key – restore to factory setting

F8：Key – return to main interface

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When the extending percentage of boom is not correct, the operator can enter into the telescoping cylinder
length sensor calibration interface and adjust it.

Before the adjustment, please make sure the length sensor is back to zero by…… and the system
functions correctly. Then enter into “auto-tele-program setting” (Telescoping Cylinder Length Sensor
Calibration) interface and adjust as per the following steps:

Step 1: Fully retract the boom, the telescoping cylinder goes back to zero point，all cylinder pins and

boom pin are locked.

Press F1, a black arrow will appear；press F8, and select Key Y at the dialogue box -YES or NO to return
to main interface, enter into the main interface. The 0% extending of the 2nd boom section is done, as
shown below:

Step 2: Manually extend the 2nd boom section to 46%, lock the cylinder pins and boom pin. similar to Step

1, press F2, a black arrow will appear . Press F8 and select “Y” at the dialogue box “YES or NO”
to return to main interface. The 46% extending of the 2nd boom section is done, as shown below.

Step 3: Following the steps as above, set 92% and 100% extending of 2nd boom section
Step 4: Completely retract 2nd section, move the empty cylinder to 6th boom, lock the cylinder pins and

the boom pin; set the 6th boom section to 0% extending as previous steps. For details please refer
to Step 1;

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Step 5: Confirm the above setting, and then press F6 to finally confirm the setting. Press F8, and select

“Y” at the dialogue box “YES or NO” to return to main interface. Enter into the setting interface

again; setting is finished, as shown below:

Step 6：Make sure step1~step 5 are correctly done. Switch off the power for around 2s. Switch on the

power to complete the setting..

5.6.3 Display Brightness Adjustment and Time Setting

► At system setup interface, press F5 to enter into display brightness adjustment interface.

F1: Key – brightness increases, by 5% at every press；
F2: Key – brightness weakens, by 5% at every press;
F3: Key – under night mode;
F4: Key – under daylight mode.

1．The above-mentioned 46% and 92% extending are actually required parameters. The figures
shown on the display may not equal to the required percentage. After calibration, extend and retract
the boom manually to check if these percentages are correct.
2．If the auto telescoping data is lost, the length figure shown on the display will remain
unchanging. Press F7 to return to factory default setting and press F8 and select “Y” to confirm.

WARNING

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► At system setup interface, press F6 and enter into time setting interface

F1：Key – move to the left digit;
F2：Key – move to the right digit;
F3：Key – increase the digital value;
F4: Key – reduce the digital value.

5.7 System information

At main interface, press F6 and enter into system information interface:

F1: Key – LMI system error code search

F2: Key – control system error code search

F3: Key – load chart search

F4: Key – port information search

F6: Key – CAN bus status search

Engine speed .

5.7.1 LMI System and Control System Error Code Search

LMI system and control system error code search interface can effectively help the crane operator or
service engineer to learn the meanings of error codes on the console( E refers to error code of the LMI
and EC refers to error code of the control system), and the error causes and corresponding eliminations,
thus greatly helps to eliminate the errors.
At system search interface, press F1 to enter into LMI system error code search interface; and press F2 to
enter into control system error code search interface.

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LMI System Error Code Search

Control System Error Code Search

Search by pressing the page up or down key at the bottom of the console.

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5.7.2 Load Chart Search

At system information interface, press F3 to search load chart. Firstly, input the code to be searched:

Load Chart Search Interface

At load chart search interface, press F1 and input the code to be inquired, then enter into corresponding
load chart interface.

Load chart data on the console is just for example, please refer to the actual load chart supplied by
the crane manufacturer.

Different cranes have different inquiry codes, please refer to the load chart search interface for
actual codes.

CAUTION

WARNING

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Load Moment Indicator for Telescopic Crane iFLEX E5

Load Chart Display Interface

5.7.3 Port Information Search

At system information interface, press F4 to enter into port information search interface, the display
shows the Expert Diagnosis System Interface as below.

Press the key to enter into the
corresponding port info search interface,
and press F8 for return to expert
diagnosis system interface.

Expert Diagnosis System Interface

F1: Key –The DI/DO status of The iFLEX E5 Mainboard (Node2)
F2: Key –The DI/DO status of The iFLEX E5 extention (Node2)
F3: Key –The AI/AO status of The iFLEX E5 extention (Node2)
F4: Key –PWM outputs status

Make sure to correctly select the joystick type on the system setup interface.

CAUTION

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5.7.4 CAN-bus Status Overview

At system information interface, press F6 to enter into CAN-bus status overview

At CAN bus status inquiry interface，it
shows the CAN communication status
and meaning of each status icon for
each components in the LMI system.
When the bus comunication fails, the
operator can inquire about the failure
source through the above interfaces,
thus time is saved for finding the
cause .

CAN-bus status overview

5.8 Virtual Wall Setting

At the main interface, press F7 to enter into virtual wall setting interface:

Max. height setting
Current operating height

Max. radius setting value
Current operating radius

Min. radius setting

Max. angle setting value
Current operating angle

Min. angle setting

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The functions for each key at virtual wall setting interface are as follows:

F2: Key – angle limit setting, set the upper and lower limit for the angle;

F3: Key – radius and height limit setting, set the upper and lower limit for the

radius and the upper limit for the height;

F6: Key – control mode setting, set the control mode:

Start: when operating data exceed the set limit value, the system will alarm and stop movements;
Stop: when operating data exceed the the set limit value, the system will alarm but will not stop the

movements

► Angle Limit Setting

F2：Key – min. angle setting, set the lower limit for the angle;

F3：Key – max. angle setting, set the upper limit for the angle;

F6：Key – angle limit cancellation, cancel limit setting for all angles.

For example, when the main boom of the crane can only luff between 45° and 65°, angle limit values
from 45°to 65°needs to be set to guaranntee the crane safety, steps are as follows:

⚫ luff the main boom to 45°, and at the angle upper and lower limit setting interface, enter F2,

then the icon will appear, which shows the angle lower limit value for the main boom
is set;

⚫ luff the main boom to 65°, and at the angle upper and lower limit setting interface, enter F3,

then the icon will appear, which shows the angle upper limit value for the main boom
is set;

⚫ Press F8, the system will prompt to save the setting, press F7 to save and F1 to cancel.

►Radius Limit Setting (Details please find the section for angle limit setting)

F1: Key – max. radius setting, set the upper limit for the radius;

F2: Key – min. radius setting, set the lower limit for the radius;

F3: Key – radius limit cancellation, cancel limit setting for all radii.

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► Height limit setting(Details please find the section for angle limit setting)

F5: Key – height limit setting, set the upper limit for the height;

F6: Key – height limit cancellation, cancel limit setting for all heights.

After setting the virtual wall, please operate after 2 seconds!
If the operator presses F6 to cancel limit setting at limit setting interface, the crane will not be
limited by the virtual wall!

CAUTION

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Load Moment Indicator for Telescopic Crane iFLEX E5

6. PRE-OPERATING CHECK

Check before starting the system:

1）Check all cable connecting the system. Broken cables shall be replaced immediately
2）Check the insulation of the connecting cable and wire of A2B switch; if the insulating layer is worn or
the wire is broken, promptly change the broken part;
3）Check the cable of A2B switch and length-angle sensor; if broken or fractured, please replace or
re-connect;
4）Verify the correct functioning of the A2B switch;
5）Check the hydraulic pipe line connecting pressure transducer, replace tighten the connectors when
leaking.

Pre-operating Check:

1) Assure the actual OM is the desired one, reset if not.
2） Check if the boom length displayed is within the tolerance range of the actual boom length; if not,
please adjust according to Section 7.2 – Length Sensor Adjustment or through the software iTOOL5;
3） Check if the angle displayed is within the tolerance range of the actual angle; if not, please adjust it
according to Section 7.3 – Angle Sensor Adjustment or through the software iTOOL5;
4） Check if the load displayed is same with the actual load;

The following tests shall be performed with care to prevent damage to the machine or injury to
personnel. Proper functioning of the system requires successful completion of these tests before
operating the machine.

WARNING

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Load Moment Indicator for Telescopic Crane iFLEX E5

5） After correctly setting the OM, raise the hook up to the height limit position to check if the A2B
switch alarms and raising -up is stopped; then lower the hook and check if the A2B switch alarm can stop;
6） Luff the boom up to the angle limit position, check if the system alarms and luffing- up is stopped;
luff down the boom and check if the alarm can stop;
7） Luff the boom down to the angle limit position, check if the system alarms and luffing- down is
stopped; luff up the boom and check if the alarm can stop;

In case the LMI System doesn’t respond correctly to the hazardous movements of the crane by
giving out alarm or stopping the unpermitted movements, it shows that the LMI is in disorder.
Make sure to repair the LMI before putting into any further operation.

WARNING

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7. ROUTINE MAINTENANCE & ADJUSTMENT
METHODS

If problems cannot be solved through maintaining and adjusting according to the methods below, please
contact us in time.

7.1 Maintenance Items

1）Check all cable connecting the system. Broken cables shall be replaced immediately
2）Check the insulation of the connecting cable and wire of A2B switch; if the insulating layer is worn or
the wire is broken, promptly change the broken part;
3）Check the cable of A2B switch and length-angle sensor; if broken or fractured, please replace or
re-connect;
4）Verify the correct functioning of the A2B switch;
5）Check the hydraulic pipe line connecting pressure transducer, and replace or tighten the connectors
when leaking.

7.2 Length Sensor Adjustment

1) When the boom length displayed is inaccurate and goes beyond the tolerance range, adjust the length
sensor according to the following procedure:

✓ Fully retract the boom to the basic boom mode
✓ Ensure that the length cable tension is correct
✓ Remove cover from cable reel
✓ Adjust the potentiometer counter clockwise and stop until the boom length value displayed on

the console equals the actual length.

Length Sensor Adjustment

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2） Length Sensor Pre-tightening
The measuring cable of coil spring may loosen for overtime use, or become broken due to careless
operation, or could not tightly coiled after being re-connected, so the cable shall be pre-tightened.

Pre-tightening Method:
Pull out the line till the coil spring bearing the load is felt (if too tight, it will break the coil spring or split
the line when telescoping the boom)，then press the cable drum( do not move it) and manually wind the
line on the box.

After the pre-tightening, adjust zero point for the length sensor.

Adjustment method:
Adjust length sensor potentiometer at base boom mode till the value displayed is same with the actual
value.

7.3 Angle Sensor Adjustment

The angle sensor is stalled in the same housing of the length sensor.

When the measured angle is different from the displayed value, use a calibrated inclinometer to measure
the actual main boom angle and compare with displayed angle on console.

Release the 2 fixing screws shown on the picture and rotate the angle sensor to adjust until the displayed
value equals the measured value. Tighten the screw tightly to the housing.

Angle Sensor Adjustment

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8. TROUBLESHOOTING

There are 2 different kinds of errors: system or operation. When an error occurs, this means the system
has a fault. The description and code of errors will appear on the screen.

The following Error Code Table gives a brief description of Error Codes elimination.

Error

Code

Error

Cause

Elimination

E01

Fallen below radius
range or angle range
exceeded

• Fallen below the minimum

radius or gone past the
maximum angle specified in the
respective load chart due to
luffing up the boom too far

• Luff down the boom to a

radius or angle specified
in the load chart.

E02

Radius range exceeded
or fallen below angle
range

• Gone past the maximum radius

or fallen below the minimum
angle specified in the respective
load chart due to luffing down
the boom too far

• Luff up the boom to a

radius or angle specified
in the load chart.

E03

Non-permitted slewing
zone (no load area)

• The slewing zone with load is

not permitted

• Slew to permitted area

E04 Operating mode not

acknowledged or non
permitted slewing zone

• A non existing operating mode

has been selected

• The boom is in a non-permitted

slewing zone

• Set the correct operating

mode for the operating
state in question

• Slew the boom to a

permitted area.

The errors showed on the table are part of the possible errors of an LMI system. The Elimination on the
table only gives the operator some basic guidelines of solving the problems. If the errors cannot be
solved by following the instruction in the table, please contact our service team:
Tel： [phone]
Fax： [phone]

CAUTION

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Error

Code

Error

Cause

Elimination

E05 Prohibited length range

• Boom has been extended either

too far or not far enough, e.g. if
it is prohibited to go beyond a
certain maximum boom length
or with load curves for jibs
where the main boom has to be
extended to a certain length

• Length sensor adjustment has

changed, e.g. the cable slid off
the length sensor reel.

• Clutch between length sensor

pot and drive is defective

• Extend/retract boom to

the correct length

• Retract boom. Check the

prestress of the cable reel
(cable must be taut). Open
the length sensor and
carefully turn the length
sensor pot
counterclockwise until the
detent by means of a
screw driver

• Replace the complete

clutch including drive
wheel and adjust length
sensor pot as described
above

E06

Radius range exceeded
or fallen below angle
range with luffing jib
operation

• Maximum radius as specified in

the load chart exceeded or fallen
below minimum angle due to
luffing down the luffing jib too
far

• Luff the jib to a radius or

angle specified in the load
chart.

E07

Overload relay check

• relay = overload active and CU

input 20 = on

• relay = no overload and CU

input 20 = off

• check cable to overload

relay and CU input 20

• check relay

• check CU input 20

E11

Fallen below lower
limit value for
measuring channel "
main boom length "

• Length potentiometer is

defective

• Electronic component in the

measuring channel is defective

• Replace length

potentiometer

• Replace sensor unit

E12 Fallen below the lower

limit value in the
measuring channel
"main boom pressure
piston side1"

• Pressure transducer is defective.

• Electronic component in the

measuring channel is defective.

• Replace pressure

transducer

• Replace sensor unit

E13 Fallen below lower

limit value in the
measuring channel "
main boom pressure
rod side1"

• refer to E12

• refer to E12

E14

Fallen below lower
limit value in
measuring channel
"luffing jib force 1"

• Force transducer defective

• Electronic component in the

measuring channel is defective.

• Replace force transducer

• Replace sensor unit

E15

Fallen below lower
limit value in
measuring channel "
main boom angle 1"

• Angle potentiometer defective

• Electronic component in the

measuring channel defective.

• Replace angle sensor

• Replace angle unit

E16

Fallen below lower
limit value in
measuring channel "fix
jib angle1 "

• Angle potentiometer defective

• Electronic component in the

measuring channel defective

• Replace angle sensor

• Replace sensor unit

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Error

Code

Error

Cause

Elimination

E17

Fallen below lower
limit value "length
telescope I (+II)"

• Length potentiometer defective

• Electronic component in the

measuring channel defective

• Replace length sensor.

• Replace sensor unit

E18

Fallen below lower
limit value in
measuring channel "
luffing jib force 2"

• Force transducer defective

• Electronic component in the

measuring channel is defective.

• Replace force transducer

• Replace sensor unit

E19

Fallen below lower
limit value in
measuring channel "
main boom angle 2 "

• Angle potentiometer defective

• Electronic component in the

measuring channel is defective.

• Replace force transducer

• Replace sensor unit

E1A

Fallen below lower
limit value in
measuring channel "fix
jib angle2 "

• Cable between the central unit

and the fix jib angle sensor
defective or loose. Water inside
the plug of the angle sensor

• Fix jib angle 2 potentiometer is

defective

• Electronic component in the

measuring channel defective

• Check cable as well as

plugs, replace, if need be.

• Replace fix jib angle

sensor

• Replace sensor unit

E1B

Fallen below lower
limit value in
measuring channel "
main boom pressure
piston side 2"

• Cable between the central unit

and the pressure sensor
defective or loose. Water inside
the plug of the angle sensor

• pressure potentiometer is

defective

• Electronic component in the

measuring channel defective

• refer to E1A

E1C

Fallen below lower
limit value in
measuring channel "
main boom pressure
rod side 2"

• Cable between the central unit

and the pressure sensor
defective or loose. Water inside
the plug of the angle sensor

• pressure potentiometer is

defective

• Electronic component in the

measuring channel defective

• refer to E1A

E1D

Fallen below lower
limit value in
measuring channel "
pressure piston side in
fix jib"

• refer to E1A

• refer to E1A

E1E

Fallen below lower
limit value in
measuring channel "
fix jib pressure rod side
"

• refer to E1A

• refer to E1A

E21 Upper limit value in

measuring channel
"main boom length"
has been exceeded.

• refer to E11

• refer to E11

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Error

Code

Error

Cause

Elimination

E22 Upper limit value in

measuring channel "
main boom pressure
piston side1" has been
exceeded

• refer to E12

• refer to E12

E23 Upper limit value in

measuring channel "
main boom pressure
rod side1" has been
exceeded.

• refer to E12

• refer to E12

E24

Upper limit value in
measuring channel
"luffing jib force 1" has
been exceeded.

• refer to E14

• refer to E14

E25 Upper limit value in

measuring channel
"main boom angle1"
has been exceeded.

• refer to E15

• refer to E15

E26

Upper limit value in
measuring channel "fix
jib angle 1" has been
exceeded.

• refer to E16

• refer to E16

E27

Upper limit value in
measuring channel
"length telescope I
(+II) has been
exceeded.

• refer to E17

• refer to E17

E28

Upper limit value in
measuring channel "
luffing jib force 2" has
been exceeded.

• refer to E18

• refer to E18

E29

Upper limit value limit
value in measuring
channel " main boom
angle "2 has been
exceeded.

• refer to E19

• refer to E19

E2A

Upper limit value in
measuring channel "fix
jib angle2 "
has been exceeded.

• refer to E1A

• refer to E1A

E2B

Upper limit value in
measuring channel "
main boom pressure
piston side 2 "

• refer to E1B

• refer to E1B

E2C

Upper limit value in
measuring channel "
main boom pressure
rod side 2 "

• refer to E1C

• refer to E1C

has been exceeded.

E2D

Upper limit value in
measuring channel "fix
jib pressure rod side "
has been exceeded.

• refer to E1A

• refer to E1A

Page 48

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Load Moment Indicator for Telescopic Crane iFLEX E5

Error

Code

Error

Cause

Elimination

E2E

Upper limit value in
measuring channel "
fix jib pressure rod side
" has been exceeded.

• refer to E1A

• refer to E1A

E31 Error in the system

program

• The system program file is

defective.

• Flash-EPROM defective

• Upload valid system

software

• Replace central unit

E37

Error in the logical
program flow

• System program file is

defective

• Flash-EPROM defective

• Upload valid system

software

• Replace central unit

E38 System program and

crane data file do not
match.

• The system program in the LMI

does not match to the
programming in the crane data
file

• Upload valid system

program file or the valid
crane data file

E39 System program and

load chart file do not
match

• The system program in the LMI

and the programming in the load
chart file do not match.

• Upload valid system

program file or the valid
load chart file

E3A

DAT data not match
TLK data

• DAT data not match TLK data

• Upload valid DAT TLK

E43 Error in the

write/read memory,
(RAM)

• Write/read memory (RAM) or

central unit defective.

• Replace central unit

E47

Error in the monitored
write/ read memory.

The CRC verification
of the monitored
write/read memory
provides an incoherent
result

• The CRC sign of the monitored

write/read memory is wrong

• The buffer battery is decharged

(< 2V at 1kOhm).

• Central unit defective.

• Restart the LMI

• Replace buffer battery on

the central unit.

• Replace central unit

E51 Error in the crane

data file

• No valid data in the crane data

file.

• Flash-EPROM defective

• Upload valid crane data

file

• Replace central unit

E52 Error in load chart file.

• No valid data in the load chart

file

• Flash-EPROM defective

• Upload valid load chart

file

• Replace central unit

E53

No additional
DAT-bank found

• Error in data programming

• Check data programming

E56 Error in crane data file.

• No valid data in the crane data

file during calibration.

• Flash-EPROM defective

• Restore or upload valid

crane data file

• Replace central unit

E57 Error in serial crane

data file.

• Calibration data file does not

contain valid data.

• Flash-EPROM defective

• Upload calibration data

file

• Replace central unit

E60

The selected DAT bank
does not contain the
correct bank number

• Incorrect value in A2.13

• DAT bank not linked

• Incorrect bank number in TLK

• Correct value

• Check LIS file

• Check TLK file

E61 Error in the CAN bus

data transfer for all
CAN units

• CAN Bus cable between the

central unit and the sensor unit
defective or not connected.

• Can bus port in the central unit

defective

• Short circuit in a CAN Bus

• Check the connection

between the central unit
and the sensor units

• Replace the central unit

• Replace Can Bus cable

Page 49

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Load Moment Indicator for Telescopic Crane iFLEX E5

cable

Error

Code

Error

Cause

Elimination

E62 Error in the can bus

data transfer of the
pressure transducer
sensor unit

• Cable between the central unit

and the sensor unit defective.

• Can bus port in the central unit

defective

• Can bus port in the sensor unit is

defective

• Sensor unit is defective

• Check the cable to the

sensor unit

• Replace the central unit

• Replace the sensor unit

• Replace the sensor unit

E63 Error in the can bus

pressure transducer
sensor unit

• The analog values of the sensor

unit are invalid

• Replace the sensor unit

E64 Error in the can bus

data transfer of the
length/angle sensor
unit

• See E62

• See E62

E65 Error in the can bus

length/angle sensor
unit

• See E63

• See E63

E66 Error in the can bus

data transfer of the 2nd
length/angle sensor
unit

• See E62

• See E62

E67 Error in the can bus of

the 2nd length /angle
sensor unit

• See E63

• See E63

E68 Error in the can bus

data transfer of the
force sensor unit

• See E62

• See E62

E69 Error in the can bus

force sensor unit

• See E63

• See E63

E71

Too large difference of
the boom angles at tip
and base boom.

• The angle on the boom head

exceeds the main boom angle.

• Check angle sensor on the

boom head.

• Check angle sensor on the

base boom.

E80

Error in the slewing
angle measurement

• The difference between the

average of the slewing angle and
one of the wipers of the slewing
potentiometer is out of the
tolerance

• Check the slewing

potentiometer adjustment

• Replace slewing angle

sensor

E82 Error control task

• The control task is not running

• Restart the system

• Load the control task

• Check SLI configuration

E83

Error Tele-Control

• Invalid Tele-Code (0) from

external Tele-Control

• Restart the system

• Check wirering

E84 Wrong rigging

condition.

• The selected rigging condition is

not contained in the crane data
file.

• Select another rigging

condition

• Check the programming

in the crane data file.

E85 Error in the radius

determination

• The computed radius is too

small (negative deflection)

• Check the programming

in the crane data file.

E86 Faulty percentage for

at least one telescope

• Telescope has a percentage < -

2% or > 106 %.

• Read out the percentages

on the console. If a
telescope has to be
extended too far: retract

Page 50

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Load Moment Indicator for Telescopic Crane iFLEX E5

tele

Error

Code

Error

Cause

Elimination

E87 Faulty length

measurement.
The determined
tele-combination does
not correspond to the
length measurement.

• Error in the length measurement

system.

• Overall length measurement

defective.

• The measured tele-length

does not correspond to the
tele percentages.

• Check measurement of

overall length

E88

Faulty main boom
position during luffing
jib operation

• During luffing jib operation the

main boom is not in the
prescribed angle range

• Angle measurement of main

boom defective.

• Luff main boom to the

permitted range

• Check angle measurement

of the main boom.

E91

No data transmission
form the console to the
central unit
(serial data
transmission only)

• 24 V supply of the console is

interrupted

• Interruption or accidental

ground in the line between
console electronics and central
unit

• Transmitter/receiver module is

defective

• Check 24 V at terminal

X1 of the console
electronics

• Check the connection

console electronics ­central unit. In case of an
accidental ground, the
transmitter module of the
console electronics might
be damaged. Therefore,
replaces the console
electronics.

• Exchange console

electronics or LMI main
board resp.

E92

Error in the data
transmission from
console to central unit
(serial data
transmission only)

• Loose connection in the line

between console electronics and
central unit

• Transmitter/receiver module is

defective

• Check the connection

between console
electronics and central
unit

• Exchange console

electronics or LMI main
board resp

E93

Error in the data
transmission from the
central unit to the
console
(serial data
transmission only)

• refer to E92

• refer to E92

Page 51

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126

Load Moment Indicator for Telescopic Crane iFLEX E5

Error

Code

Error

Cause

Elimination

E94 No data transmission

from the central unit to
the console

Serial data transmission:

• Interruption or accidental

ground in the line central unit –
console

• 5 V supply of the computer in

the central unit is missing

• 5 V supply is too low

• Transmitter/receiver module is

defective

• Computer module is defective

• Electro-magnetic interferences

(e.g. when switching contactors
or valves)

• Check line to the console

(in case of accidental
ground, replace console
electronics, too).

• Check connection to the

power unit

• Exchange the LMI main

board

• Replace console

electronics or LMI main
board

• Replace processor board.

• Eliminate the source of

interferences by inverse
diodes or varistors

Can bus data transfer:

• Cable between the central unit

and the console defective.

• Can bus port in the central unit

defective

• Can bus port in the console is

defective

• Console defective

• Check the cable to the

console

• Replace the central unit

• Replace the console

• Replace the console

E95 Error in the console

File

• The console File is defective.

• Replace the console File

E96 Error in the internal

RAM of the console.

• The CPU of the console is

defective.

• The console main board is

defective.

• Replace the CPU of the

console

• Replace the console main

board.

E97 Error in the external

RAM of the console

• The external RAM of the

console is defective.

• The console main board is

defective.

• Replace the external

RAM of the console.

• Replace the console main

board.

E97 Error in the external

RAM of the console

• The external RAM of the

console is defective.

• The console main board is

defective.

• Replace the external

RAM of the console.

• Replace the console main

board.

E98 LMI watchdog

activated

• LMI processing time limit

exceeded

• Reset system

• Connect PC terminal and

watch error messages

EAB

Short circuit in the
A2B switch circuit

• Short circuit in the A2B switch

• Short circuit in the cable to the

A2B switch

• Replace A2B switch

• Replace cable to the A2B

switch

EAC

A2B switch circuit
disconnected

• Disconnected cable in the A2B

switch

• Disconnected cable to the A2B

switch

• Connect or replace cable

in the A2B switch

• Connect or replace cable

to the A2B switch

EAD

No valid A2B switch
status

• Sensor wrong function

• CAN bus delay

• Replace A2B switch

• Replace cable to the A2B

switch

Page 52

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126

Load Moment Indicator for Telescopic Crane iFLEX E5

Error

Code

Error

Cause

Elimination

EDA

Datalogger write error

• Datalogger not connected

• No power supply

• Wrong Dosdrive status

• Check CAN bus

connection

• Check power supply

• Connect PC terminal and

Refer to Dosdrive status
list

EDB

Datalogger setup error

• Setup of the datalogger is

cleared (ser. crane data file or
battery buffered RAM)

• transfer data and setup

datalogger again

• temporary: Press horn

quitt button to work
without datalogger

EDC

Datalogger watchdog
activated

• datalogger processing time limit

exceeded

• Reset system

• Connect PC terminal and

watch error messages

EDD

Battery empty

• Battery check detected a low

voltage of the battery

• change batterie, after this

setup of RTC

• Temporary: Press horn

quitt button to work
without datalogger

EE0

Timebase invalid

• The real time clock is in an

invalid state

• Setup of Time and date

Page 53

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126

Load Moment Indicator for Telescopic Crane iFLEX E5

Question and Answer

Question

Answer

1、Why the OM setting is correct
but the current rated load is
different with the performance
diagram of manufacture （ other
parameter are all normal）？

Answer：Possible reason is your reeving setting is different
with actual data. E.g. current performance shows the rated
load is 20T and reeving setting is 1. But because the largest
load for single steel cable is 4T, the rated load displayed on
central unit is 为 4T.

2 、 Why the outrigger are fully
extended, current rated load is not
same with performance diagram?

Answer：①maybe you have forgot to open the switch of
outrigger fully extended on operation panel；②、forgot to
confirm the operation of outrigger fully extended during

console OM setting of console.

3、Why system show E04？

Answer：OM setting is wrong, please set OM correctly.

4、Why system has no mistake but
the display parameter of crane are
all wrong?

Answer：If the unit of parameter shows as kips, please set it as
metric system correctly.

5、 why the empty hoist load is
wrong after boom extended?

Answer：Confirm whether the boom extend order is correct,
please correctly use extend and restrict switch.

6、Why the LMI is warming and
load percentage exceeded 100%
while the crane still operation to
dangerous direction？

Answer：①、please check whether the enforce switch is open
or not ②、external circuit is break off

7、Why the load shows extremely
large at some large angle？

Answer：Maybe under current boom length the largest angle
has been reached, hydraulic pressure of luffing hydraulic
cylinder raise to high point causing the above phenomenon.

8、Why current load is much small,
the displayed percentage status bar
show bigger number? The
percentage calculation is not
correct?

Answer ： Our products are LMI protection equipment,
percentage status bars means percentage of actual load and
rated load, not percentage for displayed load and rated load.

Remark：All above answer are possible reason but not the only reason for the questions under the
condition of no error for system. Please contact professional engineer if your problem could not be
solved according to the preliminary judgment.

Page 54

2

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126

SkyAzúl, Inc.

16 Walnut Street

Middletown, MD 21769

Phone [phone]
Fax [phone]

[e-mail]

www.skyazul.com