iFLEX2 + iSCOUT

expert compact
LMI system for
Grove RT / TM

Contents
General Information
Warnings
System Description
What's wrong?
Angle sensing
Length sensing
Pressure sensing

Service Manual
Issue 8/2007 Rev. A
This document is listed under Order No.
50 650 69 0101e (Grove RT-TM)

MAIN MENU

General Information

TABLE OF CONTENTS
1

General Information.............................................................................................................................5

Warnings...............................................................................................................................................5

3
3.1
3.2
3.3

Description Of The System.................................................................................................................6

Description of system function...............................................................................................................6
Description Of A Can Bus System.........................................................................................................6
Description of the System Components ................................................................................................7

4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10

Whats Wrong? ....................................................................................................................................8

I have an error code indicated on the console ......................................................................................8
The displayed angle does not match the actual boom angle ................................................................8
The displayed length does not match the actual boom length ..............................................................8
The displayed slewing does not match the actual slewing angle..........................................................8
The displayed load does not match the actual load ..............................................................................8
The console display is blank..................................................................................................................8
I have an A2B problem ..........................................................................................................................8
I Have A CAN-Bus Problem...................................................................................................................8
I need to identify a spare part ................................................................................................................8
I have noticed water in some part of the system ...................................................................................8

5
5.1

Angle Sensing ......................................................................................................................................9

Angle sensing error - flow chart...........................................................................................................10

6
6.1

Length Sensing..................................................................................................................................12
Length sensing error - flow chart .........................................................................................................13

7
7.1

Pressure Sensing ..............................................................................................................................15

Pressure sensing error - flow chart......................................................................................................15

8
8.1

Slewing Sensing ................................................................................................................................16

Slew sensing error - flow chart ............................................................................................................17

9
9.1

Load sensing......................................................................................................................................18
Load sensing error - flow chart ............................................................................................................18

10

No console display ............................................................................................................................19

11

A2B Problem ......................................................................................................................................20

12
12.1
12.1.1
12.2
12.3
12.4
12.4.1
12.5

CAN-Bus communication .................................................................................................................21

E61.......................................................................................................................................................21
E61 - Flow Chart..................................................................................................................................22
E62.......................................................................................................................................................23
E63.......................................................................................................................................................23
E64.......................................................................................................................................................23
E64 - Flow Chart..................................................................................................................................24
E65.......................................................................................................................................................24

13

Troubleshooting a sensor problem using the display...................................................................25

2007 HIRSCHMANN Automation and Control GmbH

Service Manual

iFLEX2 with iSCOUT expert compact

14
14.1
14.2
14.3
14.3.1
14.3.2
14.3.3
14.3.4
14.3.5
14.3.6
14.3.7
14.3.8
14.4
14.4.1
14.4.2
14.4.3

Drawings ............................................................................................................................................ 28
Components of the LMI system PAT iFLEX2 with iSCOUT expert compact ..................................... 28
Block Diagram..................................................................................................................................... 29
Electrical System Diagram Standard System ..................................................................................... 30
Central Unit, Overview ........................................................................................................................ 30
Central Unit, Detail A........................................................................................................................... 31
Central Unit, Detail B........................................................................................................................... 32
Sensors Wiring (page 2) ..................................................................................................................... 33
Console Wiring (page 3) ..................................................................................................................... 34
Crane Interface RT530-2 / RT540E (page 4) ..................................................................................... 35
Crane Interface RT600E / RT700E / RT875E (page 4)...................................................................... 36
Crane Interface TM500E-2 (page 4)................................................................................................... 37
Main Central Unit Connector............................................................................................................... 38
Cable Reel (LG152/0056) Wiring Diagram ......................................................................................... 39
Cable Reel (LWG520/0002) Wiring Diagram ..................................................................................... 40
Luffer Extension Wiring Diagram ........................................................................................................ 41

15
15.1
15.2
15.3
15.4
15.4.1
15.5

Sensor Calibration ............................................................................................................................ 43

Activating the Service Screen for Sensor Calibration......................................................................... 43
Zero-setting the Pressure Inputs ........................................................................................................ 44
Zero-setting the slewing inputs ........................................................................................................... 45
Length Sensor Calibration Procedure................................................................................................. 46
Cable Reel Length Cable Replacement Procedure............................................................................ 49
Angle Sensor Calibration Procedure .................................................................................................. 50

16

Error Codes ....................................................................................................................................... 53

17
17.1
17.2

Troubleshooting Moisture................................................................................................................ 58
Water Ingress...................................................................................................................................... 58
Condensation ...................................................................................................................................... 59

The manufacturer reserves the right to modify the contents of this manual without notice. Hirschmann 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 Hirschmann.
Hirschmann 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 Hirschmann.
The drawings and/or photos are subject to technical modification without prior notice.
All information in this document is subject to change without notice.

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

General Information

GENERAL INFORMATION

This service manual is designed to assist a service or maintenance person in identifying system
problem areas or malfunctions. A digital voltmeter with the capability to measure current will be
required, along with standard maintenance and service tools.
NOTE: Knowledge of how to use a voltmeter to measure both voltage and current is assumed.
REFERENCE: For system operation, refer to the consoles operators manual 50 650 19 0101e.

WARNINGS

The LMI is an operational aid that warns a crane operator of approaching overload conditions and
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 crane operating procedures.
The responsibility for the safe crane 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 indicator and
crane.
Proper functioning depends upon proper daily inspection and observance of the operating instructions
set forth in this manual. Refer to Section 6. Pre-Operation Inspection and Calibration Verification of
the operators manual.

The LMI can only work correctly, if all adjustments have been properly set. For correct
adjustment, the operator has to answer thoroughly and correctly all questions asked during
the setup procedure in accordance with the real rigging state of the crane. To prevent
material damage and serious or even fatal accidents, the correct adjustment of the LMI has
to be ensured before starting the crane operation.

2007 HIRSCHMANN Automation and Control GmbH

Service Manual

3
3.1

iFLEX2 with iSCOUT expert compact

DESCRIPTION OF THE SYSTEM

Description of system function

The iFLEX2 system is a CAN bus system made up of a central microprocessor unit, operating
console, length/angle sensor, pressure transducers, and anti-two block switches. All components and
sensors are equipped with CAN bus controllers.
The PAT Load Moment Indicator system operates on the principle of reference/real comparison. The
real value, resulting from the pressure measurement is compared with the reference data, stored in
the central processor memory and evaluated in the microprocessor. When limits are reached, an
overload warning signal is generated at the operators console. At the same time, the aggravating
crane movements, such as hoist up, telescope out and boom down, will be stopped.
The fixed data regarding the crane, such as capacity charts, boom weights, centers of gravity and
dimensions are stored in memory chips in the central processor unit. This data is the reference
information used to calculate the operating conditions.
Boom length and boom angle are registered by the length/angle sensor, mounted inside the cable
reel, which is mounted on the boom. The boom length is measured by the cable reel cable, which also
serves as an electrical conductor for the anti two-block switches.
The crane load is measured by pressure transducer block attached to the piston and rod side of the
hoist cylinders.
The interactive user guidance considerably simplifies the input of operating modes as well as the
setting of geometry limit values.

3.2

DESCRIPTION OF A CAN BUS SYSTEM

CAN stands for Controller Area Network. Its intended use is as a serial bus system for a network of
controllers. Each controller connected through a CAN chip is called a "node" and is mostly used to
acquire data from a sensor. All nodes are connected to a common bus and all nodes are able to
simultaneously read the data on that bus. Also, all nodes are able to transmit data on that bus
however only one node at a given time has write access to the bus. If the message is relevant, it will
be processed; otherwise it is ignored. The unique identifier also determines the priority of the
message. The lower the numerical value of the identifier, the higher the priority.
The cable bus is a twisted pair of shielded wire. Data can be transmitted in blocks from 0-8 bytes at a
maximum transfer rate of 1 Mbit/s for networks up to 40 meters. For longer network distances the
maximum transfer rate must be reduced to 50 Kbit/s for a 1 km network distance. CAN will operate in
extremely harsh environments and the extensive error checking mechanisms ensure that any
transmission errors are detected.

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Description Of The System

3.3

DESCRIPTION OF THE SYSTEM COMPONENTS

Pressure Transducer: The pressure transducer converts hydraulic pressure into
an electric signal. A pressure transducer block houses two transducers, CAN bus
converter board, and two bus connectors. One pressure transducer is connected
to the piston side of the lift cylinder and the other to the rod side.
The Length-Angle Transducer: The length-angle sensor (LWG), often referred to
as the cable reel, is a combination of two transducers in one box, installed on the
base section of the boom. It measures the length and the angle of the boom.
A reeling drum drives a potentiometer, which is the length transducer. Part of the
length transducer circuit is the length cable on the drum, which is a multiconductor cable. It is connected to the anti-two-block switch at the boom head
and to a slip ring body in the LWG.
The angle transducer is a potentiometer driven by a weighted pendulum that is oil
damped. Both length and angle transducer are connected to a CAN bus controller
board, which is connected to the bus system.
Anti-Two-Block Switch: The anti-two-block switch monitors the load block and
its relationship with the head of the boom. In working condition the switch is
closed. When the load block strikes the weight the circuit opens, disengaging a
relay output to the lock out solenoid valves, where applicable. To check the cable
for damage, (short circuit to ground) there is a 4.7k resistor between ground and
the contact of the switch, to give a signal back to the central unit. The weight at
the anti-two-block switch keeps the switch closed until the load block strikes it.
Console: The graphic console displays all geometrical information such as length
and angle of main boom, working radius and head height of the boom. It also
displays the actual load and the maximum load permitted by load chart.
Furthermore, it has an alarm horn, a warning light for overload, and a pre-warning
light. The graphic display allows for a simple interactive configuration setup, as
well as sensor calibration (zero adjustment), and troubleshooting sensor output
screen. The console has a warning light for anti-two-block conditions and an
override switch for overload or anti-block condition.
Refer to Operators Handbook for detailed operation of the console.
Central Unit: Inside the central unit there is a CPU. The central unit has a hard
mounted connector for all signals. A status indicator (7-segment display) shows
operation and error codes.
Slew Potentiometer: This component is not supplied by PAT/Hirschmann. It is
part of the electrical swivel (slip ring assembly). The potentiometer has two wipers
which are used to determine the slewing angle (rotational positioning) of the super
structure in relation to the carrier. The slew input to the central unit is not a CAN
signal, but rather two 4..20mA analog signals.

2007 HIRSCHMANN Automation and Control GmbH

Service Manual

iFLEX2 with iSCOUT expert compact

WHATS WRONG?

So, whats wrong? Assuming you are reading these pages because of some kind of problem with the
PAT system, let us try to guide you quickly to solving the problem. In most cases, your problem will
fall under the following categories:

4.1

I HAVE AN ERROR CODE INDICATED ON THE CONSOLE

Please go to section Error Codes.

4.2

THE DISPLAYED ANGLE DOES NOT MATCH THE ACTUAL BOOM ANGLE

Start in section Angle Sensing to check the indicated angle.

4.3

THE DISPLAYED LENGTH DOES NOT MATCH THE ACTUAL BOOM LENGTH

Start in section Length Sensing to check the indicated length.

4.4

THE DISPLAYED SLEWING DOES NOT MATCH THE ACTUAL SLEWING ANGLE

Refer to section Slewing Sensing to check the slew sensor.

4.5

THE DISPLAYED LOAD DOES NOT MATCH THE ACTUAL LOAD

Please note that the indicated load is calculated by the system from the geometry information in the
computer, the operators selections, and all the sensor inputs. If the load display is off, it can therefore
be due to an error in any or several of these inputs! Refer to section Load sensing to narrow down the
source of your problem.

4.6

THE CONSOLE DISPLAY IS BLANK

If the console does not show any sign at all (no lights, no buzzer, no display), the problem is either in
the wiring between console and central unit, or the console itself. Refer to section No console display
for further troubleshooting.

4.7

I HAVE AN A2B PROBLEM

Please go to section A2B PROBLEM

4.8

I HAVE A CAN-BUS PROBLEM

Please go to section CAN-Bus Communication!

4.9

I NEED TO IDENTIFY A SPARE PART

Please go to the Spare Part Listings!

4.10

I HAVE NOTICED WATER IN SOME PART OF THE SYSTEM

Please go to section Troubleshooting Moisture!

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Angle Sensing

ANGLE SENSING

The System measures the angle of the main boom of the machine with an angle sensor. The angle
sensor is contained within the cable reel, located on the left side of the main boom.
Block Diagram

Angle
Sensor

CAN-Bus
Converter

Cable Reel

iFLEX2
CU

Pressure Transducer

The signal runs from the angle sensor to the Can-Bus converter board, both located in the cable reel.
From there, it travels as digital information on the CAN-Bus to the pressure transducer, which acts as
a T-connector to the main CAN-Bus running to the central unit.
So, what do you do when you are having a problem with your angle read-out?
Start by verifying the angle display. Refer to the section Troubleshooting A Sensor Problem Using
The Display to call up the sensor signal on your console display. The CAN-Bus is digital and as such
will either transmit the signal correctly or not at all. If your readings are off, you have to determine
what is causing the problem (reference the following flow charts).

X1
X14 (A2B)
X20
X21 (angle)
LED
CAN-Bus electronics in cable reel

The angle sensor has a potentiometer built in that is driven by a pendulum. As the angle changes, so
will the pendulum and with it the potentiometers axle. The converter board supplies a constant
voltage of 5V to the angle sensor and in return monitors the voltage of the potentiometer.
The terminal used is X21. The angle sensor is connected as follows:
Terminal X21
1
+ 5V
3
Signal
5
GND

2007 HIRSCHMANN Automation and Control GmbH

Service Manual

5.1

iFLEX2 with iSCOUT expert compact

ANGLE SENSING ERROR - FLOW CHART

Angle Sensing Error

First, verify the angle displayed through the console

by using the sensor output screen.
Select "info" twice:

compare

Open the cable reel

and locate the angle
sensor (right) and
CAN-Bus converter
board (left).

YES
2ND
Angle
sensor is
functioning
correctl

Verify that the sensor is

being supplied with 5V
by measuring between
pin 5 (GND) and Pin 1
(+) of terminal X21.

1ST

Angle sensor
range values:
4500mV at 0
2500mV at 45
500mV at 90

Does the displayed

value differ from the
actual value?

Recalibrate angle
sensor.
(Reference Angle
sensor calibration
procedure).

YES, 1st

NO

Continue with angle sensing

flow chart (next page)

Is the voltage
between the
range of 4.75
to 5.25V ?

Unplug angle sensor

and measure again.
NO

MEASURE AGAIN

2ND

Is the voltage
between the
range of 4.75
to 5.25V ?

NO

Replace converter
board

YES
If unplugging the angle sensor made the voltage return to
the acceptable range, replace the angle sensor. Follow
procedure for angle sensor installation and calibration.

10

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Angle Sensing

Angle Sensor signal varies

Ensure the angle sensor returns a voltage

between 1.875V at 90 and 3.125V at 0

Verify the voltage by measuring

Between Pin 5 (GND) and Pin3
(signal) of terminal X21.

Angle Sensor Signal

On Pin 3:
Angle
Voltage
90
1.875
75
2.083
60
2.292
45
2.500
30
2.708
15
2.917
0
3.125
Note: Actual voltages will vary
slightly.

If this angle varies significantly

from your actual angle,
replace the angle sensor.

YES

Does the indicated

angle vary by more
than +/- 0.25 from
the actual angle?

NO
Replace converter
board.

Ensure correct software has been

installed and crane operator is not in

Note: If you need to determine the angle for voltages other than
shown above, do so by using the following formula:
Angle (degrees) = 90 degrees ((Voltage-1.875) * 72)

2007 HIRSCHMANN Automation and Control GmbH

11

Service Manual

iFLEX2 with iSCOUT expert compact

LENGTH SENSING

The system measures the length of the main boom of the machine with a length sensor. The length
sensor is contained within the cable reel, located on the left side of the main boom.
Block Diagram

Length
Sensor

CAN-Bus
Converter

Cable Reel

iFLEX2
CU

Pressure Transducer

The signal runs from the length sensor to the CAN-Bus converter board, both
located in the cable reel. From there, it travels as digital information on the
CAN-Bus to the pressure transducer, which acts as a T-connector to the main
CAN-Bus running to the central unit.
So, what do you do when you are having a problem with your length read-out?
Start by verifying the length display. Refer to the section Troubleshooting A Sensor Problem Using
The Display to call up the sensor signal on your console display. The CAN-Bus is digital and as such
will either transmit the signal correctly or not at all. If your readings are off, you have to determine
what is causing the problem (reference the following flow charts).

X1 (CAN)
X14 (A2B)
X20
X21 (angle)
LED
CAN-Bus electronics in cable reel.
The length sensor has a potentiometer built in that is driven by a gear drive from the cable drum. As
the length changes, the cable drum will turn and with it the potentiometers axle. The converter board
supplies a voltage of about 4.7V to the length potentiometer and in return monitors the output voltage
of the potentiometer. The terminal used is X20. The length sensor is connected as follows:
Terminal X20
1
+ (~ 4.8V)
3
Signal
5
- (~ 0.2V)

12

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Length Sensing

6.1

LENGTH SENSING ERROR - FLOW CHART

Length Sensing Error

First, verify the length displayed through the

console is off by using the sensor output screen.
Select "info" twice:

Ensure the
cable reel has
5-8 turns of
preloading on
the reel.

Open the cable reel

and locate the length
sensor (right) and
CAN-Bus converter
board (left).

Length sensor is
functioning correctly.

YES

Does the displayed

value differ from the
actual value?

NO

Fully retract the boom and turn the

screw of the length potentiometer
with a small screwdriver counterclockwise to a soft stop, bringing the
sensor voltage to 0V (+/- 0.1 Volt).

Select "info" twice:

Measure voltage between

Pin 5 (-) and Pin 3 (signal)
of terminal X20 and compare.

Return to the indication screen and again

compare the indicated and actual length.

Replace length
sensor.
Does the indicated
length vary
significantly from the
actual length (more
than 0.3 feet)?

Proceed to next length sensing flow chart.

2007 HIRSCHMANN Automation and Control GmbH

YES

NO

13

Service Manual

iFLEX2 with iSCOUT expert compact

Length Sensor varies

See length sensor
signal chart below.

YES

Is the voltage
between the
range of 4.7V
to 5.0V ?

Ensure the length

sensor is being
supplied with 4.7V by
measuring between
Pin 5 (-) and Pin 1 (+)
of the X20 terminal.

1ST

NO

2ND

Is the voltage
between the
range of 4.7V
to 5.0V ?

YES

Unplug the length

sensor and
measure again.

NO

Replace
converter
board.

If unplugging the length sensor

made the voltage return to the
acceptable range, replace the
length sensor. Follow
procedure for length sensor

The length sensor returns a voltage between 0.16V at 0 turns of the length pot (= fully retracted) and
4.84V at 10 turns. How many turns you get at full extension depends on the gear ratio, the boom
length, the length cable used and the spooling pattern, so we cannot provide a standard table for it.
What we can give you for trouble-shooting, however is the following table that shows the expected
output voltage (measured between X20-5 and X20-3 Signal) for each complete turn of the length
potentiometer. Note that this does not sync to the number of turns of the cable reel, though:
Length Sensor Signal on Pin 3
Turns
Voltage X20-5 to
X20-3
0
0.00
1
0.46
2
0.93
3
1.40
4
1.87
5
2.34
6
2.81
7
3.28
8
3.75
9
4.22
10
4.68

Voltage GND to X20-3

0.16
0.62
1.09
1.56
2.03
2.50
2.97
3.44
3.91
4.38
4.84

Note: Actual voltages will vary slightly.

For the boom control system, the length sensors are the same as described above with the exception
of cable reel internals (location of hardware, wiring, and gear wheels). Refer to the LWG520 and
LG152 spare part list for these differences.

14

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Pressure Sensing

PRESSURE SENSING

The System measures the pressure of the boom lift cylinder for both rod- and piston-side.
Both sensors are contained within one box that also contains the electronics needed for amplification
and creation of the CAN-Bus signal.
Block Diagram:

(2)
PressureMeasuring
Cells

CAN-Bus
Converter

The signal runs from the pressure transducer as

digital information on the CAN-Bus to the central
unit.

Pressure Transducer

7.1

iFLEX2
CU

PRESSURE SENSING ERROR - FLOW CHART

Pressure Sensing Error

First, verify the pressure displayed through the

console by using the sensor output screen.

Pressure transducers are

functioning correctly.

Select "info" twice:

Does the
displayed value
differ from the
actual value?

NO

YES
Ensure that the pressure lines
are drained and disconnected.

The readout should

read 500mV (+/25mV) and 0 PSI.

Replace pressure transducers.

If the reading is slightly off, small variations can be adjusted;

see section Service Screen For Sensor Calibration.

Note: After exchanging the pressure transducer block, both transducer channels need to be zeroed,
see procedure Zero-Setting The Transducer Inputs.

2007 HIRSCHMANN Automation and Control GmbH

15

Service Manual

iFLEX2 with iSCOUT expert compact

SLEWING SENSING

The system measures the slewing (rotational position) of the cranes upper with a slewing sensor. The
slewing sensor is contained within the slip ring assembly.
Block Diagram

Slew
Potentiomet
er with (2)
outputs

Current
Converter

iFLEX2
CU

Slip Ring Assembly

The slew potentiometer has two potentiometers built in that are driven by the slip ring axle. As the
slewing angle changes, so will the axle and with it the potentiometers outputs. Use the display screen
by pressing i (info) twice to show all sensor inputs.
ANGLE
(deg)
0.0
30.3
60.0
89.9
120.1
150.1
180.0
-150.1
-120.1
-90.0
-60.1
-30.0
0.0

The table to the right show measured millivolt reading for

the slew potentiotmeter.

SL ANG 1
(mv)
717
1174
1680
2158
2641
3144
3595
3144
2642
2160
1681
1172
718

SL ANG 2
(mv)
2161
2645
3150
3595
3141
2639
2161
1681
1180
718
1168
1680
2161

Modular Slew Pot - Voltage on Service Screen

4000
3500
MILLIVOLTS

The converter board is supplied with

12V from the central unit.
The potentiometer and the board
output two signals between 4 and
20mA that go to the central unit. You
can measure them at the 12-pin crane
interface connector.

3000
2500
2000
1500
Potentiometer 1

1000

Potentiometer 2

500
0

0
45 sensor
90inputs135
Display screen
for
0

16

45

90

135

180
225
180
-135
SLEW ANGLE

270
-90

315
-45

360
0

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Slewing Sensing

8.1

SLEW SENSING ERROR - FLOW CHART

Slew Sensing Error

First, verify the slew angle displayed through the console

by using the sensor output screen.
Slew potentiometer is
functioning correctly.
Select "info" twice:
Does the
displayed value
differ from the
actual value?

Ensure that the slew pot unit

is supplied with crane voltage.

NO

YES

The slew unit output can be found on pins 8 and 9. In order to

measure current, however, you must disconnect a pin and
measure in line (between the cable from the slew unit and the
central unit). *The two outputs will vary as shown in chart below.

Pin 7 must carry crane

voltage and Pin 2 is GND.

You can also leave the wires connected as use your meter in
Voltage-mode to measure the output signals. In this case, you
will see the 420mA range as a 1.1 to 5.5 Volt range.
If the voltage or currents do not fall in line with the
charts and tables shown below, and no system
errors are present, the problem may be mechanical.

Open the slip ring unit and determine if the slew potentiometer is set

mA 2

M odular Sle w Pot - Output Curre nts

mA 3
24

(When the crane is over front, you should

see about 4mA in one channel (wire #2)
and 12mA in the other channel (wire #3)).

20

mA

16
12
8
4
0
0

90

180

270

360

De gr e e s

2007 HIRSCHMANN Automation and Control GmbH

17

Service Manual

iFLEX2 with iSCOUT expert compact

LOAD SENSING

Please note that the load displayed by the LMI is not a direct measurement, but a calculated value
that is based on a lot of factors. Outside of the measured values (sensors), those include:

9.1

Operator settings such as:

o Operating mode/configuration
o Parts of Line/Reeving
Rigging parts such as:
Hookblock weight
Sling weights, etc.
Tip height (length of load line used)
Boom weights
Boom attachments such as
Stowed jibs
Auxiliary boom nose, etc.

LOAD SENSING ERROR - FLOW CHART

Slew Sensing Error
First, verify the slew angle displayed through the console
by using the sensor output screen.
Slew potentiometer
is functioning

Select "info" twice:

Does the
displayed value
differ from the
actual value?

Ensure that the slew pot unit

is supplied with crane voltage.

Pin 7 must carry crane

voltage and Pin 2 is GND.

NO

YES

The slew unit output can be found on pins 8 and 9. In order to

measrure current, however, you must disconnect a pin and
measure in line (between the cable from the slew unit and the
central unit). *The two outputs will vary as shown in chart below.
You can also leave the wires connected as use your meter in
Voltage-mode to measure the output signals. In this case,
you will see the 420mA range as a 1.1 to 5.5 Volt range.

If the voltage or currents do not fall in line with the charts and tables
shown below, and no system errors are present, the problem may be
Open the slip ring unit and determine if the slew potentiometer is set

18

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

No console display

10 NO CONSOLE DISPLAY
If the console is not showing any lights, such as warning lights, backlighting, etc. it is most likely
missing power. Start with the following:
No console display

Ensure that no lights, warning

lights, or backlighting is visible.
Is power
being
supplied?

Check if power is being supplied. Measure

voltage at outer connector
(Pin 1 is +Ub 12V and Pin 2 is 0V).

Check fuses on the interface board (mounted to

the inside of the housing): (F5) protects the
override key switch function and the bar-graph.
The main fuse (F1) is located on the same
board.

Are fuses
in line?

YES

NO

YES
Open console

Check for power

on connector X2
of the interface
board. (Pin 1 is

Is power
being
supplied?

NO

+Ub 12V and Pin 2

is 0V).

NO

If no power was
supplied on the
connection board
but was supplied on
the external
connector, the
interface board must
be replaced.

YES

Replace fuse.

Connecting
cable is
loose or
defective.

Check wiring harness

Follow power from this connector to the console computer board,

connector X1. (Pin 1 is +Ub 12V and Pin 2 is 0V).

is power
being
supplied?

NO

YES

Check power rail signal LEDs H1H4 on the

console main board. These LEDs must
continuously light.
H4: -10 V

all power LEDs

continuously on?
H3: +10 V

NO
Console main
board need
replaced.

2007 HIRSCHMANN Automation and Control GmbH

H2: 3,3 V

YES
Software
Error

H1: 5V

19

Service Manual

iFLEX2 with iSCOUT expert compact

11 A2B PROBLEM
A2B problem

Are the control levers

locked out and is the
crane in an anti-two
block condition?

YES

Lower the hook block and/or

headache ball to correct the
two-block problem. If two
hoists are in use, both
hooks must be lowered.

Plug the bypass

plug into the boom
nose box and refer
to system wiring to
check wire
connections in
boom nose box.

NO
Check for
damaged length
cable and wiring.
If broken length
cable, refer to
system wiring.

If wiring is correct,
replace A2B
switch.

NO
Replace the
slip ring.

20

Turn power off, remove bypass plug, and

measure the resistance at the boom nose box
between terminals 1 and 3 with an ohmmeter.
Switch closed = 0 ohms (weight installed)
Switch open = 1 Megaohm (weight removed)

Are the ohmmeter

readings correct?

YES

Is the anti-two
block warning
light on?

NO

NO

Are the ohmmeter

readings correct?

YES

Ensure the
bypass
plug is
installed.

Ensure bypass plug is plugged into the

boom nose box. Remove wires and
measure the A2B signal in the cable reel
between the X1: (brown) an X2 (red)
wires on the slip ring with an ohmmeter.
Switch closed = 4700 +/- 500 Ohms
Switch open = > 1 Megaohm.

Remove wires and measure the A2B

signal in the cable reel between terminal
7 and 8 with an ohmmeter.
Switch closed = 4700 +/- 500 Ohms
Switch open = > 1 Megaohm.

Are the
ohmmeter
readings correct?

YES

A problem lies with either the wiring

harness, cable reel length/angle
boards, and/or the iFLEX2 central
unit.

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

CAN-bus communication

12 CAN-BUS COMMUNICATION
The System measures the length of the main boom, the angle of the main boom, the pressures of the
lift cylinder, and the A2B state of the machine via a CAN-Bus connection. Since this is a digital bus
connection, it is not possible to measure the signals on the bus with a multimeter. Instead, the LMI
provides you with error codes that give you an indication of the bus state.
The error codes are one of the following:
E61
E62
E63
E64
E65

Error in the CAN bus data transfer for all CAN units
Error in the can bus data transfer of the pressure transducer sensor unit
Error in the can bus pressure transducer sensor unit
Error in the can bus data transfer of the length/angle sensor unit
Error in the can bus length/angle sensor unit

Block Diagram

E65

E61

E64

CAN-Bus
Converter

iFLEX2
CU

E62
Pressure Transducer

Cable Reel

E63
The block diagram tries to clarify that: If the CU does not see any CAN-Bus component, it will report
an E61. If it sees only the cable reel, it will report an E62 (pressure transducer missing). If it sees only
the pressure transducer, it will report an E64 (cable reel missing). E63 means that the pressure
transducer is available, but is reporting an internal error. E65 means that the cable reel unit is
available, but is reporting an internal error.
So, what do you do when you are having a problem with one of those codes?

12.1

E61

In case of an E61, start by connecting the two cables on the transducer block together. If an E62
appears, the transducer block must be replaced. If an E61 appears, reconnect the cable from the from
the central unit to the transducer block. At this point, if an E61 still appears check your cabling. You can
verify that power is being supplied to the sensor by testing the CAN connectors per this layout:
Connector
M12, 5 contacts
Pin Layout (CiA DR-303-1 7.2)

Pin 1
Pin 2
Pin 3
Pin 4
Pin 5

Shield
+ Ub
Ground
CAN High
CAN Low

Measure between pins 3 and 2 for crane voltage. If you see voltage, check all pins for continuity.
The iFLEX2 must be replaced if this cable is functioning correctly. If the E61 error code has become an
E64, connect the cable reel can bus cable to the transducer block and remove the can bus connector at
the cable reel. If this causes an E61 to appear, the can bus cable between the cable reel and transducer
block must be replaced. If an E64 remains, use the Ohm-meter to check the connector in the cable reel.
Either the connector has failed or the can bus converter boards must be replaced.

2007 HIRSCHMANN Automation and Control GmbH

21

Service Manual

12.1.1

iFLEX2 with iSCOUT expert compact

E61 - Flow Chart

E61

Connect the two cables on the

Transducer block together

E61

Yes

E62

Replace Transducer Block

E64

Disconnect cables and connect cable

from c/u to transducer block

No

E61

Connect the cable reel can bus cable to

the transducer block. Remove can bus
connector at cable reel

E61

Yes

Ohm cable from c/u to the

transducer block. If cable checks
good replace c/u

Yes

Replace can bus cable between

Cable reel and transducer block

No

E64

Ohm out connector in cable reel.

If connector checks good, replace can bus
converter board.

22

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

CAN-bus communication

12.2

E62

In case of an E62 the CU is reporting no signal from the pressure transducer. Start by checking your
cabling between CU and pressure transducer, even though it is not very likely that there is a problem
with it since the same cable carries also the signals from the cable reel and those appear to be fine.
You can verify that power is being supplied to the sensor by testing the CAN connectors per the
above pin layout. If you are sure that the sensor is being supplied, you have to replace the pressure
transducer.

12.3

E63

In case of an E63, the pressure transducer is reporting an internal problem. You cannot troubleshoot
any further, but need to replace the pressure transducer.

12.4

E64

In case of an E64, the CU is reporting no signal from the cable reel unit. Start by connecting the two
cables on the transducer block together. If an E62 occurs, the transducer block must be replaced.
If an E61 occurs, measure the cable from the transducer block to the cable reel with an Ohm-meter.
Check all pins of the CAN bus cable for continuity and cross-check for short circuits.
If the continuity check fails, the cable must be replaced. If the cable appears to be fine, next check
the connector at the cable reel. You can verify that power is being supplied to the sensor by testing
the CAN connectors per the pin layout (see E61). Replace the connector if this check fails.
If the connector checks properly, the board in the cable reel might be defective.

X1
X14 (A2B)
X20
X21
LED
CAN-Bus electronics in cable reel.

X1 Pin

CAN

CAN_SHLD

CAN +UB

CAN GND

CAN_H

CAN_L

2007 HIRSCHMANN Automation and Control GmbH

23

Service Manual

12.4.1

iFLEX2 with iSCOUT expert compact

E64 - Flow Chart

Connect the two cables on the
Transducer block together

E64

E62

Replace transducer
block

E61

Yes

Ohm cable from the transducer

block to cable reel.

Cable
checks good

Yes

No

Replace
cable

Check connector
at cable reel

Connector
checks good

No

Yes

Replace
connector

Replace can bus board in cable reel

12.5

E65

In case of an E65, the cable reel is reporting an internal problem. In most cases, this will be an angle
sensor, length potentiometer or A2B wiring. Go to those chapters (Angle Sensing, Length Sensing,
A2B PROBLEM) to continue trouble shooting.

24

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Troubleshooting a sensor problem using the display

13 TROUBLESHOOTING A SENSOR PROBLEM USING THE DISPLAY

To determine whether there is a problem with a sensor, the system has sensor value screen built in
to make trouble-shooting easier. This is the right place to start if you are suspecting a problem with a
sensor (and you dont have an error code displayed).
to access the sensor
output screen, select
the INFO button twice

to review software
version information,
select the INFO and
then the "INFOHaeder" button once
The screen will show all sensor inputs as in the example below. For each sensor, an equivalent
voltage is shown in millivolts, along with the physical sensor value that that voltage refers to.
Pressure sensors are shown with physical values of [bar], angle sensors and slew sensors in degrees
and length sensors in feet (or meter for metric charts).

The values shown in the screen here are just examples of actual values. Refer to the table listed
below for actual value ranges.
If you suspect a sensor error or problem with a sensor, compare the indicated physical value of the
sensor on the display screen with the real value, i.e. length, angle, etc.
The voltages given are internal calculation values only; you will not be able to actually measure them
anywhere on the electronics! Typical values to be expected are:

Pressure transducers (piston and rod), 500mV @ 0 PSI; 4500mV @ maximum PSI
Length sensor, 500mV @ retracted boom length; voltage extended depends on the various
boom lengths.
Angle sensor, 4500mV at 0; 2500mV at 45; or 500mV at 90

Please refer to table below for more values:

2007 HIRSCHMANN Automation and Control GmbH

25

Service Manual

iFLEX2 with iSCOUT expert compact

Voltage Values
Value displayed Value
displayed [mV] +/- 10mV

Pressure Transducers
300 bar, type 314
500
1500
2500
3500
4500
Angle Sensor
500
1500
2500
3500
4500
Length Sensor
500
1500
2500
3500
4500

PSI
0
1088
2176
3263
4351

Bar
0
75
150
225
300

degrees
90
67.5
45
22.5
0

boom horizontal

feet
0

fully retracted

boom vertical

If the displayed value does differ from the actual value, please refer to the following sections to find
the cause of the problem:
If the displayed angle is incorrect, please go to section Angle Sensing.
If the displayed length is incorrect, please go to section Length Sensing
If the displayed pressures are incorrect, please go to section Pressure Sensing

26

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Troubleshooting a sensor problem using the display

SLEW POT SIGNALS:

Sig 1 (mA)
Reference Angle 0.03mA
0
4.00
45
8.00
90
12.00
135
16.00
180
20.00
-135
16.00
-90
12.00
-45
8.00

Sig 2 (mA)
0.03mA
12.00
16.00
20.00
16.00
12.00
8.00
4.00
8.00

If the displayed angle is incorrect, please go to section Slewing Sensing

2007 HIRSCHMANN Automation and Control GmbH

27

Service Manual

iFLEX2 with iSCOUT expert compact

14 DRAWINGS
14.1

28

Components of the LMI system PAT iFLEX2 with iSCOUT expert compact

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Drawings

14.2

BLOCK DIAGRAM

70 pin
Connector
Crane Power

Graphic
Console

iflex2 Central Unit

Lockout

CANBUS

Current
4..20mA

CAN-connector
CAN-connector

Slew Sensor
CAN-connector

Dual Pressure

2007 HIRSCHMANN Automation and Control GmbH

Length/Angle Sensor

A2B

29

Service Manual

14.3
14.3.1

iFLEX2 with iSCOUT expert compact

ELECTRICAL SYSTEM DIAGRAM STANDARD SYSTEM

Central Unit, Overview

to sensors
> page 2

to console
> page 3

to crane
interface
> page 4

Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential
and are not to be used or reproduced without the written consent of Hirschmann. This drawing is subject to technical modification without prior notice.

30

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Drawings

14.3.2

Central Unit, Detail A

to sensors
> page 2

to console
> page 3

Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential
and are not to be used or reproduced without the written consent of Hirschmann. This drawing is subject to technical modification without prior notice.

2007 HIRSCHMANN Automation and Control GmbH

31

Service Manual

14.3.3

iFLEX2 with iSCOUT expert compact

Central Unit, Detail B

to crane
interface
> page 4

Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential
and are not to be used or reproduced without the written consent of Hirschmann. This drawing is subject to technical modification without prior notice.

32

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Drawings

14.3.4

Sensors Wiring (page 2)

Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential
and are not to be used or reproduced without the written consent of Hirschmann. This drawing is subject to technical modification without prior notice.

2007 HIRSCHMANN Automation and Control GmbH

33

Service Manual

14.3.5

iFLEX2 with iSCOUT expert compact

Console Wiring (page 3)

Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential
and are not to be used or reproduced without the written consent of Hirschmann. This drawing is subject to technical modification without prior notice.

34

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Drawings

14.3.6

Crane Interface RT530-2 / RT540E (page 4)

Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential
and are not to be used or reproduced without the written consent of Hirschmann. This drawing is subject to technical modification without prior notice.

2007 HIRSCHMANN Automation and Control GmbH

35

Service Manual

14.3.7

iFLEX2 with iSCOUT expert compact

Crane Interface RT600E / RT700E / RT875E (page 4)

Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential
and are not to be used or reproduced without the written consent of Hirschmann. This drawing is subject to technical modification without prior notice.

36

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Drawings

14.3.8

Crane Interface TM500E-2 (page 4)

Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential
and are not to be used or reproduced without the written consent of Hirschmann. This drawing is subject to technical modification without prior notice.

2007 HIRSCHMANN Automation and Control GmbH

37

Service Manual

14.4

iFLEX2 with iSCOUT expert compact

MAIN CENTRAL UNIT CONNECTOR

This is a 70 pass connector

38

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Drawings

14.4.1

Cable Reel (LG152/0056) Wiring Diagram

TO LWG520/0002
REFER TO CABLE REEL LWG520/0002
WIRING DIAGRAM

TO BOOM BASE CONNECTOR

REFER TO CONSOLE AND SENSOR
WIRING DIAGRAM

Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential
and are not to be used or reproduced without the written consent of Hirschmann. This drawing is subject to technical modification without prior notice.

2007 HIRSCHMANN Automation and Control GmbH

39

Service Manual

14.4.2

iFLEX2 with iSCOUT expert compact

Cable Reel (LWG520/0002) Wiring Diagram

LUFFING JIB CONNECTION

REFER TO LUFFING EXTENSION
WIRING DIAGRAM

TO PRESSURE TRANSDUCER BLOCK

REFER TO CONSOLE AND SENSOR
WIRING DIAGRAM

TO LG152/0056
REFER TO CABLE REEL
(LG152/0056) WIRING DIAGRAM

Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential
and are not to be used or reproduced without the written consent of Hirschmann. This drawing is subject to technical modification without prior notice.

40

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Drawings

14.4.3

Luffer Extension Wiring Diagram

BOOM TIP CONNECTION

TO LWG520/0002
REFER TO CABLE REEL
(LWG520/0002) WIRING DIAGRAM

Hirschmann Automation and Control GmbH reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential
and are not to be used or reproduced without the written consent of Hirschmann. This drawing is subject to technical modification without prior notice.

2007 HIRSCHMANN Automation and Control GmbH

41

Service Manual

42

iFLEX2 with iSCOUT expert compact

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Sensor Calibration

15 SENSOR CALIBRATION
15.1

ACTIVATING THE SERVICE SCREEN FOR SENSOR CALIBRATION

to access the service

screen and sensor
calibration function
(from main menu):
input service code (for access to calibration menus)

For access to the calibration menus

it is necessary to input a matching
5-digit code.
Use the rotary selection wheel to
input a numeral, and then push the
wheel button to select the next digit.

If input is complete the confirmation

screen appears:
input service code (confirmation screen)

OK, confirm selected code

Cancel and return to LMI screen

Now you can follow the calibration procedure step by step or can select the type of calibration by
. Press "ESC" to finish calibration procedure.
scrolling with function key

pressure signal
piston side

pressure signal
rod side

2007 HIRSCHMANN Automation and Control GmbH

slewing angle
signal

boom length signal

boom angle signal

43

Service Manual

15.2

iFLEX2 with iSCOUT expert compact

ZERO-SETTING THE PRESSURE INPUTS

NOTE: The only thing adjustable for the pressure transducers is the zero point, which is the signal the
transducer outputs when there is no (zero) pressure sensed.

Ensure there is no pressure in the hydraulic line when

disconnecting the hoses from pressure transducers!
The display shows which transducer (piston-side, rod-side or force) is being zeroed and a horizontal
dial marks the present pressure (or force) difference in %.
NOTE: there are two calibration screens: for piston and for rod transducer.
NOTE: The range for auto-calibrating this value is from -4% to +4%. By pressing the AUTO key, the
zero setting occurs automatically and the indicator line will move to zero on the dial.
Calibration screen (pressure transducer piston side)

skip calibration step

auto-calibrate (set to zero)
cancel and return to LMI screen

Calibration screen (pressure transducer rod side)

skip calibration step

auto-calibrate (set to zero)
cancel and return to LMI screen

44

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Sensor Calibration

15.3

ZERO-SETTING THE SLEWING INPUTS

NOTE: The only thing adjustable for the slew potentiometer is the zero point, which is complete when
the boom is at the 0 position over the front of the crane.
NOTE: The range for auto-calibrating this value is from -10 to +10. By pressing the AUTO key, the
zero setting occurs automatically and the indicator line will move to zero on the dial.
Calibration screen (slewing angle)

skip calibration step

auto-calibrate (set to zero)
cancel and return to LMI screen

2007 HIRSCHMANN Automation and Control GmbH

45

Service Manual

15.4

iFLEX2 with iSCOUT expert compact

LENGTH SENSOR CALIBRATION PROCEDURE

NOTE: The length sensor can be calibrated for its zero point and its full range.
With retracted boom, the potentiometer of the length sensor has to be at its 0 position, which is all the
way counter-clockwise. For extended boom, the adjustment is done by software as described below.
The length should be calibrated to be about 0.1 feet (or 0.05m for metric) accurate for retracted and
extended lengths. Perform the following steps:
Calibration screen (boom length)

skip calibration step

start length calibration
cancel and return to LMI screen

Start procedure by pressing "OK"

Start calibration minimum length

next calibration step

cancel and return to LMI screen

Fully retract the main boom and check if indicated length is within 0.1 feet (or 0.05m for metric) of
actual retracted boom length.
If it is not, adjust length potentiometer mechanically as described below:

46

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Sensor Calibration

With boom fully retracted turn the center screw of the length pot unit counter clockwise to a soft
stop.
During adjustment an additional button "OK" appears. Check value and set actual length as fully
retracted length by pressing OK. Afterward next calibration screen appears.
Calibration screen minimum length

skip calibration step

set minimum length
cancel and return to LMI screen

2007 HIRSCHMANN Automation and Control GmbH

47

Service Manual

iFLEX2 with iSCOUT expert compact

Now extend main boom all the way out. Make sure you are within the allowed operating range
(especially maximum radius).
During telescoping out the boom an additional button "OK" appears.
Start calibration maximum length

skip calibration step

cancel and return to LMI screen

Check whether boom is fully extended, then press "OK". Afterward next calibration step (angle)
appears.
Calibration screen maximum length

skip calibration step

set maximum length
cancel and return to LMI screen

48

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Sensor Calibration

15.4.1

Cable Reel Length Cable Replacement Procedure

Replace length cable using the following procedure:

Refer to system electrical wiring diagram and cable reel - parts list
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

13.
14.

15.
16.

Cut old cable at cable drum.

Disconnect damaged length cable from junction box at the boom nose.
Open cable reel cover and disconnect bus connector.
Remove cable reel from mounting brackets.
Remove damaged length cable, which is mounted to the slip rings in the cable reel, from slip ring
terminal.
On the backside of the cable reel, open the strain relief attached to the axle in the center of the
drum. Pull existing length cable out of the cable reel.
Pull new length cable through the hole, pipe and strain relief and push it through the axle of the
reeling drum. Tighten new strain relief to ensure sealing.
Reconnect the length cable to the slip ring.
Remount cable reel to the boom.
Turn reeling drum clockwise to spool the new cable neatly onto the drum.
Set pre-load on cable reel by turning the drum counter-clockwise 5 to 8 turns.
Run the new length cable through the cable guides and wrap the length cable around the boom
tip anchor pin (4 or 5 wraps) and secure with tie wraps. Leave enough length cable to connect
into the boom tip junction box.
Connect the length cable into the boom tip junction box.
Reset length potentiometer in length angle transducer (screw is located in center of white gear);
with boom fully retracted, turn potentiometer carefully counter-clockwise until it stops. Recheck
length and angle display.
Connect bus connector
Follow Length Sensor Adjustment Procedure.

2007 HIRSCHMANN Automation and Control GmbH

49

Service Manual

15.5

iFLEX2 with iSCOUT expert compact

ANGLE SENSOR CALIBRATION PROCEDURE

The angle sensor can be calibrated for its zero point and with steep boom
Material required: calibrated inclinometer
Select Angle sensor calibration menu and start procedure by pressing "OK"
Calibration screen (boom angle)

skip calibration step

start angle calibration procedure
cancel and return to LMI screen

Start calibration for "zero degree" angle

skip calibration step

calibrate next angle
cancel and return to LMI screen

50

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Sensor Calibration

Boom down.
Release adjustment screws of the
angle sensor.
Mechanically adjust top of angle
sensor housing exact parallel with
boom by help of inclinometer.
Fix adjustment screws of the angle
sensor.

Having adjusted the angle sensor mechanically check value and press "OK" for the next step.
Start calibration for "zero degree" angle

skip calibration step

calibrate next angle
cancel and return to LMI screen

Now boom up to steep boom, (range is 70- 80)

boom up to next angle

skip calibration step

cancel and return to LMI screen

2007 HIRSCHMANN Automation and Control GmbH

51

Service Manual

iFLEX2 with iSCOUT expert compact

When the boom angle is within the calibration range, the screen will add the
CHANGE,
SET and
OK text as shown below:
calibrate angle

cancel and return to LMI screen

calibrate angle
set current angle to defined angle

Measure the boom angle with the inclinometer and when the boom is positioned in the calibration
range, compare the measured angle to the displayed angle.
If the indicated angle is within +/- 0.1 degrees of the measured angle, confirm with OK.
Otherwise, select SET to adjust the angle.
adjust angle

cancel and return to LMI screen

Increase angle value by 0.1
Decrease angle value by 0.1
Confirm angle

Once you push SET , the screen is going to change to the angle adjustment screen. Use the +
and - buttons to adjust the indicated angle to match the measured angle.
When the display shows the correct angle, press OK.
Press ESC to leave sensor adjustments and return to normal LMI screen.

52

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Error Codes

16 ERROR CODES
The following Error Code Table gives a brief description of Error Codes elimination. Refer to the noted
sections for detailed Troubleshooting information.
LMI System Error Code Table (LSQG V 1.xx):

Error code

Error

Cause

E01

Fallen below radius range or

angle range exceeded

E02

E03

E04

Radius range exceeded or

fallen below angle range
Non-permitted slewing zone (no
load area)

Operating mode not

acknowledged or non permitted
slewing zone

E05

E06

Prohibited length range

Radius range exceeded or

fallen below angle range with
luffing jib operation

E12

Luff down the boom to a radius

or angle specified in the load
chart.

Luff up the boom to a radius or

angle specified in the load
chart.

Slew to permitted area

A non existing operating

mode has been selected

Set the correct operating mode

for the operating state in
question

The boom is in a non

permitted slewing zone

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

Maximum radius as specified

in the load chart exceeded or
fallen below minimum angle
due to luffing down the luffing
jib too far
Length potentiometer is
defective
PDB variable for analog value
not supported
Electronic component in the
measuring channel is
defective
Pressure transducer is
defective.
PDB variable for analog value
not supported

Fallen below lower limit value

for measuring channel "length
main boom"

Fallen below the lower limit

value in the measuring channel
"pressure piston side"

2007 HIRSCHMANN Automation and Control GmbH

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
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
The slewing zone with load is
not permitted

E11

Elimination

Slew the boom to a permitted

area.
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
Luff the jib to a radius or angle
specified in the load chart.

Replace length potentiometer

Setup of correct PDB variable
for analog value in DGA6.i.3

Replace sensor unit

Replace pressure transducer

Setup of correct PDB variable
for analog value in DGA6.i.3

53

Service Manual

Error code

iFLEX2 with iSCOUT expert compact

Error

Cause
Electronic component in the
measuring channel is
defective.
refer to E12

Replace sensor unit

refer to E12

Force transducer defective

Electronic component in the
measuring channel is
defective.
Angle potentiometer defective
PDB variable for analog value
not supported

Replace force transducer

Replace sensor unit

Replace angle sensor

Electronic component in the

measuring channel defective.
Angle potentiometer defective
Electronic component in the
measuring channel defective.
Length potentiometer
defective
Electronic component in the
measuring channel defective
Front outrigger overloaded

Setup of correct PDB variable

for analog value in DGA6.i.3
Replace sensor unit

Replace angle sensor

Replace sensor unit

Replace length sensor.

Replace sensor unit

Cable between the central

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

Check cable as well as plugs,

replace, if need be.

1-cannel slew sensor min.

value DGA 11.5.7 <> 0
Slewing angle potentiometer
is defective
Electronic component in the
measuring channel defective
refer to E1A

move to allowed slew range

Replace slewing angle sensor

Replace sensor unit

refer to E1A

E13

E14

E15

E16

E17

E18

E1A

Fallen below lower limit value in

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

measuring channel "force"

Fallen below lower limit value in

measuring channel "angle main
boom"

Fallen below lower limit value in

measuring channel "angle 2"

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

Fallen below lower limit value in

measuring channel "slewing
angle 1".
slew below allowed range

E1B

E1C

E21

E22

E23

E24

E25

E26

54

Fallen below lower limit value in

measuring channel "slewing
angle 2"
Fallen below lower limit value in
measuring channel "luffing jib
angle"
Upper limit value in measuring
channel "main boom length"
has been exceeded.
Upper limit value in measuring
channel "pressure piston side"
has been exceeded
Upper limit value in measuring
channel "pressure rod side" has
been exceeded.
Upper limit value in measuring
channel "force" has been
exceeded.
Upper limit value in measuring
channel "main boom angle" has
been exceeded.
Upper limit value in measuring
channel "angle 2" has been
exceeded.

Elimination

Angle potentiometer defective

Electronic component in the

measuring channel defective.

refer to E11

refer to E11

refer to E12

refer to E12

refer to E12

refer to E12

refer to E14

refer to E14

refer to E15

refer to E15

refer to E16

refer to E16

Replace angle sensor

Replace sensor unit

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Error Codes
Error code
E27

E2A

E2B

E2C

E31

E32

E37

Error

Upper limit value in measuring

channel "length telescope I (+II)
has been exceeded.

Upper limit value in measuring

slew above allowed range

Upper limit value in measuring

channel "slewing angle 2" has
been exceeded
Upper limit value in measuring
channel "luffing jib angle" has
been exceeded

Error in the system program

System program and load chart

file do not match

E52

refer to E17

refer to E1A

refer to E1A

1-cannel slew sensor max.

value DGA 11.5.8 <> 0
refer to E1A

move to allowed slew range

refer to E1A

Angle potentiometer defective

Electronic component in the

measuring channel defective.

The system program file is

defective.

Flash-EPROM defective

+UB System not present at

the system start

+UB System not present at

the system finish

Contact problems at +UB

switch off/on

System program file is

defective

Error in the logical program flow

E39

E51

refer to E17

Error in the power supply

E38

E47

Elimination

channel "slewing angle 1" has

been exceeded

System program and crane

data file do not match.

E43

Cause

Flash-EPROM defective
The system program in the
LMI does not match to the
programming in the crane
data file
The system program in the
LMI and the programming in
the load chart file do not
match.
Write/read memory (RAM) or
central unit defective.

Replace central unit

+UB System and +UB Power

must be wired separately: +UB
System connected direct with
the crane battery. +UB Power
for switch on/off

+UB switch off/on again

Upload valid system software

Replace central unit

Upload valid system program
file or the valid crane data file

Upload valid system program

file or the valid load chart file

Replace central unit

The CRC sign of the

monitored write/read memory
is wrong

Restart the LMI

The buffer battery is

decharged (< 2V at 1kOhm).

Replace buffer battery on the

central unit.

Central unit defective.

No valid data in the crane
data file.

Replace central unit

Upload valid crane data file

Flash-EPROM defective

No valid data in the load chart

file

Flash-EPROM defective

Error in the crane data file

Error in load chart file.

2007 HIRSCHMANN Automation and Control GmbH

Upload valid system software

Error in the write/read memory,

(RAM)

Error in the monitored write/

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

Replace angle sensor

Replace sensor unit

Replace central unit

Upload valid load chart file
Replace central unit

55

Service Manual

Error code
E53

E56

E57

E61

iFLEX2 with iSCOUT expert compact

Error
Wrong setup of min. analog
inputs length1, angle1,
pressure1

Cause

Analog input not supported

Setup correct Flag in in DGA

6.i.2

No valid data in the crane

data file during calibration.

Restore or upload valid crane

data file

Flash-EPROM defective
Buffered data file does not
contain valid data.

Replace central unit

Reset system

Flash-EPROM defective
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
cable
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
The analog values of the
sensor unit are invalid

Replace central unit

Check the connection between
the central unit and the sensor
units

Replace the central unit

Replace Can Bus cable

Check the cable to the sensor

unit

Replace the central unit

Replace the sensor unit

Replace the sensor unit

Replace the sensor unit

Error in crane data file.

Error in buffered data file.

Error in the CAN bus data

transfer for all CAN units

E62

E63
E64
E65
E66
E67

Error in the can bus data

transfer of the pressure
transducer sensor unit

Error in the can bus pressure

transducer sensor unit
Error in the can bus data
transfer of the length/angle
sensor unit
Error in the can bus
length/angle sensor unit
Error in the data of the digtal
I/O MENTOR
Error in the can bus data
transfer of the digtal I/O
external module

E84

Wrong rigging condition.

E85

Error in the radius

determination

E89

Operating mode switchover with

load.

E98

LMI watchdog activated

EAB

Short circuit in the A2B switch

circuit
(not with radio A2B)

See E62

See E62

See E63

See E63

PDB variable invalid

Change system software

Change MENTOR

PDB variable invalid

Connect digtal I/O external CAN

module

The selected rigging condition

is not contained in the crane
data file.

Select another rigging condition

Check the programming in the
crane data file.
Check the programming in the
crane data file.

The computed radius is too

small (negative deflection)

The operating mode on the

console has been switched
over with the boom loaded.
LMI processing time limit
exceeded

Select operating mode without

load on the boom

Reset system
Connect PC terminal and watch
error messages
Replace A2B switch

56

Elimination

Short circuit in the A2B switch

Short circuit in the cable to

the A2B switch

Replace cable to the A2B

switch

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Error Codes
Error code

Error

Cause
Disconnected cable in the
A2B switch

Connect or replace cable in the

A2B switch

Disconnected cable to the

A2B switch

Connect or replace cable to the

A2B switch

Sensor wrong function

Replace A2B switch

CAN bus delay

Replace cable to the A2B

switch

Radio telegram delay module

(radio A2B)

Replace battery of radio module

(radio A2B)

Radio telegram ID is invalid

Setup ID in DGA12.9

Setup of the datalogger is

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

datalogger processing time

limit exceeded

Battery check detected a low

voltage of the battery

Not possible to save data

because other task saves
data at the same time
Not possible to save any more
data

a funktion needs more than

0.5 sec, e.g. Flash PROM
write

EAC

EAD

A2B switch circuit disconnected

(not with radio A2B)

No valid A2B switch status

EDB

Datalogger setup error

EDC

Datalogger watchdog activated

EDD

Battery empty

EDE

Record lost

EDF

Flash block full

EFD

LMI Watchdog
extra time

Elimination

transfer data and setup

datalogger again

Reset system
Connect PC terminal and watch
error messages
change batterie, after this setup
of RTC
Message disappears after a few
seconds
Message disappears after a few
seconds
Message disappears after a few
seconds

Note:
If a fault message is displayed that is not included in the present list, then please contact your local Hirschmann
Customer Service. > www.hirschmann-ac.de <

2007 HIRSCHMANN Automation and Control GmbH

57

Service Manual

iFLEX2 with iSCOUT expert compact

17 TROUBLESHOOTING MOISTURE
The PAT iFLEX LMI contains electronic components in various locations, such as central unit, sensors,
junction boxes etc. These internal components cannot be designed to withstand exposure to moisture
over a longer period of time. For this reason, the housings of the components are water protected
according to IP 65. If you find water or moisture inside any of the housings, the source for the water
ingress has to be detected and corrected to ensure proper operation.
There are two major possibilities for the occurrence of excessive moisture inside an enclosure:
Water ingress
Condensation

This outline gives instructions for detecting the cause for excessive moisture by using simple
troubleshooting methods and how to prevent the moisture ingress from happening again.

17.1

WATER INGRESS

There are different possibilities for water ingress. It is possible to find out the source of water ingress by
going through the following steps and ruling out one possibility after the other until the cause is identified:
1) Spray Cleaning
The enclosures used for the PAT LMI system are water protected to IP 65. This means protection against the
environment, such as rain. However, through the use of spray cleaner at short distances, it is possible to
force water through the gasket or strain relieves. For this reason, avoid spraying any components from short
distances with spray cleaners. Convey this fact to any member of a maintenance crew.
2) Missing / Loose Screws
All screws have to be present and to be equally tight to ensure water protection of the enclosure. If there are
screws missing, replace them. If no screw is missing, check the tightness. If any were loose, then open all
screws and then re-tighten them equally.
3) Bent Lid
An enclosure will only seal correctly if the lid is not bent. To check this, loosen all screws of the lid, take the
lid off the box and visually inspect it for deflection. If the lid is bent or damaged, it needs to be replaced. Try
to determine what has caused the lid to be bent and eliminate the reason for that. Order a new lid through
your PAT representative.
4) Defective Gasket
The gasket underneath the lid seals the unit. The gasket needs to be in good condition in order to seal
correctly. If the gasket is torn, brittle or severely bent, it needs to be replaced. Order a new gasket through
your PAT representative.
5) Loose Strain Relieves
The strain relieves allow cabling to enter the box without allowing water to enter it. The strain relieves have to
be correctly tightened in order to do this. Check the tightness by taking the external cable into one hand and
carefully trying to turn it. If the internal wires turn with the outer cable, the strain relief is loose. Get a new
grommet (insert) through your PAT representative and replace the existing one with the new one. Tighten the
strain relief correctly. Note: Whenever a strain relief is opened, i.e. to replace a cable, a new grommet needs
to be used. Never re-use any grommet or the strain relief will not seal properly!
6) Water Entry Through External Cabling
Even with a tight strain relief, water may still enter the box through the inside of the cable. In this case, you
have to find out why and where water enters the cable. Look for damages to the cable itself and inspect the
opposite side of the cable. In example, if the cable comes from a connector that is full of water, the water will
run through the inside of the cable and fill up the central unit, too.

58

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Troubleshooting Moisture

17.2

CONDENSATION

In a climate with high humidity and rapidly changing temperatures, condensation can happen inside
any enclosure, usually the larger the volume of the box, the more likely. In this case, water drops build
up on the inner components when humid air is trapped inside the box. With condensation, water
tightness is not a problem the box is sealed just fine, which is what prevents the trapped air from
exiting the box. There are two ways to deal with condensation:
If the volume is very small, a desiccant bag might be able to soak up the airs humidity.
If the effect is more severe, the only way to get rid of this effect is then to give the box the ability to breath
without sacrificing its water tightness. Contact your PAT representative for breathing elements to than can be
added to the box and will help to reduce the effects of humid climates.

2007 HIRSCHMANN Automation and Control GmbH

59

Service Manual

iFLEX2 with iSCOUT expert compact

NOTES:
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.

60

50 650 69 0101E_REV A (GROVE RT-TM).DOC / Rev. A / 2007-08-17 / rk.

Revision History

18 REVISION HISTORY
Version
Rev. A

Date
Modifications
2007-08-17 First Issue for Grove RT and TM cranes
iFLEX2 with iSCOUT expert compact

Name
Konopka

Application base: Grove RT 530 expert compact

V 1.04 / 20070511 HAC GmbH - 34230104

2007 HIRSCHMANN Automation and Control GmbH

61