HIRSCHMANN

Load Moment Indicator for

Crawler Crane
HC4900
Operator’s Manual

Service Hot Line: 400 887 9936

Xuzhou Hirschmann Electronics Co., Ltd.

No.11 Baoliansi Road, Xuzhou Economic Development Zone, JiangSu, China
Tel：+86-0516-87885799
Fax：+86-0516-87793971
Zip Code：221004
Http: //www.hirschmann-js.com
E-mail: infoecs@hirschmann-js.com
Copyright
This document contains propriety information which is protected by
copyright, and all rights are reserved. No part of this manual may be
photocopied, reproduced or translated to another language without prior
written approval of Xuzhou Hirschmann Electronics Co., Ltd.

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

Hirschmann makes no warranty of any kind with regard to this material,

including, but not limited to, the implied warranties of merchantability and
fitness for a particular purpose.

Hirschmann will not be liable for errors contained herein or for incidental or
consequential damages in connection with reference to, and performance or
use of this manual.

Applied Scope
This manual is made for the following crane manufacturer

 XCMG
This manual can be applied to the following types of crawler cranes
manufactured by the partner:

 QUY55

Special Notice
For certain reasons, it may be the case some cranes listed above don’t have
the Hirschmann LMI installed. We kindly remind the operator to check and
determine the actual types of LMI match the contents in this manual.

Using components of LMI rather than from Hirschmann may cause

problems of inaccuracy and even malfunction of the LMI system. We
recommend you use genuine Hirschmann components and parts during
repairing and service. Hirschmann is not liable of any responsibilities in case
genuine parts are not used.
Rev. Date Prepared Checked Modifications
01 2012-5-25 DXiao Xu Yi Feng First issue, English
LZhu HC4900 for XCMG
QUY55 Crawler Crane
 Table of Contents
1. GENERAL INFORMATION ........................................................................ 1
2. IMPORTANT NOTES ................................................................................. 2
3. SYSTEM DESCRIPTION ........................................................................... 4
3.1 HC4900 Controller ............................................................................... 5
3.2 IC4600 Console ................................................................................... 6
3.3 Force Sensor ....................................................................................... 7
3.4 WG Angle Sensor ................................................................................ 8
3.5 Anti-Two Block Switch ......................................................................... 9
4. OPERATION AND DISPLAY INTERFACE ............................................... 10
4.1 Data Display and Key Symbols（values are not real） ..................... 11
4.2 Load Moment Status Bar .................................................................... 12
4.3 Indicator Light ..................................................................................... 13
5. OPERATION METHOD (only for example) ............................................... 14
5.1 OM Setup ........................................................................................... 15
5.2 Reeving Setup .................................................................................... 21
5.3 Function Display ................................................................................. 22
5.4 Buzzer ................................................................................................ 26
6. HC4900 LMI SYSTEM FUNCTIONS ......................................................... 27
6.1 Warning .............................................................................................. 27
6.2 Prohibition .......................................................................................... 27
7 INSPECTION MAINTENANCE AND CONSIDERATIONS ........................ 28
7.1 Inspection Before Operation .............................................................. 28
7.2 Routine Maintenance ......................................................................... 28
7.3 Routine Consideration ........................................................................ 28
7.4 Angle Transducer Adjustment ............................................................ 29
7.5 Buzzer Alarms .................................................................................... 29
8. TROUBLESHOOTING ............................................................................... 30
9. SYSTEM WIRING DIAGRAM .................................................................... 37
1. GENERAL INFORMATION

The load moment indicator HC4900 (hereinafter referred to as LMI) is

applicable to the telescopic boom crane, lattice boom crane, all- terrain
crane and other types of cranes.

The HC4900 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 is measured by angle sensor that is mounted on the boom. The
crane load is measured by force transducers attached to the boom
pendants. 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 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 Standards:

GB12602-2009
EN13000-2010

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Operator’s Manual

2. IMPORTANT NOTES

The LMI and 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.

CAUTION
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.

CAUTION
The LMI can only protect
N
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.

WARNING
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.

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

2
 WARNING
N supply of the LMI from the crane before
Make sure to disconnect the power
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.

DANGER
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.

DANGER
N
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!

3
Operator’s Manual

3. SYSTEM DESCRIPTION

5
v
v
v
v
3
4
v
v v
v v
v v
v
2
v 1
v v
v v
v v
v
Components of LMI System

Generally, the LMI system consists of

1. HC4900 Controller 1 pc
2. IC4600 Console 1 pc
3. KMD force Transducer 1 pc
4. WG Angle Transducer 1 pc
5. Anti-Two Block Switch 2 pcs
(One for main hook and another for auxiliary hook)

4
3.1 HC4900 Controller
HC4900 controller uses 32 bit high performance processors and the
CANopen communication technology. The advanced RTOS platform
and DS350C data structure ensure and high capacity data processing

- Comply with CE certification and EMC standards.

- Comply with GB12602、GB7950、EN13000 standards.
- 32 bit high performance processors and RTOS platform
- Self Diagnostic
- CANopen interface

Technical data：
System clock： 32bit/40MHz
Program memory： 4MB Flash
Protection class： IP65
Communication interface： 1×CANopen, 1×RS232
Operating voltage： 11V～36VDC
Operating temperature： -20℃～+70℃
Storing temperature： -30℃～+80℃

5
Operator’s Manual

3.2 IC4600 Console

The console is 5.7 inch screen with 256 color resolution, In-dash
mounting, landscape or portrait orientation and protection class IP65
of front panel.

-Comply with CE and EMC standards

-Extended operating voltage, over-voltage and reverse polarity protection
-Integrated two CANbus interface and one serial port
-Support SAE J1939
-Programmable with CoDeSys

Technical data:
Operating voltage： 12～36VDC
Operating temperature： -20℃～+70℃
Storing temperature： -30℃～+80℃
Resolution： 320*240(256 colors)
Communication interface： 1×RS232, 2×CANopen2.0B
Protection class： Front IP65 Back IP44

6
3.3 Force Sensor
Force sensor KMD is perfectly designed for static and dynamic tensile
force measurements. The sensor stands out for high overload
capacity, high fatigue strength, good corrosion resistance and
maintenance-free operation.

Technical data:
Nominal load range： from 1T up to 500T
Charge of measuring body： 200%
Charge of measuring body up to flow limit: 300%
Safe to breaking point： 500%
Linearity： < 0.3% typ.
Hysteresis： < 0.5% typ.
Protection class： IP65 (IP67 optional)
Supply voltage： 10 … 30 VDC
Operating temperature range： -40℃ to +70℃

Installation
KMD force sensor is measuring unit, it
should require the conscientious and
careful treatment.
Be sure to obtain the fittings and the
relative tolerance data suggested by KMD
force sensor.
Observe the installation situation to make
sure that no elastic parts are used in the
force transmission which might affect the
measurements.
The bores in the locking pins must be in
alignment.
Make sure force sensor not to bear
sideforce.

KMD Force Sensor Installation Graph

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Operator’s Manual

3.4 WG Angle Sensor

Angle sensor WG accurately measures the boom angle. The high sealed
housing keeps the inside component away from the influence of
temperature, humidity etc.

Technical data
Measuring range：0-90°
Output signal： 4-20mA
Linearity tolerance：<±0.2°
Hysteresis tolerance：<±0.1°
Operating temperature：
-25℃～+70℃
Storing temperature：
-40℃～+70℃
Protection class：IP65

WG Angle Sensor Installation Graph

Installation
The correct positioning is important for installing angle sensors.
The angle sensors are usually installed along the right side boom, at the
inner side of boom base, if it’s viewed from the boom base to boom tip. (as
shown below).

Make sure the horizontal line of sensor is parallel to the horizontal center
line of the boom. Adjust the bolts of the sensor to reduce the angle deviation
between actual measured boom angle and displayed boom angle on the
console.
Boom bottom Angle sensor Horizontal center line of
the boom

Angle sensor Installation Graph

8
3.5 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.

Installation

The switch should be installed at the side of the boom tip where the wedge
socket of the wire rope is installed. Fix the hammer to encircle the wire rope
line which is directly attached to the wedge socket.

Hammer

Wire rope
wedge socket

Anti-Two Block Switch Installation Graph

9
Operator’s Manual

4. OPERATION AND DISPLAY INTERFACE

3
v
v
v
v 1
2
v
v v
v v
v v
v
4
v
v
v
v

5
① Data display(background lit)v
② Load moment status bar v
③ Indicator light
④ Function keys：Function keys v F1-F5 are related to the key symbols
which present on the displayv
⑤ Numerical keys：They can be used to input values or select function
items in accordance with the number on the display.
Note: The Numerical Key 1 and Numerical Key 6 can also be used to
adjust the brightness of the console on the main display.

10
4.1 Data Display and Key Symbols（values are not real）
IC4600 Console can display all the operational data such as actual load,
rated load, boom length, angle, OM code, reeving and error code etc. The
background illumination of the display can help to provide the clear and
visual graphic display either under sunlight or in dark night.

Examples of the main display (values are not real):

3 1 4 2
v v v v
v v v v
v v v v 5
v v v v v
v6
v
v7
14 vv
15 vv
8
16 vv
vv
17 9
vv
vv
10
v
3 12 11 v
Main display
①. OM code
②. Reeving
③. Load moment percentage value
④. Load moment percentage bar
⑤. Time display/Error code information symbol
⑥. Function setting key (refer to 5.3)
⑦. OM setting key (refer to 5.1)
⑧. Reeving setting key (refer to 5.2)

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Operator’s Manual
⑨. Main hook/ auxiliary hook switch symbol
⑩. Alarm off key (refer to 5.5)
⑪. Speed wind
⑫. Actual load
⑬. Rated load
⑭. Main boom length
⑮. Work height
⑯. Main boon angle
⑰. Work radius

4.2 Load Moment Status Bar

The Load moment status bar indicates the proportion between the actual
load moment and rated load moment during the crane operation. As the
proportion changes, the load moment display also changes constantly.

The Load moment status bar is marked with differently colored fields:

Green: "Safe” operation (0...90% of rated moment)

Yellow: “Pre-warning Range” (90...100% of rated moment)
Red: “Overload Range” (> 100% of rated moment)

12
4.3 Indicator Light
Pre-warning Light
This yellow Pre-warning light comes up when the load on
the machine amounts to more than 90% of the respective
nominal carrying load, which indicates that an overload
situation is immediately pending.
For the operator, this means that the machine work can
continue only with the greatest amount of caution
Overload Warning Light
This red Overload warning light indicates that an overload
condition has occurred. It lights up when the crane load has
STOP reached 100% of maximum load carrying capacity
permitted for the current operating status. The buzzer
sounds. The load-moment-increasing crane movements
are switched off at the same time. It will be removed when
putting down the heavy items or luffing up.
A2B Switch Lamp (if the machine need)
This red warning light lights up when the hoist limit switch
contacts open, i.e. when a hoist limit situation has occurred.
The buzzer sounds and load-moment-increasing machine
movements are switched off at the same time.
A hoist limit situation occurs when the hook block comes into
contact with the boom head. The danger exists in such situations
that the hoist rope will break, causing the load to fall. A hoist limit
situation could arise from the load being pulled against the boom
head or from the boom being extended or lowered without the
hoist rope having been allowed to slacken.
Exam method as below：
 Manually lifting the weight attached to the A2B switches, then the
buzzer sounds and the A2B alarm light will light.
 Slowly raise the hook or lower the boom or extend (telescope) the
boom to create a potential two-block condition, when the hook lifts the
weight, the buzzer sounds, the A2B alarm light will light and the crane
movement, such as hoisting up and luffing down will be stopped.
 If the light and buzzer do not function as above described and the
crane movements are not stopped, it shows the system is not working
properly or the crane has problems. The malfunction shall be corrected
before operating the crane.

13
Operator’s Manual

5. OPERATION METHOD (only for example)

When controller and console of the 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.
The crane drivers shall be very familiar with the operation of LMI system and
correctly adjust it before start to work.

Power on

Self Checking System

Confirm OM

Error or Not? YES

Look up the error code list to solve

Is the displayed OM the same
as the actual one? NO
Choose the same OM by OM buttons
Is the showed Reeve the same
as the actual one?
NO
Choose the same Reeving by
Operate the crane to work . Reeving buttons

14
5.1 OM Setup
Before operating the crane, please adjust the displayed OM identical to the
actual OM, according to your crane type and the actual OM.

WARNING
Correctly setting the OM would guarantee proper functioning of the
system and the crane. The OM code must be set equal to the actual
OM value, otherwise the LMI may not be able to work properly.

Press F2 key at the main display

to enter into “OM Setup Display”:

Main Display

15
Operator’s Manual
 Main Boom OM Setting
Choose “Main Boom OM Setting”
It also selects among “Fixed Jib OM
Setting”, “Runner OM Setting”,
“Main Hook Setting under Runner
OM”;”Main Hook Setting under
Fixed Jib OM” and “Auxiliary Hook
Setting under Fixed Jib OM”

Select correct main boom length

Confirm OM setting (Only if all

entries are correct，the OM display
must be the same with the actual
OM)

Back to main display

 Fixed Jib OM Setting

The setting process includes three parts. First of all, choose main boom
length, the finger image automatically points to the “MB Length” at the
display.
Choose “Fixed Jib OM Setting”
It also selects among “Main Boom
OM Setting”, “Runner OM
Setting”, “Main Hook Setting under
Runner OM”;”Main Hook Setting
under Fixed Jib OM” and “Auxiliary
Hook Setting under Fixed Jib OM”

Select correct main boom length

Confirm OM setting (Only if all

entries are correct，the OM display
must be the same with the actual
OM)

Press this key, enter into the

second step. The cursor points to
“Jib Length”
Back to main display
16
Secondly, choose Jib Length，the finger image automatically points to the
“Jib Length” at the display.

Select correct jib length

Confirm OM setting (Only if all

entries are correct，the OM display
must be the same with the actual
OM)

Press this key, enter into the third

step. The cursor points to “Jib
Angle”

Back to main display

Finally, choose Jib Angle，the finger image automatically points to the “Jib
Angle” at the display.

Select correct jib angle

Confirm OM setting (Only if all

entries are correct，the OM display
must be the same with the actual
OM)

Press this key and back to the first

step. The cursor points to “Main
Length”

Back to main display

17
Operator’s Manual
 Runner OM Setting
Choose “Runner OM Setting”
It also selects among “Main Boom
OM Setting”, “Fixed Jib OM
Setting”, “Main Hook Setting under
Runner OM”;”Main Hook Setting
under Fixed Jib OM” and “Auxiliary
Hook Setting under Fixed Jib OM”

Select correct main boom length

Confirm OM setting (Only if all

entries are correct，the OM display
must be the same with the actual
OM)

Back to main display

 Main Hook Setting under Runner OM

Choose “Main Hook Setting under
Runner OM”
It also selects among “Main Boom
OM Setting”, “Fixed Jib OM Setting”,
“Runner OM Setting”; ”Main Hook
Setting under Fixed Jib OM” and
“Auxiliary Hook Setting under Fixed
Jib OM”

Select correct main boom length

Confirm OM setting (Only if all

entries are correct，the OM display
must be the same with the actual
OM)

Back to main display

18
 Main Hook Setting under Fixed Jib OM
Choose “Main Hook Setting under
Fixed Jib OM”
It also selects among “Main Boom
OM Setting”, “Fixed Jib OM Setting”,
“Runner OM Setting”; ”Main Hook
Setting under Runner OM” and
“Auxiliary Hook Setting under Fixed
Jib OM”

Select correct main boom length

Confirm OM setting (Only if all

entries are correct，the OM display
must be the same with the actual
OM)

Back to main display

 Auxiliary Hook Setting under Fixed Jib OM

Choose “Auxiliary Hook Setting
under Fixed Jib OM”
It also selects among “Main Boom
OM Setting”, “Fixed Jib OM Setting”,
“Runner OM Setting”; ”Main Hook
Setting under Runner OM” and
“Main Hook Setting under Fixed Jib
OM”

Select correct main boom length

Confirm OM setting (Only if all

entries are correct，the OM display
must be the same with the actual
OM)

Back to main display

19
Operator’s Manual
ATTENTIION: Only when the operators select the following FOUR OM
settings, they can press F4 at the main display to switch main /
auxiliary hooks status:
1. Main Hook Setting under Fixed Jib OM
2. Auxiliary Hook Setting under Fixed Jib OM
3. Runner OM Setting
4. Main Hook Setting under Runner OM

This shortcut key“ ”provides a convenient and quick change

between the above OM. And this function is only valid for the above 4
modes and invalid for other operation modes.

To utilize this convenience, the operator must fully understand

and shall not misuse this convenience. It’s strictly prohibited to do the
following 2 operations:

1． Using auxiliary hook in Main Hook Setting under Fixed Jib Mode
2． Using auxiliary hook under Main Hook Setting under Runner Mode

The operator shall take great precaution of the hooks and wire ropes
so that they will not get entangled. It’s recommended that the operator
shall raise the main hook close to the upper limit switch while using
auxiliary hook and vice versa.

20
5.2 Reeving Setup
Reeving setting is to adjust the LMI reeving identical to the lifting cable of
the cane. Operators shall carefully adjust the displayed reeving equal to the
actual reeving before start to work.

WARNING
The Reeving must be set equal to the actual reeving, otherwise the LMI
may not be able to work properly.

Press F3 key at the main display to enter into “Reeving Setup

Display”

Input correct “Reeving Value” by “Numerical

Keys”

Confirm Reeving Value (Only if all

entries are correct，the Reeving at
the main display would be the same
with the Set Reeving)

Clean the Reeving zero.

Back to the main display

Reeving setting display

21
Operator’s Manual

5.3 Function Display

Function display offers additional functions which can be ordered. Operator
can select metric unit and imperial unit, choose Chinese language and
English language, set time, get CAN status and signal overview, test
keystoke and inquire error code information.
Press F1 key at the main display to enter into “Function Display”

Switch between metric unit and

imperial unit

Select between Chinese and

English language

Back to main display

Function display
In the metric display, the unit of length is “m” and the unit of weight is “t”. In
the imperial display, the unit of length is “ft” and the unit of weight is “klbs”.
Metric and Imperial conversion relationship: 1 m = 3.2808 feets; 1 kg =
2.20462 pounds.

CAUTION
The LMI can be calibrated online on panel and each LIM has been
completely calibrated by professional engineer at factory.

This operator’s manual doesn’t contain the calibration method. If

the operation data exceeds the permitted range, please contact crane
manufacturers or call Hirschmann Service Hotline. Any person who is
not trained and authorized must be forbidden to calibrate the LMI, or
Hirschmann shall not assume any responsibility for undesirable
consequences resulted from this action!

22
 Time and Date Setup
Press Numerical Key 1 at the Function setup display to enter into “Time and
Date Setup Display”:
Cursor up to select year month date
hour and minute items. Input correct
value of selected items by
“Numerical Keys”

Cursor down to select year month

date hour and minute items.Input
correct value of selected items by
“Numerical Keys”

Confirm all entries (the current time

and date would change into the
new setting ones)
Time and Date Setup
Clear the selected item zero

Back to the previous display

 CANbus Status Overview

Press Numerical Key 2 at the Function setup display to enter into “CANbus
Status Overview Display”:
The “CANbus status display” show CAN
communication status of all the LMI
components and the meanings of the status
symbol. When any node is fault, Operators
can quickly find out the defective node and
defective reasons.

Back to the previous display

CANbus Status Overview Display

23
Operator’s Manual
 Signal Overview
Press Numerical Key 3 at the Function setup display to enter into “Digital
Signal Overview Display”.

Press Numerical Key 4 at the Function setup display to enter into “Anolog
Signal Overview Display”.

Digital Signal Overview Display; Analog Signal Overview Display

Back to the previous display

Operators can achieve the status of the digital inputs and outputs and the
A/D conversion value of analog inputs through the display. When any input
and output are fault, operators can quickly find out the defective interface.

24
 Key Test
Press Numerical Key 5 at the Function setup display to enter into “Key Test
Display”.

Operator can test every key including function keys and numerical keys at
the key test display to confirm if the keys are normal.

The “1，2，3，4，5，6，7，8，9” in the key

test display accord with Numerical Key 1
to Numerical Key 9.

The “F1，F2，F3，F4，F5” in the key test

display accord with Function Key 1 to
Function Key 9.

Key Test Display

Method:

Press the tested key. The according blank display “OK” indicates the key is
normal. The according blank display northing indicates the key is defective.

After the test is finished, please press Numerical Key 6 and Numerical Key 0
serially back to the previous display.

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Operator’s Manual
 Error Code Information
When the system appears malfunction, the error code would appear at the
main display.Through the error code information, crane operators and
service engineers can better understand what the error code stands for, and
quickly find out the fault reasons and suggested solutions. (Operators can
inquire the error code by two ways: The error code inquiry in the display and
the “troubleshooting” item in the menual.)

Press Numerical Key 7 at the Function setup display to enter into “Error
Code Information Display”.

Scroll up for the previous error code

information

Scroll down for the next error code

information

Back to the main display

Error Code Information Display

5.4 Buzzer
The buzzer of HC4900 LMI will alarm at the following situation:

 Exceed the max. rated load moment

 The hook is approaching height limitation
 Exceed the operating range of the crane
 LMI system defective
 Operation fault

Press F5 to stop the buzzer alarming temporarily at the main

display.

26
6. HC4900 LMI SYSTEM FUNCTIONS

6.1 Warning
Under any below conditions, HC4900 LMI system will light up and send out
alarm for warning.
 The crane is overload or exceeds operating range
 The hook is approaching height limitation
 Luffing up limitation
 Malfunction

6.2 Prohibition
Cooperating with crane electrics system, the LMI system will send alarm
warning and any of the following crane’s movements will be prohibited:
 Boom luffing down
 Hoisting up

At this moment, only the movements toward safe direction are allowed:
 Boom luffing up
 Hoisting down

CAUTION
When the cut-off device is activated, this signal will always keep be
out. Functions such as “dangerous direction operation is not allowed”,
“only safe direction operation is allowed” is realized by cooperating with
the crane’s electronics system which including “safe direction inspect
switch”, “safe overflow solenoid valve” etc. The LMI system cannot judge
whether the operation is safe or dangerous itself.

27
Operator’s Manual

7 INSPECTION MAINTENANCE AND CONSIDERATIONS

7.1 Inspection Before Operation

 Check all components of the LMI system to make sure no one
damages or breaks off.
 Turn the power on and detect whether the display is normal or there is
warning, error indication and so on.
 After display works normally, detect whether all the system works
normally and whether the main boom angle, work radius and load
display are the same as the actual ones.

7.2 Routine Maintenance

 Check the angle transducer as to oil leakage.
 Check the insulating layer of all the cables. If the insulating layer or the
wire inside damaged, please replace new one immediately.
 Check the cable reel as to sufficient tight or not.
 Clean the display regularly to make it clear.

7.3 Routine Consideration

 Prevent the central unit (display)、power supply cabin、transducers from
severely shake.
 Each part of the LMI system including central unit, console, transducers
etc had been accurate adjusted and checked by protection technology
before leaving factory. Anyone not be trained professionally is prohibited
from dismantling the housing. Otherwise, the system will probably not
work normally because of humidity and dust getting into the components.

28
7.4 Angle Transducer Adjustment
Use the angle instrument to measure if
the displayed value is the same when
the actual angle is between 0°and 70°.
If the displayed value or radius is not
the same with the actual value,
operators should adjust the angle
transducer.
Release the three bolts (see the left
picture)，Slowly turn the angle
transducer till the displayed value
accords with the actual value and then
tight the three bolts again.

7.5 Buzzer Alarms

The buzzer alarms if the system shows normal without any fault codes after
started. At this moment, exam whether the conjunction between cable and
A2B is junction off or short circuit of water-in.

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Operator’s Manual

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.

CAUTION
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： +86-400-887-9936
Fax： +86-516-87793971
Email: infoecs@hirschmann-js.com

Error
Error Cause Elimination
Code
E01 Fallen below  Fallen below the  Luff down the
radius range or minimum radius or boom to a radius
angle range gone past the or angle specified
exceeded maximum angle in the load chart.
specified in the
respective load
chart due to luffing
up the boom too far
E02 Radius range  Gone past the  Luff up the boom
exceeded or maximum radius or to a radius or
fallen below fallen below the angle specified in
angle range minimum angle the load chart.
specified in the
respective load
chart due to luffing
down the boom too
far

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Error
Error Cause Elimination
Code
E04 Operating  A non existing  Set the correct
mode not operating mode has operating mode
acknowledged been selected for the operating
or non  The boom is in a state in question
permitted non-permitted  Slew the boom to
slewing zone slewing zone a permitted area.
 The selected  Check the Data
operating mode is software in the
not available in the Flash-EPROM
Flash-EPROM or
blocked
E05 Main boom  A non existing main  Set the correct
length not boom length has main boom length
available been selected for the operating
 The selected main state in question
boom length is not  Check the Data
available in the software in the
Flash-EPROM or Flash-EPROM
blocked
E06 Radius range  Maximum radius as  Luff the jib to a
exceeded or specified in the load radius or angle
fallen below chart exceeded or specified in the
angle range fallen below load chart.
with luffing jib minimum angle due
operation to luffing down the
luffing jib too far

E14 Fallen below  Cable between the  Check cable as

lower limit central unit and the well as plugs,
value in force transducer replace, if need
measuring defective or loose. be
channel "force Water inside the plug  Replace force
main boom left" of the transducer transducer
 Force transducer  Replace sensor
defective unit
 Electronic
component in the
measuring channel is
defective.

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Operator’s Manual
Error
Error Cause Elimination
Code
E15 Fallen below  Cable between the  Check cable as
lower limit central unit and the well as plugs.
value in angle sensor replace if need
measuring defective or loose. be.
channel "angle Water inside the plug  Replace angle
main boom of the angle sensor sensor
foot"  Angle potentiometer  Replace sensor
defective unit
 Electronic component
in the measuring
channel defective.
E16 Fallen below  refer to E15  refer to E15
lower limit
value in
measuring
channel "angle
luffing jib foot"

E17 Fallen below  refer to E14  refer to E14

lower limit
value in
measuring
channel "force
luffing jib left"

E24 Upper limit  refer to E14  refer to E14

value in
measuring
channel "force
main boom left"
has been
exceeded.

E25 Upper limit  refer to E15  refer to E15

value in
measuring
channel "main
boom angle
foot" has been
exceeded.

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Error
Error Cause Elimination
Code
E26 Upper limit  refer to E15  refer to E15
value in
measuring
channel "luffing
jib angle foot"
has been
exceeded.
E27 Upper limit  refer to E14  refer to E14
value in
measuring
channel "force
luffing jib left"
has been
exceeded.
E37 Error in the  System program file  Upload valid
logical program is defective system software
flow  Flash-EPROM  Replace central
defective unit
E38 System  The system program  Upload valid
program and in the LMI does not system program
crane data file match to the file or the valid
do not match. programming in the crane data file
crane data file
E39 System  The system program  Upload valid
program and in the LMI and the system program
load chart file programming in the file or the valid
do not match load chart file do not load chart file
match.
E43 Error in the  Write/read memory  Replace central
write/read (RAM) or central unit unit
memory, defective.
(RAM)

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Operator’s Manual
Error
Error Cause Elimination
Code
E47 Error in the  The CRC sign of the  Restart the LMI
monitored monitored write/read  Replace buffer
write/ read memory is wrong battery on the
memory.  The buffer battery is central unit.
The CRC decharged (< 2V at  Replace central
verification of 1kOhm). unit
the monitored  Central unit defective.
write/read
memory
provides an
incoherent
result

E51 Error in the  No valid data in the  Upload valid

crane data file crane data file. crane data file
 Flash-EPROM  Replace central
defective unit

E52 Error in load  No valid data in the  Upload valid load

chart file. load chart file chart file
 Flash-EPROM  Replace central
defective unit

E53 Wrong setup of  Analog input not  Setup correct

min. analog supported Flag in in DGA
inputs angle1, 6.i.2
force1
E56 Error in crane  No valid data in the  Restore or
data file. crane data file upload valid
during calibration. crane data file
 Flash-EPROM  Replace central
defective unit

E57 Error in serial  Calibration data file  Upload

crane data file. does not contain valid calibration data
data. file by changing
 Flash-EPROM data (OM, limits)
defective and save
 Replace central
unit

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Error
Error Cause Elimination
Code
E61 Error in the  CAN Bus cable  Check the
CAN bus data between the central connection
transfer for all unit and the sensor between the
CAN units unit defective or not central unit and
connected. the sensor units
 Can bus port in the  Replace the
central unit central unit
defective  Replace Can Bus
 Short circuit in a cable
CAN Bus cable
E62 Error in the can  Cable between the  Check the cable to
bus data central unit and the the sensor unit
transfer of the sensor unit  Replace the
pressure defective. central unit
transducer  Can bus port in the  Replace the
sensor unit central unit sensor unit
defective  Replace the
 Can bus port in the sensor unit
sensor unit is
defective
 Sensor unit is
defective
E63 Error in the can  The analog values  Replace the
bus pressure of the sensor unit sensor unit
transducer are invalid
sensor unit
E64 Error in the can  See E62  See E62
bus data
transfer of the
length/angle
sensor unit
E84 DAT data and  DAT data  Check the
TLK data do disconnect with TLK programming in
not match in jib data the crane data file.
OM

E85 Error in the  The computed  Check the

radius radius is too small programming in
determination (negative deflection) the crane data file.

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Operator’s Manual
Error
Error Cause Elimination
Code
E98 LMI watchdog  LMI processing time  Reset system
activated limit exceeded  Connect PC
terminal and watch
error messages
EAB Short circuit in  Short circuit in the  Replace A2B
the A2B switch A2B switch switch
circuit  Short circuit in the  Replace cable to
(not with radio cable to the A2B the A2B switch
A2B) switch
EAC A2B switch  Disconnected cable  Connect or replace
circuit in the A2B switch cable in the A2B
disconnected  Disconnected cable switch
(not with radio to the A2B switch  Connect or replace
A2B) cable to the A2B
switch
EAD No valid A2B  Sensor wrong  Replace A2B
switch status function switch
 CAN bus delay  Replace cable to
the A2B switch
EDB Datalogger  Setup of the  transfer data and
setup error datalogger is setup datalogger
cleared (ser. crane again
data file or battery
buffered RAM)
EDC Datalogger  datalogger  Reset system
watchdog processing time limit  Connect PC
activated exceeded terminal and watch
error messages
EDD Battery empty  Battery check  change batterie,
detected a low after this setup of
voltage of the RTC
battery

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9. SYSTEM WIRING DIAGRAM

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