User Manual - Global Cranes
Contents
1. 3 3 1 HC4900 CONTROLLER sirra 4 3 2 ICAGOO CONSOLE n 4 3 3 DAVS PRESSURE Ere VV dE 5 ao L Technical data sesasine aS 5 33 2 rri mee N RS 5 3 4 LWG208 LENGTH ANGLE SENSOR ee eeeee eene eene enne nennen nnn nnn 6 34 1 Technical data 6 34 2 cur me 6 3 5 ANTI TWO BLOCK SWITCH scccsssssssesssssrersecsessssssessecsssnscccesersrsecsessssssenee 8 2 9 1 Technical dalarini iine e ERES 8 2e giri e RE 9 4 OPERATION AND DISPLAY 10 4 1 DATA DISPLAY INTERFACE VALUES ARE NOT REAL 11 4 2 UTILIZATION DISPLAY BAR GRAPH e eene eene nnne nnne nnne nnno 13 AS INDICATOR LIGHT P 13 5 OPERATION METHOD scis vr per reve startete ua deba 15 Bol FUNCTION SETTING ance FOROR TK MNA N 16 5 2 ONLSETUD de e 16 9 3 REEVING SETUP 25 FREE 19 5 4 ERRO CODE REFERENCE TABLE 20 5 9 BUZZER ST2. between controller communication and sensor fault Mad Change controller CAN bus port fault e CAN buscable Change Can bus uer cable shortcircuit e Cable between CAN bus data controller and sensor communication of defective pressure sensor e Controller fault CAN bus port fault Sensor defect Check the connecting cable of sensor Change controller Change sensor Uneffective Can bus pressure Bio cue value of Change sensor sensor fault sensor unit P Can bus data of Refer to E62 Refer to E62 fault another e OM selected not Wrong OM code is included in the the crane data file program of the crane data file judgement Range counted is e Check the Pr range small negative program of the crane erection data file OM code divert as OM code of e Select OM code the loading Con divert as when without changes the loading changes mainboom loading Communication e Console or cable between of console fault controller and e CAN console is fault Communication fault e Change console or cable of the console 2 35 LMI watch dog open A2B switch shortcircuit A2B without wireless communication A2B switch break 2 without wireless communication A2B switch defect Data logger setting fault Watch dog software of data logger open e Voltage of e Replace battery battery is test low and set RTC 3 e LMI watch dog operated ove
3. Check angle transducer for oil leakage 7 2 Length sensor adjustment When the displayed boom length is not correct exceed the permitted error ranges please adjust as follows Retract the boom to the basic boom condition and check the pre stressing force of the cable reel cable must be tight and then open the cover of the length angle sensor cable reel and turn the axle of the length potentiometer slowly see arrow mark till the displayed value to be the same with the actual length Length sensor adjustment see arrow above 04 f HIRSCHMANN BELDEN BRAND 7 3 Angle sensor adjustment The angle sensor is installed in the same house with the length sensor First retract the boom and make sure the length displayed is equal to the actual Use the angle instrument to measure if the displayed value is the same when the actual angle is between O and 70 whether the displayed value is the same or use the tape to measure the working radius If the displayed value or radius is not the same with the actual value operators should adjust the angle sensor Lose the 3 bolts see the following pic Slowly turn the angle sensor till the displayed value accords with the actual value and then tight the 3 bolts again Angle sensor adjustment see arrows above 7 4 Buzzer alarming After start up the system there s no error code displayed at the console but the buzzer keeps sound with no interrup
4. Data display background lit Bar graph utilization Indicator light refer to 4 3 Function keys Function keys F1 F5 are related to the key symbols which present on the display pop gw c 5 Numerical keys They can be used to input values or select function items in accordance with the number on the display Note At the main interface numerical key 1 and 3 can calibrate the brightness of the console 10 fy HIRSCHMANN BELDEN BRAND Operation notice 1 OM can only be switched when the boom is fully retracted 2 Under the load lifting status of the RT crane the OM switch between 360 lifting and front lifting is automatically done by the LMI based on the rotating field of the boom 3 LMI bypass icon will be displayed on main interface if bypass switch is activated The status will be displayed for 30 minutes and then automatically close To cancel the LMI bypass condition deactivate the bypass signal 4 1 Data display interface values are not real The Data display 320x240 is an LED display with background illumination and extended temperature range on which essential data are displayed The data is dependent on the operating mode such as load values geometry and crane data symbols etc Main interface values shown are for illustration 11 HIRSCHMANN BELDEN BRAND Data display 1 Load moment percentage bar graph Load moment percentage displayed value OM code Reev
5. 2 jib section 20 0022 2 jib section 40 0023 Code of setting refers to the number required to be inputted during OM Setup to set the code for the respective OM listed in the table 35
6. f HIRSCHMANN A BELDEN BRAND HC4900 Load Moment Indicator User Manual Edition 5 July 2014 For Zoomlion RT Crane With 4 section boom Copyright 2010 by Hirschmann Electronics Shanghai Co Ltd This document contains propriety information which is protected by copyright law All rights reserved The manual may not be copied reproduced or translated into another language neither whole nor in part without advance written authorization from Hirschmann Edition 5 on July 2014 Reproductions must abide by the copyright law Declaration The manufacturer reserves the right to modify the contents of this manual without notice Hirschmann offers no guarantee whatsoever for this material including guarantees with reference to commercial availability and suitability for particular applications Hirschmann shall not be liable for errors contained herein or for identical consequential damages in connection with the furnishing performance or use of this manual Hirschmann Electronics Shanghai Co Ltd Suite 10K Huamin Empire Plaza No 728 West Yan An Road Shanghai P R China Tel 021 51082780 Fax 021 52375899 Zip code 200050 Website http www hirschmann ac com Catalogue 1 GENERAL INFORMATION 1 2 WWARWNIN Im 2 SYSTEM CONFIGURATION 2559
7. fault occurs the LMI system will send alarm warning and all of the following 5 movements will be prohibited down Telescope out e Hoist up At this moment only the movements toward safe direction are allowed e Boom luffing up Boom retract Hoist down When cut off device is activated this cut off 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 11 switch safe overflow solenoid valve etc The LMI system cannot judge the operation is safe or dangerous itself Em fy HIRSCHMANN BELDEN BRAND 7 Daily maintenance and calibrations Please maintain and adjust as follows and contact us if you have any questions 7 1 Maintenance Maintenance items listed below should be done daily e Check all components of LMI system to make sure no cable is damaged or broken e Check the insulating layer of all the cables If the insulating layer or the wire inside damaged please replace new one immediately e Check the pressure transducers at the luffing cylinder and the connection hoses for oil leakage e Check the cable reel wire for sufficient tension e Check the cable reel mounting amp torsion spring for proper function e
8. horizontal Make sure the sensor is parallel with the main boom and the bracket is straight before fixing the bracket by bolts Make sure there are at least two turns measuring cable in the drum when the cable is pulled out The recommended length of the cable effective needed measure length two turns cable about 1 meter cable for connection The cable drum of the sensor must rotate following the direction of the cable being pulled out Rotate the cable drum 4 to 5 turns to pre tighten the drum and then pull out the cable to the tip of the boom for connection Use the guiding wheel to keep the measuring cable at the same level Place guiding wheels so as to prevent cable deflection which will result in the cable being difficult to pull out and to retract smoothly o Make sure the first guiding wheel A is in front of the sensor center 1 5m 2m Ensure the guiding wheel turn width is slightly less than or equal to the cable drum turn width o Make sure the center of the cable guiding wheel A and other wheels are in alignment and also parallel with the main boom The measuring cable should be fixed to the tip of the boom tightly and the fixed point should be at the same level with the sensor center to guarantee E HIRSCHMANN BELDEN BRAND the cable is parallel with the boom e The Length Angle sensor sometimes needs to be adjusted Press the cable drum line to make the cable drum plane parallel with the boom plane Rotate the cab
9. is not 3 then Current OM will change to BBBB and error message will occur 5 3 Reeving setup Reeving setting is to adjust the LMI reeving eaqul to the lifting cable of the cane Operators shall carefully adjust the displayed reeving equal to the actual reeving before start to work A The Reeving must be set equal to the actual Reeving otherwise the LMI may not be able to work properly 90 fy HIRSCHMANN BELDEN BRAND Press F4 key at the main display to enter into Reeving setup display set Reev F3 Confirm Reeving After Push To Confirm confirmation Current REEV will change to New Reev setting us To Clear IN F4 Reset the Reeving to zero Push To Return F5 Back to the main display Current REEU B Mew Reev 8 Set Reev interface To change reave setting parts of line of chosen hookblock push N F4 button to reset Then enter the proper parts of the line of the chosen hookblock using numeric keys Press Y F3 button to confirm change NOTE Current REEV will change to New Reev setting Push F5 button to return to screen 5 4 Error Code Reference Table When the system is malfunction the error code will appear at the main display Through the error code information in the table crane operators and service engineers can better understand what the error code stands for and quickly find out the fault reasons and suggested solutions Press F4 key at the main display t
10. OPPING eese Corno peut eee pa 21 6 LMI SYSTEM FUNCTIONS ccsccccssssccssssccessescccesssscccsseseccssencesessescesesseseesess 23 MB Pic 23 6 2 PROHIBITION Cc m 23 7 DAILY MAINTENANCE AND CALIBRATIONG ccsssscccessscececsseeeceesseeecsesseeeees 24 7 1 MAINTENANCE CONTENT ssccccccsssssccceesssseccecsesseececesssseececeessseeeeeees 24 7 2 LENGTH SENSOR ADJUSTMENT 24 7 3 ANGLE SENSOR ADJUSTMENT eee eene enn nnns teta nasse sett nass seen 25 7 1 BUZZER ALARMING decis cer erp Cove EUR 25 7 5 LENGTH CABLE RETRACT UN SMOOTHLY 26 7 6 QUESTION AND ANSWER ccccsssscscccessesccccccsscssssssssseneecesessonccsesannons 26 8 HINTS AND TROUBLE SHOOTING 40 4 28 9 HC4900 CONNECTING DIAGRAM 34 10 OM LIST ined oo i i Der deiode 35 f HIRSCHMANN BELDEN BRAND 1 GENERAL INFORMATION HC4900 Load Moment Indicator LMI provides effective information to operators which will assist an operator maintain a machine to work within its design parameters LMI provides the operator with the information of the length and angle of the boom tip height working radius rated load and the actual load weight and so on Using various sensing devices the load momen
11. ance table RAM fault Change controller 2 30 Error in the monitored write read memory The CRC verification of the monitored write read memory provides an incoherent result Crane data file fault Loading curvilinear figure Wrong setting of min analogue length1 angle1 and pressure Crane data file fault Crane serial data file fault The CRC sign of the monitored write read memory is wrong e Buffering battery is tested no current 1kOhm lt 2V Controller defect No readable crane data file Flash EPROM defect No readable crane performance table Flash EPROM defect Not support analogue output No effective data file during adjustment Flash EPROM defect No effective data file in the adjusting data file Flash EPROM defect HIRSCHMANN BELDEN BRAND e Re start LMI e Change the buffering battery of controller e Change controller e Up date crane data file e Change Flash EPROM e Update effective crane data file e Change controller Set correct Flag at 6 1 2 update effective crane data file e Change controller e Update effective data file by changing and saving datas OM limits e Change controller HIRSCHMANN BELDEN BRAND CAN bus cable a Check the between controller and sensor defective connecting cable CAN bus data
12. ch result in exceed the max radius or lower than he min angle Exceed the max radius or lower than the min angle Boom up to a permitted radius or angle in the load chart Properly choose the code not exist OM according to Main boom operating actual operation and area is not permitted slew back to a permitted range OM not exist or exceed the motion of rotary range Fallen below Length potentiometer Replace length lower limit value is defective PDB potentiometer Setup for measuring variable for analog of correct PDB channel length value not supported variable for analog main boom Electronic component value in DGAG i 3 in the measuring Replace sensor unit channel is defective Fallen below the lower limit value in the measuring channel pressure piston side Fallen below lower limit value in the measuring channel pressure rod side Fallen below lower limit value measuring channel angle main boom Length sensor channel voltage exceed the max limitation Piston side pressure channel voltage exceed the max limitation Pressure transducer is defective PDB variable for analog value not supported Electronic component in the measuring channel is defective Refer to E12 Angle potentiometer defective PDB variable for analog value not supported Electronic component in the measuring channel defective CAN Circuit board defective Length sensor uni
13. comprised of four digits ABCD A Outrigger and Tire Configuration number is automatically assigned during OM Setup refer to section 10 for OM List Swing Angle number is automatically assigned based on input from swing angle sensor 0 Swing angle is greater than 3 but less than 357 1 Swing angle is between 357 and 3 NOTE Number in B position will automatically change based on swing angle C amp D Boom Configuration refer to section 10 for OM List 18 f HIRSCHMANN BELDEN BRAND 5 2 OM Setup oh Since the working conditions of the crane are different the LMI must be set up to represent the actual configuration of the crane To do that the LMI must be configured into a reprentative Operating Mode OM code Before operating the crane find out the matched OM code according to the crane type and the actual configuration then enter the appropriate information into the LMI for A outrigger configuration B parts of line of the hookblock being used and C A Correctly setting the OM guarantees the proper function of the system and the crane Only operators who are thoroughly familiar with the crane and the boom configuration operation of the system are qualified for the setting the OM codes Improperly setting the OM code in the LMI will result in false readings being displayed which can lead to a serious accident occuring Set Operating Mode F1 Select out
14. ing Rotary angle Outrigger mode Rid pressure Piston pressure O ON OO FW Operating height Time error code will be displayed when defect Wind speed NO Fixed jib boom length OO Main boom length K Main boom angle Fixed jib boom angle O Rated load capacity N Actual load Co Working radius 19 Enforced icon OEM special requirement Icon Key symbols definition a Function setting key refer to 5 1 b OM setting key refer to 5 2 c Reeving setting key refer to 5 3 OM setting key d Error code information key refer to 5 4 e Alarm off key refer to 5 5 212 fy HIRSCHMANN BELDEN BRAND 4 2 Utilization display bar graph The Utilization display bar graph indicates how much of the admissible load moment rated moment is used As the rated moment changes constantly during load operation the load moment display also changes constantly The utilization display 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 gt 100 of rated moment 4 3 Indicator light Pre warning lights This yellow pre warning light comes up when the load on the machine amounts to more than 90 of the respective maximum carrying capacity which indicates that an overload situati
15. ion when the hook lifts the weight the audible alarm sound the A2B alarm light will light and the crane movement such as hoist up luffing down telescopic out will be stopped If the light and audible alarm does not function as described and the crane movements are not stopped the system is not working properly The malfunction shall be corrected before operating the crane 14 fy HIRSCHMANN BELDEN BRAND 5 Operation method With proper adjustments the LMI will start to work automatically The crane operator must be very familiar with the operation of LMI system and correctly adjust it before operating the crane Below is a diagram of the startup screens For security Before Operte Please Make Sure 1 The operator has the ability to operate 2 operator knows the Operational processes VVell Press Y Key to Continue Push Y to continue If all system checks are okay then after pushing Y F5 button the Set Operating Mode screen will come up Set Operating Mode 8808 Current On rh Set 9822 ic Outrigger Az 1008 correct push Y to confirm else push N to cancel and reset If OM is set correctly push Y button to confirm then lt F5 button to return to main screen Otherwise set OM according to section 5 2 15 HIRSCHMANN BELDEN BRAND 5 1 Function setting Press F1 key at the main display to enter into Function setup disp
16. ity charts boom weights centers of gravity and dimensions are stored in the central data memory This data is the reference information used to calculate the operating conditions The boom angle and length is measured by means of length and angle sensors that are mounted on the boom The crane load is determined indirectly with the aid of pressure transducers fy HIRSCHMANN A BELDEN BRAND 3 1 HC4900 Controller HC4900 controller features high performance precise and limiting load moment function in harsh environment Technical data System clock 40MHz Program memory 16MB Flash Protection class IP65 Communication interface 1xCANopen1xRS232 Operating voltage 12V 30VDC Operating temperature 20 C 70 C HC4900 controller dimension Storing temperature 30 C 80 C 3 2 1 4600 Console IC 4600 monochrome console is designed for outdoor construction vehicles and mobile machinery It complies with international standards for environmental testing EMC testing and CE certification Its easy programming convenient online debugging and rich paint library functions point line arc rectangle progress bar virtual instrument panel such as function help you to more efficiently understand and utilize the LMI system Technical data Operating voltage 12 36VDC Operating temperature 20 C 70 C k 2 ie Storing temperature 30 C 80 C IO 90000000 Res
17. l TI TIT i1 6 a Tumse 5 Fle re y l 1 5 EM ale scoket sas H SB perg le pole plug 1 pale plug ale 5 TE TET i TE T l L 1 i 1 gll X l za L 1 DH E m T 5 pA lat g 5 24 ma ct a Oe ED HE Leyi 1 I c1 H Amt Sapiro oe Bs ohm E ud p LI En 9 LEE E Mi t Miu Hey pa il uec Bmw Sar dd SED 9 EI PS BAGAJ reg UE B aW 1 1 1 1 D e Ez d inih a 1 1 1 1 f HIRSCHMANN BELDEN BRAND 10 OM List OM Operating Outrigger Code of Displayed area status setting code Fully extend 0001 Half extend 1001 Fully retract 2001 Main boom OM 360 3001 Fully extend 0002 Half extend 1002 Fully retract 2002 a 1 jib section 0 0011 1 jib section 20 0012 1 jib section 40 360 0013 2 jib section 0 Operation 0021
18. lay Function Interface Press the keypad number to select 1 Time Set 2 Can Bus State 3 OM Code Description 4 Oil Sensor node ID Set You are using Metric Function setting interface F3 Switch between Metric and Imperial units F4 Switch between English and Chinese language F5 Back to the main interface Numerical key 1 time setting Numerical key 2 CANbus status query Numerical key 3 OM code query Numerical key 4 Oil Pressure node setting In the metric display the unit of length is meters and the unit of weight is t metric ton In the imperial display the unit of length is ft feet the unit of weight is kips Ibs x 1000 Metric and Imperial conversion relationship 1 m 3 2808 feet 1 kg 2 20462 pounds 16 f HIRSCHMANN Time and date setup Press numerical key 1 at the Function setup display to enter into time and date setup display F1 Cursor up to select year month date hour and minute items Time Setting F2 Cursor down to select year month Current Date 2012 10 17 Current Time 09 00 19 date hour and minute items Input correct value of selected items by numerical keys F3 Confirm all entres The current Year Month Day time and date would change into Minute the new setting ones t F4 Reset the selected item zero Time and date interface F5 Back to the previous interface CAN bus status query Pres
19. le drum and observe until the swing get smaller amplitude If the cable drum swing too much because of the shape distortion and can t be adjust please stop the installation and repair or replace the Length Angle sensor sure the spring force of the measuring cable is sufficient and the cable drum is rotating smoothly after installation is completed e Ifthe measuring cable is already at the pre tighten length when boom is retracted the pre tighten turns can be reduced 3 5 Anti two Block Switch Anti Two Block Switch is a normally open limit switch for winches lifting devices and cranes It is a simple direct installation and compact design The sealed housing protects the inside components from water inclusion humidity etc 3 5 1 Technical data Operating voltage 15 30 Operating voltage 25 70 Storing temperature 40 C 70 C Protection class IP67 Life expectancy gt 5x10 times Housing aluminum Weight 1 2kg A2B Switch dimension fy HIRSCHMANN BELDEN BRAND 3 5 2 Installation The switch should be installed on the side of boom head where the beginning of the lifting rope is fixed Make sure the hammer is connected to the lifting rope and is free to actuate the switch The signal connector and cable must be waterproof and connected correctly un A2B Switch installation diagram fy HIRSCHMANN BELDEN BRAND 4 OPERATION AND DISPLAY INTERFACE 4 HIRSCHMANN
20. nsducer installation connector pin assignment fy HIRSCHMANN A BELDEN BRAND 3 4 LWG208 Length Angle sensor LWG series Length Angle sensor can be directly installed and can precisely measure the angle and the length of boom with largest measurement length of fifty meters The sealed housing protects the inside components from water inclusion humidity etc 3 4 1 Technical data Operating voltage 15 30VDC Operating temperature 25 C 75 C Storing temperature 40 C 80 C Protection class 65 Linearity tolerance 0 2 Resolution 0 1 Hysteresis tolerance 0 1 LWG208 Length angle sensor dimension 3 4 2 Installation Length Angle sensor is installed on the main boom Manufacturers can fix the bracket of the sensor to the crane boom by welding tap blocks and bolting it in place When installing the sensor the position shall be well considered generally along the foot points of boom to the top direction The sensor left type is typically installed on the left of the boom aligned with the cab to leave room for the fly jib on the right side of the boom The sensor can be located on the right side as required The cover can be turned 180 to put the PAT name facing upward fy HIRSCHMANN BELDEN BRAND Bracket LWG208 Length angle sensor installation Length Angle sensor consists of housing a spring loaded cable drum with measuring cable and mounting equipment Make the boom
21. o enter into error code informatoin display Fault Help F3 Scroll up for the previous error E94 Error in tha can bus data transfer of the pressure transducer sensor unit code information F4 Scroll down for the next error code Causae CAN Bus cable between the central unit info rmation and the display unit defective or not connected or short circuit Can bus port in the central unit defective Elimination Check the connection between the F5 Back to the main interface Error code query interface m fy HIRSCHMANN A BELDEN BRAND 5 5 Buzzer stopping The buzzer of HC4900 console will alarm at the following situation Actual load exceeds the max rated load moment The hook is approaching height limitation A2B fault Exceed the operating range of the crane LMI system defective Operation fault Press F5 to stop the buzzer alarming temporarily Main interface A Eo The audible alarm is only temporarily silenced The fault that caused the alarm to go off still exists and should be corrected immediately The alarm will sound again if fault is not corrected or if a new fault is detected 205 f HIRSCHMANN BELDEN BRAND 6 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 exceed operating range The hook approaching height limitation e Malfunction 6 2 Prohibition If a
22. olution 320 240 monochrome Communication interface 1xRS232 1xCANopen Protection class Front IP65 Back IP44 IC4600 Console dimension ods f HIRSCHMANN BELDEN BRAND 3 3 DAVS Pressure transducer DAVS pressure transducers measure high static and dynamic pressure values of liquids or gases in rough operating environment Measurement precision is maintained even during continuous operation at extremely dynamic pressure The oil pressure transducer comes with a pressure connector with standardized G1 4 thread or other hydraulic connectors 3 3 1 Technical data 18 9 Operating voltage 8 32VDC Signal CANopen Operating temperature A0 C 85 C Storing temperature 40 C 100 C Protection class IP67 Life expectancy 10 million cycles Hysteresis tolerance 0 1 FS max 3 3 2 Installation Please notice the location of hydraulic piping and valve when installing the pressure transducer By thread connection such as follow graph screw the pressure transducer in the hydraulic piping or seat of the balancing valves or hydraulic valves Add the appropriate seal to the display to prevent oil leakage Guarantee the installation position is safe and easy for cable connecting Make sure the pressure sensor and hydraulic adaptor connect tightly The tightening moment of G1 4 connector is 20Nm pSENS gt Ub DAVS xxx 1501 2 gt 0 CAN high CAN low Pressure tra
23. on The correctness of the LMI setups must be ensured before beginning machine work in order to avoid damage to property and severe or even fatal injuries to personnel A If the LMI fails or is not functioning properly stop the operation of the crane immediately and contact an expert service engineer Hirschmann Electronics Co Ltd does not assume any responsibility for undesirable consequences resulting from continued use of the crane if the LMI is not functioning Hirschmann Electronics Co Ltd shall not be liable for damages caused by welding crane without power off the controller Hirschmann Electronics Co Ltd shall not be liable for damages caused by power on the controller at a thunderstorm weather fy HIRSCHMANN BELDEN BRAND 3 SYSTEM CONFIGURATION Cable connection Em o ww 4900 LMI System configuration HC4900 LMI system comprises a HC 4900 central unit with an IC 4600 console together with various sensors to record the measured values The system operates on the principle of reference real comparison The actual value is compared with the calculated reference values and evaluated by the system An overload warning signal is triggered on the display and operating console once limit values are reached All machine movements that increase the load moment are switched off at the same time The crane specific data specified by the manufacturer such as load capac
24. on 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 to the machine Gro operator that an overload condition has occurred It lights up when the crane load has reached 100 of maximum load carrying capacity permitted for the current operating status The acoustic alarm sounds The load moment increasing crane movements are switched off at the same time A2B switch lamp if the machine need This red warning light lights up when the A2B hoist limit switch contacts open i e when a hoist limit situation has occurred The 13 HIRSCHMANN BELDEN BRAND acoustic alarm sounds and load moment increasing machine movements are switched off at the same time An A2B 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 Test method as below Manually lifting the weight attached to the A2B switches then the audible alarm sound 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 condit
25. rigger tire 8088 configuration ER M F2 Select static load lifting or creep Le uni on tires Outrigger Low 9 F3 Confirm OM code After confirmation Current OM will correct push Y to confirm change to Set OM else push N to cancel and reset F4 Reset the OM code to zero J F5 Back to the main display OM setup interface Push N F4 button to reset the OM code Push Y F3 button once the proper configuration has been selected See following page for outrigger tire configuration amp static load lifting or creep on tires setup Refer to section 10 for 19 HIRSCHMANN BELDEN BRAND OM code table to look up proper code to enter for the boom configuration Outrigger Tire Configuration Push F1 to scroll through and select appropriate outrigger and tire configurations Ontires No need for outriggers NOTE F2 must be set for either static lifting or creep if On tires configuration is selected On outriggers extend to 0 fully retracted On outriggers extend for 50 half extended A Onoutriggers extend for 100 fully extended Static Load Lifting or Creep on Tires Mowe Push F2 to scroll to either Static Load Lifting or Creep on Tires NOTE If an incorrect OM code is entered Current OM code will change to BBBB If this occurs push F4 button and enter a permissible code example of this is if On Tires and Creep are selected but the swing angle
26. rtime e Cable of A2B switch shortcircuit e Cable to A2B switch shortcircuit e Cable of A2B switch break e Cable to A2B switch break e Sensor function fault e Can bus delay e Wireless teleport delay processing module wireless A2B Uneffective wireless teleport ID e Setting of data logger is eliminated crane data file or buffering battery fault e LMI processing data logger over time f HIRSCHMANN BELDEN BRAND e Re start the system e Connect PC final port and observe wrong information e Change A2B switch e Change the cable of A2B switch e Connect or change the cable of A2B switch e Connect or change the cable to A2B switch e Change A2B switch e Change the cable of A2B switch e Replace battery of wireless processing module wireless A2B e Set 0 at DGA12 9 e Re send data and set data logger Re start the system e Connect PC final port and observe wrong information 222 fy HIRSCHMANN BELDEN BRAND 9 HC4900 Connecting Diagram 1 EE SE 1 4 1 Bes e 9 2H Setup Hl 1 i f 1 ili 24 e Li 4 9 t 1 SL mig Hig 11 2 i E mi mi a mx E tA ml a 61 Ce
27. s numerical key 2 at the Function setup display to enter into CANbus status overview display Can Bus State The CAN bus status display show D61 ipso 1015 103 101 CAN communication status of all the d dd LMI components and the meanings of the status symbol When any node is operation use fault Operators can quickly find out 11 164608 Dispi the defective node and defective ID3 HMentor CU 1015 1496 Sensor ID68 Piston 011 Sensor ID61 Rod 011 Sensor reasons F5 Back to the previous interface CAN bus status query interface f HIRSCHMANN BELDEN BRAND code query Press numerical key 3 at the Function setup display to enter into OM code information display please use the displayed actual data on console OM Description Main Boom Main Boom Fixed Jib 10 0m 0 Main Boom Fixed Jib 10 0m 20 Main Boom Fixed Jib 10 0m 40 Main Boom Fixed Jib 17 0m 0 Main Boom Fixed Jib 17 0m 20 Main Boom Fixed Jib 17 0m 40 Main Boom Head Sheave OM Code ABO1 11 12 AB13 21 AB22 23 ABUZ When set needn t set A and B Just set the value behind and OM code query interface Operators can find code information in accordance with every different crane operating mode which offer great help for OM setup F1 Enter into OM setup display refer to 5 2 F5 Back to the previous interface The OM Code is
28. t defective e Refer to E11 Refer to E12 f HIRSCHMANN BELDEN BRAND Replace pressure transducer Setup of correct PDB variable for analog value in DGAG i 3 Replace sensor unit e Refer to E12 Replace angle sensor Setup of correct PDB variable for analog value in DGAG i 3 Replace sensor unit Replace CAN board Replace length sensor e Refer to E11 Refer to E12 29 HIRSCHMANN A BELDEN BRAND Error Cause code Rod side pressure Refer to E12 Refer to E12 exceed the max limitation Main boom bottom angle sensor channel voltage Referto E15 Referto E15 exceed the limitation UB System and UB system not UB Power must be exist at the system wired separately start UB System UB system connected direct with not exist at the the crane battery system finish UB Power for UB switch on off connect break fault Re connect break UB e Update effective software of the system e Change controller Power supply defect e Programming Logical file fault programming fault Flash EPROM fault System program The LMI system Update effective does not comply program is different system software or with crane data file from crane data file crane data file System program e The LMI system does not comply program is different with performance from performance table e Update effective system program or perform
29. t indicator monitors machine s various operational functions and provides the operator with a continuous reading of the machine s capacity The readings change continuously in response to the different operations of the machine If forbidden conditions are approached the HC4900 Load Moment Indicator will warn the operator by sounding an audible alarm lighting a warning light and locking out those functions that may aggravate the machine s condition This user manual is used for Zoomlion RT crane with a 4 section boom HIRSCHMANN BELDEN BRAND 2 WARNING The LMI control system is used to assist in the safe operation of the crane by warning 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 A Ee Safe operation is the responsibility for every machine operator Every machine operator must ensure that they read all warnings and instructions carefully and fully understand the contents Correct operation depends on daily careful checking and serious study of the Manual A NETTEN The LMI is not able to provide aid to the machine operator unless it has been properly adjusted and unless the correct load capacity chart and the correct operating code have been entered for the respective rigging configurati
30. tion Please check if the length cable is fine the A2B switch is normal the connection of A2B switch and boom head connecting box is OK or the A2B connector is short circuit for water in 205 HIRSCHMANN BELDEN BRAND 7 5 Length cable retract un smoothly Sometimes when the boom is retracted the length cable cannot return to the Original position naturally or retract not smoothly This is because that the coil spring pre tension is too low or the length cable in the cable reel has fallen off Please pre tighten the length cable several circles to solve the problem 1 Retract the boom and put it on the rack 2 Draw back the tip of the cable from the tip of the boom and retract to the cable reel 3 Pre tight the cable reel turn the cable reel to the cable out direction the length cable and the cable reel shall turn together and make sure the cable can be pulled out and retracted smoothly 4 Pull out the cable and fix it on the tip of the boom at the original place 5 After pre tight the cable reel the display of the boom length will be affected please adjust the length sensor till the displayed value equal to the actual A EE Operators shall be very cautious for the above adjustment Any incorrect length action may seriously affect the crane and the operation And after finish the adjustment please confirm once again before start to work 7 6 Question and Answer 1 Why the OM setting is correct b
31. ut the current rated load is different with the performance diagram of manufacture the parameter are all normal Answer Possible reason is your reeving setting is different with actual data E g current performance shows the rated load is 20T and reeving setting is 1 But because the largest load for single steel cable is 4T the rated load displayed on central unit is 4T 26 f HIRSCHMANN BELDEN BRAND When the outriggers are fully extended current rated load is not same with performance diagram Answer 1 maybe you have forgot to open the switch of outrigger fully extended on operation panel 2 forgot to confirm the operation of outrigger fully extended during console OM setting of console Why does the system show E04 Answer OM setting is wrong please set OM correctly When system has no mistake but the display parameter of crane are all wrong Answer The measurement units of parameters metric or imperial may be set incorrectly Go to set up and change Why the empty hoist load is wrong after boom extended Answer Confirm whether the boom extend order is correct please correctly use extend and restrict switch NOTE This situation is only for cranes with multiple extend modes Why LMI is warning and load percentage exceeded 100 while the crane still operation to dangerous direction Answer 1 please check whether the enforce switch is open or not 2 external circuit is open Why the load sho
32. ws extremely large at some large angle Answer Maybe under current boom length the largest angle has been reached hydraulic pressure of luffing hydraulic cylinder raise to high point causing the above phenomenon Why current load is much small the displayed percentage status bar show bigger number The percentage calculation is not correct Answer Our products are LMI protection equipment percentage status bars means percentage of actual load and rated load not percentage for displayed load and rated load NOTE All above answer are possible reasons but not the only reason for the system errors Please contact service engineer for further assistance 27 HIRSCHMANN BELDEN BRAND 8 Hints and Trouble Shooting Any improper operation or LMI malfunction will cause an alarm and an error code to be displayed The errors are caused by operations outside allowable parameters by incorrect inputs or by other factors The following codes are displayed on the main screen when the system is in error condition The list can be an aid in diagnosing the fault condition of the LMI system and can help in troubleshooting Due to the too much Fallen below the hoist up of the boom Boom down to a radius range which result in lower permitted radius or angle range than the min radius or angle in the load exceeded exceed the max angle chart in the capacity chart Due to the too much hoist down whi
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