ds150-interactive - crane lmi systems
Contents
1. F 6 TROUBLESHOOTING 25 Radius Press and hold the Alarm Stop button 13 then press the Outrigger Selection button 5 oi Actual Load To obtain the Actual Load when an error code is pre sent press the Alarm Stop button 13 Maximum Load Press and hold the Alarm Stop button 13 then simultaneously press the Reeving Selection button 3 and the Ou trigger Selection button 52. N 4 approaching two block condition boom angle preset limits are reached in case of a malfunction of the LMI system in case of an operating error The alarm can be silenced temporarily by pushing the button Alarm Stop 13 13 Button Alarm Stop This ALARM STOP BUTTON 13 allows the au x lt dible alarm to be silenced for approximately 15 seconds by pressing this button Reference Au dible Alarm 12 Control Identification 13 14 Boom Configuration Control Lights Sensors at the boom head and the boom extension provide the LMI with information regarding the actually used boom extension configura tion The selected boom extension configuration can be checked as the respective lamp will light up Main Boom Tele O Extension w offset ext Tele O Extension w offset retr Tele O Extension w o offset ext Tele O Extension w o offset retr moou 14 Operator s Handbook PAT DS 150 4 Pre Operation Inspection and Calibration Verification Prior to operating the crane the following electrical connections must be chek ked to ensure that the system is properly connected for the crane configuration Machines with only a Main Hoist If the crane works only with the boom and without boom extension no additio nal connections are necessary However be sure the weight of the anti two block switch is properly installed on the main hoist load line With even parts of hoisting line the weight sha
3. During crane operation the readout 4 will display the Actual Load This is the actual load at the boom gross load Slings and hook block are inclu ded If boom extension is erected it will be reflected in the actual load displayed however operator must use weight re duction values shown in the load capa city chart In case of an operating error the dis play shows an error code Reference chapter 6 Control Identification 9 5 Outrigger Setting Button and Control Lights The button Outrigger Setting 5 provi des the load moment indicator with in formation regarding the outrigger confi guration The operator has to set the system to the outrigger configuration os being used f 4 After ignition of the engine the system selects automatically the configuration without outriggers on rubber To set the system to the configuration on ou triggers the operator has to push the button gt UJ A without outriggers on rubber B onoutriggers The selected outrigger configuration can be checked as the respective lamp will light up WARNING The correct setting is of utmost importance for the proper func tion of the system and the crane Therefore only operators who are thoroughly familiar with crane load capacity charts and the use and operation of the system shall set the Outrigger Button 6 Load Moment Control Light Load Moment Control Light 6 lights u
4. locking the crane movements hoist up telescope out and boom down Check the anti two block alarm light 2 and the audible alarm 12 by perfor ming one of the following tests 1 By manually lifting the weight attached to the anti two block switches When the weight is lifted the audible alarm 12 should sound the anti two block alarm light 2 should light 2 Slowly raise the main boom load handling device to create a potential two block condition When the load handling device lifts the weight the audible alarm 12 should sound the anti two block alarm light 2 should light and the motion of the Operator s Handbook PAT DS 150 load handling device should be stopped Lower the load handling device slightly to eliminate this condition Slowly lower the boom to create a potential two block conditi on When the load handling device lifts the weight the audi ble alarm 12 should sound the anti two block alarm light 2 should light and the boom lowering function should be stopped Lower the load handling device slightly to eliminate this condition Slowly extend telesope the boom to create a potential two block condition When the load handling device lifts the weight the audible alarm 12 should sound the anti two block alarm light 2 should light and the boom telescope out function should be stopped Lower the load handling device slightly to eliminate this condition WARNING If the light and audib
5. values an authorized PAT service representative shall be called for repair of the system or reverification of the crane s LMI calibration WARNING Any structural modifications or changes to the crane shall requi re reverification of the crane s LMI calibration 20 Operator s Handbook PAT DS 150 5 SERVICE AND MAINTENANCE Daily maintenance of the load moment indicator consists of inspecting 1 The electrical wiring connecting the various parts of the system If electrical wiring is damaged it shall be replaced immediately If the insulation is worn on the length sensor cable or cable guides are damaged these parts shall be replaced Check the anti two block limit switches for freedom of movement The cable reel shall be under tension to operate properly Check the pressure transducers at the lift cylinder s and the connec ting hoses for oil leakage Other than correcting the problems identified in the Malfunctions Table and replacing faulty mechanical parts and cables no other repairs shall be performed by non expert personnel 6 TROUBLESHOOTING 21 6 TROUBLESHOOTING General In case of a malfunction of the system the load display 4 will indicate a code which identifies the system malfunction The error codes listed in the Malfunction Table will identify various faults which can occur with the LMI Following the Malfunction Table are pages which explain each fault and
6. DS 150 Load Mo ment Indicator The numbers of the illustration correspond to the num bers in the following list which describes the function of each control Operator s Handbook PAT DS 150 Fig 2 Operating Console PAT ps 50 Boom Nose Selection Button and Control Lights Anti Two Block Alarm Light Button and Control Light Reeving Selection Display Actual Load Outrigger Selection Button and Control Lights Load Moment Control Light T 10 11 12 13 14 Load Moment Prewarning Light Load Moment Limit Light By Pass Key Switch Override Key Warning Light Control Light Anti 2 Block Override Audible Alarm Button Alarm Stop Boom Configuration Control Lights Control Identification 7 1 Boom Nose Selection Button and Control Light The button 1 is used to provide the LMI with information regarding the actual boom nose con figuration of the crane If the crane is working with the Searcher Hook the operator has to push the button After pushing the button the control light below the button is used to check the previously selec ted working condition Searcher Hook WARNING The correct setting is of utmost importance for the proper func tion of the system and the crane Therefore only operators who are thoroughly familiar with crane load capacity charts and the use and operation of the system shall set the Boom Nose Sele
7. PAT LOAD MOMENT INDICATOR DS 150 0038 INTERACTIVE OPERATOR S HANDBOOK NOTICE The information in this document is subject to change wi thout notice PAT makes no warranty of any kind with regard to this mate rial including but not limited to the implied warranties of merchantability and fitness for a particular purpose PAT shall not be liable for errors contained herein or for incidental or consequential damages in connection with the fur nishing performance or use of this manual This document contains proprietary information which is pro tected by copyright All rights are reserved No part of this document may be photocopied reproduced or translated to another language without the prior written consent of PAT Copyright 1998 by PAT GmbH Second Edition 09 09 1998 ko DS150 50 150 19 0038e TABLE OF CONTENTS General Information 2 Warnings 1 3 System Description 3 3 1 System Function 5 3 2 Operating Console 5 3 3 Control Identification 5 4 Pre Operation Inspection and Calibration Verification 14 5 Service and Maintenance 20 6 Troubleshooting 21 GENERAL INFORMATION 1 1 GENERAL INFORMATION The PAT Load Moment Indicator LMI DS 150 has been designed to provide the crane operator with the essential information required to en able the machine to be used within its design parameters Using various sensing devices the Load Moment Indicator monitors va rious crane func
8. c tion Button 2 Anti Two Block Alarm Light The red Anti Two Block Alarm Light 2 lights up when the anti two block limit switch contacts open indicating that a two blocking condition is te approaching At the same time the audible alarm will sound The following crane movements will be stopped subsequently hoist up telescope out boom down Operator s Handbook PAT DS 150 3 Button and Control Lights Reeving Selection A 1 fall part of line B 2 falls parts of line C 3 falls parts of line The button Reeving Selection 3 pro vides the load moment indicator with in formation regarding the number of falls parts of line used to reeve the hook block The operator has to set the system to the actual number of falls parts of line being used After ignition of the engine the system selects automatically 1 fall lamp A To select 2 falls lamp B the operator has to push the button one time To select 3 falls lamp C he has to push the button two times The selected number of reevings can be checked anytime as the respective lamp will light up Caution The correct setting of the Reevings is of utmost importance for the proper function of the system and the crane Therefore only operators who are thoroughly familiar with crane load capacity charts and the use and operation of the system shall set the Reeving Selection Button 4 Display Actual Load 88888
9. describe the action which shall be taken to correct the fault Faults within the electronic microprocessor shall be repaired by factory trained service personnel When these faults occur the competent ser vice organization shall be contacted Malfunction Table Error Code Error E01 Fallen below the radius or above angle range E02 Radius range exceeded or fallen below angle range E03 Boom position is out of the permissible working area E04 Operating mode not existing E05 Prohibited length range NOTE If there is any Error Code displayed on the console which is not listed in the Malfunctions Table you shall call the Local Distributor 22 Operator s Handbook PAT DS 150 Operating Errors Malfunctions in the system which are caused by range exceedings or operating errors by the crane operator himself are indicated on the dis play together with an explanation These error codes are E01 E02 E03 E04 and E05 and they can normally be eliminated by the crane operator himself Error Code Cause Elimination Fallen below the minimum Lower boom back to a radius or above the angle radius or angle given in E01 given in the load capacity the load capacity chart chart due to raising the boom too far The maximum radius or Raise boom back to a minimum angle given in radius or angle given in E02 the load capacity chart the load capacity chart was exceeded due to low
10. ering the boom too far Boom position is out of Move boom back to the the permissible working permissible working area E03 ES area over front See lifting diagram in the load capacity charts Operating mode is not Be sure crane is set up E04 permissible with the actual according to proper crane configuration boom operating configurations position or area definition 6 TROUBLESHOOTING 23 E05 Boom was telescoped too far or not far enough you may only operate up toa certain maximum or minimum boom length or with load curves for boom extension where you have to telescope the main boom to a certain length Telescope boom to correct length given in the load capacity chart Length sensor adjustment changed i e length sensor cable slid off the length sensor drum For elimination refer to service manual 24 Operator s Handbook PAT DS 150 Additional Displays for Troubleshooting only Additional displays can be called up momentarily by pressing the described buttons Operating Mode Press and hold the Alarm Stop button 13 then simultaneously press E RU Selection button 3 and the Boom Nose Selection button P p Angle Press and hold the Alarm Stop button 13 then press the Reeving Selection button 3 KO Boom Length Press and hold the Alarm Stop button 13 then press the Boom Nose Selection button 1
11. l lever lockout In this position turn the key clockwise Sx the by pass key switch 9 deactivates the control lever lockout function of the LMI and of the anti two block The Override Key Warning Light will blink All other dis play indicating and alarm functions will continue to work a X In this position turn the key counter clock wise the anti two block control lever lock out is by passed This does not influence the LMI system WARNING Since this switch deactivates the cut off function of the LMI sy stem and the anti two block system the following instructions shall be adhered to the by pass key shall be used with discretion as unwar ranted use of it to override the control lever lockout sy stem can result in harm to the crane and danger to pro perty and persons never use the by pass key to either overload or operate the crane in a range not permissible 12 Operator s Handbook PAT DS 150 10 Override Key Warning Light The red OVERRIDE KEY WARNING LIGHT C gt 10 flashes to indicate that the cut off function SHEP of the LMI system is deactivated 11 Control Light Anti 2 Block Override This light 11 flashes to indicate that the cut off P function of the anti two block system is deactiva ted 12 Audible Alarm The AUDIBLE ALARM 12 which sounds du ring the following conditions overload condition
12. le alarm do not function as described and the crane movements are not stopped the system is not wor king properly The malfunction shall be corrected before opera ting the crane If the crane is equipped with a boom extension repeat the test procedure for the boom extension anti two block switch Check that the display of the main boom length agrees with the actual boom length Check that the display of the main boom angle agrees with the actual boom angles Check that the display of the operating radius of the crane agrees with the actual radius 4 Pre Operation Inspection and Calibration Verification 19 Check the load display by lifting a load of known weight The accuracy of the load indication shall be within the tolerance of SAE J159 Operation After being properly checked the LMI is operational The operator shall be tho roughly familiar with all controls of the LMI and he shall properly set the Ree ving Button 3 before operating the crane The proper function of the system shall be checked by lifting a load of known weight and comparing the load to the information displayed on the LMI Hated loads include the weight of the hook block slings and auxiliary load handling devices Their combined weights shall be subtracted from the listed load capacities as stated on the load capacity chart to obtain the net load to be lifted WARNING If any of the displays reflect a deviation between displayed and actual
13. ll be attached to the dead end line With odd parts of hoisting line the weight shall be attached to the line of lowest speed If the crane works with boom extension the connecting cable shall be installed between the junction box on the boom extensionand the boom junction box The weight attached to the main hoist anti two block switch shall be removed In that case the anti two block switch has to be locked with the red Anti Two Block Retainer which is fixed with a red lanyard at the anti two block switch described on pages 15 and 16 Then the weight shall be reattached to the boom extension anti two block switch WARNING Failure to re position the anti two block switch weight will pre vent the overhoist system from functioning properly No weight shall be on the main hoist anti two block switch when the boom extension is being used NOTE If the installed anti two block switch is different from the switch illustra ted on page 15 Fig 1 refer to manufacturers documentation for confi guration and operation Machines with Main and Auxiliary Hoists If the boom extension is not in the operating position the by pass plug shall be installed in the main boom junction box The weight of the main hoist anti two block switch shall be installed 4 Pre Operation Inspection and Calibration Verification If the boom extension s in the operating position the connecting cable shall be installed between the junction boxe
14. ly inspection and observations of the operating instructions set forth in this manual We draw your attention to section 4 of this handbook WARNING The displays will only aid the operator when the LMI is properly programmed for the crane configuration being utilized To pre vent property damage or serious bodily injury or death to per sonnel ensure the LMI is properly programmed before operating the crane 3 SYSTEM DESCRIPTION The PAT Load Moment Indicator DS 150 consists of a central micro processor unit operating console length angle sensor pressure trans ducers and anti two block switches The 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 evalua ted in the micro processor When limits are reached an overload war ning signal is generated at the operator s console At the same time the dangerous 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 and angle sensor The angle sensor is mounted separately on the boom The boom length i
15. om the Anti Two Block switch Release the cable 3 For storage slide the retainer from right side 5 over the Anti Two Block switch until the clips A lock into the holes B Fig 3 Removal of the Anti Two Fig 4 Retainer in Storage Position Block Retainer 4 Pre Operation Inspection and Calibration Verification 17 Pre Operation Inspection and Calibration Verification After the electrical connections have been checked to insure that the system is properly connected for the crane configuration the following checks shall be made 1 Check the electrical wiring connecting the various parts of the system for physical damage 2 Check the anti two block switches and weights for free move ment 3 Check the spring loaded cable reel to be sure it is free to ro tate has tension and the cable is reeled properly WARNING The following tests shall be performed with care to prevent da mage to the machine or injury to personnel Proper functioning of the system requires successful completion of these tests be fore operating the machine If the operator cannot see the load handling device approaching the boom nose he shall have an assistant signal person watch the load handling de vice The operator shall be prepared to stop the machine immediately should the LMI system not function properly as indicated by lighting the red warning light 2 sounding the audible alarm 12 and
16. p when the crane operates within its per OK missible working range When an overload condition is approa ching or is reached or in case of an error the light goes out Operator s Handbook PAT DS 150 7 Load Moment Prewarning Light The yellow LOAD MOMENT PREWARNING LIGHT 7 will light up when the load on the cra ne enters the defined prewarning area It indica tes that an overload condition is approaching This means for the operator to continue his crane operation with extreme caution The definition and setting of the prewarning area is linked to the data EPROM used in the central unit 8 Load Moment Limit Light The red LOAD MOMENT LIMIT LIGHT 8 warns the operator that a rated load condition has been reached It lights up when the load on the crane reaches the crane load capacity The audible alarm also sounds when this condition has been reached The following crane movements will be stopped concurrently hoist up telescope out boom down 9 By Pass Key Switch The BY PASS KEY SWITCH 9 can de activate the cut off function of the LMI or anti two block momentarily to allow the crane operator to override the control lever lockout It can be operated only by using the matching key The by pass switch has 3 positions which are further described as follows Control Identification 11 mid position In this position the by pass switch 9 is without influence to the LMI and anti two block contro
17. s 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 transducers attached to the pi ston and rod side of the lift cylinders 4 Operator s Handbook PAT DS 150 Fig 1 Components of PAT LMI System DS 150 1 Anti Two Block Switch 2 Pressure Transducers 3 Length Sensor Anti Two Block Cable Reel 4 Operating Console 5 Central Micro Processor Unit 6 Angle Sensor System Function 5 3 1 System Function After ignition of the engine the system starts with an automatic test of all lamps the display the audible alarm and the complete system After the system has passed through the system test without errors the System is ready for operation The console will display the actual load on the LC display of the operating console Fig 2 In case of system s malfunction an error code number will also be dis played on the load display at the console 3 2 Operating Console The console has 2 functions terminal for input of instructions to the system by the crane operator display of actual load and error code The operating console is located in the operator s cabin in front of the operator This unit contains different control lights buttons and a dis play which are described in chapter 3 3 3 3 Control Identification Figure 2 illustrates the controls and display of the
18. s on the boom extension and the main boom Weights shall also be attached to the anti two block switches on both the main boom and boom extension If the boom extension is in the operating position and no load line is being used on main boom to prevent injury or damage to equipment the weight shall be removed from main boom switch In that case the anti two block switch has to be locked with the red Anti Two Block Retainer which is fixed with a red lanyard not shown at the anti two block switch Installation of Anti Two Block Retainer in Locking Position Procedure see Fig 1 and 2 1 Pull the cable out of the switch and bend back parallel to the boom and hold 1 2 Slide the retainer from left side with it s slot over the cable between the crimped stop and the switch 2 Push it firmly straight onto the cable guide of the Anti Two Block switch 3 3 Straighten the cable completely into the slot and release the cable 4 ner in Locking Position Fig 1 Setting of Anti Two Block Retai Fig 2 Retainer in Locking Position 16 Operator s Handbook PAT DS 150 4 Turn the flag of the retainer for best visibility for the operator 5 Removal and Storage of the Anti Two Block Retainer Procedure see Fig 3 and 4 1 Pull the cable out of the switch 1 and bend back parallel to the boom and hold 2 2 Move the retainer down 3 and then left 4 to remove it fr
19. tions and provides the operator with a continuous rea ding of the total calculated weight being lifted by the crane The reading continuously change as the crane moves through the motions needed to make the lift If non permitted conditions are approached the DS 150 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 crane s condition 1 LOAD MOMENT generally the product of a force and its moment arm specifically the product of the load and the load radius Used in the determination of the lifting capacity of a crane 2 WARNINGS The LMI is an operational aid which warns a crane operator of approa ching overload conditions and also warns of overhoist conditions which could cause damage to equipment and personnel The device is not and shall not be a substitute for good operator judgement experience and use of accepted safe crane operating procedures The responsibility for the safe operation of the crane shall remain with the crane operator who shall ensure that all warnings and in structions supplied are fully understood and observed Prior to operating the crane the operator must carefully and tho roughly read and understand the information in this manual to en sure that he knows the operation and limitations of the indicator and crane 2 Operator s Handbook PAT DS 150 Proper functioning is dependent upon proper dai
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