I

User Manua I User Manual

3. System description 4. System composing

The HC4900 LMI system can be installed on various kinds of 1. Central unit (Mentor)
cranes and measure the load moment and judge whether it is overload to 2. CAN signal junction box

prevent the crane from dangerous operation. 3. LCD Graphic Display

Because of the load moment value is not easy to measure and even 4. Pressure transducer

not easy eyeballing so it will result in the operator's wrong judgment. 5. Length/Angle sensor

while our HC4900 system can monitor the crane's operation real-time 6. Anti-Two-Block switch and weight

that enables the operation in a safety range.

The HC4900 system can monitor the crane information such as

boom length, boom angle, max hoist height, working radius, rated
capacity and actual load, etc. The LMI calculated the load moment
value from the force component's measuring data. when the operation

exceed the allowed safety range the LMI will send warning signal to the

LCD Graphic screen and send control signal to the central unit to,warn
the operator to stop the illegal operation.

The following chapters will describe the HC4900 LMI's

characteristics, functions, operations and warnings. HC4900 LMI structure

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 User Manua I

5. Operation description
il
After the proper calibration the LMI system can start work ril

automatic. So the crane operator should be very familiar with the LMI Self test of LMI

operation and operate the crane after proper adjustment.

Look up the error
code and debar the

Is the showed OM the

same as the actual

Is the showed Reev Set correct Reeving

the same as the actual

Is the showed Length

the same as the actual

Is the showed Radius Adjust the Main boomAngle

the same as the actual to make them to be the same

Need set the upper and Set the upper and

lower LimitAnsle lower limit ansle

Operate the crane

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User Manua I
User Manua I

6. System's function and operating method 1. A2B light

2. Pre-warning Light
6.l Display content
3. Overload warning Light
A. Bar graph (load moment percentage)

B. Time display

C. OM display

D. Reeving display (display the number of steel wires)

l1
E. Main Boom length
f;- -'1'I
F. Display the number of the balance weight
i;- §
il- G. Actual load
H :lt
H. Max limit angle display
P
-{} I. Min limit angle display
I;
-{4 J. Outrigger display ( l/2: half-extended, 212: full-extended)
K. Rated load capacity

L. Tare button

M. Alarm stop

N. Working radius display

O. Lower limit angle setting button

P. Main boom angle display

Picture 1: Main interface
Q. Upper limit angle setting button

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User Manua I
User Manua I

R. The largest lifting height at the current position

S. Function key
TñfiEflffi
T. Moment percentage Digital indication I rtfl.i+E
2 E+i[E
3 i¿t¿HiEt
Note: Use the two number keys of 3 and 8 on the LMI to change
i ffiffi#H
the background color while the numher keys 4 and 9 can make the

displayed number's color reverse flrc background's color.

W

6.2 Operational method

Picture 2: Function setting interface
'ii'l' I

6.2.1 Switchover between English and Chinese

;li, Press the button ml ," switchover between Chinese and English.
Íi
The IC4600 LCD on LMI 4900 system can switchover between Please pay attention that the English interface can not be saved for a

English and Chinese. long time and needs to be reset after the system is power off and restart.

The default language is Chinese. The English display can be

following the below operation: Function inte¡fat:e

I 0l{ set
Press the function k., [-Ei on the interface of Picture 1 (the letter 2 Reev set
3 llemory inquirc
{ §ystem Fault
S ) to enter into the Function setting interface. 5 Time set

Picture 3: English interface of function setting

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User Manua I User Manua I

operat lng
6.2.2ONI setting
input right operating node

The OM setting is used for adjusting the LMI parameter according

press to shift
pre§s to confir¡t
to the actual crane's condition. When operate the crane please make sure press to return
the displayed operation mode is the same as the actual operation mode.

Before operate the crane please check the corresponding OM code

| *'il
r-Olrl-r
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according to your crane type and actual mode and then adjust the OM to l*i
be the same as the actual OM.
Picture 4: OM setting interface
By pressing the number and function key the displayed OM can be
Warning
same as the actual OM. Let's take an example: if you want to set OM to
The correct setting is of utmost importance for the proper
be 0001, you can press the function rcV H to move the"x"to the
function of the system and the crane. Therefore only operators who
first digital position and press number "0", then use the same method to
are thoroughly familiar with use and operation of the system shall
set this function.
input the 2"d and 3'd number. Press the function key
[E ,o move
the"*"to the final digital and input the numbe r "1" ull pr"., tfr"
When it is need to adjust the operating mode please press the function k"y iüI{i to confirm this operation.

numeric key "1" , which correspond to OM setting under the Function

setting interface (see Picture 3), to enter into the follow picturc 4 "Set 6.2.3 Reeving setting

operation mode interface". This function is for setting the number of the rope for LMI system.

Before operate the crane the operator is asked to adjust the displayed

reeving to be same with the actual one.

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 The relationship between the actual reeving and displayed one is as correct password to query the overload record. ( Attention: Only
following: manufacturer has this right)
Displayed reeving number: 1----------16 6.2.5 Error code check
Number of the actual steel wire ropes: 1----------16 Press the number key 4 of error code checking on the function
Press the number key 2 of reeving setting on the function setting interface to enter into the error inquire interface (Picture 6
interface to enter into the reeving setting inteÍface. below). This interface can provide you the meaning of the error code
rEEU and offer convenient for using and maintenance.
Irrput reeu bg number keg
p,'"" [Iito sh ift m1
p""*" fñii.o Fallen belo¡¡ radius
corrf irm rallge trr angle range
exceeded
press
lülto return CAUSE
[all,.rr belou the ni-
rrimum radius trr Uone
past the maximnm an-

rEl E
i*i
gle specilied i¡t the
respectiue load cha-
rt due to luffing
tlre boom too far
EI,III IIIAI IOI{
up

Luff doun the boo¡r to

a raclins or angle s-
pecified i¡r the load l+
clrart.
Picture 5: Reeving setting interface
The operational method of setting reeving is same as the oM
Picture 6: Error Inquire
setting in this interface.
Press the button [Tl and [I . check the different error code,
6.2.4 Memory inquire
press the button lpi ,o return the function setting interface.
Press the number key 3 of memory inquire on the function
6.2.6 Time"setting
interface to enter into the memory inquire interface and then input the
Press the number key 5 of time setting on the function setting
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User Manua I
User Manual

interface to enter into the password input interface.

confirm the time setted and return to the main interface for normal

operation.

Attention: Only manufacturer has right to set date.

6.3 Setting the upper and lower limit

input passuord
The LMI system function for the limitation of the boom angle to
ffi

hi warn the operator of extreme caution under dangerous condition:

Isl buildings, bridges, high-voltage wire etc.

Warning
Press the button a enter into the time setting interface as the
lgi This limit function is only of warning use but without control
Picture 7 shows:
function. For each time reset the LMI system you need to reset the
time setting limit value.
current ti¡re

6.3.1 Setting the upper limit angle

07-0ü-13-13 :,18

Luff up the boom to maximal safe position and then press the
S7-08-13 13:48
button ffli on the main interface to set present boom angle on the H

indicating area of the main interface as angle upper limit. When this

limit value exceeded, the " ffi " indication light will light up and send
Picture 7: Time Setting
audible alarm sound to warn the operator to take extreme operation.
Press the button [Ii to choose the item needs to be changed and

adjust the correct time through the numeric keys. Press the button [*i a
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User Manua I User Manua I

6.5 Indicating light explanation

6.3.2 Setting the lower limit angle

Luff down the boom to minimal safe position and then press the 6.s.1A2B indication light
ffi
W
button [._E
o, the main interface. The disprayed angle value on the I The red warning light will light up as soon as the anti-two-block
indicating area of the main interface will be recorded as the lower limit limit Switch contact open, indicating that a two-blocking condition is
approaching. At the same time the audible alarm will sound.
angle. when the angle is lower than this limit value the " m ,,

indication light will light up and The following crane movements will be stopped subsequently:
send out audible alarm sound to warn

the operator to take extreme operation. hoist up, telescope out, boom down.

In order to avoid any injury to people or crane, please check the

6.3.3 Cancel angle limit
A2B system before operating the crane in the following procedure:
Press the number key"0"then the setted angle limits are canceled.
a. Manually lifting the weight attached to the anti two-block
6.4Buzz stopping
switches, then the audible alarm sound and the anti two-block alarm
The HC4900 system warning buzzer will sound alarm under the light will light.
following conditions:
b. Slowly raise the hook or lower the boom or extend(telescope)
----- Reach maximal of rated capacity the boom to create a potential two-block condition, when the hook
----- The hook reaches to height limit
lifts the weight, the audible alarm sound, the anti two-block alarm
----- Exceed the permitted movement radius of the crane
light will light and the crane movement such as hoist up, boom
----- Load moment indicator malfunction
down, telescope out will be stopped.
----- Error operation
c. If the light and audible alarm does not function as described and
Press the 0", "i.Ei" in the main interface and the audible alarm the crane movements are not stopped, the system is not working
will be stopped last for 40s.
properly. The malfunction shall be corrected before operating the
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 User Manua I

crane.
7 . HC4900 system functions
6.5.2 Pre-warning light
ffi
The yellow load moment pre-warning Light will light up when
1. Warning

the load on the crane reaches the defined pre-warnin g areag}vo-l}}vo

-overloadcondition
of the rated capacity, thus indicating that an overload condition is
-zblock
approaching' This means the operator shall continue his crane
operation
-rnalfunction
Under any above conditions, HC4900 system will light up and
with extreme caution.
send out alarm for warning.
6.5.3 Overload alarm light
2. Prohibited
The red warning light will righi up when the load on the crane cooperating with crane electrics system the rMI system will send
reaches the defineci overload capacity of !007o rated capacity and the alarm warning and any of the following crane's movements will be
buzz sends out audible sound. The light will light up when the system prohibited:
has error situation and the operation of lifting hook, extended boom and luffing down
downward luffing will be stopped. This status will be canceled along -Boom out
with dropping the weighr or upward luffing. _
-Telescope
Hoist up

At this moment only the movements toward safe direction is

allowed:

luffing up
-Boom retract
-Boom down
-]{sis¡
aa
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User Manua I

The LMI system has this cut-off function however the operation
8. Daily maintenance and adjustment method
toward dangerous direction is not allowed when overload,

anti-two-block limit or system error condition happens (Alarm at the Please maintain and adjust according to the following content. If
you have any problem please contact us.
same time). Because this cut-off device is an interacted system, in case

of any error it may cause big danger. 8.1 Maintenance content

1. Check all the cable connection of the system. Damaged cables

Notice
shall to be replaced immediately.
When the cut-off device is activated this cut-off signal will
2. check the insulating layer of the length sensor and A2B switch
always keep be out. Functions such as "dangerous direction
cable and the cable guides. If the insulating layer or the wire inside
operation is not allowed", "only safe direction operation is allowed"
damaged, you should replace one immediately.
is realized by cooperating with the crane's electronics system which
3. Inspection of the anti-two block switch as to easy running.
including " safe direction inspect switch", "safe overflow solenoid
4. Check the cable reel as to sufficient tight or not.
valve" etc. The LMI system cannot judge the operation is safe or
5. Check the pressure transducers at the luffing cylinder and the
dangerous itself.
connection hoses as to oil leakage.

8.2 Length sensor calibration

when the displayed boom length is not correct (exceeds the

permitted error range), please calibrate it:

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 and.turn the axle of the length

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User Manua I User Manua I

potentiometer slowly ( as the arrow marks, increase follow clockwise

and decrease counter-clockwise) till the displayed value to be the same

with the actual length.

Angle sensor Adjust (as the Íurow pointing)

8.4 Buzzing alarm

Length sensor adjust (as the above arrow) After start the system it displays without any malfunction or error
8.3 Angle sensor calibration code but the btzzer keep sound alarm, in this case please check if any

The angle and length sensor are installed in the same housing. disconnection or water inside the connection between length cable and

First withdraw the lifting boom to basic length boom and the displaying A2B switch.

boom length shall be the same as the actual boom length while checking. 8.5 The cable of reel retract not smoothly

Use the angle indicator to measure when the actual angle is between Sometimes when retract the boom it happens that the length cable

Ooand 7O'whether same as the displayed value or not. Also could use a
cannot return to the original position naturally or retract not smoothly. It
tape to measure the working radius if the displayed value or radius is is because of the coil-spring's pre-tight is too low or the length cable in
not the same with the actual value, you should adjust the angle sensor. the cable reel fall off.
Please loosen the three bolts(as the affow pointing)and then slowly turn Please pre-tighten the length cable several circles to solve the

the angle sensor till the displayed value accord with the actual one. problem:

After that, please tight the bolts again. l. Retract the boom and put it on the rack

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User Manua I

2. Draw back the tip of the cable from the tip of the boom and
9. Error information and málfunction solve method
retract to the cable reel
In case of a system malfunction or fault operation, an effor code to
3. Pre-tight the cable reel 3 to 5 circles, to make the cable can be

pulled out and retracted smoothly.

identify the error source will be displayed on the LCD. The code

numbers listed in the malfunction table identify various malfunctions

4. Pull out the cable and fix it on the tip of the boom again
that might occur in the LMI system which may cause by operating faults
5. After pre-tight the cable reel the display of the boom length will
of the crane operator or by exceeding preset areas.
be affected, so at this moment please adjust the length sensor till the

displayed value the same with the actual length.

Important Notice
If there is any Error Code displayed on the console which is not
Notice
listed in the Malfunctions Table you shall call us by:
The operator shall be careful the above calibration. The crane
can only be operated under correct adjustment and confirmation Tel: 0516-87885700 Fax: 0516-87793971
after adjustment.

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 Manua I

Error Error
Error Cause Elimination Error Cause Elimination
Code
Code
Fallen below o Fallen below the Luff down the Prohibited Boom has been Extenüretract
radius range minimum radius or boom to a length range extended either too far boom to the
or angle range gone past the radius or angle or not far enough, e.g. correct length
exceeded maximum angle specified in the if it is prohibited to go Retract boom.
specified in the load chan.
801 beyond a certain Check the
respective load chart maximum boom prestress ofthe
due to luffing up the
length or with load cable reel (cable
boom too far
curves for jibs where must be taut).
the main boom has to Open the length
be extended to a sensor and
Radius range Gone past the Luff up the 805 certain length carefully turn
exceeded or maximum radius or boom to a Length sensor the length
fallen below fallen below the radius or angle adjustment has sensor pot
angle range minimum angle specified in the changed, e.g. the cable counterclockwis
specified in the load chart. slid off the length e until the
802 respective load chan sensor reel. detent by means
due to luffing down of a screw
the boom too far driver

Operating o A non existing o Set the correct Radius range Maximum radius as Luff the jib to a
mode not operating mode has operating mode exceeded or specified in the load radius or angle
acknowledged been selected for the fallen below chart exceeded or specified in the
or non o The boom is in a operating state E06 angle range
fallen below minimum load chart.
804 permitted non-permitted slewing in question angle due to luffing
with luffing
slewing zone zone o Slew the boom down the luffing jib
jib operation
to a permitted too far
area.
 User Manua I

Error Error
Error Cause Elimination Error Cause Elimination
Code Code
Fallen below o Length potentiometer Replace length Fallen below o Angle potentiometer o Replace angle
lower limit is defective potentiometer lower limit defective sensor
value for o PDB variable for Setup of correct value in o PDB variable for o Setup ofcorrect
measuring analog value not PDB variable measuring analog value not PDB variable
supported for analog value supported for analog value
E11 channel E15 channel
o Electronic component in DGA6.i.3 o Electronic component in DGA6.i.3
"length main "angle main o
in the measuring Replace sensor in the measuring Replace sensor
boom" boom" channel defective. unit
channel is defective unit

Fallen below o Pressure transducer is o Replace Upper limit Refer toBl2 Refer toBl2
the lower defective. pressure value in
limit value in o PDB variable for transducer measuring
the measuring analog value not o Setup ofcorrect channel "main
supported PDB variable Ezt
Et2 channel boom length"
"pressure
o Electronic component for analog value
has been
in the measuring in DGA6.i.3
piston side" o exceeded.
channel is defective. Replace sensor
unit
Upper limit Refer toBl2 Refer toBl2
value in
Fallen below Refer toBl2 Refer toBl2
measuring
lower limit
channel
value in the
822 "pressure
measuring
E13 piston side"
channel
has been
"pressure rod
exceeded
side"
User

Error Error
Error Cause Elimination Error Cause Elimination
Code Code
Upper limit Refer toBl2 o Refer toBl2 Error in the +UB System not +UB System
value in power supply present at the system and +UB Power
measuring start must be wired
channel +UB System not separately: +UB
present at the system System
823 "pressure rod
832 finish connected direct
side" has been
Contact problems at with the crane
exceeded. +UB switch off/on battery. +UB
Power for
switch on/off
Upper limit Refer toBl2 Refer toBlz +UB switch
value in off/on asain
measuring
Error in the . System program file is a Upload valid
logical defective system software
channel 837 o Flash-EPROM
824 program flow a Replace central
"force" has defective unit
been
exceeded. System o The system program Upload valid
program and in the LMI does not system program
Upperlimit Refer toElZ Refer toElZ 838 crane data file match to the file or the valid
programming in the crane data file
value in do not match.
crane data file
"measuring
channel "main System The system program o Upload valid
E2s boom angle" program and in the LMI and the system program
has been load chart file programming in the file or the valid
E39
exceeded. do not match load chart file do not load chart file
match.
User Manua I

Error Error
Error Cause Elimination Error Cause Elimination
Code Code
Error in the o Write/read memory o Replace central Wrong setup Analog input not Setup correct
write/read (RAM) or central unit unit of min. supported Flag in DGA
E43 defective. 6.i.2
memory analog inputs
E53
(RAM) lengthl,
Error in the The CRC sign of the Restart the LMI angle1,
monitored monitored write/read Replace buffer pressurel
write/ read memory is wrong battery on the Error in crane o No valid data in the a Restore or
memory. The buffer battery is central unit. data file. crane data file during upload valid
decharged (<2Y at Replace central E56 calibration. crane data file
The CRC
lkohm). unit o Flash-EPROM a Replace central
verification of
E,47 Central unit defective. defective unit
the monitored o
Error in serial Calibration data file Upload
write/read does not contain valid calibration data
crane data
memory data. file by changing
file.
provides an E,57 Flash-EPROM dara (oM,
incoherent defective limits) and save
result o Replace central
Error in the a No valid data in the a Upload valid unit
crane data crane data file. crane data file Error in the o CAN Bus cable Check the
E51 CAN bus data between the central connection
file a Flash-EPROM a Replace central
defective unit transfer for all unit and the sensor between the
unit defective or not central unit and
Error in load No valid data in the Upload valid CAN units
E61 connected. the sensor units
chart file. load chart file load chart file o Can bus port in the Replace the
Flash-EPROM Replace central central unit defective central unit
B,52
defective unit o Short circuit in a CAN Replace Can
Bus cable Bus cable

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 User Manua I

Error Error
Error Cause Elimination Error Cause Elimination
Code Code
B,62 Error in the o Cable between the o Check the cable 885 Error in the o The computed radius o Check the
can bus data central unit and the to the sensor radius is too small (negative programming in
transfer of the sensor unit defective. unit deflection) the crane data
determination
pressure
o Can bus port in the o Replace the file.
central unit defective cenffal unit
transducer
o Can bus port in the o Replace the E89 Operating The operating mode Select operating
sensor unit
sensor unit is sensor unit mode on the console has mode without
defective switchover been switched over load on the
with load. with the boom loaded. boom
E63 Error in the The analog values of Replace the
can bus the sensor unit are sensor unit
pressure invalid 898 LMI LMI processing time Reset system
transducer watchdog limit exceeded Connect PC
sensor unit activated terminal and
watch error
E,64 Error in the o SeeE62 o SeeE62 messages
can bus data EAB Short circuit o Short circuit in the o Replace A2B
transfer of the in the A2B A2B switch switch
length/angle switch circuit o Short circuit in the o Replace cable to
sensor unit (not with cable to the A2B the A2B switch
switch
radio A2B)
E84 Wrong o The selected rigging o Select another
rigging condition is not rigging EAC A2B switch o Disconnected cable in o Connect or
contained in the crane condit¡on circuit the A2B switch replace cable in
condition.
data file. o Check the disconnected o Disconnected cable to the A2B switch
programming in (not with the A2B switch o Connect or
the crane data radioA2B) replace cable to
file. the A2B switch

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 User

10. OM information
Error
Error Cause Elimination
Code
No validA2B o Sensor wrong function o Replace A2B OM

switch status o CAN bus delay switch Crane

OM explanation
Main Lateral rear district Front listrict
o Radio telegram delay o Replace cable to Type OM Full Half Full Half
Extended Extended Extended Extended
module (radio A2B) the A2B switch
outrisser outrisser outrieser outrisser
o Radio telegram ID is o Replace battery
EAD invalid of radio module
Main boom 0001 0001 1001 0101 1101

(radio A2B) ¡4u¡¡¡ +jib 0.

o QY16K 0021 0021 to2l ot21 tl2t
Setup ID in
QY2sK
DGA12.9 ¡4¿n + jib 15. 0022 0022 ro22 ot22 n22
QY25K5
QY30K5 ¡4¿i1 +jib 30" oo23 oo23 t023 0123 tt23
Datalogger o Setup of the o Transfer data
setup error datalogger is cleared and setup Head sheave oo24 0024 to24 o724 n24
(ser. crane data file or datalogger again
EDB battery buffered Main boom 0001 0001 1001 0101 1101

RAM)
Main + 1" jib 0. 0011 001 1 I011 0111 l11t

Datalogger processing Reset system QY30K

Main + l't jib 15" 00t2 oot2 tot2 ot12 lttz
Datalogger
time limit exceeded Connect PC QY35K Main + 1" jib 30' 0013 0013 1013 0113
watchdog 1113
EDC terminal and QY35Ks
activated watch error Main + 2't jib 0' 0021 0021 ro2t otzt tt2t
QY40K
messages
QYs0K
Main + 2'tiib 15' 0022 oo22 t0z2 0122 tt22
Battery empty Battery check detected Change battery,
Main + 2't jib 30. 0023 0023 t023 0t23 tt23
a low voltage of the after this setup
EDD
battery ofRTC Head sheave 0031 003 I 1031 0131 1131

DlNO--white wire, the rear and front detection switch or the

fifth outrigger, the positive is the lateral rear and the second place of
 I
User Manua I
U¡

the corresponding OM equals to 0. I l. HC4900 LMI cable connection

DINI--brown extended and half extended outrigger

l
detection switch, the positive is extended and the first place of the

corresponding OM equals to 0.

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