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EN HC4900 徐工 QUY55 V1.3 120525
EN HC4900 徐工 QUY55 V1.3 120525
EN HC4900 徐工 QUY55 V1.3 120525
Declaration
All information in this document is subject to change without notice.
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.
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
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!
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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
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
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℃
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Operator’s Manual
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.
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Operator’s Manual
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
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
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
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Operator’s Manual
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.
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
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:
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.
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Operator’s Manual
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
Confirm OM
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.
Main Display
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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”
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”
Finally, choose Jib Angle,the finger image automatically points to the “Jib
Angle” at the display.
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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”
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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”
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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
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.
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Operator’s Manual
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.
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”
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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”.
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.
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”.
5.4 Buzzer
The buzzer of HC4900 LMI will alarm at the following situation:
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.
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Operator’s Manual
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.
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Operator’s Manual
8. TROUBLESHOOTING
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
30
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
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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"
32
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
34
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
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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
36
9. SYSTEM WIRING DIAGRAM
37