FUWA HEAVY INDUSTRY COMPANY LIMITED

FUWA HEAVY INDUSTRY COMPANY LIMITED FTQ03 RT CRANE LMI OPERATION MANUAL

PREFACE
This manual is applicable to the installation, commissioning, operation and
maintenance of LMI on telescopic boom truck crane,RT crane.
The LMI is an auxiliary device for the safety operation of the crane.
However, this device can not instead of the actual experience of the
excellent operators, and can not instead of the actual situation in the field,
and can not instead of the safety operation rules of the crane. Therefore,
the operator should strictly operate according to the operation rules, and
constantly accumulate work experience, flexibly handle different scene
conditions.
When the LMI is judged to be overloaded, it can send out the automatic
stop control signal. This control signal is only through the crane electric
system and hydraulic control system to stop crane.
It is important to point out that, if the LMI fails, the LMI shows error data
before the problem is solved, and can not be used as a reference for the
operation. You can only operate according to the crane safety operation
regulation and the load chart.
The LMI does not have the function of limiting protection when debug.
Therefore, the safety operation rules of the crane must be observed
during debugging, and the crane must be operated according to the rated
load chart.
This series of LMI conforms to the national standard: GB12602-90 "safety
technical specification for overloading protection device of crane" and
national standard GB7950-1999 "general technical condition of torque
limiter of arm frame type crane".

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Catalogue
1 General overview
2 Main specifications
3 Computer overview
4 Operating function description
4.1 state indicator lamp
4.2 panel key instructions
4.3 main interface description
4.4 help information
4.5 function menu
4.6 sensor adjustment page
4.7 angle adjustment page
4.8 length adjustment page
4.9 lower chamber pressure (rod free chamber) adjustment page
4.10 upper chamber pressure (rod cavity) adjustment page
4.11 internal parameter adjustment page
4.12 internal parameter 2 adjust the page
5 Signal line connection schematic
6 Installation location description
6.1 length angle sensor installation
6.2 pressure transmitter installation
6.3 host installation
7 Error code and analysis
7.1 fault prompt host fault
7.2 angle sensor fault or length sensor fault
7.3, the failure of the lower chamber pressure transmitter
8. Installation type
8.1 fixed beam installation method
8.2 installation clamp installation method
8.3 embedded installation method

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1. General overview
FTQ03 lifting moment limiter is a safety protection device for monitoring
hoisting equipment. Its display and control part are integrated, compact
and easy to install. It is suitable for the application of medium and small
tonnage lifting equipment.
The main features are as follows:
1. using large size liquid crystal lattice graphics display, the boom length,
angle, working amplitude, rated load, load and load rate of the crane arm
are displayed at the same time. It is simple and easy understand, and the
operation is more convenient. With error information, according to the
error information of the main monitor page and the Chapter 7th of the
manual error code and analysis, customer can solve error by himself.
2. this type limiter also has the function of communication with PC. It can
connect to the computer to debug and monitor data, so as to improve
work efficiency.
3. has the function of calendar, and the bit system provides accurate time
(year / month / hour / minute).
4. has the data-logger function, and can automatically record the data
when overloading, such as the time (year / month / day / time / time /
time) of overloading, rated load, actual load, angle value, arm length,
amplitude, load rate and other important data value, providing real and
reliable original data for post error analysis.
5. GPRS function (this function is option), support remote debug, remote
monitor of the data, reduce maintenance time. Both convenient customer,
and convenient maintenance engineer, can make the lowest loss for
customer.

2. Main specifications:
Working power: DC24V (-15% to +35%)
Alarm type: the load rate is more than 90%, when the intermittent alarm,
FUWA HEAVY INDUSTRY COMPANY LIMITED FTQ03 RT CRANE LMI OPERATION MANUAL

yellow light working.

over 100%,the red light working.
over 105%, alarm working without break off,and stop the crane .
Control mode: transistor high level to ground output, rated current 0.5A,
voltage DC24V
Environmental requirements: working temperature -20 C ～ +60 C
Storage and transportation temperature -40 C ～ +70 C
Relative humidity <95%, at 25 degrees centigrade
Vibration acceleration a=4g, frequency f=10 ～60Hz
Impact acceleration a=7g, frequency f=0.7 t～ 1.7Hz
Mode of work: continuous work
Comprehensive precision of the system: the comprehensive error ≤±5%

3. Computer overview

LMI monitor computer photo

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4. Operating function description

4.1 Status indicate light instruction
LMT: Over-limit alarm light that are working when one of the below
occurs,
I, Main boom angle is over,angle too big.
II, Main boom full extend open,angle is too small.
III, With fixed jib,jib angle is too small,or install the fixed jib but the main
boom angle is too small.
<90%： The safety indicator light up when the load rate is <90%,
indicating that the system is in a safe state.
>90%： The warning indicator lights are lit when the load rate is >90%
and less than 100%, and the peak sound intermittently rings, which
prompts users to pay attention to safety.
>100%： When the load rate is >100% but less than 105%, the lamp is
flashing and will give alarm long time without break off.
Give alarm, tell the operator crane is overload.
When the load rate exceeds 105%, the output overload signal is
prohibited to operate the crane to dangerous direction.

4.2 Screen key instruction

F1-F6 is the screen operation key, according to the icon on the page, it has
different facility.
Key photo Facility

Main hook, auxiliary hook switch option

Set hook pulley times options

Setting options

Buzzer on state (mute invalid) option

FUWA HEAVY INDUSTRY COMPANY LIMITED FTQ03 RT CRANE LMI OPERATION MANUAL

Buzzer off state (mute valid) option

Functional menu options

Help information options

Cancel the current operation

Move one or one option to the left

Move one or one option to the right

Move up a bit or an option or data plus 1

Move down a bit or an option or data reduce 1

Confirm or store an option

Circulate move up and down a set of options

Increase or reduce an option at the speed of x10

Contrast adjustment of display screen

Input icon
Enter password options
Password correct, unlock status

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4.3 Main interface description

30

MAINHOOK

Boom Forbid
Length
Angle

Hight

MAINBOOM
+AUX BOOM

2022-07-01
Radius 11:30:38

Above photo is main interface, the monitor show this interface when
standard working. Shown the main boom angle, boom length, max.lifting
height, working radius,rated load chart, actual load and load chart ratio.
The top two lines show the current working state, indicating which hook is
used to work, the main hook falls(rope times on hook pulley) and the
current working condition.
FUWA HEAVY INDUSTRY COMPANY LIMITED FTQ03 RT CRANE LMI OPERATION MANUAL

Hook state shown: main hook, auxiliary hook.

Main hook falls(rope times on pulley)shown:8,6,5,4,3.different crane
show this data different.
* The working condition is as follows*:
I, the main boom plus jib ( main boom working, jib mounted on side of
boom).
II, the main boom without jib (main boom working, no jib mounted on the
side of boom).
III, the fixed jib is 0 degree, and with the main hook (the jib 0 degrees
installation angle working ,but install main hook).
IV, the jib is 0 degrees without main hook (the jib 0 degree installation
angle, but not install main hook, use jib hook).
V, the jib 15 degrees, use the main hook (the jib 15 degrees installation
angle work, but install main hook),
VI, the jib 15 degrees without main hook. (the jib 15 degrees installation
angle ,but not install main hook, use jib hook only).
**Remark**:
I, In the working condition, ‘the main boom plus jib, the main boom
without jib, the jib 0 degrees with main hook, the jib 15 degrees with main
hook’. press F1,can switch between main hook or auxiliary hook.
II, In the case of ‘0 degrees without use main hook ,15 degrees without
use main hook’, only can use auxiliary hook.

The progress bar below indicates the current load rate, green color means
below 90%, yellow color is 90%-100%, and red color is 100%-125%.
Under the progress bar, display the working condition of the current
system, if no error, indicate data in good condition. Also can display the
error information.
The error display include:
computer error.
Over upper limit of the main boom angle (if this error, actual load value

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display ‘----‘).
Full extend boom angle over lower limit.
The jib angle is over lower limit.
The bottom row is for press button function description.

4.4 Real-time data monitoring

This interface is used when debug or maintain the LMI. The data displayed
is current real-time data and can not be modified(above photo data is only
as for example, not real data).
FUWA HEAVY INDUSTRY COMPANY LIMITED FTQ03 RT CRANE LMI OPERATION MANUAL

The calculated value is listed as the current real-time calculation value.

The sample value is a direct data of the analog digital conversion. The
range of the sampling value should be between 1620-8191. Otherwise,
the system sensor or the host has a fault. The specific value of the display
should be provided to the professional for reference.
The F1 or F6 can exit and return to the previous menu.

4.5 Function menu

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4.6 Sensor adjustment interface

In the 4.5 interface, press F1 to enter the sensor demarcate to debug,
then enter password 123, as shown below.

Key Description:
F1: returns to the main interface.
F2: cancel the password for the current input and becomes 000.
F3: the cursor moves.
F4: the value increase by 1. F5: the value reduce by 1.
F6: determines the password entered .if password correct, enter into
the angle calibrate interface.
FUWA HEAVY INDUSTRY COMPANY LIMITED FTQ03 RT CRANE LMI OPERATION MANUAL

After the input is completed, enter the debug interface of the sensor
demarcate, as shown below.

In the above photo, press F1, enter into the interface for calibrate angle
(the above photo is unified as the ‘sensor calibration interface’ in next
page).

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4.7 Angle calibrate interface

In the 4.6 sensor calibration interface, press F1, enter into the interface
for calibrate angle, as shown below

Press F2 up and down move option, cycle switch ‘small angle setup’, ‘small
angle sampling’, ‘big angle setup’ and ‘large angle sampling’.
‘Small angle setup’ and ‘large angle setup’ as input options, need you
input. press F2 moving to this line , press F4,set value plus 1 , press
F5,value reduce 1 .
Hold press F3, at the same time press F4, set value plus 10.
FUWA HEAVY INDUSTRY COMPANY LIMITED FTQ03 RT CRANE LMI OPERATION MANUAL

Hold press F3, at the same time press F5 key, set value reduce 10.
The input range of the ‘small angle setup’ is 0.0 ～ 10.0 degree, and the
‘big angle setup’ input range is 70.0～85.0 degree.
According to the actual angle value, modify the angle data, then press the
F6 to save setting.
‘Small angle sampling’ and ‘large angle sampling’ are sampling value
storage options. Using basic boom and the hook no lifting, the main boom
is at a small angle, and the small angle sampling value is observed. After
the number is stabilized, the small angle sampling value is saved by press
F6.
Similarly, the basic boom and the hook no lifting is used to make the main
boom at a large angle. The large angle sampling value is stabilized and the
large angle sampling value is saved by press F6.
After calibrate small angle/big angle, to use the basic boom, the hook no
lifting. the main boom stop at any angle, to use angle instrument measure
the actual angle, compare the actual angle with the computer calculated
angle. If too much different, need to calibrate the small/big angle again.
Press F1 in any state of this page, and the page will switch to the
calibration main page.

4.8 Boom length calibrate interface

In the 4.6 sensor calibration interface, press F2, enter into the interface
for calibrate boom length, as shown below

I, After retract the main boom to the basic boom, enter the basic boom
length, then press F6, then press F2 to switch to the next line, and then
press F6.
II, After the main boom is fully extended, enter the longest boom length at
the longest boom and press F6, then switch to the next line and press F6.
Complete length calibration

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Boom length data calibrate step similar the angle data calibration.
FUWA HEAVY INDUSTRY COMPANY LIMITED FTQ03 RT CRANE LMI OPERATION MANUAL

4.9 Main hook weight adjust interface

In the sensor calibration interface, press F3 to enter this calibration

interface, as shown in the following figure:
Retract the main boom to the basic boom, and select two heavy cargos,
which are 80% and 30% of the maximum load chart rate.
1. up the main boom to about 75 degree, and select 80% of the current
maximum load (maximum load *0.8= weight). Lift this heavy cargo and
wait for stability.
2. Input the heavy cargo weight (80% of the weight mentioned in) into the
"large heavy cargo setting weight", and press the F6 key to save.
3. Press F2 to switch the cursor to the next line "angle AD, force AD", and

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then press F6 to confirm and save the data.

4. Input the heavy cargo weight (30% of the weight mentioned in) into the
"small heavy cargo setting weight", and press the F6 key to save.
5. Press F2 to switch the cursor to the next line "angle AD, force AD" and
press F6 to confirm and save.
6. Switch the cursor to the line of hook weight, put down the heavy cargo
(the hook is empty, no lifting), and then press F6 to obtain the empty hook
weight.
7. Press F2 to switch to the last row of calibration data storage, and press
F6 to save, and then complete the main hook weight calibration.
*above the large and small heavy cargo must are big different weight, two
cargo weight can’t be same or near weight.
FUWA HEAVY INDUSTRY COMPANY LIMITED FTQ03 RT CRANE LMI OPERATION MANUAL

4.10 auxiliary hook weight adjust interface

In the sensor calibration interface, press F4 to enter this calibration

interface, as shown in the following figure:
Retract the main boom to the basic boom, and select two heavy cargos,
which are 80% and 30% of the maximum load chart rate.
1. up the main boom to about 75 degree, and select 80% of the current
maximum load (maximum load *0.8= weight). Lift this heavy cargo and
wait for stability. For example ,5*0.8=4t.
2. Input the heavy cargo weight (80% of the weight mentioned in) into the
"large heavy cargo setting weight", and press the F6 key to save.
3. Press F2 to switch the cursor to the next line "angle AD, force AD", and

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then press F6 to confirm and save the data.

4. Input the heavy cargo weight (30% of the weight mentioned in) into the
"small heavy cargo setting weight", and press the F6 key to save. For
example , 1*0.3=0.3t
5. Press F2 to switch the cursor to the next line "angle AD, force AD" and
press F6 to confirm and save.
6. Switch the cursor to the line of hook weight, put down the heavy cargo
(the hook is empty, no lifting), and then press F6 to obtain the empty hook
weight.
7. Press F2 to switch to the last row of calibration data storage, and press
F6 to save, and then complete the auxiliary hook weight calibration.
FUWA HEAVY INDUSTRY COMPANY LIMITED FTQ03 RT CRANE LMI OPERATION MANUAL

4.11 Parameter setup interface(Tri-pulley type load sensor

program, inner parameter no need adjust)
Please see the 4.5 function menu interface ,Press F2 ,enter into interface
of inner parameter setup,input password 123,after enter into ,display as
below:

Parameter setup interface, press F1, enter into page Inner parameter 1.

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Lmt: rated boom length, unit m.

Lgt: the center position of rated boom length, unit 0.1m.
DNmt: the deformation coefficient of rated boom length, unit mm/t
The above data will be set up by Fuwa company at China.
press F2 loop to switch the selected content, when select one line, press
F4 set value plus 1, press F5 set value reduce 1.
Hold F3 ,at the same time press F4, set value increase 10. Hold F3, at the
same time press F5, set value reduce 10.
after modifying the set value, the F6 to save setting.
Press F1 ,not save setting and switch to calibrate main interface page.
FUWA HEAVY INDUSTRY COMPANY LIMITED FTQ03 RT CRANE LMI OPERATION MANUAL

4.12 Inner parameter 2 adjust page(Tri-pulley type load sensor

program, inner parameter no need adjust)

The internal parameter is the system set up parameter, and

please don’t to adjust parameters when it working normally.

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5 Signal cable connection Schematic

The above is the LMI wiring diagram control line and the signal line. The
line circled by the circle is a five core 1.0 shielding line. The output line is
defined as follows:
Red: the limiter power input to the positive end.
Black: the limiter power input to the negative end.
Blue: overload output control terminal, normal output 24V, overload 0V
output.
Yellow: cylinder switching, to control cylinder rod extend/retract.

The length angle signal input LMI output is seven core navigation pin end,
FUWA HEAVY INDUSTRY COMPANY LIMITED FTQ03 RT CRANE LMI OPERATION MANUAL

and the seven core navigation plug-in hole end connection corresponding
to the length sensor can be connected.
The output of the main hook/auxiliary hook weight signal input LMI is five
core air plug hole end, and the five core navigation plug-in hole end
connection corresponding to the sensor can be connected.

Computer cable connection diagram:

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6．Install location description

FUWA HEAVY INDUSTRY COMPANY LIMITED FTQ03 RT CRANE LMI OPERATION MANUAL

6.1 Boom length/Angle sensor install

Put the boom horizontally, confirm the sensor install position (as below
photo), ensure that the pull wire cable is parallel to the boom, the cable
head is fixed on the head of the boom, attention that there is no friction
touch between the outlet and the cable, and the cable in the cable box
should be longer than the varying length of the main boom when it is fully
extended. Remove the paint from the side welding of the boom, weld the
sensor mounting post to the side of the boom and tighten the installation
bolt.
Penempatan horizontal jib, untuk menentukan sensor lokasi instalasi
(seperti yang ditunjukkan di bawah ini), harus memastikan bahwa kabel
dan paralel boom, tarik kepala tetap di kepala jib, memperhatikan outlet
dan kabel tanpa gesekan, tarik string harus lebih besar dari perluasan
penuh utama lengan ketika perubahan panjang. Menghapus cat dari sisi
weld boom, mengelas kolom pemasangan sensor ke sisi Boom dan
kencangkan pemasangan baut.

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6.2 Tri-pulley load sensor install

Pls welding the load sensor steel body onto boom head(red arrow), so can
fix it.
Have two sets load sensor, the main hook wire rope and auxiliary hook
wire rope need pass the three pulley , pls see below yellow line .

6.3 computer install

Install the computer in the location shown below in the operator cabin.
Connect cable according to the electrical wiring diagram.
Menginstal komputer di kamar pengemudi seperti ditunjukkan pada
gambar di bawah. Kabel menurut diagram pengkabelan listrik.
FUWA HEAVY INDUSTRY COMPANY LIMITED FTQ03 RT CRANE LMI OPERATION MANUAL

7．Error phenomenon and Analysis

7.1 display computer error
Is the control circuit board internal error, please contact the manufacturer
for maintenance.
7.2 angle sensor or boom length sensor error
A: check the length angle sensor (red color box)inside whether have
water. If inside have water ,please turn off the power immediately and
then dry it up again.
B: check whether the interconnect plug is off. Reconnect firmly.
C: enters the host's status monitoring interface to see if the length and
angle sampling values are correct, with a range of 1620-8191. If not,
contact the manufacturer for repair.
Note: if there is a length or angle failure, the other relevant data displayed
is ‘----‘ condition.
7.3 ‘the upper limit of the angle of the main boom, the ultra lower limit of
the full boom angle, the ultra lower limit of the jib angle" is the alarm
information, which suggests that the operator has reached the safety limit.
Do not continue the dangerous operation.

8．Install dimensions
8.1 Fixed beam install type

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8.2 Installation clamp install type

8.3 Embedded installation type