PAT LMI MANUAL - DS50/0002

7600004-004 A Company April 2000

Manitowoc Boom Trucks

PAT LMI MANUAL - DS50/0002�Operator Handbook

Manitowoc Boom Trucks, Inc.3000 S. Austin Ave

Georgetown, TX 78627-1609

Sales: (512) 942-3000

Sales Fax: (512) 863-3776

Service: (512) 942-3000

Service Fax: (512) 942-3094

Web Site: www.manitowocbt.com

A Company

FORWARD

The purpose of this manual is to provide the customer with the operating procedures essential for the promotion of safe and proper machine operation for its intended purpose. It is impor-tant to over-stress proper usage. All information in this manual should be READ and UNDER-STOOD before any attempt is made to operate the machine.

SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICA-TION AND OPERATION, CONFORMANCE WITH GOOD SAFETY PRACTICE IN THIS AREA IS THE RESPONSIBILITY OF THE USER AND HIS OPERATING PERSONNEL.

ALL PROCEDURES HEREIN ARE BASED ON THE USE OF THE MACHINE UNDER PROPER OPERATING CONDITIONS, WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN. ALTERATION AND/OR MODIFICATION OF THE MACHINE IS STRICTLY FOR-BIDDEN WITHOUT WRITTEN APPROVAL FROM MANITOWOC BOOM TRUCKS, INC.

REMEMBER, EQUIPMENT IS ONLY AS SAFE AS THOSE WHO OPERATE IT!

Second Edition 03/18/1997 -CSH. (con: K2AA V1.0) 031-300-190014_A-MBT.DOC

LOAD MOMENT INDICATOR

DS 50 / 0002OPERATOR'S HANDBOOK

Operator's Handbook DS 50 / 0002


NOTICE

The information in this document is subject to changewithout notice.

PAT does not assume any warranty of any kind with regardto this material, including, but not limited to the impliedwarranties of marketability and fitness for a particular

purpose.

PAT shall not be liable for errors contained herein or forincidental or consequential damages in connection with the

furnishing, performance or use of this manual.

This document contains proprietary information which isprotected by copyright. All rights reserved.

No part of this document may be photocopied, reproduced,or translated to another language without the prior written

consent of PAT.



TABLE OF CONTENTS

1 General Information 1

2 Warnings 2

3 System Description 33.1 System Function 53.2 Control Identification 6

4 Pre-Operational Inspection 104.1 Anti two-block devices 104.2 Inspection and Calibration Verification 11

5 System Operation 145.1 Operating Mode Selection 145.2 Reeving Selection 155.3 Data Display 175.4 Error Display 185.5 System and Display test 18

6 Service and Maintenance 19

7 Troubleshooting 20



1

1 GENERAL INFORMATION

The PAT Load Moment Indicator1 (LMI) DS 50 has been designed toprovide the crane operator with the essential information required toenable the machine to be used within its design parameters.

Using different sensing devices, the Load Moment Indicator monitorsvarious crane functions and provides the operator with a continuousreading of the crane’s capacity. The readings continuously changeas the crane moves through the motions needed to make the lift.

The LMI provides the operator with information regarding the lengthand angle of the boom, working radius, rated load and the totalcalculated weight being lifted by the crane.

If non permitted conditions are approached, the DS 50 Load MomentIndicator will warn the operator by sounding an audible alarm andlighting a warning light.

Always refer to operational instructions and load chartsprovided by the crane manufacturer for specific craneoperation and load limits.

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 thelifting capacity of a crane.



2

2 WARNINGS

The LMI is an operational aid that warns a crane operator ofapproaching overload conditions and also warns of overhoistconditions which could cause damage to equipment and personnel.

The device is not, and shall not be, a substitute for good operatorjudgment, experience and use of accepted safe crane operatingprocedures.

The responsibility for the safe crane operation shall remain with thecrane operator who shall ensure that all warnings and instructionssupplied are fully understood and observed.

Prior to operating the crane, the operator must carefully andthoroughly read and understand the information in this manual toensure that he knows the operation and limitations of indicator andcrane.

Proper functioning depends upon proper daily inspection andobservance of the operating instructions set forth in this manual. Wedraw your attention to section 5 of this handbook.

The LMI can only work correctly, if all adjustments have beenproperly set. For correct adjustment, the operator has to setthe operating code and the parts of line (reeving) thoroughlyand correctly in accordance with the real rigging state of thecrane. To prevent material damage and serious or even fatalaccidents, the correct adjustment of the LMI has to beensured before starting the crane operation.



3

3 SYSTEM DESCRIPTION

The PAT Load Moment Indicator DS 50 consists of a central microprocessor unit with build in length- and angle sensor, operatingconsole, pressure transducers, and anti-two block switch(es).

The system operates on the principle of reference/real comparison.The real value, resulting from the pressure measurement iscompared with the reference data, stored in the central processormemory and evaluated in the micro processor. When limits arereached, an overload warning signal is generated at the operator’sconsole.

The fixed data regarding the crane, such as capacity charts, boomweights, centers of gravity and dimensions are stored in memorychips in the central processor unit. This data is the referenceinformation used to calculate the operating conditions.

Boom length and boom angle are registered by the length/anglesensor, mounted inside the cable reel which is mounted on theboom. The boom length is measured by the cable reel cable whichalso serves as an electrical conductor for the anti two-blockswitches.

The crane load is measured by pressure transducers attached to thepiston and rod side of the hoist cylinder.

The console has 2 functions:• displays information to the operator• input terminal for operating mode and reeving (parts of line)

The operator’s console is mounted in the operator’s field of vision.For a better identification of displays and operating elements, theyare continuously backlit during operation.



4

Fig. 1: Components of the LMI system PAT DS 50



5

3.1 System Function

Upon switching on, the system starts with anautomatic test of the LMI system, of lampsand audible alarm.

During the test, the LC display shows8:88.8.8

First, the operating mode is determined byinput of the operating code number

System awaits acknowledgment

Next is the selection of the reeving

System awaits acknowledgment

Upon acknowledgment of the inputs thesystem is ready for operation.



6

3.2 Control Identification

This unit contains a display and different controls which aredescribed as follows:

Fig. 2: Operating Console

1 LC Display2 Load Moment Limit Light3 Load Moment Prewarning Light4 Alarm Light “Anti-Two-Block”5 Button “UP”6 Button “DOWN”7 Button and Control Light “OK”8 Button and Control Light “SELECT OPERATION CODE”9 Button and Control Light “SELECT REEVING”



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LC-Display

The LC Display has five digits. Thereadout depends on the operating modusand the operator’s selection.Please refer to section 4, Operation of thesystem.

Load Moment Limit Light

The red LOAD MOMENT LIMIT LIGHT (2) warns theoperator that a rated load condition has beenreached. It lights up when the load on the cranereaches the crane load capacity. The audible alarmalso sounds when this condition has been reached.

Load Moment Prewarning Light

The yellow LOAD MOMENT PRE-WARNING LIGHT(3) will light up when the load on the crane reachesthe defined prewarning area, thus indicating that anoverload condition is approaching.This means for the operator to continue his craneoperation with extreme caution.

Alarm Light “Anti-2-Block”

The red “Anti Two-Block Alarm Light” (4) lights upwhen the anti-two-block limit switch contacts open,indicating that a two-blocking condition isapproaching. At the same time the audible alarm willsound, and the telescope out and winch up functionsare locked out. If machine is equipped with aoverload shut-off, the boom down function is alsolocked out.



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Cursor "up"

Key for the stepwise increase of the displayed value:• when selecting the operation code• when selecting the reeving• when selecting the geometry data

( refer to chapter 5.3)

Cursor "down"

Key for the stepwise decrease of the displayed value:• when selecting the operation code• when selecting the reeving• when selecting the geometry data

( refer to chapter 5.3)

Button “OK”

Key for acknowledgment of an error message.

The correct setting of the operation mode and thereeving is of utmost importance for the proper functionof the system and the crane. Therefore only operatorswho are thoroughly familiar with use and operation ofthe system shall set the following buttons:



9

Button " set operating mode"

Button to start the function "set operating mode ".For the proceeding please refer to chapter 5.1.

Button "set reeving"

Button to start the function "set reeving" (parts ofline).For the proceeding please refer to chapter 5.2.



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4 Pre-Operational Inspection

Prior to operating the crane, the following electrical connectionsmust be checked to ensure that the system is properly connected forthe crane configuration.

4.1 Anti two-block devices

If the crane works only with the main boom and without boomextension, check the weight to ensure it is attached to the anti two-block switch on the main hoist load line.

Weight installation - The hoist line runs through the A2B weight. Witheven parts of hoisting line, the weight shall be attached to the dead-end line. With odd parts of hoisting line, the weight shall be attachedto the line of lowest speed.

If a extension exists, install the connecting cables between theboom extension junction box and the boom point junction box.Remove the weight from the main boom anti-two block switch andre-attach it to the boom extension anti-two block switch on theauxiliary hoist line.

Failure to position the anti two-block switch weight will prevent theoverhoist system from functioning properly. No weight shall be onthe main hoist anti two-block switch when the boom extension isbeing used.



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4.2 Pre-Operation Inspection and CalibrationVerification

After the electrical connections have been checked to insure that thesystem is properly connected for the crane configuration, thefollowing checks shall be made:

1. Check the electrical wiring connecting the various parts of thesystem for physical damage.

2. Check the anti two-block switches and weights for freemovement.

3. Check the spring-loaded cable reel to be sure it is free to rotate,has tension and the cable is reeled properly.

The following tests shall be performed with care to prevent

damage to the machine or injury to personnel. Properfunctioning of the system requires successful completionof these tests before operating the machine.

4. Check the anti two-block alarm light (4) and the audible alarm by

performing one of the following tests a, b, or c. If the crane isequipped with a boom extension, perform the test procedure onboth the main boom and boom extension anti two-blockswitches.

When checking system the operator must use caution. If theoperator cannot see the load handling device approaching the boomnose, he/she shall have an assistant (signal person) watch the loadhandling device. The operator shall be prepared to stop the machineimmediately should the LMI system not function properly. Properoperation will be indicated by:• lighting the red warning light (4)• sounding the audible alarm• locking out of the hoist up and telescope out functions• and if the overload shutoff option is installed, a lockout of the

boom down function will occur



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a) By manually lifting the weight attached to the anti two-blockswitches. When the weight is lifted, the audible alarm shouldsound, the anti two-block alarm light (4) should light.

b) Slowly raise the main boom load handling device to create apotential two-block condition. When the load handling device liftsthe weight, the audible alarm should sound, the anti two- blockalarm light (4) should light and the motion of the load handlingdevice should be stopped. Lower the load handling deviceslightly or telescope the boom in to eliminate this condition.

c) Slowly extend (telescope) the boom to create a potential two-block condition. When the load handling device lifts the weight,the audible alarm (17) should sound, the anti two-block alarmlight (24) should light and the boom telescope out function shouldbe stopped. Lower the load handling device slightly or telescopethe boom in to eliminate this condition.

NOTE: If the crane is equipped with the overload shutoff option, atwo-block condition will also lockout the boom down function. Ifoperating properly, the lockout feature will always permit operationof the hoist down, telescope in , and boom up functions.

If the light and audible alarm do not function as describedand the crane movements are not stopped, the system is notworking properly. The malfunction shall be corrected beforeoperating the crane.

5. Check that the display of the main boom length agrees with theactual boom length.

6. Check that the display of the main boom angle agrees with theactual boom angles.

7. Check that the display of the operating radius of the crane agreeswith the actual radius.

8. Check the load display by lifting a load of known weight. Theaccuracy of the load indication shall be within the tolerance ofSAE J159.



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After being properly checked, the LMI is operational. The operatorshall be thoroughly familiar with all controls of the LMI beforeoperating the crane (see Section 3.2). The proper function of thesystem shall be checked by lifting a load of known weight andcomparing the load to the information displayed on the LMI (seeSection 5.2).

Rated loads include the weight of the hook block, slings, andauxiliary load handling devices. Their combined weights shall besubtracted from the listed load capacities as stated on the loadcapacity chart to obtain the net load to be lifted.

If any of the displays reflects a deviation between displayedand actual values, an authorized PAT service representativeshall be called for repair of the system and/or verification ofthe crane’s LMI calibration.

Any structural modifications or changes to the crane shallrequire verification of the crane’s LMI calibration.



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5 SYSTEM OPERATION

The LMI System DS 50 allows the operator to assess and evaluatethe lift to meet the manufacturer specified load charts for the crane.

The correct setting is of utmost importance for the properfunctioning of the system and the crane. Therefore, thecrane must not be operated without setting the appropriateoperating code.

5.1 Operating Mode Selection

start function:

(automatically after system start)

• manually at each modification of the crane

configuration by pressing key

The operating mode key and the cursor keyslight up. The operating mode selection isdisplayed:

XX= present operating code

Troubleshooting


15

select mode: • use cursor keys and to modify

the operating code

confirm

selection:

• by pressing again key .

The cursor keys and the operating selectionkey go out.

NOTE: If the system is turned off, alladjustments remain stored. When the systemis turned back on, the adjustments can be

acknowledged by merely pressing key:

(provided that the crane configuration has notbeen modified!).

5.2 Selection of the Reeving (parts of line)

start function:

(automatically after finishing operation modeselection)

manually upon modification of the reeving by

pressing key

The reeving key and the cursor keys light up. Thereeving selection is displayed:

XX= present reeving



16

select

reeving:

• use cursor keys and to modify

the reeving

confirm

selection:

by pressing again key

.

The cursor keys and the reeving key go out.

NOTE: If the system is turned off, all adjustments remain stored.When turning on again the system these adjustments can be

acknowledged by merely pressing keys:

and then

Verify the operating mode and reeving displayed with the cranesconfiguration.

Troubleshooting


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5.3 Data Display

In case neither the operating mode selection nor the reevingselection are active, the LC display serves as data display:

Press keys and to select the values. There are 9

display positions:

Display PositionY

Displayed ValueXXXX

0 error message1 main boom length2 main boom angle3 radius4 utilization in %5 tip height6 capacity7 actual load8 load moment



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5.4 Error Display

In case of operating error or system malfunction an error code isdisplayed. (for detailed information refer to chapter 7troubleshooting)Error messages are given priority on the display:

XX=error code

Press key to acknowledge an error message (exception:

console error messages)

5.5 System and Display Test

Press keys and simultaneously to select the test

function.All lamps light up, the buzzer is turned on and the following isdisplayed:

During the test, the data transmission to the central unit isinterrupted so that 2 seconds later approx. the cutoff relay is de-energized.

Troubleshooting


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6 SERVICE AND MAINTENANCE

Daily maintenance of the load moment indicator consists ofinspecting:

• 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 cableguides 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 hoist cylinder and theconnecting hoses for oil leakage.

Other than correcting the problems identified in the MalfunctionsTable and replacing faulty mechanical parts and cables, no otherrepairs shall be performed by non expert personnel.



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7 TROUBLESHOOTING

General

In case of a malfunction of the system, the display (1) will indicate acode that identifies the system malfunction.

The error codes listed in the Malfunction Table will identify variousfaults that can occur with the LMI. Following the Malfunction Tableare pages which explain each fault and describe the action whichshall be taken to correct the fault.

Faults within the electronic microprocessor shall be repaired byfactory trained service personnel. When these faults occur, thecompetent service organization shall be contacted.

Malfunction Table

Error Code ErrorE01 Fallen below the radius or above angle rangeE02 Radius range exceeded or fallen below angle

rangeE03 Boom position is out of the permissible working

areaE04 Operating mode not existingE05 Prohibited length range

NOTE:If there is any Error Code displayed on the console which is notlisted in the Malfunctions Table you shall call the LocalDistributor.

Troubleshooting


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Operating Errors

Malfunctions in the system which are caused by range exceeding oroperating errors by the crane operator himself are indicated on thedisplay. These error codes are E01, E02, E03, E04, and E05 andthey can normally be eliminated by the crane operator himself.

ErrorCode

Cause Elimination

E01Fallen below the minimumradius or above the angle givenin the load capacity chart due toluffing up the boom too far.

Luff down boom to a radius orangle given in the load capacitychart.

E02The maximum radius orminimum angle given in the loadcapacity chart was exceededdue to luffing down the boomtoo far.

Luff up boom to a radius orangle given in the load capacitychart.

E03Boom position is out of thepermissible working area (overfront).

Move boom back to thepermissible working area. Seelifting diagram in the loadcapacity charts.

E04

Operating mode at the consoleincorrectly set.

Correctly set operating mode tothe code assigned to theoperating mode of the crane.

Operating mode is notpermissible with the actualcrane configuration or boomposition

Be sure crane is set upaccording to proper operatingconfigurations.

E05

Boom was telescoped too far ornot far enough, you may onlyoperate up to a certainmaximum or minimum boomlength or with load curves forboom extension where you haveto telescope the main boom to acertain length.

Telescope boom to correctlength, given in the loadcapacity chart.

Length sensor adjustmentchanged i.e. length sensor cableslid off the length sensor drum.

For elimination refer to servicemanual.

PAT LMI MANUAL - DS50/0002

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