Zoomlion HC3901 Operation Manual
HIRSCHMANN
Load Moment Indicator
for Crawler Crane
HC3901
Operator’s Manual
Hirschmann Electronics（Shanghai）Co.,Ltd
Suite 12A, Huamin Empire Plaza, No.726, West Yan An Road, Shanghai, P.R.China
Tel: 021-51082780
Fax: 021-52375899
Zipcode: 200050
Website: http://www.hirschmann.com
Copyright
This document contains propriety information which is protected by copyright, and all rights are
reserved. No part of this manual may be photocopied, reproduced or translated to another language
without prior written approval of Hirschmann Electronics (Shanghai) Co., Ltd.
Declaration
All information in this document is subject to change without notice.
Hirschmann makes no warranty of any kind with regard to this material, including, but not limited to,
the implied warranties of merchantability and fitness for a particular purpose.
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
Zoomlion
This manual can be applied to the following types of crawler cranes manufactured by the partner:
ZCC1100H
Special Notice
Using components of LMI rather than from Hirschmann may cause problems of inaccuracy and
even malfunction of the LMI system. We recommend you use genuine Hirschmann components and
parts during repairing and service. Hirschmann is not liable of any responsibilities in case genuine parts
are not used.
Rev. Date Prepared Checked Modifications
01 2014-08-04 Guo Tao Zhou Fei First issue, English
HC3901for Zoomlion ZCC1100H
Table of Contents
1. GENERAL INFORMATION .................................................................................................................... 1
2. IMPORTANT NOTES .............................................................................................................................. 2
3. SYSTEM DESCRIPTION ......................................................................................................................... 3
3.1 HC3901 Controller ............................................................................................................................. 4
3.2 WG Angle Sensor ............................................................................................................................... 5
3.3
Force Sensor........................................................................................................................................ 6
4. OPERATION AND DISPLAY INTERFACE .......................................................................................... 7
4.1 Data display（values are only for example） .................................................................................... 8
4.2 EN13000 ............................................................................................................................................. 8
4.3Weight status bar .................................................................................................................................. 9
4.4 Indicator light ...................................................................................................................................... 9
5. OPERATION METHOD and PROCESS (only for example) ................................................................ 10
5.1 Reeving Setting ................................................................................................................................. 11
5.2 Function Setting ................................................................................................................................ 12
5.3 Error Code Information .................................................................................................................... 15
5.4 Angle Limit Setting ........................................................................................................................... 16
6. SYSTEM FUNCTIONS .......................................................................................................................... 17
6.1 Warning ............................................................................................................................................. 17
6.2 Prohibition ........................................................................................................................................ 17
7 INSPECTION MAINTENANCE AND CONSIDERATIONS ............................................................... 18
7.1 Inspection before Operation ............................................................................................................. 18
7.2 Routine Maintenance ........................................................................................................................ 18
7.3 Routine Consideration ...................................................................................................................... 18
7.4 Buzzer Alarms .................................................................................................................................. 18
7.5 Angle Sensor Adjustment ................................................................................................................. 18
8. TROUBLESHOOTING .......................................................................................................................... 19
1. GENERAL INFORMATION
The load moment indicator HC3901 (hereinafter referred to as LMI) is applicable to the telescopic
boom crane, lattice boom crane, all- terrain crane and other types of cranes.
The HC3901 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
The system operates on the principle of reference/real comparison. The boom angle is measured by
angle sensor that is mounted on the boom. The crane load is measured by force transducers attached to the
boom pendants. The real value, resulting from all the sensors measurement is compared with the
reference data, stored in the controller. If non-permitted conditions are approached, the LMI will warn the
operator by audible alarm, warning light and at the same time, some dangerous movements such as lifting
and luffing down will be stopped with the help of the crane control system.
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.
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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.
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.
The LMI can only protect 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.
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.
If there is any change in the crane’s configuration data, the LMI needs to be re-calibrated.
Make sure to disconnect the power supply of the LMI from the crane before 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.
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.
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!
CAUTION
WARNING
DANGER
2
3. SYSTEM DESCRIPTION
3
2
Components of LMI System
Generally, the LMI system consists of
1. HC3901 Controller 1 pc
2. WG103 Angle Sensor 1 pc
3. KMD force Sensor 1 pc
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Operator’s Manual
3.1 HC3901 Controller
HC3901 controller uses 16 bit high performance processors and the CANopen communication
technology. It is the safety protector specially designed to meet the required safety standards under the
harsh environment.
Technical data：
Operating temperature: –20°C ～ +70°C.
Operating voltage: 11 ... 36V DC
Operating current: 200mA@24V
Communication interface: 1×CANopen, 1×RS232
Installation: External and horizontal
Display Size: 5.7 inch
Program memory: 2 x 2 MB
Data memory: 2 x 1 MB
Communiacation interface: 1×SAEJ1939，1×CANopen2.0B，2×RS232
Input analog: 6
Input digital: 6
Output digital: 6 (It can be set to PWM output, but it will reduce the no. of output digital.)
Relay output: 1 (max. 5A)
Protection class: IP65
Installation：
When the system is on, it’s forbidden to plug and unplug the cable connecting with the controller.
Before implementing any welding work on the crane body, the operator must take off cables
connecting the controller in order to avoid damage.
This system uses scaffolding installation.
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3.2 WG Angle Sensor
Angle sensor WG accurately measures the boom angle. The high sealed housing keeps the inside
component away from the influence of temperature, humidity etc.
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
Angle Sensor Installation Graph
Angle Senso r Installation Graph
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Operator’s Manual
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
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 side force.
KMD Force Sensor Installation Graph
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