Zoomlion HC4900 Operation Manual
HC4900 Load Moment Indicator
User Manual
Edition 6 / Aug, 2014
For Zoomlion RT Crane
With 5-section boom
Copyright
©2010 by Hirschmann Electronics
（
Shanghai）Co., Ltd
This document contains propriety information which is protected by copyright
law. All rights reserved. The manual may not be copied, reproduced or
translated into another language, neither whole nor in part, without advance
written authorization from Hirschmann.
Edition 6 on Aug 2014
Reproductions must abide by the copyright law.
Declaration
The manufacturer reserves the right to modify the contents of this manual without
notice.
Hirschmann offers no guarantee whatsoever for this material, including guarantees with
reference to commercial availability and suitability for particular applications.
Hirschmann shall not be liable for errors contained herein or for identical or
consequential damages in connection with the furnishing, performance, or use of this
manual.
Hirschmann Electronics（Shanghai）Co., Ltd
Suite 10K, Huamin Empire Plaza, No.728, West Yan An Road, Shanghai, P.R.China
Tel: 021-51082780
Fax: 021-52375899
Zip code: 200050
Website: http://www.hirschmann-ac.com
Catalogue
1. GENERAL INFORMATION ............................................................................ - 1 -
2. WARNING.......................................................................................................... - 2 -
3. SYSTEM CONFIGURATION .................................................................................. - 3 -
3.1 HC4900 C
3.2 IC4600 C
3.3 DAVS P
ONTROLLER
ONSOLE
RESSURE TRANSDUCER
.................................................................................... - 4 -
........................................................................................... - 4 -
.......................................................................... - 5 -
3.3.1 Technical data ................................................................................... - 5 -
3.3.2 Installation ........................................................................................ - 5 -
3.4 LWG208 L
ENGTH/ANGLE SENSOR
........................................................... - 6 -
3.4.1 Technical data ................................................................................... - 6 -
3.4.2 Installation ........................................................................................ - 6 -
3.5 A
NTI-TWO BLOCK SWITCH
........................................................................ - 8 -
3.5.2 Installation..................................................................................... - 9 -
4
．．．．
OPERATION AND DISPLAY INTERFACE ............................................................ - 10 -
4.1 D
ATA DISPLAY INTERFACE
4.2 U
TILIZATION DISPLAY (BAR GRAPH
4.3 I
NDICATOR LIGHT
..................................................................................... - 13 -
（（（（
VALUES ARE NOT REAL
)......................................................... - 13 -
））））
........................... - 11 -
5. OPERATION METHOD ...................................................................................... - 15 -
5.1 F
UNCTION SETTING
.................................................................................. - 16 -
5.2 OM S
5.3 R
5.4 E
5.5 B
5.6 C
ETUP
.............................................................................................. - 19 -
EEVING SETUP
RROR CODE REFERENCE TABLE
UZZER STOPPING
HANGE CYLINDER
...................................................................................... - 20 -
.................................................................................. - 22 -
................................................................................. - 22 -
........................................................... - 21 -
6. LMI SYSTEM FUNCTIONS ................................................................................. - 24 -
6.1 W
6.2 P
ARNING
ROHIBITION
................................................................................................ - 24 -
........................................................................................... - 24 -
7 DAILY MAINTENANCE AND CALIBRATIONS ....................................................... - 25 -
7.1 M
AINTENANCE
7.2 L
ENGTH SENSOR ADJUSTMENT
7.3 A
NGLE SENSOR ADJUSTMENT
7.4 B
UZZER ALARMING
......................................................................................... - 25 -
............................................................... - 25 -
................................................................. - 26 -
.................................................................................. - 26 -
7.5 L
ENGTH CABLE RETRACT UN-SMOOTHLY
7.6 Q
UESTION AND ANSWER
......................................................................... - 27 -
................................................ - 27 -
8. HINTS AND TROUBLE SHOOTING ..................................................................... - 29 -
9. HC4900 CONNECTING DIAGRAM ..................................................................... - 35 -
10. OM LIST .............................................................................................. - 36 -
1. GENERAL INFORMATION
HC4900 Load Moment Indicator (LMI) provides effective information to
operators, which will assist an operator maintain a machine to work within its
design parameters. LMI provides the operator with the information of the length
and angle of the boom, tip height, working radius, rated load and the actual
load weight and so on.
Using various sensing devices, the load moment indicator monitors machine’s
various operational functions and provides the operator with a continuous
reading of the machine’s capacity. The readings change continuously in
response to the different operations of the machine.
If forbidden conditions are approached, the HC4900 Load Moment Indicator will
warn the operator by sounding an audible alarm, lighting a warning light and
locking out those functions that may aggravate the machine’s condition.
This user manual is used for Zoomlion RT crane with a 4-section boom.
- 1 -
Caution
Warning
Warning
Caution
2. WARNING
The LMI control system is used to assist in the safe operation of the crane by
warning 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.
Safe operation is the responsibility for every machine operator. Every
machine operator must ensure that they read all warnings and
instructions carefully and fully understand the contents. Correct operation
depends on daily careful checking and serious study of the Manual.
The LMI is not able to provide aid to the machine operator unless it has
been properly adjusted and unless the correct load capacity chart and
the correct operating code have been entered for the respective rigging
configuration. The correctness of the LMI setups must be ensured before
beginning machine work in order to avoid damage to property and severe
or even fatal injuries to personnel
If the LMI fails or is not functioning properly, stop the operation of the
crane immediately and contact an expert service engineer. Hirschmann
Electronics Co., Ltd. does not assume any responsibility for undesirable
consequences resulting from continued use of the crane if the LMI is not
functioning!
Hirschmann Electronics Co.,Ltd. shall not be liable for damages caused
by welding crane without power off the controller.
Hirschmann Electronics Co.,Ltd. shall not be liable for damages caused
by power on the controller at a thunderstorm weather.
- 2 -
3. SYSTEM CONFIGURATION
HC4900 LMI System configuration
Cable
Connection
HC4900 LMI system comprises a HC 4900 central unit with an IC 4600 console
together with various sensors to record the measured values.
The system operates on the principle of reference/real comparison. The actual
value is compared with the calculated reference values and evaluated by the
system. An overload warning signal is triggered on the display and operating
console once limit values are reached. All machine movements that increase
the load moment are switched off at the same time.
The crane-specific data specified by the manufacturer, such as load capacity
charts, boom weights, centers of gravity and dimensions, are stored in the
central data memory. This data is the reference information used to calculate
the operating conditions. The boom angle and length is measured by means of
length and angle sensors that are mounted on the boom. The crane load is
determined indirectly with the aid of pressure transducers.
- 3 -
3.1 HC4900 Controller
HC4900 controller features high-performance, precise and limiting load
moment function in harsh environment.
Technical data
：：：：
System clock: 40MHz
Program memory: 16MB Flash
Protection class: IP65
Communication interface:
1×CANopen1×RS232
Operating voltage: 12V～30VDC
Operating temperature: -20°C
～
+70°C
HC4900 controller dimension Storing temperature:-30°C
～
+80°C
3.2 IC4600 Console
IC 4600 monochrome console is designed for outdoor construction vehicles
and mobile machinery. It complies with international standards for
environmental testing, EMC testing, and CE certification. Its easy programming,
convenient online debugging, and rich paint library functions (point, line, arc,
rectangle, progress bar, virtual instrument panel, such as function) help you to
more efficiently understand and utilize the LMI system.
Technical data:
Operating voltage: 12～36VDC
Operating temperature: -20°C～+70°C
Storing temperature: -30°C～+80°C
Resolution: 320*240(monochrome)
Communication interface: 1×RS232,
1×CANopen
Protection class: Front IP65 Back IP44
IC4600 Console dimension
- 4 -
3.3 DAVS Pressure transducer
DAVS pressure transducers measure high static and dynamic pressure
values of liquids or gases in rough operating environment. Measurement
precision is maintained even during continuous operation at extremely dynamic
pressure. The oil pressure transducer comes with a pressure connector with
standardized G1/4 thread or other hydraulic connectors.
3.3.1 Technical data
Operating voltage: 8～32VDC
Signal: CANopen
Operating temperature:-40°C～+85°C
Storing temperature: -40°C～+100°C
Protection class: IP67
Life expectancy: ＞10 million cycles
Hysteresis tolerance: 〈±0.1%FS max.
DAVS Dimension
3.3.2 Installation
Please notice the location of hydraulic piping and valve when installing the
pressure transducer. By thread connection (such as follow graph), screw the
pressure transducer in the hydraulic piping or seat of the balancing valves or
hydraulic valves. Add the appropriate seal to the display to prevent oil leakage.
Guarantee the installation position is safe and easy for cable connecting. Make
sure the pressure sensor and hydraulic adaptor connect tightly. The tightening
moment of G1/4 connector is 20Nm
Pressure transducer installation Connector pin assignment
- 5 -
3.4 LWG208 Length/Angle sensor
LWG series Length/Angle sensor can be directly installed and can precisely
measure the angle and the length of boom with largest measurement length of
fifty meters. The sealed housing protects the inside components from water
inclusion, humidity etc.
3.4.1 Technical data
Operating voltage:
Operating temperature
15～30VDC
: -25
°C
～
+75°C
Storing temperature
: -40
°C
～
+80°C
Protection class
Linearity tolerance
: IP65
: 〈±0.2°
Resolution: 〈±0.1°
Hysteresis tolerance:
LWG208 Length/angle sensor dimension
〈
±0.1°
3.4.2 Installation
Length/Angle sensor is installed on the main boom. Manufacturers can fix the
bracket of the sensor to the crane boom by welding tap blocks and bolting it in
place. When installing the sensor, the position shall be well considered, generally
along the foot points of boom to the top direction. The sensor (left type) is typically
installed on the left of the boom (aligned with the cab) to leave room for the fly (jib)
on the right side of the boom. The sensor can be located on the right side as
required. The cover can be turned 180° to put the PAT name facing upward.
- 6 -
A
Bracket
LWG208 Length/angle sensor installation
Length/Angle sensor consists of housing, a spring-loaded cable drum with
measuring cable and mounting equipment.
Make the boom horizontal. Make sure the sensor is parallel with the main
boom and the bracket is straight before fixing the bracket by bolts.
Make sure there are at least two turns measuring cable in the drum when
the cable is pulled out. The recommended length of the cable = effective
needed measure length + two turns cable+ about 1 meter cable for
connection.
The cable drum of the sensor must rotate following the direction of the
cable being pulled out. Rotate the cable drum 4 to 5 turns to pre-tighten
the drum and then pull out the cable to the tip of the boom for connection.
Use the guiding wheel to keep the measuring cable at the same level.
Place guiding wheels so as to prevent cable deflection, which will result in
the cable being difficult to pull out and to retract smoothly:
o Make sure the first guiding wheel A is in front of the sensor center
1.5m～2m. Ensure the guiding wheel turn width is slightly less than or
equal to the cable drum turn width.
o Make sure the center of the cable guiding wheel A and other wheels
are in alignment and also parallel with the main boom.
The measuring cable should be fixed to the tip of the boom tightly and the
- 7 -
fixed point should be at the same level with the sensor center to guarantee
the cable is parallel with the boom.
The Length/Angle sensor sometimes needs to be adjusted. Press the
cable drum line to make the cable drum plane parallel with the boom plane.
Rotate the cable drum and observe until the swing get smaller amplitude.
If the cable drum swing too much because of the shape distortion and
can’t be adjust, please stop the installation and repair or replace the
Length/Angle sensor.
Make sure the spring force of the measuring cable is sufficient and the
cable drum is rotating smoothly after installation is completed.
If the measuring cable is already at the pre-tighten length when boom is
retracted, the pre-tighten turns can be reduced.
3.5 Anti-two Block Switch
Anti-Two Block Switch is a normally open limit switch for winches, lifting devices
and cranes. It is a simple, direct installation and compact design. The sealed
housing protects the inside components from water inclusion, humidity etc.
3.5.1 Technical data
Operating voltage: 15～30V
Operating voltage: -25V～+70V
Storing temperature: -40℃～+70 ℃
Protection class: IP67
Life expectancy: ＞5×106 times
Housing: aluminum
Weight: 1.2kg
A2B Switch dimension
- 8 -
3.5.2 Installation
The switch should be installed on the side of boom head where the beginning of
the lifting rope is fixed. Make sure the hammer is connected to the lifting rope and
is free to actuate the switch.
The signal connector and cable must be waterproof and connected correctly.
A2B Switch installation diagram
- 9 -
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