Belden Hirschmann HC4900 User manual

HC4900 Load Moment Indicator
User Manual
Edition 5 / July, 2014
For Zoomlion RT Crane
With 4-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 5 on July 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: [phone]
Fax: [phone]
Zip code: 200050
Website: http://www.hirschmann-ac.com

Catalogue
1.GENERALINFORMATION................................................................................‐1‐
2.WARNING......................................................................................................‐2‐
3.SYSTEMCONFIGURATION...............................................................................‐3‐
3.1HC4900CONTROLLER...................................................................................‐ 4‐
3.2IC4600CONSOLE.........................................................................................‐ 4‐
3.3DAVSPRESSURETRANSDUCER.........................................................................‐ 5‐
3.3.1Technicaldata................................................................................‐5‐
3.3.2Installation.....................................................................................‐5‐
3.4 LWG208 LENGTH/ANGLE SENSOR..........................................................‐ 6‐
3.4.1Technicaldata................................................................................‐6‐
3.4.2Installation.....................................................................................‐6‐
3.5 ANTI-TWO BLOCK SWITCH.......................................................................‐ 8‐
3.5.1 Technical data............................................................................‐8‐
3.5.2 Installation..................................................................................‐9‐
4．OPERATIONANDDISPLAYINTERFACE..........................................................‐  10‐
4.1 DATA DISPLAY INTERFACE（VALUES ARE NOT REAL）...........................‐ 11‐
4.2 UTILIZATION DISPLAY (BAR GRAPH).......................................................‐ 13‐
4.3 INDICATOR LIGHT...................................................................................‐ 13‐

5.OPERATIONMETHOD....................................................................................‐  15‐
5.1FUNCTION SETTING.................................................................................‐16‐
5.2 OM SETUP.............................................................................................‐ 16‐
5.3 REEVING SETUP....................................................................................‐ 19‐
5.4 ERRO CODE REFERENCE TABLE...........................................................‐ 20‐
5.5 BUZZER STOPPING.................................................................................‐ 21‐
6.LMISYSTEMFUNCTIONS...............................................................................‐  23‐
6.1 WARNING..............................................................................................‐ 23‐
6.2 PROHIBITION.........................................................................................‐ 23‐
7DAILYMAINTENANCEANDCALIBRATIONS......................................................‐  24‐
7.1 MAINTENANCE CONTENT........................................................................‐ 24‐
7.2 LENGTH SENSOR ADJUSTMENT..............................................................‐ 24‐
7.3 ANGLE SENSOR ADJUSTMENT................................................................‐ 25‐
7.4 BUZZER ALARMING................................................................................‐ 25‐
7.5 LENGTH CABLE RETRACT UN-SMOOTHLY...............................................‐ 26‐
7.6 QUESTION AND ANSWER.......................................................................‐ 26‐
8.HINTSANDTROUBLESHOOTING...................................................................‐  28‐
9.HC4900CONNECTINGDIAGRAM...................................................................‐  34‐
10.OMLIST......................................................................................................‐  35‐

- 1 -
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.

- 2 -
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.
Caution
Warnin
g
Warnin
g
Caution

- 3 -
3. SYSTEM CONFIGURATION
HC4900 LMI System configuration
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.
Cable
connection

- 4 -
3.1 HC4900 Controller
HC4900 controller features high-performance, precise and limiting load
momentfunctioninharshenvironment.
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

- 5 -
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

- 6 -
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: 15～30VDC
Operating temperature: -25°C～
+75°C
Storing temperature: -40°C～
+80°C
Protection class: IP65
Linearity tolerance: 〈±0.2°
Resolution: 〈±0.1°
Hysteresis tolerance: 〈±0.1°
LWG208 Length/angle sensor dimension
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.

- 7 -
A
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:
oMake 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.
oMake 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
fixed point should be at the same level with the sensor center to guarantee
Bracket

- 8 -
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: ＞5×106times
Housing: aluminum
Weight: 1.2kg
A2B Switch dimension

- 9 -
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

- 10 -
4．OPERATION AND DISPLAY INTERFACE
1. Data display(background lit)
2. Bar graph(utilization)
3. Indicator light (refer to 4.3)
4. Function keys：Function keys F1-F5 are related to the key symbols
which present on the display
5. Numerical keys：They can be used to input values or select function
items in accordance with the number on the display.
Note：At the main interface, numerical key 1 and 3 can calibrate the
brightness of the console.
4
12
3
5

- 11 -
Operation notice：
1. OM can only be switched when the boom is fully retracted.
2. Under the load lifting status of the RT crane, the OM switch between
360 lifting and front lifting is automatically done by the LMI based on
the rotating field of the boom.
3. LMI bypass icon will be displayed on main interface if bypass switch
is activated. The status will be displayed for 30 minutes and then
automatically close. To cancel the LMI bypass condition, deactivate
the bypass signal.
4.1 Data display interface（values are not real）
The Data display (320×240) is an LED display with background illumination and
extended temperature range, on which essential data are displayed. The data
is dependent on the operating mode, such as load values, geometry and crane
data, symbols, etc.
Main interface (values shown are for illustration):
a
b
c
d
e
5
1
1
4
6
7
1
2
3
1
4
1
3
9
17
1
6
18
1
5
1
0
1
2
19

- 12 -
Data display：
1. Load moment percentage bar graph
2. Load moment percentage displayed value
3. OM code
4. Reeving
5. Rotary angle
6. Outrigger mode
7. Rid pressure
8. Piston pressure
9. Operating height
10. Time (error code will be displayed when defect)
11. Wind speed
12. Fixed jib boom length
13. Main boom length
14. Main boom angle
15. Fixed jib boom angle
16. Rated load capacity
17. Actual load
18. Working radius
19. Enforced icon (OEM special requirement)
Icon Key symbols definition：
a. Function setting key (refer to 5.1)
b. OM setting key (refer to 5.2)
c. Reeving setting key (refer to 5.3) OM setting key
d. Error code information key (refer to 5.4)
e. Alarm off key (refer to 5.5)

- 13 -
4.2 Utilization display (bar graph)
The Utilization display (bar graph) indicates how much of the admissible load
moment (rated moment) is used. As the rated moment changes constantly
during load operation, the load moment display also changes constantly.
The utilization display is marked with differently colored fields:
Green: "Safe” operation (0...90% of rated moment)
Yellow: “Pre-warning range” (90...100% of rated moment)
Red: “Overload range” (> 100% of rated moment)
4.3 Indicator light
Pre-warning lights
This yellow pre-warning light comes up when the load on the
machine amounts to more than 90% of the respective maximum
carrying capacity, 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.
Overloadwarninglight
This red Overload warning light indicates to the machine
operator that an overload condition has occurred. It lights up
when the crane load has reached 100% of maximum load
carrying capacity permitted for the current operating status.
The acoustic alarm sounds. The load-moment-increasing crane
movements are switched off at the same time
A2B switch lamp (if the machine need)
This red warning light lights up when the A2B (hoist limit) switch
contacts open, i.e. when a hoist limit situation has occurred. The
STOP

- 14 -
acoustic alarm sounds and load-moment-increasing machine
movements are switched off at the same time.
An A2B (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.
Test method as below：
Manually lifting the weight attached to the A2B switches, then the audible
alarm sound 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
audible alarm sound, the A2B alarm light will light and the crane movement
such as hoist up, luffing down, telescopic out will be stopped.
If the light and audible alarm does not function as described and the crane
movements are not stopped, the system is not working properly. The
malfunction shall be corrected before operating the crane.

- 15 -
5. Operation method
With proper adjustments, the LMI will start to work automatically. The crane
operator must be very familiar with the operation of LMI system and correctly
adjust it before operating the crane. Below is a diagram of the startup screens.
If all system checks are okay, then after pushing Y (F5 button), the Set
Operating Mode screen will come up.
If OM is set correctly, push Y (F3 button) to confirm, then ◄┘(F5 button) to
return to main screen. Otherwise set OM according to section 5.2.
Power On
Push Y to
continue

- 16 -
5.1 Function setting
Press F1 key at the main display to enter into Function setup display：
F3：Switch between Metric and
Imperial units
F4：Switch between English and
Chinese language
F5：Back to the main interface
Numerical key 1：time setting
Numerical key 2：CANbus status
query
Numerical key 3：OM code query
Numerical key 4：Oil Pressure node
setting
Function setting interface
In the metric display, the unit of length is “m” (meters) and the unit of weight is
“t” (metric ton). In the imperial display, the unit of length is “ft” (feet) and the unit
of weight is “kips” (lbs. x 1000). Metric and Imperial conversion relationship: 1
m = 3.2808 feet; 1 kg = 2.20462 pounds