Load Moment Indicator: Maintenance and Operator's Manual

L.M.I.
Maintenance and operator's manual
Chapter 7
Load Moment
Indicator
C 64440-04/a Chapter 7 - Page 1

L.M.I.
TABLE OF CONTENTS
Load Moment Indicator.
DESCRIPTION PAGES
CEC PAT
DS 60/0002 ...................................................................... 3
Error Code List............................................................... 24
Spare parts .................................................................... 39

DS 60 /0002
Central Unit with Contents
Operator’s Console
General Information
Important Notes
System Description
Configuration Setup
Pre-Operation Inspection
Service and Maintenance
Troubleshooting
Appendix
User Manual
Issue 3/2002 Rev. C
This Document has the part-no.

24 060 19_0002e
Page 3
CONTENTS
1. General Information .................................................................3
2. Warnings ...................................................................................4
3. System Description..................................................................5
3.1 System functions ........................................................................6
3.2 Operator’s console .....................................................................6
3.3 Control identification...................................................................7
4. Configuration setup ...............................................................12

4.1 Adjusting the text message language ......................................12
4.2 LMI Setup procedure................................................................13
Enabling a new attachment ......................................................17
4.3 Selecting display levels ............................................................18
5. Pre-Operation Inspection ......................................................19

5.1 Operation .................................................................................19
6. Service and Maintenance ......................................................20
7. Troubleshooting .....................................................................21
7.1 General ....................................................................................21
7.2 Error code list ...........................................................................22
Appendix: Important Notes ...........................................................31
The information in this document is subject to change without notice. PAT makes no warranty of any kind with regard to this
material, including, but not limeted to the implied warranties of merchantability and fitness for a particular purpose. PAT shall
not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, perfor-
mance, or use of this manual. This document contains proprietary information which is protected by copyright. All rights re-
served. No part of this document may be photocopied, reproduced, or translated to another language without the prior writ-
ten consent of PAT.
© 2002 PAT GmbH · D-76275 Ettlingen · Hertzstr. 32 - 34 · ++49 (0) 7243 709-0 · FAX ++49 (0) 7243 709-222 · Email: pat.ettlingen@pat-group.net 2
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System description
1. General Information
This manual describes the function, operation and maintenance of the PAT DS 60 Load Moment1
Indicator (LMI).
The LMI has been designed to provide the crane operator with the essential information required to
enable the machine to be used within its design parameters.
Using various sensing devices, the Load Moment Indicator monitors various crane functions and pro-
vides the operator with a continuous reading of the crane's capacity. The readings continuously
change as the crane moves through the motions needed to make the lift.
If non permitted conditions are approached, the DS 60 Load Moment Indicator will warn the operator
by sounding an audible alarm, lighting a warning light and locking out those functions that may aggra-
vate the crane's condition.
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 the lifting capacity of a crane.
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System description
2. WARNINGS
The LMI is an operational aid which warns a crane operator of approaching overload conditions which
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 crane operating procedures.
The responsibility for the safe operation of the loader shall remain with the operator who
shall ensure that all warnings and instructions supplied are fully understood and observed.
Prior to operating the loader, the operator must carefully and thoroughly read and under-
stand the information in this manual to ensure that he knows the operation and limitations
of the indicator and loader.
Proper functioning is dependent upon proper daily inspection and observations of the op-
erating instructions set forth in this manual.
The displays will only aid the operator when the LMI is properly programmed and the proper
load capacity chart is selected (LMI setup procedure) for the crane configuration being utili-
zed. To prevent property damage or serious bodily injury or death to personnel, ensure the
LMI is properly programmed before operating the loader.
System description
3. SYSTEM DESCRIPTION
The PAT Load Moment Indicator DS 60 consists of a central micro processor unit with built-in opera-
ting console and various peripheral sensors. The system components are connected via CAN bus.
System description
The system works according to the principle of variance comparison. The actual value which is ob-
tained by pressure measurement, is compared with the set values stored in the central data memory,
and evaluated by the microprocessor. When the limit values are reached, an overload warning signal
is triggered on the display and control console. At the same time, any crane movements that could
increase the load are disabled.
The crane-related data specified by the manufacture, such as load charts, boom weights, centres of
gravity and dimensions, are stored in memory chips in the central data memory. These data form the
reference values for calculating the operating states.
In some cases, the system function is controlled by automatic components such as boom length and
angle transmitters, and in other cases by manual devices, such as keys on the display and control
console.
The boom angle and the boom length are detected by a length/angle sensor mounted on the boom.
The utilization is measured using pressure sensors mounted on the piston and rod sides of the boom
and compensation cylinder.
3.1 System functions
After the system is switched ON, it starts with an automatic

test run of the LMI system, the displays and control elements
as well as of the acoustic alarm. During the test run, the start
screen is displayed.
After the system has passed through the system test without
errors and the setup procedure for the operating mode has
been finished, the system is ready for operation.
The language for text messages can be switched over, if re-
quired. (refer to chapter 4.1)
In case of malfunction, an appropriate error code „E##“ ap-
pears on the data display (1). (In this context, refer to chapter
7.)
3.2 Operator’s console
The console has two functions:

• terminal for input of instructions to the system by the crane operator
• display of important data and information
The console is located in the crane cabin in the operator's field of vision. To improve identification of
the display and control elements, these are backlit during operation. This unit contains different dis-
plays and controls which are described in chapter 3.3.
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System description
3.3 Control Identification
The illustration shows the controls and displays of the DS 60 safe load indicator.
The numbers of the illustration correspond to the numbers in the following list which describes the
function of each control.
4 5 6 2 1 7 10
I
II
3 8 9
1 Data display (backlit)

2 Color marking for bargraf (utilization)
3 Symbols
4 Indicator „normal utilization“
5 Indicator „prewarning overload“
6 Indicator „overload“
7 Selection key „up“
8 Selection key „down“
9 Alarm-off key
10 Operation mode key
Control Identification
(1) Data display
The Data display (1) is an illuminated LC display which

shows several values.
The figure shows the display during normal operating (va-
lues are not real).
I
II
(2) Utilization bar graph
This utilization bar graph display (2) indicates how much of

the loader‘s rated capacity is being used. (utilization)
As the rated capacity of the loader changes as it is moved
through its various motions, the utilization display will con-
stantly change as well.
The bar graph is marked with different colors:
• green: and safe section (0%...90% of rated cap.)
• yellow: prewarning section (90%...100% of rated cap.)
• red: overload section (>100% of safe working load)
(3) Symbols for display values
Symbols (3) below the display data are the designators for
the values displayed above the marked areas.
The display level label (I or II, at the left) marks the level
selected.
I Display level selection is made by way of the selectors up
II (7) or down (8), respectively.
(4) „Normal utilization“ Indicator
This green lamp will light up when the load on the crane is
below 90 % of the loader‘s rating capacity, indicating that
the utilization is normal.
(5) „Prewarning“ indicator
The yellow prewarning light (5) will light up when the load on
the crane is over 90 % of the crane rating, indicating that an
overload condition is approaching.
IMPORTANT
This means for the operator to continue his crane ope-
ration with caution.
(6) Overload indicator
The red overload light (4) warns the operator that a rated
load condition has been reached.
The audible alarm also sounds when this condition has be-
en reached.
Press button to interrupt the audible alarm.
NOTE
Audible alarm message acknowledgement can be acti-
vated after 5 seconds alarm duration, at the earliest.
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(7) „up“ Selector
This selector selects display elements during the following

functions:
• Selection of display level
• Selection of language
• Selection of operating mode
(8) „down“ Selector
This selector selects display elements during the following

functions:
• Selection of display level
• Selection of language
• Selection of operating mode
(9) „Audible Alarm Acknowledgement“ button
An acoustical alarm message can be acknowledged by acti-

vation of this selector.
However, audible alarm message acknowledgement can be
activated after 5 seconds alarm duration, at the earliest.
The acoustical alarm will sound upon the following events:
System test, overload condition, malfunction of the load
moment indicator system, or after recognized operator er-
rors.
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(10) „Operating mode“ Selector
The function “Setup operating mode“ is activated by this

selector.
The setup procedure is described in chapter 4.2.
The correct setting of the Operating Mode Code is of

utmost importance for the proper function of the sy-
stem and the loader. Therefore, only operators who are
thoroughly familiar with the load capacity charts and
the use and operation of the system shall set the Opera-
ting Code.
Failure to properly program the LMI with the correct
operating mode code may result in property damage or
serious bodily injury or death to personnel.
To assure the crane is properly programmed, verify that
the operating mode code (shown at data display) and
the load capacity chart match the lifting configuration of
the crane.
Configuration Setup
4. CONFIGURATION SETUP
4.1 Adjusting the text message language
Text messages can optionally be displayed in German, English, French or Italian. It is not necessary
to repeat this language adjustment when starting the system as it will be stored until the next adjust-
ment. The procedure is described as follows:
Input Display Remarks
simultaneous Function is started.

selection ! Language set up last is displayed.
.
Select required language by repeated
. presses of selector „Operating mode“
(10).
.
The language displayed last is stored.

simultaneous
selection ! All text messages are displayed in the
newly selected language.
This terminates the function „ Selection of text message language“.
Configuration Setup
4.2 Setup of „Operating mode“
After every component change it is absolutely necessary to program the LMI reflecting this new
equipment status, i.e. to reset the operating mode. To do this, the system is equipped with an
interactive query system where the operating mode code does not have to be directly entered but
rather the system itself chooses a suitable operating mode depending on the successive entries as
well as on the digital input signals.
Only the actual existing and enabled equipment configurations are queried.
In the following you will find instructions on how to proceed in order to obtain information about the
current configuration and the settings of the operating mode:
• Querying the current configuration

After activating the “Operating mode”
button, the following data is shown
successively (scrolls) on the display:
a) Attachment's identification
b) Current support status
c) Current slewing range
After reactivating the “Operating mode”

button, the query of the current
configuration is ended and the normal
operational data is displayed.
I
II
Configuration Setup
• Changing the operating mode

After activating the “Operating mode”
button, the following data is first shown
(scrolls) on the display:
d) Attachment's identification
e) Current support status
f) Current slewing range
Changing the attachment:

Select the designation of the enabled,
effectively mounted attachment using
the selection buttons.
or
.
.
.
Confirm the selected attachment.

(if “OK” is shown on the display, no further
settings are required, i.e. the support and the
current slewing range correspond to the given
values in the load bearing table; the display
changes to normal operating mode and the
operating mode setup is thereby ended.)
If “OK” is not shown on the display, the

support basis and/or the slewing range
must be changed.
Continuation >>
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Configuration Setup

Depending on the signals the system
evaluates, the support basis required
for the operating mode is shown on
the display. If several possibilities are
shown successively, you can select
which support basis you want to use.
Place the supports according to the

display.

settings are required, i.e. the current slewing
range corresponds to the given value in the
load bearing table; the display changes to
normal operating mode and the operating
mode setup is thereby ended.)
If “OK” is not shown on the display,

additional settings will be required.
Continuation >>
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Configuration Setup

Depending on the signals the system
evaluates, the slewing rage required
for the operating mode is shown on
the display.
.
Slew the superstructure according to
. the display.

settings are required, i.e. all settings correspond
to the given values in the load bearing table; the
display changes to normal operating mode and
the operating mode setup is thereby ended.)
The function
“Operating mode setup”
is finished.
I
II
If “E 04” is shown on the display,

no operating mode is stored in
the selected configuration.
After activating the “Operating mode
button”, the display shows the setting
where no operating mode has been
stored.
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Configuration Setup
Enabling a new attachment
To be able to use an additional attachment, you need an eight-digit “Enabling code” which corres-
ponds to the attachment, obtainable from the manufacturer.
Afterwards, you will find the instructions for enabling an attachment:
is held down,
then press the

System ready for input of the enabling
code.
button
Select the first digit of the enabling
code with the selection buttons (here 1)
Select the next position by pressing the

operating mode button, the previously
entered digit is shown as a star
After all digits have been correctly

entered according to the enabling code,
the name of the enabled attachment
appears on the display (Example display
given here)
If the code input was erroneous,

“access denied” will appear on the
display
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Configuration Setup
4.3 Selecting Display levels
One additional level for displaying further geometry data can be selected by way of the
selectors and . The values on each level are designated by symbols below the display.
number of display level
if required: error code
Level I:
rated actual radius operating

load load code
number of display level
if required: error code
Level II:
length angle height
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Pre-Operation Inspection / Service / Maintenance
5. PRE-OPERATION INSPECTION
Prior to operating the machine, the following points must be checked:

1. Check the spring-loaded cable reel to be sure it is free to rotate, has tension and the cable is
reeled properly.
2. Check that the display of the main boom length agrees with the actual boom length.
3. Check that the display of the main boom angle agrees with the actual boom angles.
4. Check that the display of the operating radius of the crane agrees with the actual radius.
5. Check the load display by lifting a load of known weight.
5.1 Operation
After being properly checked, the LMI is operational. The operator shall be thoroughly familiar with all
controls of the LMI and he shall properly set the Reeving Switch (external unit) before operating the
crane. The proper function of the system shall be checked by lifting a load of known weight and com-
paring the load to the information displayed on the LMI.
Rated loads include the weight of the hook block, slings, and auxiliary load handling devices. Their
combined weights shall be subtracted from the listed load capacities as stated on the load capacity
chart to obtain the net load to be lifted.
If any of the displays reflect a deviation between displayed and actual values an authorized
PAT service representative shall be called for repair of the system or re-verification of the
crane's LMI calibration.
Any structural modifications or changes to the crane shall require re-verification of the cra-
ne's LMI calibration.
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Pre-Operation Inspection / Service / Maintenance
6. SERVICE AND MAINTENANCE
Maintenance of the load moment indicator consists of inspecting:

1. The electrical wiring connecting the various parts of the system. If electrical wiring is damaged, it
shall be replaced immediately.
2. The cable reel shall be under tension to operate properly.
3. Check the pressure transducers at the lift cylinder(s) and the connecting hoses for oil leakage
Other than correcting the problems identified in the Error Code List, no other repairs shall
be performed by non expert personnel.
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Troubleshooting
7. Troubleshooting
7.1 General Information
In case of a malfunction of the system, the data display (1) will indicate a code "E##" which identifies
the system malfunction.
The error codes listed in the Malfunction Table will identify various faults which can occur with the
LMI. Following the Malfunction Table are pages which explain each fault and describe the action
which shall be taken to correct the fault.
Error Code
Example:
Faults within the electronic microprocessor shall only be repaired by factory trained service personnel.
When these faults occur, the competent service organization shall be contacted.
Error Code List
7.2 Error Code List
Error Code List
DS 60
System program: DALA V 1.1
Error ”CAN”
Error: Initiation of the CAN-bus
Cause: The SLI checks which sensors are present on the CAN-bus and activates them.
Elimination: No action necessary
Error ”E01”
Error: Angle range exceeded.
Cause: Exceeding maximum angle specified in the respective load chart due to luffing up the
boom too far.
Elimination: Luff down the boom to a angle pre-set in the load chart
Error ”02”
Error: Fallen below angle range
Cause: Fallen below minimum angle specified in the respective load chart due to luffing down
the boom too far
Elimination: Luff up the boom to an angle pre-set in the load chart
Error Code List
Error ”04”
Error: Operating mode not available
Cause: a) Operating mode switch at console is wrong.
b) Wrong machine type programmed
c) Wrong equipment mounted.
Elimination: a) Set the operating mode in accordance with the assignment to the operating condition
b) Check Address $58 in the serial EEPROM.
c) check selected Operating-Mode
Error ”05”
Error: Prohibited length range
Cause: a) Boom has been extended too far or not enough, e.g. if operation is only admitted up
to a certain boom length or for load charts of jibs with the boom having to be ex-
tended to a certain length
b) Length sensor adjustment was modified, e.g. rope slid off the length sensor reel
c) Clutch between length sensor pot and drive is defective
d) Failure of the +5V-supply for the analogue part of the LMI-analogue board
e) Cable between central unit and length sensor is defective or slack
f) Length potentiometer is defective
Elimination: a) Retract or extend boom to the correct length

b) Retract boom. Check prestress of the cable reel (rope has to be under traction).
Open the length sensor and carefully turn the length pot counterclockwise to the de-
tent by use of a screwdriver
c) Completely replace the clutch with the drive wheel and adjust length sensor pot as
described under b.)
d) Check +5V-voltage. If there is no voltage or break down at a charge of 50 Ohm ap-
prox. exchange analogue board
e) Check cable as well as connector and exchange, if necessary
f) Replace length potentiometer
Error ”06”
Error: Radius range exceeded or fallen below angle range during luffing jib operation.
Cause: Gone past the maximum radius or fallen below the minimum specified in the respective
load chart due to luffing down the jib too far.
Elimination: Luff up the luffing jib to a radius or angle indicated in the load chart.
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Error Code List
Error ”07”
Error: No acknowledgement from the overload relay
Cause: a) Overload relay is caught, defective or not being driven
b) Processor board is defective
Elimination: a) Replace main board
Error ”08”
Error: No acknowledgement of the anti-two-block switch relay.
Cause: a) anti-two-block relay is caught, defective or not being driven
Elimination: a) Replace main board
Error ”11”
Error: Fallen below limit for measuring channel "Length telescopic boom"
Cause: a) Cable between length sensor and central unit is defective, not connected or there is
water in the connectors
b) Length sensor potentiometer is defective
c) Electronic board in measuring channel is defective
Elimination: a) Check cable and connector as well and replace, if necessary

b) Replace length sensor potentiometer
c) Replace main board
Error ”E12”
Error: Fallen below lower limit value for measuring channel "pressure transducer piston side,
Cylinder 1 (Luffing cylinder)"
Cause: a) Cable between central unit and pressure transducers is defective or there is water in
the connectors
b) Pressure transducer is defective

b) Replace pressure transducer
Error Code List
Error ”E13”
Error: Fallen below lower limit value for measuring channel "pressure transducer rod side,
Cylinder 1 (Luffing cylinder)"
the connectors

Error ”E14”
Error: Fallen below lower limit value for measuring channel "pressure transducer piston side,
Cylinder 2 (Aux. cylinder)"
the connectors

Error ”E15”
Error: Fallen below lower limit value for measuring channel "angle main boom"
Cause: a) Cable between central unit and angle sensor is defective, loose or there is water in
the connectors
b) Angle sensor is defective
Elimination: a) Check cable as well as connectors and replace, if necessary

b) Replace angle sensor
c) Replace main or analogue board
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Error Code List
Error ”E16”
Error: Fallen below lower limit value for measuring channel "pressure transducer rod side,
Cylinder 2 (Aux. cylinder)"
the connectors

Error ”21”
Error: Upper limit value for measuring channel "Length telescopic boom" exceeded
Cause: a) Cable between length sensor and central unit is defective, not connected or there is
water in the connectors
b) Length sensor potentiometer is defective

b) Replace length sensor potentiometer
Error ”E22”
Error: Upper limit value for measuring channel "pressure transducer piston side, Cylinder 1
(Luffing cylinder)" exceeded
the connectors

Error Code List
Error ”E23”
Error: Upper limit value for measuring channel "pressure transducer rod side, Cylinder 1" ex-
ceeded
the connectors

Error ”E24”
Error: Upper limit value for measuring channel "pressure transducer piston side, Cylinder 2
(Aux. cylinder)" exceeded
the connectors

Error ”E25”
Error: Upper limit value for measuring channel "angle main boom" exceeded
Cause: a) Cable between central unit and angle sensor is defective, loose or there is water in
the connectors
b) Angle sensor is defective

b) Replace angle sensor
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Error Code List
Error ”E26”
Error: Upper limit value for measuring channel "pressure transducer rod side, Cylinder 2
(Aux. cylinder)" exceeded
the connectors

Error ”E31”
Error: Error in the system program. When checking the system program in the LMI the gener-
ated CRC values do not correspond with those stored
Cause: a) EPROM is defective
b) Main board is defective
Elimination: a) Replace EPROM

b) Replace main board
Error ”E37”
Error: Error in the logical program flow
Cause: a) System program part EPROM is defective
b) Processor board 80C535A is defective
c) Main board is defective

b) Replace processor board 80C537A
Error ”E38”
Error: Wrong system program in the LMI
Cause: The system program part in the EPROM does not correspond with the program part in
the EPROM
b) Check program code in the data part of the EPROM
Error Code List
Error ”E41”
Error: Error in the internal RAM of processor board 80C537A
Cause: a) Processor board 80C537A is defective
Elimination: Replace main board
Error ”E42”
Error: Error in the external RAM
Cause: a) CMOS-RAM is defective
Error ”E48”
Error: Error in the internal RAM of the processor board 80C537A during cyclic RAM test
Cause: Internal RAM defective
Error ”E51”
Error: Error in the data part of the EPROM
Cause: a) Data EPROM is defective
c) No valid data in the data-EPROM-part of the EPROM
Elimination: a) Check data part of the EPROM

b) Replace EPROM
d) Check the data-EPROM-part of the EPROM.
Error ”57”
Error: Error in the data EEPROM
Cause: a) EEPROM is not initialised
b) EEPROM is defective
c) Processor board is defective
Elimination: a) Initialise EEPROM

b) Replace processor board
c) Replace processor board
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Error Code List
Error ”70”
Error: One of the 2 redundant systems recognised operating mode ”Man Basket” but the 2nd
doesn’t.
Cause: a) The wiring of the digital-inputs are wrong.
b) Operating modes in data-EPROM wrong coded.
c) Different data-EPROMs used in the two redundant systems.
Elimination: a) Check wiring.

b) Check data-EPROMs.
c) Check data-EPROMs.
Error ”78”
Error: Error anti-two-block switch
Cause: a) Cable between central unit and anti-two-block switch is defective or loose

b) Replace processor board
Error ”91”
Error: The SLI does not receive a heartbeat from the pressure sensor (sensor seems to be dead)
Cause: a) Electronic in the sensor defective.
b) Cable has a short circuit or is broken.
Elimination: a) Check sensor and replace if necessary.

b) Check the cable.
Error ”92”
Error: The SLI does not receive a heartbeat from the length/angle sensor
(sensor seems to be dead)
Cause: c) Electronic in the sensor defective.
d) Cable has a short circuit or is broken.
Elimination: c) Check sensor and replace if necessary.

d) Check the cable.
Remarks:
If an error message is displayed which is not contained in the list above, please contact the competent PAT
service department.
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Appendix: Important Notes
PAMPHLET 1 Cut-off Values for Boom Cranes with Variable Capacity depending
on Variable Radius
The crane cut-off values are calculated by us on the basis of the load charts and construction drawings supplies
by the crane manufacturers.
These theoretical cut-off values must be checked by testing the crane with weighed test loads in all operating
modes and at least in the following equipment conditions depending on the crane type.
• Cranes with fixed boom length during operation:
Minimum, medium and maximum radius with shortest, medium and longest boom length as well as with
shortest, medium and longest jib length with these boom lengths.
• Cranes with variable boom length during operation:
Minimum, medium and maximum radius at each length step as well as with all jibs.
PAMPHLET 2 Important notes for crane operators
The LMI is an operational aid which warns a crane operator of approaching overload conditions and also warns
of overhoist conditions which 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 crane operating procedures. The responsibility for the safe operation of the crane 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
the crane/SLI manual to ensure that he knows the operation and limitations of the indicator and crane.
Proper functioning is dependent upon proper daily inspection and observations of the operating instructions set
forth in the manual.
This system can be equipped with an override key on the central micro-processor unit. This
key switch bypasses cut-off functions of the load moment indicator device. The switch may
only be used by authorized personnel during emergency situations. Failure to follow this
instruction may result in property damage and/or personal injury.
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PAMPHLET 3 Important notes for crane users

In the Federal Republic of Germany, the directives of the Union of German Engineers VDI (Verein Deutscher
Ingenieure) 3570 are effective for the construction of safe load indicators. There, too, it is directed to the signifi-
cant and the limits of the safe load indicator.
"Safe load indicators shall, during crane operation, hinder accidents, endangering of persons, things, the load,
the crane due to overload within the limits possible. User and crane operator must take into account that a safe
load indicator cannot realize all dangers in time and that a malfunction by non-perceptible influences indeed is
possible. Therefore they are not dispensed from circumspection and the responsibility to the observance of the
operating instructions and the load of the crane. Safe load indicators are not intended for regular operation.
They shall only respond in emergency cases. The capacity of the hoisting appliance shall not be reduced by
safe load indicator".
Instructional Pamphlet VDMA

for safe load indicators (load moment limiting devices) on boom cranes
The boom crane delivered to you has a safe load indicator (overload cut-off device) according to §24 of the accident preven-
tion regulation UVV "boom cranes" which will cut off the hoist and boom hoist unit of the crane when exceeding the admissi-
ble safe load. The opposite movement must remain possible in order to be able to relieve the crane of the load after the safe
load indicator has reacted, e.g. it must be possible to lower the load when the hoist was cut off.
Installation of a safe load indicator (overload cut-off device) has the purpose to prevent the crane from lifting a load which
would endanger its stability. Hence the safe load indicator (overload cut-off device) is an emergency switch which, in the
event of overload, cuts off all movements increasing the load moment thus avoiding a possible damage or accident. The
following must be observed for the safe load indicator to comply with its function as a safety device.
1. Safe load indicators (overload cut-off devices) must not be used operationally to cut off the hoist or boom hoist unit. The
crane operator must in any case previously make sure that the load to be lifted will not exceed the lifting capacity of the
crane. Superheavy loads exceeding the lifting capacity of the crane must not be lifted even with a safe load indicator in-
stalled. The unit must not be loaded beyond the respectively admissible load.
2. Freeing loads which are stuck may only be effected in agreement with the crane manufacturer and with cranes especially
equipped for this purpose. During these jobs it is not allowed to use the safe load indicator (overload cut-off device) as an
operational unit for force measurements.
3. The built-in safe load indicator must be regularly serviced and checked as to its functional safety before starting opera-
tion. According to the accident prevention regulation UVV "boom cranes" §35 maintenance of the crane also includes
regular checks of the safe load indicator.
4. Generally, the safe load indicator does not adjust automatically to the various operating conditions of the crane. When
changing the operating condition of the crane, the operator is therefore responsible of changing the safe load indicator
over to the new load or load moment range as well. For this purpose, observe the manufacturers operating instructions
for the safe load indicator installed. Safe operation of the device and accident-free operation of the crane depend to a
high extent on careful observance of this instruction. Maladjusted safe load indicators, e.g. set to a high load moment
with retracted outriggers, are much more dangerous than cranes without a safe load indicator since the crane operator is
given a wrong feeling of safety which might be the cause of serious accidents.
5. When changing the crane over to various operating conditions, the safe load indicator installed must be changed over to
the new load or safe load ranges resp. by the crane operator, e.g.:
a) when extending or retracting the outriggers (changing over to high or little load moment);
24 / 060 / 24 060 19 0002E_Rev C.doc / 2002-03-08 Rev. C / rk.
Page 34
b) when changing the boom length by:

- extending or retracting (telescoping) manually;
- mounting or dismounting intermediary parts;
c) when slewing or pivoting the crane to the range of greater or smaller stability moment (changing over to high or little
load moment);
d) when passing into another load capacity range by several parts of line in the cables of the hoist or boom hoist unit.
6. It must be strictly pointed out that due to wrong operation of the crane it might not be possible for the safe load indicator
to respond or resp. that the engine might not be cut off quickly enough. In this case you cannot exclude an accident de-
spite of a safe load indicator installed.
In particular, this applies to:
- underhooking the load or the load handling accessories;
- excessive retardation forces,
- loads falling into the line,
- diagonal pull,
- moving the crane to an area of higher gradient,
- yielding ground,
- wind pressure.
7. If there is a device available to switch off or bridge the safe load indicator (load moment limiting system), it must only be
used with regard to special measures of precaution and in presence of the crane super-intendance, for instance when
testing the crane and for special applications provided for by the crane manufacturer. The safe load indicator must not
be switched off or bridged operationally under no circumstances in order to lift loads which exceed the respectively ad-
missible loading capacity of the crane.
Careful observance of the regulations contained in this instructional pamphlet and in the operating in-
structions of the crane manufacturer is the precondition for the safe function of the safe load indicator
(overload cut-off device).
In all cases of doubt consult the operating instructions of the manufacturer. Should this be not suffi-
cient, it is necessary to inquire at the company concerned.
Unauthorized interventions in the mechanism of the safe load indicator will void the warranty.
Publisher: VDMA Fachgemeinschaft für Hebezeuge und Fördermittel

im Verein Deutscher Maschinenbau Anstalten e.V.
Düsseldorf - Oberkassel
24 / 060 / 24 060 19 0002E_Rev C.doc / 2002-03-08 Rev. C / rk.
Page 35
PAMPHLET 4 Instructions to ensure the electromagnetic compatibility (EMC) with

electronic systems under the effect of electromagnetic fields
Electromagnetic fields increasingly affect electronic systems and can thus cause malfunctions for whose elimi-
nation we shall indicate some preventive measures according to today's state of engineering below:
1. The preventive measures are mainly based upon the idea to shield the electronic circuits from irradiated
high frequency interferences:
- All components will have metal housings outside with grounding possibility;
- The cables used will have braided shields. The shield applied must be highly conductive as to the sur-
face of all junction areas;
- Coupling of crane ground and electronic ground at only one point of the system.
2. The general measures listed in item 1, however, cannot ensure complete protection against electromag-
netic fields in individual cases because the size and the type of the effect depends on the local conditions.
The influencing factors, inter alia, are as follows:
- Particularly unfavorable arrangement of the antenna as to the system;

- Very high transmitter powers;
- Impossible to observe the measures of item 1 consistently by reason of local conditions;
- Long cables;
- Interferences coupling into the supply lines.
With unfavorable conditions you can therefore not do without taking any measures exceeding the preven-
tive ones experimentally on site, taking into account the principles mentioned in item 1, e.g.:
• Adding filters or short-circuiting the interfering frequencies by means of capacitors;

• Making or removing ground connections;
• Using double shielded cables (guarded shield system).
24 / 060 / 24 060 19 0002E_Rev C.doc / 2002-03-08 Rev. C / rk.
Page 36
PAMPHLET 5 Notes for Protection of Labour During Repair of Display and Oper-
ating Consoles
Caution: LCD displays contain fluid chemicals.

Therefore, you have to proceed carefully when:
• operating devices with LCD displays

• storing or carrying them (risk of fracture)
• clearing spare or unusable LCD displays
Possible risks are chemical reactions because of skin contact with broken LCD displays. In
case of contact with chemicals, carefully clean the parts of body affected with soap. Cau-
tion in case of open wounds.
PAMPHLET 6 Installation instructions for display and operator's console without

closed metal housing
In order to avoid radio interferences, high frequency devices and systems subject to the general approval the
Federal Minister of the Post Office and Telecommunication published in the gazette no. 163/1984 as order no.
1045/1984 and no. 1046/1984 have to observe the limits and requirements stipulated.
In case of display and operator's console without closed metal housing (panel-mounted) type, the cable shield
must be applied via a bare clamp on the panel directly in front of the console.
24 / 060 / 24 060 19 0002E_Rev C.doc / 2002-03-08 Rev. C / rk.
Page 37
Revision History
Revision History
Revision Date Modifications Name

Vers. A 2001-09-21 original issue, english Konopka
system programm DALA V 1.0 (7-2001)
Vers. B 2001-10-05 corrections Konopka
Vers. C 2002-03-08 Layout correction Konopka
Adaption chapter 4.2 Configuration Setup to
system program DALA V 1.1
DS60 TFC45 PIECES DE RECHANGE
PPM Terex Spare parts
Désignation Référence
Parts Parts ref
Console DS60 71 30 2170

DS60 central unit
LWG152/0005
Capteur de longueur et angle 71 50 2237
Lenght – Angle sensor LWG152/0005
Boîtier ANACAN 74 05 0102

Anacan box
Capteur pression 600b 71 09 2537

Pressure transducer 600b
Câble capteur pression 72 20 1724

Pressure transducer cable
Câble bus CAN (11m) 71 20 2174

CAN bus cable (11m)
DS60_TFC45_PR Indice 0 Date : 22/04/2005 Page 1 sur 3

Page 39
1
2
6 7

Page 40
REPERES DESIGNATION REFERENCES

Parts Numbers Parts Parts ref
1 Capteur d’angle WG143/0006 64 143 06 0006

Angle sensor WG143/0006
2 Potentiomètre de longueur 67 000 30 0009

Length potentiometer
3 Carte interface LWG-CAN 68 000 30 0103

Interface board LWG-CAN
4 Câble tirant 1+tresse (26m) 47100201

Measuring cable 1+shield
5 Ressort 67 152 11 0003

Spring
6 Ensemble pignon (36/64) 68 000 11 0062

Gear wheel with slip clutch
7 Collecteur (2 pistes) 68 000 10 0042

Slip ring assembly 2 conductors
8 Ensemble manilles 47101501

Page 41
L.M.I.

Load Moment Indicator: Maintenance and Operator's Manual

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L.M.I.

Maintenance and operator's manual

C 64440-04/a Chapter 7 - Page 1

Load Moment Indicator.

C 64440-04/a Chapter 7 - Page 2

Service and Maintenance

Issue 3/2002 Rev. C

This Document has the part-no.

1. General Information .................................................................3

4. Configuration setup ...............................................................12

5. Pre-Operation Inspection ......................................................19

6. Service and Maintenance ......................................................20

Appendix: Important Notes ...........................................................31

3.1 System functions

After the system is switched ON, it starts with an automatic

3.2 Operator’s console

The console has two functions:

3.3 Control Identification

1 Data display (backlit)

(1) Data display

The Data display (1) is an illuminated LC display which

(2) Utilization bar graph

This utilization bar graph display (2) indicates how much of

(3) Symbols for display values

(4) „Normal utilization“ Indicator

(5) „Prewarning“ indicator

(6) Overload indicator

Press button to interrupt the audible alarm.

(7) „up“ Selector

This selector selects display elements during the following

(8) „down“ Selector

This selector selects display elements during the following

(9) „Audible Alarm Acknowledgement“ button

An acoustical alarm message can be acknowledged by acti-

(10) „Operating mode“ Selector

The function “Setup operating mode“ is activated by this

The setup procedure is described in chapter 4.2.

The correct setting of the Operating Mode Code is of

4.1 Adjusting the text message language

Input Display Remarks

simultaneous Function is started.

The language displayed last is stored.

This terminates the function „ Selection of text message language“.

4.2 Setup of „Operating mode“

Input Display Remarks

After reactivating the “Operating mode”

• Changing the operating mode

Input Display Remarks

Changing the attachment:

Confirm the selected attachment.

If “OK” is not shown on the display, the

Input Display Remarks

Place the supports according to the

(if “OK” is shown on the display, no further

If “OK” is not shown on the display,

Input Display Remarks

(if “OK” is shown on the display, no further

If “E 04” is shown on the display,

Enabling a new attachment

Input Display Remarks

then press the

Select the next position by pressing the

After all digits have been correctly