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PAT America, Inc.

LOAD MOMENT INDICATOR

DS 160

OPERATOR’S MANUAL
9333104064 REV D 10/24/2002

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 Operator’s Manual DS 160

NOTICE
PAT America, Inc. makes no warranty of any kind with regard to this material, including, but not limited
to, the implied warranties of merchantability and/or its fitness for a particular purpose.

PAT America, Inc. will not be liable for errors contained in this manual or for incidental or
consequential damages in connection with the furnishing, performance, or use of this manual. This
document contains proprietary information, which is protected by copyright, and all rights are reserved.

No part of this document may be photocopied, reproduced, or translated to another language without
the prior written consent of PAT America, Inc.

PAT America, Inc. reserves proprietary rights to all drawings, photos and the data contained therein.
The drawings, photos and data are confidential and cannot be used or reproduced without the written
consent of PAT America, Inc. The drawings and/or photos are subject to technical modification
without prior notice.

All information in this document is subject to change without notice.

MANUAL REVISIONS

REV DATE NAME DESCRIPTION

- 10/9/01 MO Create manual
A 12/10/01 CH ECN 01-316
B 03/29/02 CH ECN 02-100
C 4/14/02 JR ECN 02-159
D 10/24/02 CH ECN 02-182

© 2001 PAT America, Chambersburg, PA 17201, USA

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 Operator’s Manual DS 160

TABLE OF CONTENTS

1 GENERAL INFORMATION................................................................................................ 1

2 WARNINGS .......................................................................................................................1

3 SYSTEM DESCRIPTION................................................................................................... 2
3.1 SYSTEM FUNCTION ........................................................................................................................ 3
3.2 OPERATING CONSOLE ................................................................................................................... 4
3.2.1 LC Display ............................................................................................................................ 4
3.2.2 Control Identification............................................................................................................. 5
4 SYSTEM OPERATION .................................................................................................... 10
4.1 LMI SETUP PROCEDURE.............................................................................................................. 10
4.1.1 Operating Mode Selection .................................................................................................. 11
4.1.2 Outrigger Selection Screen ................................................................................................ 12
4.1.3 Crane Level Screen............................................................................................................ 13
4.1.4 Hoist Selection Screen ....................................................................................................... 14
4.1.5 Reeving (Parts-of-Line) Selection Screen .......................................................................... 15
4.2 LIMIT SETTINGS ........................................................................................................................... 16
5 RADIO ANTI TWO-BLOCK SWITCH (OPTIONAL) ......................................................... 18
5.1 RADIO ANTI-TWO BLOCK TRANSMITTER AND RECEIVER DESCRIPTION .......................................... 18
5.1.1 RECEIVER ......................................................................................................................... 19
5.1.2 Transmitter / Switch............................................................................................................ 20
5.2 SETUP ........................................................................................................................................ 21
5.2.1 Clear Existing Setup/Switches............................................................................................ 21
5.2.2 First ID Setup ..................................................................................................................... 21
5.2.3 Second ID Setup ................................................................................................................ 21
5.3 OPERATION ................................................................................................................................. 22
6 PRE-OPERATION INSPECTION AND CALIBRATION VERIFICATION ......................... 23
6.1 PRE-OPERATION INSPECTION AND CALIBRATION VERIFICATION ................................... 23
6.2 ANTI TWO-BLOCK RETAINER INSTALLATION .................................................................................. 24
7 OPERATION.................................................................................................................... 25

8 SERVICE AND MAINTENANCE...................................................................................... 26

9 TROUBLESHOOTING ..................................................................................................... 27
9.1 GENERAL .................................................................................................................................... 27
9.2 OPERATING ERRORS ................................................................................................................... 27
9.3 ANALOG INPUT CHANNEL ERRORS ............................................................................................... 28

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 General Information 1

1 GENERAL INFORMATION

The PAT Load Moment Indicator 1 (LMI) DS 160 has been designed to provide the crane operator with
the essential information required to operate the machine within its design parameters. The LMI
provides the operator with information regarding the length and angle of the boom, working radius,
rated load and the total calculated weight being lifted by the crane.

The DS 160 LMI basically consists of a central microprocessor unit, operator’s console, length and
angle sensor, pressure transducer sensor, and anti-two block switches. The system operates on the
principle of reference/real comparison. The real value, resulting from the load measurement is
compared with the reference data, stored in the central processor memory and evaluated in the
microprocessor. If non permitted conditions are approached, the DS 160 LMI will warn the operator by
sounding an audible alarm, lighting a warning light and locking out those functions that may aggravate
or worsen the crane’s condition.

2 WARNINGS

The LMI 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 crane operating procedures.
The responsibility for the safe crane 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 indicator and crane.

Proper functioning depends upon proper daily inspection and observance of the operating instructions
set forth in this manual. Refer to Section 6. Pre-Operation Inspection and Calibration Verification of
this handbook.

The LMI can only work correctly, if all adjustments have been properly set. For correct
adjustment, the operator has to answer thoroughly and correctly all questions asked during
the setup procedure in accordance with the real rigging state of the crane. To prevent
material damage and serious or even fatal accidents, the correct adjustment of the LMI has
to be ensured before starting the crane operation.

Always refer to operational instructions and load charts provided by the crane manufacturer
for specific crane operation and load limits.

1
LOAD MOMENT: generally the product of a force and its moment arm; specifically, the product of the load and the load-radius. Used in the determination of
the lifting capacity of a crane

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2 Operator’s Manual DS 160

3 SYSTEM DESCRIPTION

The PAT Load Moment Indicator DS 160 consists of a central microprocessor unit, operating console,
length/angle sensor, pressure transducers, and anti-two block switches.

The system operates on the principle of reference/real comparison. The real value, resulting from the
load measurement is compared with the reference data, stored in the central processor memory and
evaluated in the microprocessor. When limits are reached, an overload warning signal is generated at
the operator’s console. At the same time, the crane functions, such as hoist up, boom down and
telescoping out will be stopped.

The fixed data regarding the crane, such as capacity charts, boom weights, centers of gravity and
dimensions are stored in memory chips in the central processor unit. This data is the reference
information used to calculate the operating conditions.

The length/angle sensors inside the cable reel, which is mounted on the boom, measure the boom
length and angle. The boom length is measured by the cable reel cable that also serves as an
electrical conductor for the anti two-block switches.

The crane load is measured by pressure transducers attached to the piston and rod sides of the hoist
cylinders.

1. A2B Switch(-es)
2. Pressure Transducers
3. Cable Reel
4. Console
5. Central Unit (in cab or
outside)
e

d
f g

0 1 2 3 4

STOP TARE Fig. 1: Components of the LMI

5 6 7 8 9 System PAT DS 160
LIM OK

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 System Description 3

3.1 SYSTEM FUNCTION

START
Upon switching on crane ignition switch, the system starts with
an automatic test of the LMI system, of lamps and audible alarm.
During the test, the LC Display shows the crane model and serial
number.
SELF TEST
The last selected operating mode will be displayed and must
only be confirmed OK if that configuration setup equals the
crane’s actual configuration. Otherwise it must be deleted to
enter a new configuration. (⇒ chapter 4)

OK or Select OK
operating The operating configuration is determined by selecting from a list
configuration of possible operating configurations.
(⇒ chapter 4)

new
The configuration setup entered will be displayed and the
reeving (parts-of-line) must be entered. (⇒ chapter 4)
Select new
operating configuration
Upon acknowledgment of the inputs the system is ready for
operation.

OK or select
operating
configuration

OK

OPERATIONAL

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4 Operator’s Manual DS 160

3.2 OPERATING CONSOLE

The console has 3 functions:

• inputs by the crane operator (operating configuration, reeving, and calibration)

• input of geometry limit values and signalization of exceeded limit values
• display of important data and information

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

3.2.1 LC Display

The LC display (LCD) used in the PAT DS 160 operator’s console is a wide temperature-range
alphanumeric display with transflective characteristics that give it a high visibility in sunlight and during
backlit night operation. Due to the nature of any LCD, it works on the principle of polarization of light. It
should be noted that dual polarizations that are at a certain angle to each other can reduce the
amount of light up to completely eliminating it if that angle becomes perpendicular. This can have
significance if the operator is wearing polarized sunglasses that happen to be perpendicularly
polarized in relation to the LCD’s polarization. In this rare case, the operator has to work without
sunglasses or find different sunglasses that do not have this characteristic, in order to avoid having the
visibility of the display impaired.

The LCD contains an automatic temperature compensation that will adjust the LCD’s contrast
according to the surrounding temperature.

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 System Description 5

3.2.2 Control Identification

This unit contains a display and different controls that are described as follows:

1. LCD Area
2. Load Moment Prewarning Light
3. Load Moment Limit Light
4. Button “BY-PASS LMI Lock-out
1 function”
5. Button “Tare”
6. Button “info”
7. Button "SCROLL UP"
2 3 4 0
5 1
6 2
7 3
8 4
8. Button “SELECT OPERATION
MODE”
STOP TARE
9. Alarm Light “Anti-Two-Block”
5 6 7 8 9
10. Button "BY-PASS Anti-Two-Block"
LIM OK
11. Button “Alarm Stop”
12. Button and Control Light “LIMITS”
9 10 11 12 13 14 15
13. Button “REEVING (Parts-Of-Line)”
14. Button "SCROLL DOWN"
Fig 2: Operator’s Console 15. Button "OK"

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6 Operator’s Manual DS 160

1 LC-Display

1
2 9

3 8

4 7

5 6

The LCD visualizes texts and numerical values:

1. Load Moment Bargraph 6. Reeving (Parts-Of-Line)

2. Actual Load 7. Tip Height
3. Capacity (Max. Load) 8. Boom Length
4. Load Radius 9. Boom Angle
5. Operating Mode

Load Moment Pre-warning Light

The yellow LOAD MOMENT PRE-WARNING LIGHT (2) will light up when the
load on the crane reaches the defined pre-warning area, thus indicating that an
overload condition is approaching.
This means for the operator to continue his crane operation with extreme caution.

Load Moment Limit Light

The red LOAD MOMENT LIMIT LIGHT (3) warns the operator that a rated load
STOP condition has been reached. It lights up when the load on the crane reaches the
crane load capacity. The audible alarm also sounds when this condition has been
reached.
The following crane movements will be stopped concurrently:
− Hoist up
− Boom down
− Telescope Out

Crane lockouts are dependent on crane models, if lockouts do not function as

described refer to crane manufactures documentation.

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 System Description 7

Button "By-pass LMI"

While pushing this button, the control lever lockout function of the LMI is
deactivated.

Since buttons (4) and (10) deactivate the kick-out function of the LMI system / the anti two-
block system, the following instructions must be obeyed:

• The by-pass function shall be used with discretion, as unwarranted use of it to override
the control lever lockout system can result in harm to the crane and danger to property
and persons.

• Never use the by-pass function to either overload or operate the crane in a non-
permissible range.

Button “Tare”
The button “TARE” is used to indicate the “Net load” on the LCD. Net load is the
present load, less lifting tackle and hook block. The Tare Button has to be activated
TARE before lifting.

After pushing the “Tare Button” the load display is set to zero (taring) and the
control light lights up. After lifting a load the display shows the net load (pay load).
The net load display will change to the actual load display when the boom radius is
changed (either by angle or length).

Button “info”
Use this button to access screens that give additional information.

Button "SCROLL UP"

Use this button to increase values or to scroll up.

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8 Operator’s Manual DS 160

Button "SELECT OPERATION MODE "

Use this button to start the function "set operating mode".
For the proceeding please refer to ⇒ chapter 4.1.

The correct setting is of utmost importance for the proper function of the system and the
crane. Therefore only operators who are thoroughly familiar with use and operation of the
system shall set this button.

Alarm Light “Anti-2-Block”

The red “Anti Two-Block Alarm Light” lights up when the anti-two-block limit
switch contacts open, indicating that a two-blocking condition is
approaching. At the same time the audible alarm will sound.
The following crane fructions will be disabled subsequently: hoist up,
telescope out, and boom down (refer to DS160 sevice manual or the crane
owner’s manual for a complete description of the anti-two-block system).

Button "By-pass A2B"

While pushing this button, the lockout function of the anti-two-block switch is
deactivated.

Since buttons (4) and (10) deactivate the kick-out function of the LMI system / the anti two-
block system, the following instructions must be obeyed:

• The by-pass function shall be used with discretion, as unwarranted use of it to override
the control lever lockout system can result in harm to the crane and danger to property
and persons.

• Never use the by-pass function to either overload or operate the crane in a non-
permissible range.

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 System Description 9

Button and Control Light “Alarm Stop”

This ALARM STOP BUTTON allows for the audible alarm to be silenced for
approximately 15 seconds by pressing this button.

Button "LIMITS"
Button to start the function "program limit values".
LIM For the proceeding please refer to ⇒ chapter 5.1.

Button "REEVING (Parts-Of-Line)”

Button to start the function "select parts of line"
Please refer to ⇒ chapter 4.2.

Button "SCROLL DOWN"

Use this button to decrease values or to scroll down.

15 Button "OK"
Use this button to confirm settings.
OK

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10 Operator’s Manual DS 160

4 SYSTEM OPERATION

The LMI setup procedure allows the operator to input the crane configuration. The operator must
complete the configuration setup procedure for the Load Moment Indicator system by confirming
(pressing OK) to set the system into operation or changing it to enter a new configuration. The
previous configuration setup will be displayed and must match the current crane operating
configuration.

4.1 LMI SETUP PROCEDURE

If the system is turned off, all adjustments remain stored. When turning the system on again these
adjustments can be acknowledged by merely pressing the OK button (provided that the crane
configuration has not been modified!).

During the programming procedure the Load Moment Prewarning Light (2) and the Load Moment Limit
Light (3) will light up and the crane functions will be interrupted.

Note: If a configuration is selected which is not available, the display will indicate error code E04. In
this case, the procedure has to be repeated with valid values!

The correct setting is of utmost importance for the proper functioning of the system and the
crane. Therefore, only operators who are thoroughly familiar with the crane and the
operation of the system should execute the setting of the system according to the operating
configuration of the crane.

The LMI programming procedure consists of the following steps:

• set the operating mode (crane configuration)
• select the outrigger configuration
• verify crane is level
• select the hoist in use (for machines with dual hoist option)
• select the reeving (parts-of-line)

For easy operation, the computer guides the operator through the procedure step by step. (interactive
operation)

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 System Operation 11

4.1.1 Operating Mode Selection

...starts:
• manually after each modification of the crane configuration by
pressing " SELECT OPERATION MODE " (8) button.

A screen similar to the following one will appear:

OK
If this operating mode corresponds with the current machine configuration, press .

Otherwise, use the scroll buttons and to scroll between the possible operating modes
(configurations) of your machine.

When you have found the operating mode that corresponds with the current machine configuration,
OK
press . This will automatically bring you to the …

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12 Operator’s Manual DS 160

4.1.2 Outrigger Selection Screen

A screen similar to the following one will appear for the outrigger selection.

OK
If this outrigger selection corresponds with the current machine configuration, press .

Otherwise, use the scroll buttons and to scroll between the possible outrigger selections for
your machine.

When you have found the outrigger selection that corresponds with the current machine configuration,
OK
press . This will automatically bring you to the …

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 System Operation 13

4.1.3 Crane Level Screen

A screen similar to the following one will appear verifying if the crane is level.

OK
If the crane is level, press . If the crane is not level to manufacturers specification, refer to
manufacturer manual, then level crane to specifications.

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14 Operator’s Manual DS 160

4.1.4 Hoist Selection Screen

A screen similar to the following one will appear if you have a second hoist option

Use the scroll buttons and to toggle between auxiliary and main hoist.

When you have selected the hoist that corresponds with the current machine configuration, press
OK
. This will automatically bring you to the …

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 System Operation 15

4.1.5 Reeving (Parts-of-Line) Selection Screen

...starts:
• manually by pressing "REEVING " (13) button, if the machine is not
equipped with a dual hoist option.

• automatically after selecting the hoist, if the machine is equipped with

a dual hoist option.

A screen similar to the following one will appear:

Use the scroll buttons and to increase or decrease the number of parts of line until it
matches the current reeving of your machine.

OK
When you have selected the correct reeving, press .

This concludes the setting of the reeving and/or operating mode. If you have selected a valid operating
mode, the system will bring you back to the operating screen. If you have selected an invalid operating
mode, the system will show an E-04.

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16 Operator’s Manual DS 160

4.2 LIMIT SETTINGS

The operator has the option to activate a maximum and minimum geometric limit for boom angle,
radius, and boom tip height. When a limit is activated, the working screen will display an ‘A’ in front of
the angle indication, ‘R’ in front of the radius indication, ‘H’ in front of the tip height indication. When
the limit is exceeded the system will alert the operator by sounding an audible alarm, lighting the horn
silence button, flashing the limit button, and flashing the letter ‘A’, ‘R’, or ‘H’ on the display. There is no
cutout associated with the limit function. Use the following procedure to set or delete a limit.

Press the limit button ‘LIM’, the following screen will come up:

ANGLE
RADIUS
TIP HEIGHT
EXIT

Use the ‘UP’ and ‘DOWN” arrow buttons to select the limit to set or delete, the selection should now be
flashing. Then press ‘OK’.

 angle limit setting: The following screen will be displayed

SET MAX. ANGLE

SET MIN. ANGLE
DELETE LIMITS
EXIT

Use the ‘UP’ and ‘DOWN” arrow buttons to select the maximum/minimum angle, delete angle limits, or
exit limit function. Then press ‘OK’.

Only one of the functions MIN/MAX can be completed at a time.

MOVE BOOM TO MIN Limit
MIN. ANGLE Boom to the minimum angle and press ‘OK’.
ANGLE XX.X DEG
EXIT “PUSH OK”’ MAX. Limit
Boom to the minimum angle and press ‘OK’.

Use the ‘UP’ and ‘DOWN” arrow buttons to select another angle limit or exit the angle limit function.

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 System Operation 17

 radius limit setting: The following screen will be displayed

SET MAX. RADIUS

SET MIN. RADIUS
DELETE LIMITS
EXIT

Use the ‘UP’ and ‘DOWN” arrow buttons to select the maximum/minimum radius, delete radius limits,
or exit limit function. Then press ‘OK’.

Only one of the functions MIN/MAX can be completed at a time.

MOVE BOOM TO MIN Limit
MIN. RADIUS Boom to the minimum radius and press ‘OK’.
RADIUS XX.X FT
EXIT “PUSH OK”’ MAX. Limit
Boom to the minimum radius and press ‘OK’.

Use the ‘UP’ and ‘DOWN” arrow buttons to select another radius limit or exit the radius limit function.

 Tip height limit setting: The following screen will be displayed

SET MAX. TIP HEIGHT

DELETE LIMITS
EXIT

Use the ‘UP’ and ‘DOWN” arrow buttons to select the maximum tip height, delete tip height limits, or
exit limit function. Then press ‘OK’.

MOVE BOOM TO MAX. Limit

MAX. TIP HEIGHT Boom to the maximum tip height and press ‘OK’.
TIP HEIGHT XX.X FT
EXIT “PUSH OK”’

Use the ‘UP’ and ‘DOWN” arrow buttons to select another tip height limit or exit the tip height limit
function.

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18 Operator’s Manual DS 160

5 RADIO ANTI TWO-BLOCK SWITCH (OPTIONAL)

5.1 RADIO ANTI-TWO BLOCK TRANSMITTER AND RECEIVER DESCRIPTION

The anti-two block system alerts to an impending two-block condition. This alert can come in the form
of an audible alarm and visual LED on the console face or with the optional function lockout if the
crane is so equipped.

The PAT Radio Anti Two Block uses radio communication electronics that transmits an OK signal ~
every two seconds on up to three separate channels. This is to ensure accurate and consistent
reception of data and to reduce the possibility of unnoticed failure. The separate channels greatly
reduce the probability of failure due to external interferences. Unique, serialized transmitter identifiers
are used to ensure proper operation even though other cranes are in the area.

The transmitter is modular by design, containing three separate parts, the transmitter, the switch and
the battery housing. It was designed so these individual components can be replaced easily and
separately.

The receiver is mounted into a receiver box, which is water-tight when submerged in up to three feet of
water. The receiver box provides the following indications: Power (status), LINK, Low Battery, A2B.
If battery saving measures are used, the battery life will be greater than one year or up to two years,
even with transmitting every two seconds. Several power saving methods are incorporated into the
design of the electronics as well as the other hardware.

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 Radio Anti Two-Block Switch (optional) 19

5.1.1 RECEIVER

Radio Anti-Two-Block Receiver LEDs:

POWER (Green) Shows that there is power to the system.

Indicates the status of the communication link between the main hoist
LINK (Green) A2B transmitter and the receiver. Failure of the communication link will
turn off the Green LED and turn off the output to the lockout relay.

LOW BATTERY (Yellow) Indicates that the battery of the main transmitter needs to be replaced.

Indicates an impending two-block condition of the main hoist. The Red

LED will light when the load-handling device has lifted the A2B weight.
A2B ALARM (Red)
This LED will light simultaneously with the engaging of the lock out
solenoids (if installed).

ID button
The yellow ID button, located in the lower right-hand corner of the receiver board, is used to set the
transmitter ID of the transmitter into the receiver.

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20 Operator’s Manual DS 160

5.1.2 Transmitter / Switch

The transmitter and battery housing are made of a special plastic that resists impact and will not
become brittle even in low temperatures.

Transmitter LED:
The transmitter has an LED on the bottom for diagnostics.
The LED should be on when in a two-block condition or
when the weight is lifted. The LED will flash rapidly during a
2-block condition and will stop flashing after the switch is in
a two-block condition for more than 15 seconds. The LED
will flash randomly approximately every 2 seconds when
the switch is transmitting. When in sleep mode, the LED
will not flash.

Storage of the A2B transmitter for Travel:

The weight should remove from the switch when traveling
to extend battery life. The system is in permanent lockout
and the system will not function until the chain is unhooked.
To use the feature, attach any part of the chain into the
hook. When it is desired to use the switch again, simply
unhook the chain to allow the switch to close.

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 Radio Anti Two-Block Switch (optional) 21

5.2 SETUP

ID SET
BUTTON

5.2.1 Clear Existing Setup/Switches

Press and hold the yellow “ID” button for 15 seconds, the ID LED will begin to blink and then go off
when cleared. Note: It is only necessary to complete this operation when changing from a duel switch
setup to a single switch. When setup is complete, the new transmitter switch will over write the old ID
code.

5.2.2 First ID Setup

To configure the system, install batteries into the transmitter to be used. Turn on the crane power.
Open the receiver enclosure and slide out the receiver board. Press and hold the yellow ID button on
the OEM module for 7 seconds until the ID 1 LED blinks. Release the yellow ID button. The receiver
will search for a transmitter for the next 30 seconds. Pull on the cable of the transmitter and then
release it. The yellow ID 1 LED should now be on solid. The transmitter and receiver are now set up
and will work only with each other.

5.2.3 Second ID Setup

To program second radio a2b switch: ground wire 2 from the receiver inside the central unit (refer to
system wiring diagram inside the central unit). Install batteries into the transmitter to be used. Turn on
the crane power. Open the receiver enclosure and slide out the receiver board. Press and hold the
yellow ID button on the OEM module for 7 seconds until the ID 2 LED blinks. Release the yellow ID
button. The receiver will search for a transmitter for the next 30 seconds. Pull on the cable of the
transmitter and then release it. The yellow ID 1 LED should now be on solid. The transmitter and
receiver are now set up and will work only with each other.

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22 Operator’s Manual DS 160

5.3 OPERATION
The function of the system must be tested daily before each use of the crane hoist. Refer to Pre-
Operation Inspection and Calibration Verification.

During the normal operation of the system the LINK and POWER LED’s should be on.

POWER LED
The POWER LED shows that the OEM module is getting power from the crane. The receiver is on any
time the crane is operating and supplying power to the system.

LINK LED
The LINK LED indicates the status of communication of the transmitter(s). During normal operation of
the system, the LED will be on. The LED is off when there is an interruption in the transmission. The
system should not be operated if the LINK LED is not lit.

LOW BATTERY LED

The low battery indicator will light indicating that you have a limited time to operate before the system
goes dead. When the battery level is to the point that it is too low to operate, the system will stop
functioning. Use any off-the-shelf alkaline C-cells; Duracell, Eveready, etc.

A2B ALARM LED

Indicates an impending two-block condition of the main hoist. The Red LED will light when the load-
handling device has lifted the A2B weight. This LED will light simultaneously with the engaging of the
lock out solenoids (if installed).

Test the electronics

Cycle the power to the system, each LED on the receiver will light for 2 seconds when the system is
powered. All of the indicator lights must come on or the system is not functioning properly. If any light
does not function, do not use the system until it has been repaired.

Following the successful testing, the LINK LED should come on. If the LED’s do not come on, there is
an error in the transmission. Do not use the system until it has been repaired or replaced, refer to the
Troubleshooting manual.

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 Pre-operation Inspection and Calibration Verification 23

6 PRE-OPERATION INSPECTION AND CALIBRATION VERIFICATION

6.1 PRE-OPERATION INSPECTION AND CALIBRATION VERIFICATION

Before operating the crane, the following electrical connections must be checked to ensure that the
system is properly connected for the crane configuration.

If the crane works only with the boom and without boom extension or jib, check bypass plug(s) and the
weight on the anti two-block switch(s) is properly installed on the hoist load line(s). With even parts of
hoisting line, the weight shall be attached to the dead-end line. With odd parts of hoisting line, the
weight shall be attached to the line of lowest speed.

If the crane works with boom extension or jib, the weight for the anti two-block switch shall be moved
to the active/lifting hoist rope. In this case, the inactive anti two-block switch has to be locked with the
red Anti Two-Block Retainer, which is fixed with a red lanyard at the anti two-block switch (described
on the next pages).

Failure to re-position the anti two-block switch weight will prevent the over hoist system
from functioning properly.

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

1. Check the electrical wiring connecting the various parts of the system for physical damage.
2. Check the anti two-block switches and weights for free movement.
3. Check the spring-loaded cable reel to be sure it is free to rotate, has tension and the cable is reeled
properly.

The following tests shall be performed with care to prevent damage to the machine or injury
to personnel. Proper functioning of the system requires successful completion of these
tests before operating the machine.

If the operator cannot see the load-handling device approaching the boom nose, he shall have an
assistant (signal person) watch the load-handling device. The operator shall be prepared to stop the
machine immediately should the LMI system not function properly as indicated by lighting the red
warning light (4), sounding the audible alarm (12) and locking the crane movements, hoist up,
telescope out and boom down.
4. Check the anti two-block alarm light (4) and the audible alarm (12) by performing one of the
following tests:
a. By manually lifting the weight attached to the anti two-block switches. When the weight is lifted,
the audible alarm (12) should sound, the anti two-block alarm light (4) should light.
b. Slowly raise the main boom load-handling device to create a potential two-block condition. When
the load-handling device lifts the weight, the audible alarm (12) should sound, the anti two- block

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24 Operator’s Manual DS 160

alarm light (4) should light and the motion of the load-handling device should be stopped. Lower
the load-handling device slightly to eliminate this condition.
c. Slowly lower the boom to create a potential two-block condition. When the load-handling device
lifts the weight, the audible alarm (17) should sound, the anti two-block alarm light (24) should
light and the boom lowering function should be stopped. Lower the load-handling device slightly
to eliminate this condition.

If the light and audible alarm do 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.

5. If the crane is equipped with a boom extension, repeat the test procedure for the boom extension
anti two-block switch.

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

7. Check that the display of the operating radius of the crane agrees with the actual radius.

8. Check the load display by lifting a load of known weight.

6.2 ANTI TWO-BLOCK RETAINER INSTALLATION

Installation of Anti Two-Block Retainer in Locking Position Procedure (see Fig. 1 and 2):

1. Pull the cable out of the switch and bend back parallel to the boom and hold (1).
2. Slide the retainer from left side with its slot over the cable between the crimped stop and the switch
(2). Push it firmly straight onto the cable guide of the Anti Two-Block switch (3).

Fig. 1: Setting of Anti Two-Block Retainer in Locking Fig. 2: Retainer in Locking Position
Position

3. Straighten the cable completely into the slot and release the cable (4).
4. Turn the flag of the retainer for best visibility for the operator (5).

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 Pre-operation Inspection and Calibration Verification 25

Removal and Storage of the Anti Two-Block Retainer Procedure (see Fig. 3 and 4):

1. Pull the cable out of the switch (1) and bend back parallel to the boom and hold (2).
2. Move the retainer down (3) and then left (4) to remove it from the Anti Two-Block switch. Release
the cable.
3. For storage slide the retainer from right side (5) over the Anti Two-Block switch until the clips (A)
lock into the holes (B).

Fig. 3: Removal of the Anti Two-Block Retainer Fig. 4: Retainer in Storage Position

7 OPERATION

Upon correct inspection the LMI is operational. The operator shall be thoroughly familiar with all
controls of the LMI before operating the crane. The proper function of the system shall be checked by
lifting a load of known weight and comparing 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 reflects 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
crane’s LMI calibration.

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26 Operator’s Manual DS 160

8 SERVICE AND MAINTENANCE

Daily 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. If the insulation is worn on the electrical wiring or cable guides are damaged, these parts shall be
replaced.
3. Check the anti two-block limit switches for freedom of movement.

Other than correcting the problems identified in the Malfunctions Table and replacing faulty
mechanical parts and cables, no other repairs shall be performed by non-expert personnel.

When the LMI system is turned on, it will go through a self-test. During this time, the console must
display the following screen:

Make sure the display is working and all the lights come on during this time. Listen to the buzzer
sound. If any of the components above fails, please contact you’re nearest service representative
before operating the system!

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 Service and Maintenance 27

9 TROUBLESHOOTING
9.1 GENERAL

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

The error codes listed in the Malfunction Table will identify various faults that 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.

Faults within the electronic microprocessor shall be repaired by factory trained service personnel.
When these faults occur, the competent service organization shall be contacted.

9.2 OPERATING ERRORS

Malfunctions in the system, which are caused by, range exceeding or operating errors by the crane
operator himself are indicated on the display together with an explanation. These error codes are E01,
E02, E03, E04, (E05) and they can normally be eliminated by the crane operator himself.
Error Cause Elimination
Code
Fallen below the minimum radius or above Refer to Load Chart. Boom down to a radius or
E01 the angle given in the load capacity chart angle given in the load capacity chart.
due to luffing up the boom too far.
The maximum radius or minimum angle Refer to Load Chart. Boom up to a radius or
E02 given in the load capacity chart was angle given in the load capacity chart.
exceeded due to luffing down the boom
too far.
Boom position is out of the permissible Move boom back to the permissible working
E03 working area area.
(over front). See lifting diagram in the load capacity charts.
Operating mode in the console incorrectly Correctly set operating mode to the code
E04 set. assigned to the operating mode of the crane.
Operating mode is not permissible with Be sure crane is set up according to proper
the actual crane configuration, boom operating configurations.
position or area definition.
Prohibited length range Refer to Load Chart. Extend/retract boom to the
E05 correct length

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28 Operator’s Manual DS 160

9.3 ANALOG INPUT CHANNEL ERRORS

These errors occur if the input signal of an analog input channel falls below (E1x) the minimum
(500mV) or exceeds (E2x) the maximum (4500mV).

The analog channels are used as follows:

Sensor Pins Terminal X1 Lower Limit Upper Limit
Piston Pressure Transducer 32 E12 E22
Rod Pressure Transducer 33 E13 E23
Length Sensor 34 E11 E21
Angle Sensor 35 E15 E25

Troubleshooting a Sensor Problem using the Display

For a sensor error or problem with a sensor, look at the output voltage of the pressure transducer,
length, and angle sensors on the display screen and compare the reading with the following:
Pressure transducers (piston and rod), 500mV @ 0psi
Length sensor, 500mV @ retracted boom length
Angle sensor, 4500mV at 0°, 2500mV at 45°, or 500mV at 90°

Note: The sensor output voltages displayed will not be the same as measured in the central unit.
Refer to DS160 troubleshooting manual, 9828100587, for voltage and current measurements at the
terminal strip inside the central unit.

To access the analog output screen use the following procedure.

1. From the operating screen, press and hold the information button for 5 seconds.
2. The screen show the following selections:
• sensor outputs
• exit
3. Use the ‘UP’ and ‘DOWN’ arrows to high light (text flashes) sensor outputs, and then
press ‘OK’ to display a similar screen as shown below:

4. Press the ‘OK’ button to exit back to operating screen.

All Analog input voltages (shown in millivolts), received from the sensors will be displayed here as
described below. The minimum values are show in the screen pictured.

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