Crane LMI Computer Replacement
Crane LMI Computer Replacement
Experts in Full-Replacement Crane Computer Systems*
Experts in Full-Replacement Crane Computer Systems*
LMI Computer Replacement Kits
LMI Computer Replacement Kits
Simple to Use - Rugged Reliability - Cost Effective
Simple to Use - Rugged Reliability - Cost Effective
Mobile Crane LMI Replacement
Often a Grove, Terex, LinkBelt or other mobile / RT crane that has an old LMI such as a PAT DS350 or a Greer Microguard that is failing. Many times the computer is in override because its impossible to operate the crane due to constant errors and false lockouts. The crane is usually in good condition and a new computer can provide years of trouble free use.
Boom Truck LMI Replacement
The majority of these installations are on National or Manitex boom trucks. Some with older PAT DS50 or DS350 systems in them. These are very easy and fast projects due to the simple nature of the boom truck.
Lattice Crane LMI Replacement
Often times this crane computer / LMI replacement is for an older Link Belt LS or HS crane, especially with older PAT DS350 vertical consoles. A new system for these is very simple with angle sensor and linerider on the base section and A2B and wind on the boom tip. Both wired and wireless options are available.
Offshore & Marine Crane Computers
Offshore and marine crane systems usually involve an ATEX or CSA designation for explosion proof work. There are several options for systems that satisfy this need and have potted electronics that are completely encased in resin to protect them from the harsh marine environment. We usually provide a few of these marine tanker or offshore drilling rig systems a year.
Carry Deck Crane Computer
Because of their smaller size the carry deck crane systems are unique in needing a more compact solution. Usually a proportional cable reel is used in conjunction with a load pin at the boom tip. We have completed a number of Broderson and Shuttlelift carry deck crane systems.
Crane LMI Computer Replacement Projects
Crane LMI Computer Replacement Projects
We have provided LMI computer replacement options and/or parts for hundreds of customers over the years. Here are a few of the most recent complete LMI computer replacement system jobs. Most of these jobs involve the replacement of an aging LMI system that has become unreliable, however the crane itself is in great shape and continues to be used. Some of our customers come to us without any LMI on their crane and we work with them to get a complete new system for them.
Grove TM1300
Grove TM1300
- Full replacement of old PAT DS350 LMI
- Load on both main line and auxiliary
- Anti two block on both main and whipline
- Full load chart programming
- Retain full lockout capabilities
Grove Crane Computer Replacement Overview
This customer is a large builder in the northwest focusing on large commercial facilities as well as custom build homes. Their crane was in overall good condition as it had been well maintained and had conservative use in their construction projects. The crane's old PAT DS350 LMI system however had deteriorated significantly and was giving constant E95 error codes (undetermined error). We worked with this customer to find an LMI replacement system that was in their budget with functionality on both main and auxiliary line and was rugged enough to withstand the northern winters and provide years of trouble free use.
Link Belt HC248H
Link Belt HC248H
- Full replacement of old PAT DS350
- New graphical display
- Load on main line
- Anti Two Block on main line
- Wind speed sensor at boom tip
- Full load chart programming
- Full lockout capabilities
Link Belt Crane Computer Replacement Overview
This customer is a large concrete construction provider in the mid Atlantic & east coast region. They approached BTS about a replacement for their PAT DS350 Vertical RCI console. Unfortunately the lead time to get a replacement from Europe was about 4 months and cost over $20,000. The customer was not able to wait that long, nor did it make any sense to spend that amount of money to replace one component of such an aging system. In the end we were able to provide a complete new RCI system to them for less than the price it would have cost for the replacement display.
Grove RT528C
Grove RT528C
- Full replacement of old PAT DS350 GW
- Load on main line
- Anti Two Block on main line
- Full load chart programming
- Full lockout capabilities
Grove Crane LMI Replacement Overview
This customer operates an excavation and construction company in the midwest providing highway and bridge construction services as well as support to the oil and gas pipeline industry. This Grove crane was built in the mid nineties however was in great shape and well cared for. The computer system however was an old PAT DS350 GW system that had outlived its useful life. This project was a simple swap out of the old system for the new. The customer got full load carts and will have years of trouble free use of this crane computer system.
National Boom Truck Crane
National Boom Truck Crane
- Complete new crane computer
- Wired dynamometer secured at top of main section
- Reuse current A2B switch
- New cable reel with integrated angle sensor
- Full load chart programming
- Full lockout capabilities
National Boom Truck Crane Computer Replacement Overview
We usually complete several of these boom truck systems a month for customers, many of whom are in the tree service industry. The National boom truck is particularly simple as it requires only a load sensor and length / angle sensor. The original anti two block system can be reused if it is in good condition, thereby saving that expense.
Shuttlelift CD5540F
Shuttlelift CD5540F
- New display with full load chart capabilities
- Load pin on main line as sensor
- Anti Two Block on main line
- Mini cable reel for boom extention
- Full lockout capabilities
Shuttlelift Crane Computer Replacement Overview
This customer provides commercial and residential contracting services along the great lakes. They had a Shuttlelift utilized for smaller projects and for work in their yard. They wanted a compact option for the smaller crane. We were able to work with them on a smaller system using a mini cable reel and load pin configuration. The small unobtrusive system will give the years of safe use of this smaller crane.
Sumitomo SC500
Sumitomo SC500
- Complete new crane comptuer
- Wired linerider load on main line
- Wireless anti two block at boom tip
- Wireless wind speed at boom tip
- Full load chart programming
- Full lockout capabilities
Sumitomo Lattice Crawler LMI Replacement Overview
This customer provides steel erection, precast concrete structures, and concrete pours in the south. They needed a complete new installation for this lattice crawler crane. This was a simple installation with display and linerider for load as well as wireless anti two block and windspeed at the boom tip. This system will provide the owner years of simple and safe crane computer operation.
Introducing the i4500 Series: The Next Generation in Crane Safety Technology
In the world of lifting and construction, precision, reliability, and safety define success. That’s why we’re proud to introduce the i4500 Series All-in-One Rated Capacity Indicator (RCI) — the latest advancement in crane safety technology designed to set a new benchmark for performance and protection on every job site. Developed after extensive market research and direct collaboration with crane operators, service technicians, and fleet owners, the i4500 Series represents the result of listening to the people who rely on their equipment every day. Every feature was built with one goal in mind: to make crane operation smarter, safer, and more efficient than ever before.
Smarter Integration for Modern Cranes
The i4500 Series isn’t just an upgrade — it’s a new generation of rated capacity indicator designed to integrate seamlessly with virtually all types of cranes. Its flexible architecture allows it to adapt to everything from small mobile cranes to large, complex lifting systems, making it one of the most versatile safety solutions on the market. Beyond standard load-moment indication, the i4500 goes further. It’s engineered to monitor advanced operational parameters such as boom sequencing, outrigger positioning, range limiting, and real-time wind speed. By consolidating this data into a single intuitive system, operators can make faster, more confident decisions without switching between multiple displays or devices.
Centralized Safety and Operational Insight
At the heart of the i4500 Series is its ability to centralize all critical crane data into one easy-to-read interface. The system integrates safety information, engine performance data, and even live camera feeds, displaying everything clearly on a vibrant, full-color display.
This single-screen visibility allows operators to stay fully aware of their crane’s status and surroundings — improving situational awareness, reducing the risk of error, and helping prevent costly downtime. With the i4500, everything you need to know about your crane’s performance is right at your fingertips.
Effortless Updates and Field Service
Another key innovation of the i4500 system is its USB-based data management. Operators and technicians can easily update load charts, calibration files, or system software directly from a USB stick — eliminating the need for specialized tools or complex service procedures. This approach ensures the system stays current and adaptable as lifting requirements change or as new configurations are added to the fleet. This thoughtful design not only reduces service time but also helps minimize operator training and simplifies compliance with evolving safety standards. In short, the i4500 doesn’t just make cranes smarter — it makes maintaining them easier.
The Future of Crane Safety, Delivered Today
Every element of the i4500 Series has been developed to elevate crane safety and efficiency to the next level. From its advanced monitoring capabilities and all-in-one integration to its intuitive, full-color user interface, the i4500 empowers operators to work with greater confidence and control. When you combine innovation, practicality, and ease of use, the result is a system that doesn’t just meet the demands of modern lifting — it defines them. The i4500 Series: Built for today’s cranes, ready for tomorrow’s challenges.
In the world of lifting and construction, precision, reliability, and safety define success. That’s why we’re proud to introduce the i4500 Series All-in-One Rated Capacity Indicator (RCI) — the latest advancement in crane safety technology designed to set a new benchmark for performance and protection on every job site. Developed after extensive market research and direct collaboration with crane operators, service technicians, and fleet owners, the i4500 Series represents the result of listening to the people who rely on their equipment every day. Every feature was built with one goal in mind: to make crane operation smarter, safer, and more efficient than ever before.
Smarter Integration for Modern Cranes
The i4500 Series isn’t just an upgrade — it’s a new generation of rated capacity indicator designed to integrate seamlessly with virtually all types of cranes. Its flexible architecture allows it to adapt to everything from small mobile cranes to large, complex lifting systems, making it one of the most versatile safety solutions on the market. Beyond standard load-moment indication, the i4500 goes further. It’s engineered to monitor advanced operational parameters such as boom sequencing, outrigger positioning, range limiting, and real-time wind speed. By consolidating this data into a single intuitive system, operators can make faster, more confident decisions without switching between multiple displays or devices.
Centralized Safety and Operational Insight
At the heart of the i4500 Series is its ability to centralize all critical crane data into one easy-to-read interface. The system integrates safety information, engine performance data, and even live camera feeds, displaying everything clearly on a vibrant, full-color display.
This single-screen visibility allows operators to stay fully aware of their crane’s status and surroundings — improving situational awareness, reducing the risk of error, and helping prevent costly downtime. With the i4500, everything you need to know about your crane’s performance is right at your fingertips.
Effortless Updates and Field Service
Another key innovation of the i4500 system is its USB-based data management. Operators and technicians can easily update load charts, calibration files, or system software directly from a USB stick — eliminating the need for specialized tools or complex service procedures. This approach ensures the system stays current and adaptable as lifting requirements change or as new configurations are added to the fleet. This thoughtful design not only reduces service time but also helps minimize operator training and simplifies compliance with evolving safety standards. In short, the i4500 doesn’t just make cranes smarter — it makes maintaining them easier.
The Future of Crane Safety, Delivered Today
Every element of the i4500 Series has been developed to elevate crane safety and efficiency to the next level. From its advanced monitoring capabilities and all-in-one integration to its intuitive, full-color user interface, the i4500 empowers operators to work with greater confidence and control. When you combine innovation, practicality, and ease of use, the result is a system that doesn’t just meet the demands of modern lifting — it defines them. The i4500 Series: Built for today’s cranes, ready for tomorrow’s challenges.
Who is this Computer Replacement Kit for?
Who is this Computer Replacement Kit for?
Crane Manufacturers
- Grove
- National
- Manitex
- Link Belt
- Broderson
- Libherr
- Terex
Old LMIs
- PAT DS 350
- PAT DS50
- Hirschmann DS160/Maestro
- Greer MG Series
- LSI LS Series
- None / No LMI
We are EXPERTS in the
LMI Crane Computer Industry
We are EXPERTS in the
LMI Crane Computer Industry
LMI Crane Computer Industry
As experts in the crane LMI computer industry, BTS has often been asked to publish advice in Crane & Rigging Hot Line magazine
As experts in the crane LMI computer industry, BTS has often been asked to publish advice in Crane & Rigging Hot Line magazine
Aftermarket Crane Safety Products
Aftermarket Crane Safety Products
BTS has always been on the forefront of advocating for crane safety through crane LMI or RCI computer systems. This is one of the earliest industry articles highlighting the need for aftermarket crane computer systems for those with aging or non existent systems.
Water & Electronics Dont Mix
Water & Electronics Dont Mix
Preventing unnecessary crane down time due to water intrusion is one of the main goals of the BTS service team. Undoubtedly water in the LMI cables or system boxes themselves has been the number one cause of failures or erratic crane computer behavior.
Wiring & Insulation Issues
Wiring & Insulation Issues
Addressing two key issues of insulation and wire gauge on live wires in the crane computer LMI system. Especially prone to neglect are wires and cables that run between the sensors and the main console / central unit computer. Over years of weather exposure there can be significant deterioration that results in incorrect sensor readings and unreliable error code messages
Crane LMI Computer Replacement Kit
Crane LMI Computer Replacement Kit
The crane LMI Computer replacement kit is a computerized crane monitoring system, designed as an operator aid. It comprises sensors fitted to the crane and a display located in the cabin of the crane. This version measures the boom cylinder pressure or the tension in the hoist rope, the boom angle and length, and it indicates safe or critical conditions, while performing an authorized lift of loads.
All the sensors are linked through a single CAN Bus (Controlled Area Network). The pressure sensors or a dynamometer provide electrical signals that are proportional to ther load lifted. An inclinometer provides a signal that is proportional to the boom angle and a reeling drum provides a signal that is proportional to the boom extension. The radius and the load are calculated from these signals with the dimensional crane data preprogrammed in the RaycoWylie i4300 system.
During operation the load lifted by the crane is calculated from the measured boom cylinder pressure and is automatically compared with corresponding data related to the maximum permissible crane loading. The actual load is expressed as a percentage of the permitted load (% SWL). If this percentage exceeds a preset value, alarms and safety functions are activated. The values of the hook load, the permissible load, the main boom angle and the radius are displayed in a digital form on a graphic liquid crystal display (LCD).
The required crane duty charts are stored in a non-volatile memory and can only be modified with the approval of the crane manufacturer. The calculated crane parameters and calibration data are stored in an additional non-volatile memory. The calibration of the system is performed only with the use of known loads, boom angles, and other pre-determined data.
All the sensors are linked through a single CAN Bus (Controlled Area Network). The pressure sensors or a dynamometer provide electrical signals that are proportional to ther load lifted. An inclinometer provides a signal that is proportional to the boom angle and a reeling drum provides a signal that is proportional to the boom extension. The radius and the load are calculated from these signals with the dimensional crane data preprogrammed in the RaycoWylie i4300 system.
During operation the load lifted by the crane is calculated from the measured boom cylinder pressure and is automatically compared with corresponding data related to the maximum permissible crane loading. The actual load is expressed as a percentage of the permitted load (% SWL). If this percentage exceeds a preset value, alarms and safety functions are activated. The values of the hook load, the permissible load, the main boom angle and the radius are displayed in a digital form on a graphic liquid crystal display (LCD).
The required crane duty charts are stored in a non-volatile memory and can only be modified with the approval of the crane manufacturer. The calculated crane parameters and calibration data are stored in an additional non-volatile memory. The calibration of the system is performed only with the use of known loads, boom angles, and other pre-determined data.
Load Moment Indicator General Information
Load Moment Indicator General Information
Understanding what an LMI is and the limitations of a crane computer system are critical to crane safety
Understanding what an LMI is and the limitations of a crane computer system are critical to crane safety
A Load Moment Indicator LMI system operates on the principle of reference/real comparison. The real value, resulting from the pressure measurement and geometric sensors, is compared with the reference data stored in the central processor memory and is evaluated in he microprocessor. An analog indication of % capacity is displayed via an operator’s console. When limits are reached, an overload warning signal is generated. At the same time, the crane movements that increase load moment such as hoist down, telescope out, and boom down will be locked out. The fixed data regarding the crane, such as dimensional data, capacity charts, boom weights, and centers of gravity are stored in memory chips in the central processor unit. This data is the reference information used to calculate the operating conditions. Boom length and boom angle are registered by the length/angle sensor, located inside the cable reel, mounted on the boom. The boom length is measured by the cable reel cable, which also serves as an electrical conductor for the anti-two- block switch. The crane load is measured by pressure transducers attached to the piston and rod side of the lift cylinder. Controls on the operator’s console allow the operator to select the operating mode (main boom, jib, etc.) as well as the parts of the line currently in use. The system will then limit operation to the capacities on the selected load chart, or the maximum permissible line pull in that configuration. After the engine is started and the PTO is engaged, the LMI powers up and conducts an automatic test of the complete system. After two successful system tests without errors, the system is ready for operation. In case of a system error, both the overload and anti-two-block lights on the central unit will illuminate. The interactive user guidance considerably simplifies the input of operating modes as well as the setting of geometry limit values
Limitations of a Load Moment Indicator (LMI)
Limitations of a Load Moment Indicator (LMI)
The LMI is an operational aid that warns a crane operator of approaching overload conditions and 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 the operators manual
