Faun cranes are typically fitted with safe load indicators (SLIs) and load moment indicators (LMIs) as their primary load monitoring systems. These systems continuously measure and display the crane’s actual load against its rated capacity, triggering warnings or cut-outs before an overload condition can occur. The sections below unpack how each component works, what regulations apply, and what your options are for upgrading an existing Faun crane setup.
What types of load monitoring systems are fitted to Faun cranes?
Faun cranes are fitted with safe load indicators, load moment indicators, and rated capacity indicators as standard load monitoring systems. Each system serves a specific function: the SLI monitors the actual suspended load, the LMI accounts for load moment by combining weight with boom radius and angle, and the RCI presents the operator with a real-time percentage of the crane’s rated capacity at any given configuration.
In practice, these systems work together rather than in isolation. A Faun mobile crane operating at extended radius faces a very different structural risk than the same crane lifting the same weight at minimum radius. The LMI captures this relationship by factoring in boom angle, length, and outrigger configuration alongside the raw load value. The result is a system that reflects the crane’s actual structural limits rather than a single fixed weight threshold.
More advanced installations also incorporate anti-collision systems, which are particularly relevant when multiple cranes operate in close proximity on a shared site. Winch force indicators are another common addition on Faun cranes used for suspended platform or personnel hoisting applications, where the monitoring requirements are more stringent.
How does a safe load indicator work on a Faun crane?
A safe load indicator on a Faun crane works by continuously comparing the actual load on the hook against the crane’s rated capacity for its current configuration. Sensors feed real-time data into a central processing unit, which calculates the load as a percentage of the rated limit. When that percentage approaches the threshold, the system triggers an audible and visual warning; if the load continues to rise, it activates a cut-out that prevents further hazardous movement.
The SLI does not simply measure weight in isolation. It reads the boom angle and length alongside the load cell output and cross-references these values against the crane’s pre-programmed load charts. This means the safe working limit changes dynamically as the operator slews, luffs, or extends the boom, and the display updates accordingly in real time.
The operator interface typically shows the current load, the rated capacity for the active configuration, and a percentage bar that makes the safety margin immediately readable at a glance. On modern Faun crane installations, this display is integrated into the cab and may also feed data to a remote monitoring unit or data logger for record-keeping purposes.
What sensors does a Faun crane load monitoring system use?
A Faun crane load monitoring system relies on a combination of load cells or load pins, angle sensors, length transducers, and pressure sensors to build a complete picture of the crane’s loading condition. Each sensor type captures a different variable, and the control unit combines all inputs to calculate the true load moment and compare it against the rated capacity chart.
Load cells and load pins
Load cells and load pins are the primary force-measuring components. On a Faun crane, a load pin is typically installed at the boom head sheave or in the hoist rope anchorage point, converting the mechanical tension in the rope into an electrical signal. Load cells may also be used at the outrigger pads to confirm that the crane is correctly supported before a lift begins. These sensors are available in stainless steel construction and can be certified to ATEX, UL, or IECEx standards where hazardous area compliance is required.
Angle and length sensors
Angle sensors measure the boom elevation relative to horizontal, while length transducers track how far the telescopic sections have extended. Together, these two inputs allow the system to calculate the horizontal radius of the load, which is the key variable in determining the load moment. Without accurate angle and length data, the load chart comparison would be meaningless, because the same suspended weight represents a very different structural demand at 20 degrees versus 70 degrees of boom elevation.
Pressure sensors
Hydraulic pressure sensors are used on some Faun crane configurations as an alternative or supplementary method of measuring hoist line tension. They read the pressure in the hoist cylinder circuit and convert it to an equivalent load value. While pressure-based measurement is generally considered less precise than a direct load cell measurement, it provides a useful secondary check and is often used where retrofitting a load pin is not straightforward.
What regulations require load monitoring on Faun cranes?
Load monitoring on Faun cranes is required by a combination of European machinery directives, EN crane standards, and national lifting regulations. In Europe, the Machinery Directive and its successor, the Machinery Regulation, require that cranes be equipped with devices to prevent overloading. EN 13000, the harmonised standard for mobile cranes, specifies in detail what a rated capacity limiter must do and how it must perform.
Beyond the machinery legislation, operators working under the Lifting Operations and Lifting Equipment Regulations (LOLER) in the UK, or equivalent national regulations in other jurisdictions, are required to ensure that lifting equipment is suitable for the intended use and is not subjected to loads beyond its rated capacity. A functioning load monitoring system is one of the primary means of demonstrating compliance with this duty.
Offshore and port environments typically impose additional requirements. Classification societies such as DNV, Lloyd’s Register, and Bureau Veritas publish their own rules for crane safety systems on vessels and offshore installations, and these rules generally mandate a higher level of redundancy and data logging than onshore applications. If a Faun crane is deployed in an offshore context, the monitoring system must meet both the applicable machinery standard and the relevant classification society requirements.
Can Faun crane load monitoring systems be upgraded or retrofitted?
Yes, Faun crane load monitoring systems can be upgraded or retrofitted, and this is a common requirement as older systems become obsolete or as operational demands increase. A retrofit typically involves replacing the original sensors, display unit, and control electronics with modern equivalents that offer improved accuracy, better operator interfaces, and connectivity for remote data access or cloud-based logging.
The feasibility of a retrofit depends on the physical condition of the crane and the availability of accurate load chart data for the specific model. The load charts are essential because the new control unit must be programmed with the rated capacities for every boom configuration the crane can operate in. Where original manufacturer documentation is available, this process is straightforward. Where documentation is incomplete, a load chart verification exercise may be needed before the new system can be commissioned.
Modern retrofit systems can add capabilities that were not available when the crane was originally built. These include wireless data transmission, mobile app readout, cloud data logging, and integration with anti-collision systems. For cranes operating in ATEX-classified hazardous zones, all replacement components must carry the appropriate certification, which narrows the choice of compatible hardware but does not prevent a retrofit from being carried out.
How is a Faun crane load monitoring system calibrated?
A Faun crane load monitoring system is calibrated by applying known test loads and adjusting the system’s output until the displayed values match the actual loads within the required tolerance. Calibration covers each sensor in the system individually before the complete system is verified as a whole against the crane’s load charts across multiple boom configurations.
The calibration process typically begins with the load cells or load pins. A traceable reference load, applied using a calibrated test weight or a reference force transducer, is used to set the zero point and the span of each sensor. The angle and length sensors are calibrated separately using physical measurement references, and the pressure sensors are checked against a calibrated pressure gauge if they form part of the system.
Once the individual sensors are calibrated, the complete system is verified by conducting test lifts at different boom angles, radii, and load levels. The displayed values are compared against the known test loads, and any deviations are corrected through the system’s calibration software. A calibration certificate is issued at the end of the process, documenting the results and confirming that the system meets the required accuracy standard. Periodic recalibration is required at intervals defined by the applicable standard and the crane’s inspection regime, typically annually or after any significant repair or sensor replacement.
What happens when a Faun crane exceeds its rated load?
When a Faun crane exceeds its rated load, the load monitoring system first triggers an audible and visual warning to alert the operator. If the overload condition continues or the load reaches the cut-out threshold, the system automatically inhibits the crane movements that would make the situation worse, typically preventing further boom extension, lowering of the boom angle, or raising of the hoist load. The crane can still be moved in the safe direction to reduce the load moment.
The cut-out function is a critical safety layer, but it is not a substitute for good lift planning. By the time the cut-out activates, the crane is already at or beyond its structural limit for that configuration. Repeated overload events accelerate fatigue in the boom structure, slewing ring, and outrigger components, and can cause cumulative damage that is not immediately visible but shortens the crane’s safe working life.
Modern Faun crane load monitoring systems log overload events with a timestamp and the load values recorded at the time of the event. This data is valuable for maintenance planning, incident investigation, and demonstrating due diligence to insurers or regulatory inspectors. Data logging also creates a record that can be reviewed remotely, allowing fleet managers or safety officers to identify patterns of misuse or operational practices that need to be addressed through training.
How PAT-Krüger supports Faun crane load monitoring
We design, manufacture, and install complete load monitoring solutions for Faun cranes, whether you need a direct replacement for an obsolete system, a full retrofit with modern connectivity, or a new installation on a crane that has never had a functioning SLI or LMI. Our approach is built around the specific crane model, its load charts, and the operating environment, so every system we deliver is calibrated and programmed for the exact configuration it will be used in.
Our capabilities relevant to Faun crane load monitoring include:
- Supply and installation of safe load indicators, load moment indicators, and rated capacity indicators
- Custom-fabricated load pins and load cells from 50 kg to 1,000 tonnes, including ATEX, UL, and IECEx-certified variants for hazardous area applications
- Angle sensors, length transducers, and pressure sensors suited to mobile crane configurations
- Retrofit and upgrade projects for Faun cranes with obsolete or non-functional monitoring systems
- Calibration services using traceable reference loads, with full documentation and certification
- Cloud data logging and remote access via secure private cloud, including mobile app readout for fleet managers
- Anti-collision system integration for multi-crane sites
- Worldwide maintenance, repair, and PCB repair services to extend system lifespan
If your Faun crane is operating with an outdated load monitoring system, is due for recalibration, or you need a complete retrofit that meets current EN 13000 and regulatory requirements, contact our team to discuss your specific crane model and operational requirements. We will provide a solution that is engineered for your crane, not a generic off-the-shelf fit.
Frequently Asked Questions
How often should a Faun crane load monitoring system be recalibrated, and what triggers an early recalibration?
Most Faun crane load monitoring systems require recalibration at least annually, in line with EN 13000 requirements and typical crane inspection regimes. However, early recalibration should be carried out after any sensor replacement, significant repair, a recorded overload event, or any incident where the crane has been subjected to abnormal forces such as a sudden shock load or structural impact. If the displayed load values appear inconsistent with expected readings during routine lifts, that is also a strong indicator that the system should be checked and recalibrated before further use.
What is the difference between a safe load indicator (SLI) and a rated capacity indicator (RCI), and does a Faun crane need both?
An SLI monitors the actual load on the hook and compares it against the crane's rated limit, triggering warnings and cut-outs when thresholds are approached. An RCI presents the operator with a real-time percentage of the crane's rated capacity for its current configuration, making the safety margin immediately visible without requiring the operator to interpret raw load values. While the terms are sometimes used interchangeably, they serve complementary functions — the SLI is the protective mechanism, while the RCI is the operator-facing readout. Many modern Faun crane installations combine both functions within a single integrated system.
Can a Faun crane load monitoring system be integrated with telematics or fleet management software?
Yes, modern retrofit and replacement systems for Faun cranes can be equipped with wireless data transmission modules that feed operational data — including load history, overload events, and utilisation patterns — directly into cloud-based platforms or fleet management software. This allows safety officers and fleet managers to review crane performance remotely without relying on on-site paper records. When evaluating a retrofit, it is worth confirming that the chosen system supports open data formats or APIs compatible with your existing fleet management tools, rather than locking data into a proprietary platform.
What are the most common reasons a Faun crane SLI or LMI gives inaccurate readings, and how can they be diagnosed?
The most common causes of inaccurate readings are sensor drift over time, damaged or corroded wiring connections, a faulty load pin or load cell, and incorrect load chart programming in the control unit — particularly if the crane has been modified or re-rated since the system was last commissioned. Angle and length sensor misalignment is another frequent culprit, as even a small offset in boom angle measurement can produce a significant error in the calculated load moment at extended radii. A systematic diagnostic should begin with checking sensor outputs individually against known references before investigating the control unit or software configuration.
Is it possible to retrofit a load monitoring system to a Faun crane if the original load charts are missing or incomplete?
A retrofit is still possible, but missing or incomplete load charts must be addressed before the new control unit can be programmed and the system commissioned. In practice, this means undertaking a load chart verification exercise, which may involve sourcing documentation from the original manufacturer, consulting crane registers, or engaging a competent engineer to verify the crane's rated capacities through structural assessment. Attempting to commission a load monitoring system without accurate load chart data would undermine the entire purpose of the system, since the cut-out thresholds would not reflect the crane's actual structural limits.
What should an operator do if the load monitoring system activates a cut-out during a lift?
The immediate priority is to move the crane in the safe direction to reduce the load moment — for example, by reducing the boom radius or slewing to a more favourable position — rather than attempting to override or bypass the cut-out. Once the load moment has been reduced and the system has reset, the operator should assess whether the planned lift is actually within the crane's rated capacity for that configuration before proceeding. The overload event should be recorded and reported, as repeated cut-out activations may indicate a lift planning issue, an incorrect outrigger configuration, or a system calibration problem that needs to be investigated.
What ATEX certification considerations apply when retrofitting load monitoring components to a Faun crane operating in a hazardous area?
When a Faun crane operates in an ATEX-classified zone, every component of the load monitoring system — including load pins, sensors, cabling, and display units — must carry the appropriate ATEX certification for the specific zone category and gas or dust group present on site. This requirement applies equally to retrofit projects, meaning that standard commercial sensors cannot simply be substituted for ATEX-rated equivalents without verifying the full certification chain. It is also important to ensure that the system integrator holds the necessary competencies to install and commission equipment in hazardous areas, as improper installation can invalidate the certification even if the individual components are correctly rated.
Related Articles
- What force sensors are used in forklift weighing systems?
- Are There Retrofit Systems for Sany Crane DS350G/C?
- The Surprising Truth About Loadpin Technology: Why It's Revolutionizing Industrial Safety Standards
- What is a remote monitoring system and how does it work in industrial settings?
- Which heavy duty weighing systems are best?