PAT DS 50 Operator's Manual

LOAD MOMENT INDICATOR
DS 50 / 0002
OPERATOR'S MANUAL
MANITEX
Second Edition 03/18/1997 – CSH (con:K2AA V1.0) 031-300-190014_A.doc
NOTICE
The information in this document is subject to change without notice.
limited to the implied warranties of marketability 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, performance or use of this manual.
This document contains proprietary information, which is protected by copyright. All rights
reserved.
No part of this document may be photocopied, reproduced, or translated to another language
without the prior written consent of PAT.
Second Edition 03/18/1997 – CSH (con:K2AA V1.0) 031-300-190014_A.doc
TABLE OF CONTENTS
1 General Information 2
2 Warnings 2
3 System Description 3
3.1 System Function 5
3.2 Control Identification 6
4 Pre-Operational Inspection 9
4.1 Anti two-block devices 9
4.2 Pre- Operation Inspection and Calibration Verification 10
5 System Operation 12
5.1 Operating Mode Selection 12
5.2 Selection of the Reeving 13
5.3 Data Display 14
5.4 Error Display 15
5.5 System and Display test 15
6 Service and Maintenance 15
7 Troubleshooting 16
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Operator's Manual DS 50 / 0002
1 GENERAL INFORMATION
The PAT Load Moment Indicator1 (LMI) DS 50 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 different sensing devices, the Load Moment Indicator monitors various crane functions and provides the operator with a continuous reading of the capacity of the crane. The readings continuously change as the crane moves through the motions needed to make the lift.
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.
If non-permitted conditions are approached, the DS 50 Load Moment Indicator will warn the operator by sounding an audible alarm and lighting a warning light.
Always refer to operational instructions and load charts provided by the crane manufacturer for specific crane operation and load limits.
2 WARNINGS
The LMI is an operational aid that warns a crane operator of approaching overload conditions and 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 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. We draw your attention to section 5 of this manual.
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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.
Operator's Manual DS 50 / 0002
The LMI can only work correctly, if all adjustments have been properly set. For correct adjustment, the operator has to set the operating code and the parts of line (reeving) thoroughly and correctly 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
3 SYSTEM DESCRIPTION
The PAT Load Moment Indicator DS 50 consists of a central micro processor unit with build in length- and angle sensor, operating console, pressure transducers, and anti-two block switch(es).
The system operates on the principle of reference/real comparison. The real value, resulting from the pressure 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.
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.
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The length/angle sensor mounted inside the cable reel, which is mounted on the boom registers boom length and boom angle. The boom length is measured by the cable reel cable, which also serves as an electrical conductor for the anti two-block switches.
Pressure transducers attached to the piston and rod sides of the hoist cylinder measure the crane load.
The console has two functions:
displays information to the operator
input terminal for operating mode and reeving (parts of line)
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.
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Operator's Manual DS 50 / 0002
Fig. 1:
Components of the LMI system PAT DS 50
Operator's Manual DS 50 / 0002
3.1 System Function
Upon switching on, the system starts with an automatic test of the LMI system, of lamps and audible alarm.
During the test, the LC display shows
8:88.8.8
First, the operating mode is determined by input of the operating code number
System awaits acknowledgment
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Next is the selection of the reeving
System awaits acknowledgment
Upon acknowledgment of the inputs, the system is ready for operation.
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Operator's Manual DS 50 / 0002
3.2 Control Identification
This unit contains a display and different controls that are described as follows:
Fig. 2: Operating Console
LC Display
1
Load Moment Limit Light
2
Load Moment Prewarning Light
3
Alarm Light “Anti-Two-Block”
4
Button “UP”
5
Button “DOWN”
6
Button and Control Light “OK”
7
Button and Control Light “SELECT OPERATION CODE”
8
Button and Control Light “SELECT REEVING”
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Operator's Manual DS 50 / 0002
LC-Display
The LC Display has five digits. The readout depends on the operating modus and the operator’s selection. Please refer to section 4, Operation of the system.
Load Moment Limit Light
The red LOAD MOMENT LIMIT LIGHT (2) warns the operator that a rated load 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.
Load Moment Prewarning Light
The yellow LOAD MOMENT PRE-WARNING LIGHT (3) will light up when the load on the crane reaches the defined prewarning area, thus indicating that an overload condition is approaching.
This means for the operator to continue his crane operation with extreme caution.
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Alarm Light “Anti-2-Block”
The red “Anti Two-Block Alarm Light” (4) 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, and the telescope out and winch up functions are locked out. If machine is equipped with an overload shut-off, the boom down function is also locked out.
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Cursor "up"
Cursor "down"
Button “OK”
Operator's Manual DS 50 / 0002
Key for the stepwise increase of the displayed value:
when selecting the operation code
when selecting the reeving
when selecting the geometry data
( refer to chapter 5.3)
Key for the stepwise decrease of the displayed value:
when selecting the operation code
when selecting the reeving
when selecting the geometry data
( refer to chapter 5.3)
Key for acknowledgment of an error message.
The correct setting of the operation mode and the reeving 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 the following buttons:
Button " set operating mode"
Button to start the function "set operating mode ". For the proceeding, please refer to
chapter 5.1.
Button "set reeving"
Button to start the function "set reeving" (parts of line). For the proceeding, please refer to
chapter 5.2.
Operator's Manual DS 50 / 0002
4 Pre-Operational Inspection
Prior to operating the crane, the following electrical connections must be checked to ensure that the system is properly connected for the crane configuration.
4.1 Anti two-block devices
If the crane works only with the main boom and without boom extension, check the weight to ensure it is attached to the anti two-block switch on the main hoist load line.
Weight installation - The hoist line runs through the A2B weight. 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 an extension exists, install the connecting cables between the boom extension junction box and the boom point junction box. Remove the weight from the main boom anti-two block switch and re-attach it to the boom extension anti-two block switch on the auxiliary hoist line.
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Failure to position the anti two-block switch weight will prevent the overhoist system from functioning properly. No weight shall be on the main hoist anti two-block switch when the boom extension is being used.
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Operator's Manual DS 50 / 0002
4.2 Pre-Operation Inspection and Calibration Verification
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.
4. Check the anti two-block alarm light (4) and the audible alarm by performing one of the following tests a, b, or c. If the crane is equipped with a boom extension, perform the test procedure on both the main boom and boom extension anti two-block switches.
When checking system the operator must use caution. If the operator cannot see the load-handling device approaching the boom nose, he/she 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. Proper operation will be indicated by:
lighting the red warning light (4)
sounding the audible alarm
locking out of the hoist up and telescope out functions
and if the overload shutoff option is installed, a lockout of the boom down function will occur
a) By manually lifting the weight attached to the anti two-block switches. When the weight is lifted, the
audible alarm 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 should sound, the anti two- block alarm light (4) should light and the motion of the load handling device should be stopped. Lower the load-handling device slightly or telescope the boom in to eliminate this condition.
c) Slowly extend (telescope) 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 telescope out function should be stopped. Lower the load-handling device slightly or telescope the boom in to eliminate this condition.
NOTE: If the crane is equipped with the overload shutoff option, a two-block condition will also lockout the boom down function. If operating properly, the lockout feature will always permit operation of the hoist down, telescope in, and boom up functions.
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.
Operator's Manual DS 50 / 0002
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5. Check that the display of the main boom length agrees with the actual boom length.
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. The accuracy of the load indication shall be within the tolerance of SAE J159.
After being properly checked, the LMI is operational. The operator shall be thoroughly familiar with all controls of the LMI before operating the crane (see Section 3.2). Lifting a load of known weight and comparing the load to the information displayed on the LMI (see Section 5.2) shall check the proper function of the system.
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 and/or verification of the crane’s LMI calibration.
Any structural modifications or changes to the crane shall require verification of the LMI calibration of the crane.
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Operator's Manual DS 50 / 0002
5 SYSTEM OPERATION
The LMI System DS 50 allows the operator to assess and evaluate the lift to meet the manufacturer specified load charts for the crane.
The correct setting is of utmost importance for the proper functioning of the system and the crane. Therefore, the crane must not be operated without setting the appropriate operating code.
5.1 Operating Mode Selection
start function:
select mode:
confirm
selection:
(automatically
Manually at each modification of the crane
configuration by pressing key,
The operating mode key and the cursor keys light up. The operating mode selection is displayed:
XX= present operating code
use cursor keys
the operating code
By pressing again, key
after system start)
and to modify
.
The cursor keys and the operating selection key go out.
NOTE: If the system is turned off, all adjustments remain stored. When the system is turned back on, the adjustments can be
acknowledged by merely pressing key:
(if the crane configuration has not been modified!).
Troubleshooting
5.2 Selection of the Reeving (parts of line)
(automatically after finishing operation mode selection)
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start function:
select
reeving:
confirm
selection:
manually
pressing key
The reeving key and the cursor keys light up. The reeving selection is displayed:
XX= present reeving
use cursor keys
By pressing again, key
upon modification of the reeving by
and to modify
the reeving
The cursor keys and the reeving key go out.
.
NOTE: If the system is turned off, all adjustments remain stored. When turning on again the system these
adjustments can be acknowledged by merely pressing keys:
and then
Verify the operating mode and reeving displayed with the configuration of the crane.
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Operator's Manual DS 50 / 0002
5.3 Data Display
In case neither the operating mode selection nor the reeving selection are active, the LC display serves as data display:
Press keys and to select the values. There are 9 display positions:
Display Position
Y 0 error message 1 main boom length 2 main boom angle 3 radius 4 utilization in % 5 tip height 6 capacity 7 actual load 8 load moment
Displayed Value
XXXX
Troubleshooting
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5.4 Error Display
In case of operating error or system malfunction an error code is displayed. (for detailed information refer to chapter 7 troubleshooting) Error messages are given priority on the display:
XX=error code
Press key to acknowledge an error message (exception: console error messages)
5.5 System and Display Test
Press keys and simultaneously to select the test function.
All lamps light up, the buzzer is turned on and the following is displayed:
During the test, the data transmission to the central unit is interrupted so that 2 seconds later approx. the cutoff relay is de-energized.
6 SERVICE AND MAINTENANCE
Daily maintenance of the load moment indicator consists of inspecting:
The electrical wiring connecting the various parts of the system. If electrical wiring is damaged, it shall be replaced immediately.
If the insulation is worn on the length sensor cable or cable guides are damaged, these parts shall be replaced.
Check the anti two-block limit switches for freedom of movement.
The cable reel shall be under tension to operate properly.
Check the pressure transducers at the hoist cylinder and the connecting hoses for oil leakage.
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.
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Operator's Manual DS 50 / 0002
7 TROUBLESHOOTING
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 that explain each fault and describe the action that 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.
Malfunction Table
Error Code Error
E01 Fallen below the radius or above angle range E02 Radius range exceeded or fallen below angle
range
E03 Boom position is out of the permissible working
area E04 Operating mode not existing E05 Prohibited length range
NOTE:
If there is any Error Code displayed on the console which is not listed in the Malfunctions Table you shall call the Local Distributor.
Troubleshooting
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Operating Errors
Malfunctions in the system that are caused by range exceeding or operating errors by the crane operator himself are indicated on the display. These error codes are E01, E02, E03, E04, and the crane operator himself can normally eliminate E05 and them.
Error
Code
E01
E02
E03
E04
E05
Cause Elimination
Fallen below the minimum radius or above the angle given in the load capacity chart due to luffing up the boom too far. The maximum radius or minimum angle given in the load capacity chart was exceeded due to luffing down the boom too far. Boom position is out of the permissible working area (over front).
Operating mode at the console incorrectly set.
Operating mode is not permissible with the actual crane configuration or boom position Boom was telescoped too far or not far enough, you may only operate up to a certain maximum or minimum boom length or with load curves for boom extension where you have to telescope the main boom to a certain length.
Luff down boom to a radius or angle given in the load capacity chart.
Luff up boom to a radius or angle given in the load capacity chart.
Move boom back to the permissible working area. See lifting diagram in the load capacity charts. Correctly set operating mode to the code assigned to the operating mode of the crane.
Be sure crane is set up according to proper operating configurations.
Telescope boom to correct length, given in the load capacity chart.
Length sensor adjustment changed i.e. length sensor cable slid off the length sensor drum.
For elimination, refer to service manual.
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