This document provides instructions for calibrating the sensors on a crane load monitoring system. It explains that the pressure, angle, and extension sensors must be calibrated to ensure accurate load and boom position measurements. It then describes the calibration process for different types of reeling drums, which involves setting the sensors to zero, spanning their ranges, and adjusting voltages. Proper calibration is important for the system to function correctly and safely.
This document provides instructions for calibrating the sensors on a crane load monitoring system. It explains that the pressure, angle, and extension sensors must be calibrated to ensure accurate load and boom position measurements. It then describes the calibration process for different types of reeling drums, which involves setting the sensors to zero, spanning their ranges, and adjusting voltages. Proper calibration is important for the system to function correctly and safely.
This document provides instructions for calibrating the sensors on a crane load monitoring system. It explains that the pressure, angle, and extension sensors must be calibrated to ensure accurate load and boom position measurements. It then describes the calibration process for different types of reeling drums, which involves setting the sensors to zero, spanning their ranges, and adjusting voltages. Proper calibration is important for the system to function correctly and safely.
This document provides instructions for calibrating the sensors on a crane load monitoring system. It explains that the pressure, angle, and extension sensors must be calibrated to ensure accurate load and boom position measurements. It then describes the calibration process for different types of reeling drums, which involves setting the sensors to zero, spanning their ranges, and adjusting voltages. Proper calibration is important for the system to function correctly and safely.
The pressure sensors are calibrated during production. It is necessary to zero and span the angle and extension sensors so the computer can measure the length and angle of the boom and calculate load. The System is calibrated using the Operator’s Display Console. The calibration procedure ensures the sensors, cables, and hydraulic connections are correctly installed and adjusted. WARNING! OBSERVE SAFE PRACTICES AT ALL TIMES. ENSURE THE CRANE CAPACITY LIMITATIONS ARE UNDERSTOOD AND THE CRANE CAPACITY PLATE IS FOLLOWED. DO NOT EXCEED THE MANUFACTURER’S SPECIFIED LIFTING LIMITATIONS.
Required Tools • ¼” nut driver or T15 Torx driver • Digital level calibrated and accurate to 0.1° • 100’ measuring tape - fiber type graduated in tenths of feet • Digital volt/Ohm meter capable of measuring to three decimal places
NOTE: The computer calculates measurements in feet and tenths of a foot.
Identifying the System Configuration A240700 Reeling Drum The A240700 Reeling Drum Assembly is used on cranes with boom spans of 35 feet or less. The reel provides storage for the Reeling Drum Cable and the angle and length sensors. The Reeling Drum Cable carries the Anti-Two-Block signal back to the Reeling Drum Assembly. The cable must be stored on the Reeling Drum in a single layer to preserve the accuracy of the length measurement. The levelwind sheave ensures the Reeling Drum Cable is stored in a single layer. The angle and length sensors are housed in a sealed enclosure inside the Reeling Drum Assembly to protect them from the elements. The sensors are accessed from the back side of the reel after removing the access cover. NOTE: Do NOT remove the Temporary Cable Clamp until the cable is connected to the crane. If removed early, the cable can snap back into the housing and damage the unit.
• Pre-2009 Reeling Drums have trim pots on the sensor baseplate inside the housing. • Post-2009 Reeling Drums do not have trim pots on the sensor baseplate inside the housing.
NOTE: To avoid removing the protective cover, refer to the part number sticker on the side of the unit and contact Greer with the Serial Number. Tension Arm Reeling Drum Potentiometer and Pulley
Connector Slip-Ring Assembly
Temporary Cable Clamp
Level-wind Sheave
Reeling Drum Cable
A240634 and A240635 Reeling Drums All cranes IC200 and larger are equipped with a 90-foot span Reeling Drum. This Reeling Drum is 14” in diameter and is installed on the side of the boom. The reel provides storage for the Reeling Drum Cable and the angle and length sensors. The Reeling Drum Cable carries the Anti-Two-Block signal back to the Reeling Drum Assembly. The cable must be stored on the Reeling Drum in a single layer to preserve the accuracy of the length measurement. The Reeling Drum also houses the angle and length sensors. To access the sensors, remove the 12 retaining screws from the cover and remove the cover.
• Pre-2009 Reeling Drums have trim pots on the sensor baseplate inside the housing. • Post-2009 Reeling Drums do not have trim pots on the sensor baseplate inside the housing.
NOTE: Remove the cover to view the sensor baseplate inside the Reeling Drum housing. Computer Assembly: The computer consists of the grey box and attached pressure sensors. The computer uses the pressure sensors readings, along with the Angle and Length sensors, to determine the Actual Load, Load relative to Maximum Capacity, warn of approaching overloads, detect Two-Block conditions, and the Angle and Length of the boom. • Chipped computers – Will have a part number that begins with A4506xx. • Flash computers – Will have a part number that begins with A4507xx or A4508xx.
Calibration Instructions for Different Configurations
For Systems with the A240700 Reeling Drum
Replacing the Reeling Drum
1. Position the crane on firm, level ground with outriggers properly extended and set. 2. Fully retract the boom. 3. Place the digital level on the boom and adjust the boom until the digital level reads 0.0°. 4. Remove the Reeling Drum Cable from the tie-off and remove the 4 bolts from the existing Reeling Drum. Remove the Reeling Drum from the boom. 5. Install the new Reeling Drum using the existing mounting holes. NOTE: Do NOT remove the Temporary Cable Clamp until the cable is connected to the crane. If removed early, the cable can snap back into the housing and damage the unit. 6. Pull the Reeling Drum cable out and attach the loop to the Cable Tie-Off. 7. Remove the Temporary Cable Clamp. 8. The Reeling Drum is pre-tensioned and is ready for calibration. a. For a Chipped Computer, contact the BMC Parts Department at (913) 888-0606 with the Crane Serial Number and the System Chip number. Obtain the System Chip number in one of the two following ways: i. Turn the key to “ON” and watch the Greer Display. Under the BMC crane model designation, the System Chip number will be displayed as D586xxx. ii. If the crane or computer is inoperable, remove the cover from the Greer Computer box located on the turret. The System Chip number is on the lable for the chip as shown in the following picture. For Systems with the A240634 and A240635 Reeling Drums
Replacing the Reeling Drum
1. Position the crane on firm, level ground with outriggers properly extended and set. 2. Fully retract the boom. 3. Place the digital level on the boom and adjust the boom until the digital level reads 0.0°. 4. Remove the existing Reeling Drum Cable from the tie-off and remove the Reeling Drum from the boom. 5. Install the new Reeling Drum using the existing hardware and mounting location.
Pre-Tensioning the Reeling Drum
1. With the boom fully retracted and the new Reeling Drum installed, slowly rotate the Reeling Drum clockwise until a “click” is heard. 2. Slowly rotate the Reeling Drum counterclockwise five (5) complete rotations. NOTE: A temporary marker can be placed on the Reeling Drum to help facilitate the rotation count. 3. Pre-Tensioning of the Reeling Drum is now complete.
Installing the Anti-Two-Block cable
1. Before attaching the new Reeling Drum Cable to the tie-off post, ensure the existing cable guides achieve proper placement of the first cable guide. 2. Ensure the distance between the First Cable Guide is at least 4’ from the center point of the Reeling Drum. The inside edge of the First Cable Guide must align with the outside edge of the Reeling Drum. NOTE: The Reeling Drum Cable path to the boom head through the cable guides to the tie-off post may follow a straight line parallel to the boom, as shown. Alternatively, the Reeling Drum Cable may curve toward the boom depending on the placement of the cable guides in the latter segments of the boom.
Adjusting the Extension Sensor
1. With the boom at 0°, push the extension sensor arm down to disengage the gear.
2. While holding the gear in this position, rotate the extension sensor clockwise until the end of the potentiometer travel is reached. 3. Rotate the sensor a 1/2-turn counter-clockwise to establish the proper starting point. NOTE: Confirm by checking the voltage. Refer to Reeling Drum Voltage Checks (For A240634 and A240635 Reeling Drums).
NOTE: On A240700 reeling drum, remove the belt and rotate the extension pot clockwise until it stops, and rotate counter clockwise 1 turn and reinstall the belt. Entering Calibration Mode 1. Use a calibrated digital level to ensure the boom is fully retracted and set to 0°. 2. Turn the System on and go through the operator setup. Ensure all options on the machine are shown in the operator setup. 3. Enter the Calibration Mode by pressing and holding the Up Arrow and Setup buttons simultaneously for 8-10 seconds or until the screen appears in Calibration Mode.
Hold Simultaneously 4. “Angle Zero” will appear in the Rated Capacity window.
Angle Zero Routine
5. The Information window will read “Angle = X.X” and “OK = SET”. 6. Press the Setup button to set the Angle Zero. “Angle = 0.0” will be displayed. The Angle Zero routine is complete. Extension Zero Routine 7. Press the Up Arrow button to access the “ExtensnZero” routine. This allows the length sensor to be calibrated. Ensure the boom is completely retracted. 8. The Rated Capacity window will display “EXTENSN ZERO”. The Information window will display “Exten = (XX.X) and “OK = SET”. 9. Press the Setup button will set the Extension Zero. “Exten = 0.0” will be displayed.
10. The Extension Zero routine is now complete.
Angle Span Routine
11. Press the Up Arrow to access the “ANGLE SPAN” routine. 12. Raise the boom to exactly 60.0° as shown with the calibrated digital level. With the boom at exactly 60.0°, press the Setup button and the lower window will display “ANGLE = 60.0”. The Angle Span routine is now complete. Length Trim Routine 13. Press the Up Arrow button to access the “LENGTH TRIM” routine. The Information window will read “Length = X.X” (Retracted length). 14. Fully extend the boom until you hear the cylinder bottom out. The lower window will display “OK = TRIM”. 15. Press the Setup button and the “Length = XX.X” value will change to display the proper boom length. The Length Trim routine is now complete.
Rodside Offset Routine
16. Press the Up Arrow button to access the “RODSIDE OFFSET” routine. The number in the lower right corner will likely read “0”.
17. Press and hold the Up Arrow button until the display shows the default setting of 0.0. Press the Setup button again to return to the main operating screen. After the Calibration Routine 18. Set up the machine and attach a tape measure, graduated in tenths of a foot, to the centerline of rotation. 19. With the boom horizontal and fully retracted, measure the load radius with the empty hook hanging and compare to what is displayed on the Operator’s Display Console. The display should be within +0.5 ft. 20. Repeat the test at full extension and record the results. The hook weight should read the same as shown on the crane capacity chart. NOTE: Hook weight varies with crane model and parts of line. 21. Raise the boom to 60° and measure the radius with the boom fully retracted and fully extended. The display should be within +0.5 ft. The hook weight should read as shown on the crane capacity chart. NOTE: Hook weight varies with crane model and parts of line. 22. Attach a known weight between 500lbs and 1000lbs. Check and read the load at full extension between 45° and 60°. The display should indicate the weight of the load, load handling equipment, and hook weight within +10% over the actual load.
