[KR KRUGER MESSTECHNIK FOR HEBEZEUGE OPERATORS MANUAL LMI SYSTEM MARK 3D (AD 102/103) nacht Frasngodorweg 17 1045239 Eston Poattaen 164260 Telefon (0201) 4086-0 Postgiro Eason (81236019045) 167295-438 145222 Essen Teeter (0201) 4086848 Banker Natonabank AG Esean (82 96020030) 154547 Toler 8579552 Deutsche Bark RG Essen (@LZ 3607000) 6 186183BoD RODS” BaRoY= BRoDa * © PN PQOHHHOH VAMNAG PARAL BOLOBEY NMYUNNNN Qoakane [R KRUGER MESSTECHNK FOR HEBEZEUGE CONTENT Foreword KRUGER load moment indicating system MARK 3D What it is What it does Within the system The system function The anti-2-block switch Description of components Boom length and angle sensor (cable ree!) Lift cylinder pressure sensors (hydraulic) Central processor Control panel Working range selector Luffing jib attachment Control panel Displays Program setting key switch By-pass key switch farming lights and buttons Operating instructions Start-up Crane operation Operating after shut-off Shut-off by-pass Light flash on the panel and its cause Shut-off light “WARNING/HORN® comes on Shut-off light “WARNING/HORN’ fiashes Pre-warning light "PRE-WARNING' comes on, Angle pre-set light "BOOM ANGLE LIMIT* comes on Tare light "TARE" comes on Test light "TEST* is off Code information Remarks for lattice boom cranes Preventative maintenance Remarks for service Jo. Options 1 Posttach 164260 Teeton (0201) 4086-0 Postg Esson (BL2 360 10043) 167295-488 base exten Teel (0201) 4096149 ‘Bankon” Nasonalbank AG Essen (BLZ3E020030) 154547 olen 8570552 Deutsche Bark AG Essen (BLZ 38070050) 6186183,[q KRUGER KROGER MESSTECHK FOR HEBEZEUGE 1, FOREWORD This manual describes the principles and basic operation of the KRUGER Load Moment Indicating System Mark 3D. The purpose of this device is to aid the operator in recognizing conditions where structural failure or loss of stability of the crane might result. While the system will sense and alert the operator to impending overload conditions, the operator must always remember: WARNING THE SYSTEM UTILIZES A SERIES OF ELECTRICAL, MECHANICAL AND HYDRAULIC COMPONENTS AND CANNOT BE 100% FAIL-SAFE. WARNING DO NOT CONSIDER THE SYSTEM SUBSTITUTE FOR GOOD JUDGMENT, EXPERIENCE AND ACCEPTED SAFE CRANE OPERATING PRACTICES. THE OPERATOR IS SOLELY RESPONSIBLE FOR SAFE OPERATION OF THE CRANE. WARNING CERTAIN PROGRAMMING OF THE KRUGER SYSTEM_IS_NECESSARY BEFORE PERFORMING EACH LIFT. IF INCORRECTLY PROGRAMMED, THE SYSTEM WILL NOT SENSE AND ALERT THE OPERATOR TO AN IMPENDING OVERLOAD CONDITION. THEREFORE, THE CONTENTS OF THIS MANUAL SHOULD BE READ AND THOROUGHLY UNDERSTOOD BEFORE ATTEMPTING TO OPERATE THE CRANE. 2 Ansett Posttach 164260 Toefon (2201) 4onst-0 Postgio Esson(8LZ 96010043) 167235438 Felngesocweg 17 beaseoo essen Tootax (C201) 4086149 Banker Natonatbane AG Essen (BLZ 36020090) 184587 sa8200 Eston Teer 9579552 Deutsche Bark AG Escen(8LZ 36070080) 6105165,[IK KRUGER MESSTECHNK FOR HEBEZEUGE 2. THE KRUGER LOAD MOMENT INDICATOR SYSTEM MARK 3D 24 What it is: ‘An electronic/mechanical sensing system developed to indicate approaching crane manufacturers maximum rated lifting capacities. 22 What it does: By correctly setting the unit on the control panel it monitors (see paragraph 5) LOAD MOMENT. ACTUAL LOAD ON HOOK MAXIMUM ADMISSIBLE LOAD ON HOOK RADIUS BOOM LENGTH BOOM ANGLE - JIB OFFSET ANGLE or LUFFING JIB ANGLE BOOM TIP HEIGHT (of main boom or jib) > SERVICE INFORMATION - PRESSURE OF BOOM LIFT CYLINDER 23 Within the system it: - Continually measures boom length (cranes with extendable boom only) - Continually senses boom angle in respect to the horizontal + Senses the position of the crane boom, while the upper is rotating (if limited working areas are given by the load chart) - Electronically duplicates the crane manufacturers rated lifting capacity chart. 24 The system function: It is to integrates the programmed inputs from the control panel switches, boom length, boom angle, lift cylinder hydraulic pressure and working area and compares the summary to the stored manufacturers rated lifting capacities in the central processor. 3 Anserrit Postach 164260 0 (0201)40961-0 —_—Postlro Essen (1.2 280:0040) 17295-490 Fraingeortaog 1? Baszz2 Ean (020) 4086'22 _—_‘Banken”faonark a Suen (2 020020) S¢S47 -sad0 essen o579sse Deutsche Bark AG Esson (LZ 26070080) 686109IK KRUGER MESSTECHNIK FOR HEBEZEUGE The following conditions might occur: 2.41: The actual loading is less than the rated capacity. The load moment, consisting of the actual hook load, attachments, own weight and dynamic forces of the boom, is displayed on the load moment meter (needle of the load moment meter in green area). 2.4.2: The actual loading is approaching the rated capacity. The needle of the load moment meter is moving into the yellow area and the yellow pre-wamning light will come on at a preset percentage of the rated capacity. 2.4.3: The actual loading equals the rated capacity The needle of the load moment meter is on the line between the yellow and the red area. Simultaneously the system activates an audio/visual alarm and (if installed and properly connected) the shut-off system then prevents the operator from increasing the load moment being applied to the crane by restricting movement of the following motions: - Hoisting up = Boom lowering Boom extending 4 Ansehat Posttacn 184260 Telefon (0201) 4086-0 Posto Essen (BLZ 360 10040) 167295498 Fooingssotwog 17 as222 essen ‘elear (0200 4088149 [Sanka Natonalbane AG Esson(BLZ 6020030) 184547 usage Essen Telex 8579582 Deutsche Bark AG Essen (226070050) 6786 18225 [kK KRUGER MESSTEGHWK FOR HEBEZEUGE The Anti-2-Block Switch This switch is installed at the boom head (jib/extension etc.) and is activated by a counterweigt it suspended by chains which prevents the hook block from being raised to where it contacts the boom head. The lengths of the chains are in ac- cordance with hook speed anu sensitivity of the shut-off system and should not be shortened or a possible two-block condition could result. ‘The counterweight should be attached to the line of zero speed or if not available to the fine of lowest speed. When operating with jib (extension etc.), the jib anti-2-block switch must be connected with a jumper cable to the receptacle at the boom head. When operating with main boom only this receptacle on the boom head must be equipped with a jumper plug to close the jib (extension etc.) anti-2-block circutt. When the counterweight is being lifted by the hook block, an audible/visual alarm will occur and the shut-off system will be activated (if installed and properly connected) to prevent the operator from being able to use following motions: - Hoisting up - Boom lowering Boom extending NOTE ‘A momentary by-pass key switch is located on the control panel to override the shut-off system, while the boom is being stored on the boom rest or the crane is rigged with a jib (extension etc.). ‘The momentary by-pass key switch deactivates the shut-off system by turning the key to the right and holding it in position. WARNING THE KEY SHOULD NOT BE USED TO LIFT LOADS HIGHER THAN PER- MITTED BY THE COUNTERWEIGHT ATTACHED TO THE ANTI-2-BLOCK SWITCH. IT IS RECOMMENDED THAT THE SYSTEMS ANTI-2-BLOCK BY- PASS KEY SWITCH BE USED WITH DISCRETION AS UNWARRENTED USE OF IT TO OVERRIDE THE SHUT-OFF SYSTEM CAN RESULT IN LOSS OF LIFE, DESTRUCTION OF PROPERTY AND IRREPARABLE DAMAGE TO THE CRANE. THE OPERATOR USING THE MOMENTARY BY-PASS KEY SWITCH MUST USE SOUND JUDGEMENT. Ansehnt Postlach 184260 ‘Telefon (0200 4086-0 Postgiro Essen (BL2 360 10049) 18726-4938 Fringodorweg 17 (045222 Eseon Teltar (0207) 4096149 ‘Bankon Natnatbank AG Essen (BL2 3602000) 154547 45259 Essen oloe 0579552 Deutsche Bark AG Essen (Lz 36070050) 6106163,i KRUGER MESSTEGHNIK FOR HEBEZEUGE SYSTEM MARK 3 _D UGKRAFTAUFHERNER TENSION LOAD CELL WINKELGEBER ‘ANGLE. SENSOR ABELTRONNEL tae REEL HUBENDSCHALTER WOIST-LIMIT SNITCH ie2-B) USLESER LAENBEN/WINKELEEBER BOOM LENGTH/ANGLE SENSOR ANTEIGEGERAET (CONTROL PBNEL TRENNAGNETE WOTION SHUT-OFF ELECTR. ZENTRALEINMEIT CENTRAL FROCESSOR REHBERE1CHSERFASSUNE 6 Woriine ares sex60R nacht Posttach 164260 Telefon (0207 4061-0 Postgio Estan (BL2 6010043) 197295-409 Faingadoreeg 17 (Bu48282 Essen elton (020) 40861 «9 Banton’ Natonsioark AG Exson (BZ 020030) 156547 Bsrosse Davison bank AG Essen (2.2 86070080) 6186103 ‘4s29 Een Telexi KRUGER MESSTECHNIK FOR HEBEZEUGE 3. DESCRIPTION OF COMPONENTS 34 Boom Length and Angle Sensor (Cable Reel) Boom length is measured by a cable attached to the boom head. This special cable is wound on a spring loaded cable ree! mounted on the boom base section. The cable also contains electrical wires that connect to the Anti-2-Block Switch on the boom/jib head, the load cell (for luffing jib attachment), and others. The cable reel rotation mechanically drives an electrical variable resistor (potentiometer) that transmits boom length signal to the central processor. Boom angle is sensed by a pendulum which is an integrated part of the cable reel. it drives a variable resistor (potentiometer) that transmits boom angle information to the central processor. 3.2 Lift Cylinder Pressure Sensors (Hydraulic) ‘Two pressure strain gauge sensors that separately measure hydraulic pressure at the rod side and the piston side of the lift cylinder(s) are used to transmit cylinder pressure information to the electronic. Alternatively there could be installed a complete hydraulic measuring system which contents two pressure transducers with an electronic pe-board for the adjustment of the compensation ratio 3.3 Central Processor The Central Processor consists the standard elements (main printed circuit board, control lights, relays, terminals etc.). In regard to the main printed circuit board vertically placed are 3 po-boards (voltage convertor, processor and analog inputs) and two possibilities for options. A by-pass key switch, located at the bottom of the central processor box or in . other places, deactivates the shut-off system (if installed and connected). Meters, lights and hor on the Control Panel are indicating even when the shut-off system is deactivated, 7 Aanzehait Postiacn 164260 “Teleton (0201) 6096-0 Postgko Exxon (BLZ 96010049) 167295498 Frelngadodweg 17 Deasaz2 essen option (0200) 4088149 Benker’ Natonatank AG Essen (BL2 6020030) 154547 sts280 Essen Jelex 8570552 Deutsone Bark AG Essen (LZ 26070050) 6186 189,Q [i KRUGER KROGER MESSTECHNIK FOR HEBEZEUGE WARNING ST iS RECOMMENDED THAT THE SYSTEMS BY-PASS KEY SWITCH IS USED. WITH DISCRETION, AS UNWARRENTED USE OF IT TO OVERRIDE THE SHUT-OFF SYSTEM CAN RESULT IN LOSS OF LIFE, DESTRUCTION OF PROPERTY AND IRREPARABLE DAMAGE TO THE CRANE. THE KEY SWITCH CAN BE USED IN OVERRIDING THE SYSTEM IN CASE OF EXTREME EMERGENCY. THE OPERATOR USING THE KEY IN EXTREME EMERGENCY SHOULD USE SOUND JUDGEMENT. NOTE THE CUSTODY OF THIS KEY IS TO BE CONTROLLED BY THE DISTRIBUTOR CUSTOMER AND/OR HIS AGENTS AND SUCH POLICIES ARE NOT DICTATED OR CONTROLLED BY KRUGER. 3.4 Control Panel This unit is located in the operators cab. It has basically two functions: 1. To transmit the information selected by the operator by means of selector ‘switches to the central processor and 2. To display information received from the central processor to the operator. This contro! panel is connected to the central processor by a multiconductor cable. All instruments are illuminated for work in dim light conditions. The control panel is mounted inside the operators cab in either horizontal (AD102) or vertical (AD103) version depending on application and location. 8 Anson Postach 184260, Teton (0201) 4006-0 Post Esson (612 96910043) 167205-498 Froingadorweg 17 easaz2 essen Toto (0201) 4096149 ‘Banken” Natonabank AG Esson (01.2 36020020) 154547 braseae essen Toler 8570850 ‘Deutsche Bank AG Essen (2L2 36070050) 618613(Ke KRUGER MESSTECHNK FOR HEBEZEUGE 35 Working Range Selector By means of one or more roller switches located between the superstructure and the carrier, it senses the rotational position of the superstructure with respect to this carrier, in case there are varying lifting capacity charts for different working areas, and automatic switch-over is given. NOTE IN CASE OF FAILURE OF THE ROLLER SWITCHES AUTOMATIC SWITCH- OVER TO THE LOWER RATED LIFTING CAPACITY CHART IS GIVEN. 3.6 Luffing Jib Attachment If the crane is equipped with a luffing jib attachment, following components are there in addition: 3.6.1 Jib Angle Sensor The Iuffing jib angle to the horizontal plane is sensed by a pendulum which drives a variable resistor (potentiometer) that transmits jib angle information to the central processor. 3.6.2 Load Cell The strain gauge load cell (terision sensor or load pin) senses the line force and transmits the data to the central processor. 3.6.3 Cable Reel This is a mechanical cable ree! (cord reel) to connect the jib anti-2-block switch with the main boom head connector. It also transmits, if applicable, load cell outputs from the load cell, located at the jib head, to the main boom head connector. 9 Anson Posttach 164260 n (20H) 4861-0 Posigiro Eston (BLZ 26010049) 167235-439 Fraingedorweg 17 (5202 Eseen (020) 4086109 Banton Netonstoans AG Essen (8L2 96020090) 154547 ‘Duaszi9 Essen Toler 8579552 Deutsche Bark AG Encen (BLZ 96070040) 6186189K KRUGER MESSTECHNIK FOR HEBEZEUGE 4 CONTROL PANEL 44 Displays (number see appendix) Loadmoment (1) The cranes loading condition is displayed on a multi-coloured analog meter scale. © Needle in green area (0-90%): APPROVED The actual foading is below the rated capacity. 2 Needle in yellow area (90-100%): CAUTION The actual loading is approaching the rated capacity. © Needle on the line between yellow and red area (100-110%): PROHIBITED The actual loading equals or exceeds the maximum rated capacity. Actual Load (2) Displays the actual load, including attachments, in metric tons or pounds (as requested). Max. Load (4) The maximum rated capacity (incl. attachments) in metric tons or pounds (as requested). Unless otherwise noted by the crane manufacturer, the system automatically interpolates between given ratings. Radius (5) The actual load radius in metres or feet (see LCD-bar on the right hand side of the instrument), e.g. the horizontal distance from a vertical projection of the crane's axis of rotation to the supporting surface to the center of vertical hoist line or tackle with load applied. The radius indication appears, if information button (6) is not pressed (light off)! Information (5) By pressing the button “Info" (6) the indication appears depending on the positions of the selector switch (7). Length The actual main boom length in metres or feet (see LCD-bar on right of the instrument), e.g. the length from the main boom pivot pin to the main boom head sheaves. 10 Anson Posttach 164260 ‘Totton (0201) 408 61-0 Postgio Esten(8LZ 26010049) 167235-428 oingasrweg 17 BusSa02 essen Totter (201) 4080149, Banton’ Natonalbane AG Esson(8LZ 95020090) 154547 (usage essan Telex 8579552 Deutsche BarkiAG Essen (BLZ 36070080) 6 186189[IK KRUGER NESSTECHNNK FUR HEBEZEUGE Angle The actual angle between the base section of the main boom and the horizontal plane in degrees. Jib Angle When using an offsetable jib the angle between main boom and jib in degrees (see LCD bar on the right hand side), When using a luffing jib the angle between jib and horizontal plane in degrees. Height The actual boom height in metres or feet (see LCD-bar on right of the instrument), ie. the vertical distance from the supporting surface to the lower boom head sheaves or, if any jib attachment is installed, the vertical distance from the supporting surface to the jib head sheaves. Service Coded trouble shooting information (see chapter 6) The following LCD readouts are mainly for service purposes and, therefore, only marked by numbers: "1" unused / especially for options, marked with "1" on the right of the LCD display. "2" unused / especially for options, marked with "2" on the right of the LCD lisplay. “3* internal number of the program or configuration order; could be different from the program number shown on the LCD display (8), marked with ‘nr' on the right of the LCD display. "4" measured value of an additional pressure transducer for service or maintenance or indication of a used load cell in case of hoist rope measurements marked with “d" on the right of the LCD display. “5*- value of the adjusted compensation ratio marked with *:1* on the right of the LCD display. "6" Pressure of rod side liting eyinder marked with *o" on the right of the LCD isplay. "7" pressure of piston side lifting cylinder marked with "u" on the right of the LCD display. W Anse Postach 104260 Teafon(€201) 40861-0_—Postgo Essen (9LZ 96010045) 107295-438 Fangedotveg 17 eases exon “tern asea® Banton” Natonaberc Assen 6236030030 154547 ‘D4s209 Essen Telex 8579852 Deutsche Bark AG Essen (8.2 36070080) 680105,IK KROGER MESSTECHNIK FUR HEBEZEUGE Parts-Ot-Line / Program (8) The parts of line (0 .... 24) are shown on the left side of the LCD display. The value will be set by pushing the cursor buttons (10) or (3), if the key-switch (9) is turned into the left position. ‘The system takes into consideration the max. line pull of the single line. If the part of line value set is lower than the actual parts of line installed on the boom the system may derate the max capacity If*00" is set, the system will ignare the parts-of-line. The program number (0 .... 999) is shown on the right side of the LCD display. The value will be set by pushing the cursor buttons (10) or (3), if the key-switch (9) is tuned into the right position. The program number is flashing, if an automatic switching of the internal program number has occurred. WARNING If the program number and parts-of-line have not been set correctly by the operator, this might result in incorrect rating condition. Angle Preset (8) [Option] By pressing the button (10) the lower angle limit (00 .... 90) is shown on the left side of the LCD display. The value is set by pushing the button (10) and turning the key-switch (9) into the lett position; then the value can be changed by using the cursor buttons (10) or (3). By pressing the button (1) the upper angle limit (00 .... 90) is shown on the right side of the LCD display. The value is set by pushing button (10) and tuming the key-switch (9) into the right position. Then the value can be changed by using the cursor buttons (10) or (3). The angle limit only affects a waming {audible alarm and light (10) on]. If the lower angle limit is set to 00", no warning will be given, if the actual angle is 0 degrees or below. 12 Ansett Posttaeh 64260 Telefon (0201) 4096-0 Posto esson (6.2 96010048) 167295490 Fingadrteg 17 o-ase22 eaten (ozo) 4086140 ‘Banker’ Natonafbene AG Essen (8LZ 96020090) 154547 48259 Essen 57oss2 DDeveche BankAG Escon(BLZ 30070050) 6183189,[IK KRUG KRUGER MESSTECHNK FOR HEBEZEUGE 42 Program Setting Key-Switch (9) Program / Upper Angle Limit Turn the key-switch into the right position to set the configuration or the upper angle limit - see chapter 4. During the setting process the display (2} shows "E:Pr*. Parts of Line / Lower Angle Limit ‘Tum the key-switch into the eft position to set the configuration or the lower angle limit - see chapter 4.1 During the setting process the display (2) shows "E:Pr’ 43 By-Pass Key-Switch 431 "A-2-B" (14) Turn to the lett to override the shut-off system activated by the anti-2-block switch, whiie the boom is being stored on the boom rest or the Crane is rigged with a jib (extension etc.). This momentary by-pass key switch deactivates the shut-off system by turning the key to the right and holding it in position. NOTE THE CUSTODY OF THIS KEY IS TO BE CONTROLLED BY THE DISTRIB- UTOR/CUSTOMER AND/OR HIS AGENTS AND SUCH POLICIES ARE NOT DICTATED OR CONTROLLED BY KRUGER. WARNING 4 THE KEY SHOULD NOT BE USED TO LIFT LOADS HIGHER THAN PER- MITTED BY THE COUNTERWEIGHT ATTACHED TO THE ANTI-2-BLOCK SWITCH. IT IS RECOMMENDED THAT THE SYSTEMS ANTI-2-BLOCK BY- PASS KEY SWITCH BE USED WITH DISCRETION AS UNWARRENTED USE OF IT TO OVERRIDE THE SHUT-OFF SYSTEM CAN RESULT IN LOSS OF ‘ LIFE, DESTRUCTION OF PROPERTY AND IRREPARABLE DAMAGE TO THE CRANE. THE OPERATOR USING THE MOMENTARY BY-PASS KEY SWITCH MUST USE SOUND JUDGEMENT. 43.2 LMI Shut-Off By-Pass (Option) Turn to the right to override the LMI shut-off, if wired. (see "NOTE" and "WARNING* of chapter 4.3.1) 13 Anschit Posttach 164260 Telofon (9201) 4086-0 Postgio Essen (012 30010040) 167235-408 Foingedorweg 17 base eseen “elotan (0201) 4088189 Bante” Natonalban AG Ese (@L.2 3602000) 184547 oasasa Eaten ele” 8579552 Deutsche Bank AG Essen (GL? 26070080) 6 12618[KR KRUGER MESSTECHNK FOR HEBEZEUGE 44 Warning Lights and Buttons 441 Test (13) Pilot light, test and quit button 44.2 Pre-Waming (11) Load moment pre-warning light, according to the charts (e. g. 90 % rated capacity) 4.4.3 Warning/Hor (12) Illuminated at rated capacity, according to the load charts and at malfunction of the system. This light flashes when the anti-2-block switch is activated, The audible warning is momentarily by-passed when this button is pressed. 4.4.4 Boom Angle Limit (10) lliuminated once the preset boom angles are exceeded. The audible alarm will sound simultaneously. 4.45 Tare (3) To determine the net load. After pressing this button, the LCD-instrument "Actual Load” (2) will read "0.0" and this button is illuminated. Alter repressing this button, the last data willbe displayed and the button light wil go off. If the boom angle is changed by more than 5 degrees or the boom lengths by more than 1m, the system will automatically display the gross load and the button . light will go off, 4.4.6 Information (6) When pressing this button the indication (5) switches from "Radius" to the indication selected by information selector switch (7). The light is on. 14 Anse Teton 0201) 0961-0 __Posigro ssen 6.2 800040 167235400 Frases 17 ‘stor (21) s088t49 _—Bankenatnabane AG Eaeon (92 202002) 14547 (0-48280 Esson Toler 8579552, Deutscne Sank AG Essen (@L2 36070050) 6186183I KRUCER MESSTECHNK FOR HEBEZEUGE 5. OPERATING INSTRUCTIONS 5A Start-Up 5.1.1 Tum on the crane ignition switch in accordance with the crane manufacturer's instructions. ‘When power has been applied to the system and there is no malfunction the lights (10), (8), (11), (12) and the audible alarm are on for almost 2 sec the LCD display "Information" (5) shows code "E:0" (if not, see chapter 6), the green light "Test (13) and the shut-off light (12) are still on, the needle of the LMI-meter (1) is in the ed area and the LMI-system is in shut-off condition. 5.1.2 Press Green Button "Test" (13) The program number and the parts-of-line selected before are shown on the LCD. display (8). The system is now ready for operation. 5.1.3 Setting Of Program Number (Configuration) And Parts-Of-Line ‘After turning the key-switch (9) into position program or parts-of-line the display (2) shows "E:Pr’; the LMI system is in shut-off condition. The corresponding values are to be set by buttons (10) or (3). Keeping the buttons pressed the value - increasing or decreasing - will run quickly. When the values have been set turn the key-switch (9) into the neutral position; the system is ready to work. 5.1.4 Setting of Upper And Lower Angle Limit (Option) Press the button (10) and at the same time turn key-switch (9) into position right or left for upper or lower limit setting. The display (2) shows "E:Pr* and the LMI is in shut-off condition. The corresponding values are to be set by the buttons (10) or (3). Keeping the buttons pressed the values are increasing or decreasing quickly. . The value range is 00 .... 90. When the values have been set turn key-switch (9) into the neutral position; the system is ready to work again 18 Anacit Posten 104200 ‘Telefon €201)40863-0 oso Eason LZ 36010040) 167235-498 Ficingdoineg 17 ——«BuaSoa2 even Ttotor (201) 8086149 Banka Ratonaark AG Esco (82 602002) 14547 uaseee essen Jelex es79G82 ‘Deutsche Bark AG Essen (LZ 26070080) 6106183,52 5.3 Ba (K& KRUGER MESSTECHNIK FOR HEBEZEUGE Crane Working Condition if the LMI is already adjusted and all conditions are set, nothing else is necessary to set up the system. For changing the configuration or angle limits see chapter 5.1.3 and 5.1.4. Depending on the crane configuration and its load chart the information display (5) is set to angle or radius. The selection of the information does not affect the LMI operation. NOTE The correct setting of program and parts-of-line must be selected by the operator or a possible incorrect rating condition may result. Reset After Shut-Off Condition Generally there is an automatic reset when the reasons for system shut-off are no longer existing. It is possible to change the wiring for manual reset. In this case the green "Test" button (18) must be pressed to get the system into working condition. Shut-Off By-Pass If the system is by-passed at the (external) main by-pass key-switch, a sign ‘n* can be given on the LCD display (8) between parts-ot-line and program number. See NOTE and WARNING of chapter 3.3. 16 Portia 164260 Telefon (0201) 4086-0 Postgr Ess0n (012 36010045) 167235-458 Folngadorweg 17 A822 eseen Teeter (0201) 4086149 Banker” Natonabank AG Essen (BLZ 96020030) 164547 (D-45299 Essen Tex” 8579552 ‘Gousche Bank AG Essen (ELZ 36070050) 61861836.1 614 6.1.4 (@ KRUGER MESSTECHNK FOR HEBEZEUGE LIGHT FLASH ON THE PANEL AND ITS CAUSE Shut-off light (12) "Warning/Horn" comes on: Maximum allowable lifting capacity is being reached. Needle of the load moment meter (1) is in the red. = Lower load, retract boom or raise the boon With extended manual boom section or jib, the main boom was retracted in opposition to the regulation of the rating chart. Extend boom fully. The crane is working without outriggers. Maximum boom length is reached, as imposed by the rating chart. = Retract boom. The boom in reference to the boom angle is in a position where no loads are permitted to be lifted as imposed by the rating chart Return boom to a position within the limits of the rating chart. The light is on and 6.1.1 through 6.1.4 do not apply. Turn selector switch (7) into position ‘E* and relay the number from the LCD instrument (5) "Crane Information" to the listing of error codes in chapter 6.7. Key-switch (9) was changed either intentionally or accidently. © Set switches to neutral position and check program number, parts-of-line and angle limits. 7 Postiac 164260 “oleon (0201) 4080-0 Postairo Essen (8:2 3601004) 167235498 Po ee ee ecu asnntap Sree” anmonabeni AO Beek, ocr eeoanosch 164567[K KRUGER MESSTECHNIK FOR HEBEZEUGE 62 Shut-off light (12) "Waming/Horn* flashes. 6.2.1 Two-Biock condition © Lower load line by hoisting down or retracting the boom. 63 Yellow light (11) *Pre-Waming* comes on. 6.3.1 Appr. 90% of rated capacity is reached. CAUTION ! 64 Angle preset light (10) "Boom Angle Limit" comes on. 6.4.1 Setted boom angle has been exceeded. * Correct by booming up/down. NOTE NO SHUT-OFF CONDITION ! 65 Tare light (3) "Tare* is on. 65.1 Thenet load is displayed on the LCD instrument (2) "Actual Load’. 66 Test light (13) "Test" is off. 6.6.1 A fault in the circuitry occured. Contact your authorized KRUGER service representative. 18 ose Postach 104260 Telefon (20%) 40061-0 Pasig Eason (@LZ 96010042 167225-436 Frowngedotwes 17 Bs4S002 sen “tor (020) 4006189 Gara” Neto Assen 0296080000 1s4st7 Diasego Essen Telex Bs70260 Devt Bank AG Essen (LZ 36070020} 6106 180[@ KRUGER KRUGER MESSTECHNK FOR HEBEZEUGE 67 Coded information on LCD instrument (5) "Crane Information" when selector switch (7) in position "E". 67.4 Information from control panel: E:0 System stand-by E:Pr Program setting key-switch (9) not in neutral position E:E1, £2, P1, P2 ‘Al, A2, A3, EE Electronic faults EA Data receiving fault E- No data transmission EE System stop Et System Eprom Pi, At Port IC NSC 81o/1 P2) Aa Port IC NSC 810/2 AB NOVRAM X 2444 19 Anse oxic 64260 Telefon (020%) 0861-0 —_—Posgra Essen L260 10045) 167295-498 Frongedntwogs? ——uasaansson Telfer 20) 08140 ——_-Eanken”Natonabark AG Eeeon (92 98020090) 54547 vas259 Essen Telex” 8570552 Deutsche dank AG Essen (LZ 36070080) 6186103[KK KRUGER MESSTECHNIK FOR HEBEZEUGE 6.7.2 _ Information from central processor. E:00 E:01/02/03 E:04 g 2956 88 ry s. § 8 8 ROS SRB) NOTE ‘System in operation Eprom 1/2/3 faulty Port faulty RAM faulty ADC faulty Shut-off cirouit faulty Anti-2-block system activated Shut-off activated Hydraulic pressure sensor on piston side (or complete hydraulic) faulty Boom length sensor faulty Boom length sensor output too low/high Option (Telescope order changed) Option (Telescope order wrong) Boom length not in accordance with rating chart (too short/ too long) Boom angle sensor Boom angle sensor output too high Below angle limit Above angle limit Channel 4 without signal {Pressure rod side /fuffing jb angle / DMS device) yhannel 5 without signal (Service pressure transducer / Options) Channel 6 without signal (2nd length signal / Options) Channel’7 without signal (Compensation ratio / Options) No radius calculation Radius not in accordance with rating charts, Angle not in accordance with rating charts, too low / high Unused radius / angle area Area (slewing) out of load chart Unsused program number Outrigger control active Unused parts-o-line No load calculation Retracting to min. boom length! (Option) Selected telescope order wrong / Tele 2 rectracting! (Options) Error in data transmission Loss of program or faulty data processing Error in extended calculation program Eprom (Option) IF PROBLEMS CANNOT BE ELIMINATED BY FOLLOWING INSTRUCTIONS GIVEN IN PARAGRAPH 5 AND 6, CONTACT YOUR AUTHORIZED KRUGER REPRESENTATIVE. 20 Ansct Poatineh 164260 “oleon (0201) 4086-0 Postgio Eston (BL2 360 10043) 167235-498 Froingsdorig 17 (b:45252 Essen aston (2200) 4008149 anon” Natonaiark AG Enron (BL2 96020030) 14567 bases eseon Yolen 9570552 Deutscne Bark AG Esson (BL 36070050) 6185188(kK KRUGER MESSTECHNIK FOR HEBEZEUGE REMARKS FOR LATTICE BOOM CRANES The descriptions of chapters 1 ... 6 are also applicable for lattice boom cranes. Instead of hydraulic pressure transducers DMS-devices will be used for measurement in the pendant or hoist line. There will be no length measurement; the system will receive the length information from the load chart. There is no deflection calculation. Sometimes the deflection will be compensated by using a second angle transducer in the boom tip. A friction calculation will be integrated in the load calculation for compensation. Special drawings and descriptions will complete this manual, if a lattice boom is concerned. at Posten 164260 Teleon (0201) 0061-0, Postgiro Eston (B12 36010040) 167235-498 Piiotingadortweg 17. Danese basen Jolotan (o201y aocet 49 eee Netlonuirank a becom tae seo 20030) 184547IK KRUGER MESSTECHNK FOR HEBEZEUGE PREVENTIVE MAINTENANCE There are electrical, electronic, mechanicat and hydraulic components included in the KRUGER load moment system Mark 3D. It should be serviced only by qualified individuals. The operator must accept responsibility beyond just "operating". He should make a daily walkaround inspection of the crane. This inspection should include a check of the load moment system. He should be alert of any evidence of vandalism and damage before starting the crane. This daily inspection for damage should include: Check anti-2-block switch(es) and freedom of counterweight Check all connectors and plugs at the boom head for correct setup. Check if jumper cables are connected when a jib (extension), etc.) is attached ooaa0a Check anti-2-block switch (indication and shut-off) by manual liting the counterweight(s). Warning light and horn should come on, and (if installed and properly connected) the shut-off system should be activated after the counterweight is lifted up. 1 Check entire length of cable to boom length sensor (cable reel) for physical damage. 1 Check cable reel for spring tension and free rotation. a Check hydraulic and central processor boxes. Check angle transducer and load cell for damage (if installed). INSPECTION CHECK THE LOAD MOMENT SYSTEM WITH CERTIFIED WEIGHTS. FOLLOW PROCEDURE OUTLINED IN THE OPERATING INSTRUCTIONS. TEST A MINIMUM OF TWO SEPARATE RATING LIFTING CAPACITIES FOUND ON THE RATING CHART SUPPLIED BY THE CRANE MANUFACTURER. IF THE LOAD MOMENT SYSTEM INDICATES AN ERROR, RECALIBRATION BY A QUALIFIED INDIVIDUAL IS NECESSARY. NOTE WHEN REQUIRED BY LAW, CALIBRATION MUST BE VERIFIED. 22 nae Postiacn 194260 Toeton (0201) 4006-0 Postao Essen (8L2 60 10043) 16725-4938 Fingering 7 -asa02 sen Teel (9201) 4068109 akon Nasnalbani AG Essen (BL2 30020090) 154587 Doses Eseon Telex 8570552, Deutsche Bark AG Esso (LZ 36070050} 6188 188,Ke KROGER MESSTECHNK FOR HEBEZEUGE 9. REMARKS FOR SERVICE a4 Indication Unit 9.1.1 Disassembling All components are connected and screwed, so no soldering is necessary for disassembling. All components are fastened at the backside of the front panel. After remiovement of 8 screws and disconnection of a 14-pin plug as well as of two wires from the buzzer the complete electronic can be taken off, ‘The processor and the data transmission-ICs are placed in sockets. 9.1.2 Fuses The 12V consumption power is proofed by a 1A fuse (slow blow) placed on the back side of the CPU pe-boar¢. 9.1.3 Jumpers There ate 3 jumpers on the CPU pc-board. They must be placed in the same direction to the heat-sink 9.1.4 Code Switch (Pos. 0... F) In the middle of the CPU pc-board a code switch has been placed which can be adjusted by a littie screw driver. The positions are: = test operation (see chapter 9.1.6) 1 = normal operation 2= like "1*- but length indication in “ft” 3= like *2"- but load indication in Ib" 8= service operation for data transfer (see chapter 9.4) 9= test operation for data transmission Also the code switch on the CPU pe-board of the control unit must be in position 9. After pressing the green " *Information* (5) shows a line * a special description to find out what is wrong with the data transmission line. 23 Anacit Poutach 164260 ‘elton 0201) 40863-0 —_Posgro Ean (@L2 20 10048) 7295-408 Fraiyodadneg 17 Dasa san Totetor (0201) 208618 Berkon Naor AG toon (2 6020020) 154547 45230 Eaten Toler AS70552 ‘ours Bart AG son @L2 36070050) 6186183[IK KRUGER MESSTECHNIK FOR HEBEZEUGE 9.1.5 LM Needle Display The display will be mechanically pre-adjusted so that the needie is at the end of the red area, if there is no current through the display. The working range is to be adjusted as follows: Code switch at the CPU pe-board must be in pos. “0”, and the green button "Test" (13) must be pressed. The needle has to be adjusted to the green / yellow edge with the poti at the CPU-board. 9.1.6 Buttons, Lights And Displays For testing of all lights, push-buttons, switches and LCD displays the CPU code ‘switch must be in position "0" and the green button "Test" (13) must be pressed. This affects the lights to flash every 2 sec. (except the green light (13) and the info switch (6).) At the same time, the bars of the LCD displays are blank - all on - blank - informations - blank - ete. The informations on the LCD displays are: (2) = indication unit type, i. e. "AD 103" (8) = program version, i. e. "V30" (4) = position of CPU cod code switch is “ itch and information selector switch (7), i. e. information switch is “Length” (6) = positions of push buttons nothing active key-switch for program (9) key-switch for parts-of-line push-button "Down" (10) push-button "Up" (3) push-button “Tare’ (3) push-button “pre-waming" (11) Option! push-button "Horn off" (12) push-button "Inform." (6) LMI by-pass key-switch (ext. main, if wired) End of the test by switching the code switch to pos. "1" and pressing the green button “Test" (13). 24 Ansett otc 164260 _—‘Tlfon (0201) 4086-0—_Posgro Essn (LZ 36010048) 1725-438 lngedrveg 17 Boast een Telstox (201) 08149 Ganken”Nalongank AG Eta (2 602000) 54547 (Dea5239 essen Telex 8570552 Deutsche Bank AG Essen (GL2 96070080) 61051839.3 9.3.1 9.3.2 9.3.3 [IR KRUGER MESSTEGHNIK FOR HEBEZEUGE Central Unit Power Consumption The voltage inputs are only at pin 1 for 12/24 V and pin 2 for OV. The consumption is proofed by a 2A (slow blow) fuse at the DC/DC pe-board U1 Two green LEDs are on the mother board, the left one shows 12V ok, the right one shows 5V ok. General Components The connection pins, the relay functions and 5 slots are at the mother board. Ut, 2 and 8 are used as standard, U4 is mainly for some options and US is to be used for the DSD test device. The pe-boards U1, U2 and U4 could be replaced without any adjustments. The analog pc-board U3 has to be adjusted as per chapter 9.3.5, ifits to be replaced It is not allowed to remove the pe-board or to put in at power-on condition. The functions of the relays marked by a red LED are as follows: KA A-2-B-switch K2 shut-off condition (LMI and errors), activation of Bosch relay K7 K3 activation of Bosch relay K8 - some options K4 activation of Bosch relay K9 - some options KS Option K6 internal help function (no LED) K7 LMI shut-off relay (Bosch) KB -K10 Bosch relays - some options U1 - DC/DC Power Consumption System fuse = 2A (slow blow) DC/DC converter 24V - 12V (not used for 12V crane systems) - measuring point pins 3 - 5. DC/DC converter 12V - SV digital power consumption - measuring point pins 6 + 7. DC/DC converter 12V - 5V’analog power consumption - measuring point pins 13 +14. Voltage control and system reset activate the red LED. If the 5V is 5 % less or the 12V is 20 % less, the red LED comes on and the system program stops. If the 5V is 5 % higher or the 12V is 20 % higher, the fuse will be destroyed. At this moment the system gets power, the LED flashes; this is the system start pulse. 25 Postach 164260 Tetafon (0201) 4086-0 Postgiro Esson (@L2 96010048) 167235-438 .as222 Essen ‘Teletax (0201) 40861 49 Banlon_ Natlonalbank AG Essen (BLZ 360 200 20) 154547[kK KROGER MESSTECHWK FOR HEBEZEUGE 9.3.4 U2-CPU The processor- and date transfer-ICs are placed on sockets. The jumper for the overwrite protection of the EEprom (data Eprom Il) must be placed in direction to the port NCS 810, if some overwritings are to be made with the DSD terminal. In the middle of the board two additional jumpers are possible; one of them must be placed on the right side (top view, connector below). ihe code switch can be adjusted with a little screw-driver; the positions are as follows: O= test operation After pressing the green button "Test" (13) at the indication panel the system switches all relays on and off in a 1-sec-rhythm. In case of a fault or if the A- 2-B condition is activated, the rhythm will stop. += normal operation 4= like "1", but the angle solution is 0.1 degree for angle indication; all optional functions are inactive Instead of the piston side pressure indication there is the calculated compensated pressure. 5 = test operation for options &= service operation for data transfer (see chapter 9.4) 9= test operations for data transmission (see chapter 9.1.4) U3 - Analog PC-Board The adjustment of the analog input channels depends on the system configuration which is listed in a special description. On principle the voltage range of the passive transducer is 1... 49V and of the active transducer 2.5... 7.5 V. When adjusting the best way is to start with the min. value. The adjusted value is always the read-out value of the indication unit. 26 Ansett Posttach 164260 Telefon (0201) 4086-0 Postgio Esson(BLZ 360 10042) 167235438 Pratngedotneg 17 bvasez2 Eston ‘altar (2201) 40881 89 Benen” Naionatank AG Esson (SLZ 35020030) 154547 b-as200 Eston olor 9579952 ‘Deuce Bank AG Essen (@L2 96070020) 6106189IK KRUGER MESSTECHIWK FOR HEBEZEUGE ‘The normal inputs are: For hydraulic cranes Ch pressure (piston side) length angle pressure (rod side) options (pressure servie, angle luffing jib, DMS) options (2nd length, DMS) = compensation ratio Noses For lattice boom cranes Ch. 4 DMs 2 angle 3 options (luffing jib angle, OMS) 4 options (DMS) 5-7 options Channel 8 is always used for an ADC reference voltage. 93.6 U4- Options In case of options please refer to special description. 9.3.7 US Interface DSD Terminal For use of the DSD terminal the interface pc-board must be inserted. There is a special manual for using the DSD. 9.4 Data Transfer Between Central Unit and Indication Unit Four lines are required for the data transfer: RXD, CTS, RTS and TXD connected at the junction pins 41, 42, 44 and 45. In case of faults the following error codes will appear: Ee E:98 EA: See chapter 9.14, 9.34 and special description for elimination of faults. 27 Ansett poatach 164260 Telefon 0201) 4086-0 stg Eston (9LZ 96010049) 167295428 Froingadetveg 17 ulsae2 Essen Telfer 0201) 4080169, Banker Nabonaibank AG Essen (BLZ 36020030) 158547 Dias2so seen Telex 8570552 Deutsche Bark AG Essen (LZ 36070050) 6195183,(K KRUGER MESSTEOHNK FOR HEBEZEUGE 95 Basic adjustments for angle- and length transducer Angle: 1 Move main boom exact to 0 degree 1 Loose 3 screws at the angle Poti and turn it until the output voltage is 1.0V +/- 3mV. C1 Fasten the screws and check the output again. The pendulum must be in the position very close to the mechanical stop. 1 Angle adjustment at the analog po-board (U3): Move the boom to an angle of e.g. 5 degrees and adjust the readout value with the min. poti. Move the boom to an angle of e.g. 70 degrees and adjust the readout value with the max. poti. Test the lower angle again, then also the upper angle until both settings are 0k. Length: 1 Telescoping the boom to min. length. Q Turn the clutch of the length transducer transmission to an output voltage of 1.0V +/- 3mV. Length adjustment at the analog pe-board (U3): Telescoping the boom to min. boom length and adjust the readout value with the min. poti. Telescoping the boom to max. boom length (include mech. extension) and adjust the readout value with the max. poti. Test the min. length again, then also the max. length until both settings are o.k. 1 Telescoping the boom to the half and measure the length by tape. Adjust the readout value with the DSD device: Modus "M", at adress SEFEH put in a value between 00 and OFFH until the readout is 0.k. (Adress SEFFH = 00 !) 28 Anachit Posttch 164260 Telefon (0201) 40861-0 Postgiro Essen (8LZ 26010049) 167235498 Fraingadorveg 17 Bease22 essen Totton 0207) 4086149 Banker Natonalbers AG Essen (BL2 6020030) 66547 48250 Eston oer 8579552 Deutsche Bark AG Essen (LZ 96070050) 6105183Vv MARK 3D le G ESSTECHNIK FUR REBEZEUGE Zz f A 2) a » 4 4) fe 2» ¥ DISPLAY RADIUS, BOOM LENGTH BOOM ANGLE JIB ANGLE HEIGHT ERROR CODE SERVICE - INFORMATION SELECTED INFORMATION MAX. LOAD ACTUAL LOAD PARTS. OF LINE PROGRAM (CONFIGURATIONS) ANGLE LIMIT FUNCTIONS SELECTOR BUTTON RADIUS/INFORMATION BYPASS. LMI SELECTOR SWITCH BYPASS (A~2-B) HOIST LIMIT ‘SHUT OFF LMI LIGHT HORN OFF PUSH BUTTON PREWARNING LIGHT PILOT LIGHT START/TEST BUTTON TARE LIGHT TARE PUSH BUTTON ANGLE LIMIT LIGHT SELECT BUTTON ANGLE LIMITS SELECT BUTTON FORWARD SELECT BUTTON REVERSE PROGRAM SELECTOR SWITCH PARTS OF LINE F=>|(w} (<1) (>) &) (@) Ya (6) ale CD (A) () 01062592 5 4 @ ® ® a 9) @) BEER acl: BEE B aa): Ho w/o Bee aso |o|.eo...| [Bae ao 8 A = Gua ® ® | ® 9 0 3 13 i 2 4 «6 7?® Bue S Ee tn 0 ry _ Bea 5 =H | Spee BR es } ® ® w/o BBS