For Accessories 11A & 11B - Manitex€¦ · lined in ASME B30.23-1998; this standard explains in...

7600012-013 A Company February 2002

Manitowoc Boom Trucks

Radio Remote Control Systemw/Tool circuit Option

For Accessories 11A & 11B

InstallationPartsService

Manitowoc Boom Trucks, Inc.3000 S. Austin Ave

Georgetown, TX 78627-1609

Sales: (512) 942-3000

Sales Fax: (512) 863-3776

Service: (512) 942-3000

Service Fax: (512) 942-3094

Web Site: www.manitowocbt.com

INTRODUCTION

The Radio Remote Control System is designed to oper-ate Manitowoc Boom Trucks crane functions from theground or Manitowoc Boom Trucks Approved manbaskets. Approval must be obtained from ManitowocBoom Trucks, Inc. prior to use with any other carrier ordevice. Manitowoc Boom Trucks makes no represen-tations as to the suitability of radio remote controls foruse on equipment other than Manitowoc Boom Truckscranes.

SAFETY

Manitowoc Boom Trucks Inc. cannot foresee all haz-ards that may arise in the field, therefore, safety re-mains the responsibility of the crane owner/user.The safety information that follows is a supplement tothe crane’s Operator Manual and is intended as a guideto assist the qualified crane operator in the safe opera-tion of the Radio Remote Control System. Referencemust also be made to the rules and procedures out-lined in ASME B30.23-1998; this standard explains ingreater detail the rules and responsibilities that are ap-plicable to the personnel working with and around ae-rial equipment.

Local, state, and other governmental agencies may re-quire stricter operating practices. When a conflict inpractices exists, follow the strictest practice.

To alert personnel to hazardous operating practicesand maintenance procedures, safety messages areused throughout this manual. The safety messagesare explained below.

Danger is used to identify animmediate hazard that can re-sult in loss of life or personal

injury if the warning is ignored.

Caution is used to identify apotential hazard that can re-sult in loss of life or personal

injury if the warning is ignored.

IMPORTANT Important is used to identify an operatingpractice or maintenance procedure that can result indamage to or destruction of equipment if warning is ig-nored.

NOTE Note is used to highlight an operation or main-tenance procedure.

Warnings

Do not operate the crane un-less you comply with the fol-lowing provisions.

Avoid injury to personnel or damage to craneand property by adhering to the following warn-

Radio Remote Controls Page 1

7600012-013 February 2002

RADIO REMOTE CONTROL SYSTEMManitowoc Boom Trucks Assemblies 6000815

© 2002

Table of Contents

INTRODUCTION ...................................................................1

SAFETY.................................................................................1

Warnings .............................................................................1

Safe Operating Practices ....................................................2

Area of operation when crane is equippedwith a man basket..............................................................2

Man basket on the Main Boom point. ...............................2

Man basket on the Jib point. .............................................2

SYSTEM COMPONENTS .....................................................3

SYSTEM DESCRIPTION.......................................................4

Radio Remote Transmitter ..................................................4

Radio Remote Receiver ......................................................4

Radio Remote Electrical Harness .......................................4

Proportional Actuator System ..............................................4

Inlet Valve (consists of the following) ................................4

Boom Hoist/Tele Pump Unloader Valve............................5

Swing Limits.......................................................................5

Proportional Electro-Hydraulic Actuators..........................5

Electrical Harness for Electro-Hydraulic Actuators ...........5

Pilot Unloader Valve (EV9) ................................................5

Swing Unloader Valve (EV49) ...........................................5

Local/Remote Key-Switch..................................................5

Tool Circuit Diverter/Relief Valve ..........................................5

INSTALLATION .....................................................................6

PRE-OPERATION CHECKS .................................................6

Visual Inspection .................................................................6

Functional Test....................................................................6

Testing The Radio Remote Control Transmitter................6

Testing Joystick Functionality ...........................................7

Testing Swing Limit System ..............................................7

Testing the Tool Circuit Switch/System.............................7

APPENDIX.............................................................................9

Calibration Procedure .........................................................9

Checking Control Console Linkage ..................................9

Checking Actuator linkage ................................................9

Set-up of Crane for Linear Actuator Calibration ................9

Turning the radio remote control system “ON”.................9

Verifying Electrical connections ......................................10

Calibrating Initial Crane Function Speed ........................10

If crane function does not move . . . . . . . . . . . . 11

If crane function moves too quickly . . . . . . . . . . 11Calibrating The Maximum Crane Function Speed..........11

If crane function stops before the joystickreaches maximum position . . . . . . . . . . . . . . 11

If the joystick stops first, crane functionappears slow . . . . . . . . . . . . . . . . . . . . . . 11

Linear Actuator “Low Range” Calibration........................12

Placing the Transmitter in normal operation mode.........12

TECNORD INST MANUAL For C-Series

PARTS

ings and safe operating practices as well asrules and procedures outlined in the ASME stan-dard referenced in this publication.

The Radio Remote Control System shall be operatedonly by personnel who are trained in the safe andproper operation of the crane and this system.

Operators must read and become thoroughly familiarwith all operation and safety instructions in this publica-tion, the Hetronic Operating Manual as well as those inthe crane’s Operator and Owner Manuals and ifequipped, the applicable man basket publication. Ifthe crane was originally equipped with a man basket,the publication is supplied with the crane and shouldbe maintained with the cranes’s owner manuals. Addi-tional copies of any of these publications are availablethrough your Manitowoc Boom Trucks Dealer. Do notoperate the crane unless all the applicable manuals areaccessible to the crane operator and crew.

Manitowoc Boom Trucks cranes and componentsdo not provide electrical isolation. For more informa-tion, refer to the Operation Near Electric Power Linessection of the Operator’s Manual.

Do not rely on the crane Overload Warning Alarmand/or LMI Alarm to warn the operator that the manbasket is out of the allowed area of operation. Thesesystems, including those with a “man basket operatingmode” are intended only as an operational aid andshall not substitute good operator judgment, experi-ence and use of accepted safe crane operating proce-dures. Refer to “Area of operation when crane isequipped with a man basket” under “Safe OperatingPractices” for additional man basket positioning notes.

Safe Operating PracticesThe operating practices outlined below are to be ad-hered to in addition to those discussed in the crane’sOperator and Owner’s Manuals.

� Check truck maintenance status, check fluid lev-els, check engine start and stop systems.

� Perform all scheduled checks and maintenanceprocedures as outlined in the crane’s OperatorManual before operating Radio Remotes. Donot operate the crane unless all functions andcontrols have been tested and are operatingproperly.

� Do not operate the crane until the outriggers andstabilizers have been extended and the crane islevel on a firm supporting surface.

� All controls on the Radio Remote Control Trans-mitter must be tested for proper operation at thestart of each shift. Do not operate the crane un-less all functions and controls have beentested and are operating properly.

� If the crane is equipped with a man basket, occu-pants must use a safety belt or body harness andsecure with lanyard to designated attach pointson the crane.

� Keep all protective and safety devices in placeand in proper working order. Do not tamper withsettings or disable safety devices when operatingthe crane.

� Check crane surroundings and overhead, noteany obstructions and electrical power lines, takenecessary precautions when operating aroundthese obstructions.

� Operate controls in a slow, controlled, cautiousmanner with no sudden movements of the crane.

� Do not operate cranes equipped withmanbaskets if winds are in excess of 20 mph(32.2 km/hr).

Area of operation when crane is equippedwith a man basket.

� The Area Of Safe Operation in which a man basketmay be positioned is governed by two differentoperating areas as described below:

� The crane’s boom may be swung and operatedonly within the Area of Operation as defined inthe Load Chart on the crane.

� The Area Of Safe Operation for positioning theman basket is defined by decals on the JibPoint, Boom Point, Operator Control Station(s)and/or manbasket. Operation of the man bas-ket is confined to these two areas.

� Boom length decals and boom angle decals withpointers are provided on the crane to assist theoperator when controlling the crane from theground or from the man basket.

Man basket on the Main Boom point.

� When using the remotes for operation of thecrane with a man basket on the main boom point,the boom length and boom angle are used to de-fine the Area of Safe Operation.

� Boom length decals and boom angle decals withpointers are provided on the crane to assist theoperator when controlling the crane from theground or from the man basket.

Man basket on the Jib point.

� When using the remotes for operation of thecrane with a man basket on the jib point, the Areaof Safe Operation is defined by the boom angleonly.

� The main boom must be fully retracted when theboom is lowered to the ground for installation ofthe man basket on the jib point, as well as whenentering or exiting the man basket from theground.

� Decals located on the Jib Point places limits onthe minimum angle allowed for safe man basketoperation when the main boom is extended.

� Minimum angle restrictions do not apply when themain boom is fully retracted.

Page 2 Radio Remote Controls

February 2002 7600012-013

SYSTEM COMPONENTS

The Radio Remote Control System w/Tool Circuit consists of the following items, refer to Figure 1.

1 Radio Remote Control Transmitter

2 Radio Remote Control Receiver

3 Electro-Hydraulic pressure reducing, pres-sure maintaining, dump & pilot pressurevalves.

4 Electro-Hydraulic Actuators (4)

5 Actuator Linkage

6 Engine Throttle Air Solenoid

7 Selector Switch, Manual-Remote

8 Rechargeable Batteries (2)

9 Battery Charger

10 Power On/Off Keys, Receiver (2) andTransmitter (1)

11 Tool Circuit Couplers

12 Hose Reel


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Figure 1 - Remote Control System w/Tool Circuit Components

Boom Angle Indicator Boom Angle Indicator

Engine Throttle Interface

8,9,107

6 2

4

5

1

12

Hoses from ToolCircuit DiverterValve insidePedestal

Hose Exten-sions, connectsto couplers onBoom point

11

11

Customer suppliedcouplers must con-form to dimensionalstandard -ISO 7241/1 Series A

Female coupler

(1) ea. required(not supplied)

Male coupler

Telescopic Jib

Boom

SYSTEM DESCRIPTION

The Radio Remote Control System is an add-on optionand is designed to interface with the Manitowoc BoomTrucks C, T & S series cranes.

Radio Remote Transmitter

The microcomputer in the transmitter processes theoperator's commands and converts them into serialdata. The command signals each receive an individualand unique address code. These commands are thentransmitted to the receiver.

The transmitter includes the following functions:

� Boom Up/Down - Winch Up/Down Joystick

� Swing CW/CCW - Boom Telescope In/Out Joy-stick

� On/Off/Program Selector Switch

� Start Communication Momentary Switch

� Winch Enable/Disable Selector Switch

� Overload Override Momentary Switch

� Red Emergency Stop Push/Pull Switch

� Low/High Range Selector Switch

� Low/High Throttle Selector Switch

� Engine Start/Stop (Calibration) MomentarySwitch

� Tool Circuit ON/OFF Switch

Radio Remote Receiver

The individual and unique address code sent by thetransmitter ensures that the receiver only responds tocommands issued by the corresponding transmitter.Thus eliminating any possibility of unintentional opera-tion.

The radio remote control system incorporates an Ac-tive Emergency-Stop System, which constantly moni-tors the communication between the transmitter andthe receiver. If this communication is lost due to: radiointerference, battery power loss, turning the transmitteroff, etc. the system will immediately send a maintainedE-Stop signal. This E-Stop signal removes all powerfrom the electro-hydraulic actuators and hydraulic un-loader valves; in addition, it will send an engine stopsignal stopping the truck's engine.

Radio Remote Electrical Harness

The electrical harness provided with the radio remotecontrol system, provides the crane interface with the ra-dio remote receiver, as follows:

� Power "ON" - Power signal (12V) provided fromthe crane's electrical system to the radio receiver;indicates that the truck's PTO is engaged. The ra-dio remote control system will power up, onlywhen there is power to the crane.

� Engine Start - Power signal (12V) provided by theradio receiver to the crane's electrical system; al-lows the operator to remotely start the truck's en-gine through the radio remote control system.

� Engine Stop - Power signal (12V) provided by theradio receiver to the crane's electrical system; al-lows the operator to remotely stop the truck's en-gine through the radio remote control system.

� Override - Power signal (12V) provided by the ra-dio receiver to the crane's electrical system; al-lows the operator to override the crane's hydrauliclockouts through the radio remote control sys-tem.

� Engine High-Throttle (DIN Connector) - Power(12V) and ground signal provided by the radio re-ceiver to the throttle air solenoid; enables the op-erator to select the engine high throttle featurethrough the radio remote control system.

� Boom Hoist and Boom Tele Unloader Valve (DinConnector) - Power (12V) and ground signal pro-vided by the radio receiver to a hydraulic two posi-tion, two way, normally open solenoid operatedunloader valve. Power is supplied only when anyone of the radio remote control joysticks is out ofneutral. Power is also supplied to this unloadervalve when the Local/Remote switch is set to Lo-cal.

� Tool Circuit Diverter/Releif Valve (DIN Connector)- Power (12V) and ground signal provided by theradio receiver to a hydraulic two position, fourway, normally open solenoid operated divertervalve. Power is supplied only when the Local/Re-mote Key Switch is set to “Remote” and Tool Cir-cuit Switch on the transmitter is set to “ON”.

Proportional Actuator System

The Proportional Actuator System requires a hydraulicpilot pressure of 250 psi to operate.

Inlet Valve (consists of the following)

� VCP - spring-loaded pressure maintenance valve

� VRP - pressure reducing valve

� EV49 - solenoid operated 2-way normally openventing valve

� EV9 - solenoid operated 3-way valve

The inlet valve is plumbed into the crane's swing circuitbetween the pump and the crane control valve. Pilotpressure is supplied by directing oil from the swingpump through the VCP valve. The VRP valve limits thepilot pressure at the actuators to 250 psi. Valve EV49vents the swing pump oil back to tank when both joy-sticks on the radio transmitter are in neutral. Valve EV9vents pilot pressure back to tank when both joystickson the radio transmitter are in neutral.


February 2002 7600012-013

Boom Hoist/Tele Pump Unloader Valve

This solenoid operated 2-way, 2 position, normallyopen venting valve is plumbed into the crane's hydrau-lic circuit between the pump and the crane's main con-trol valve (boom hoist, boom tele and outriggers). Thisvalve vents the boom hoist and boom telescope pumpoil back to tank when both joysticks on the radio trans-mitter are in neutral. This valve must be energized fornormal crane operation when using the levers at thecontrol console or operator station.

Swing Limits

On cranes without continuous rotation, the swing func-tion is limited to 372 Deg. Using a torque rod systemprovides this limit. When the swing limit is reached thetorque rod is engaged to oppose the operator's move-ment of the swing control lever, returning it to neutral.When using a radio remote control system, a means ofstopping the rotation of the crane is required to preventthe torque rod from opposing the force created by theelectro-hydraulic actuators and therefore preventingdamage to the control rod system.

A dual 2-position, 2-way normally open solenoid valvesystem is in place to vent the swing motor's supplyhoses. Both solenoid valves must be energized to al-low swinging of the crane in either direction. When aswing limit is reached the swing limit switch is engagedand removes the power supplied to the correspondingsolenoid valve, therefore venting the hydraulic oil sup-plied to the motor to tank and stopping the crane.

Proportional Electro-Hydraulic Actuators

The pilot pressure generated by the inlet valve feedstwo proportional valves (VPA and VPB) inside each ac-tuator. These valves generate variable hydraulic pres-sure in response to a pulse-width modulated (PWM)current signal alternatively fed to the coils through theelectronic circuit board (ECB). This variable hydraulicpressure is acting on the ends of the servo piston (SP),which are connected, to the control rods of each valve.This servo piston could generate as much as 250 Lbs offorce to move the crane's control valve.

As the servo piston moves a position transducer (TP)generates a feedback signal to provide the desiredcontrol in response to a given position of the radio re-mote control joystick.

Electrical Harness for Electro-Hydraulic Actuators

The harness provides the interface between the radioremote receiver, the electro-hydraulic actuators, andthe crane dump valves:

� Power and ground for the Radio Remote Controlsystem connected directly to the truck's battery.

� Miniature Din Connectors (4) for the Electro-Hy-draulic Actuators.

� #1 Swing Control

� #2 Boom Telescope Control

� #3 Winch Control

� #4 Boom Hoist Control

Pilot Unloader Valve (EV9)

Power (12V) and ground signal provided to energizethe unloader valve, when radio remote joystick is out ofits neutral position.

Swing Unloader Valve (EV49)

Power (12V) and ground signal provided to energizethe unloader valve when radio remote joystick is out ofits neutral position, or the Local/Remote switch isswitched to Local control.

Local/Remote Key-Switch

Changes the crane control from "Local" to "Remote".

� In the "Local" position, the key-switch providespower to Valve EV49 and the Boom Hoist/TeleUnloader Valve; allows normal operation of thecrane from the levers on the control console oroperator's station.

� In the "Remote" position, the control of the craneis transferred to the radio remote control sys-tem; therefore any movement of the crane'scontrol levers will not produce a crane move-ment. In this key position, solenoids on EV49and the Boom Hoist/Tele Unloader Valve arede-energized, thereby venting pump flow tothese hydraulic circuits back to tank. Power issupplied to the solenoid on these venting valvesonly when one of the radio remote control joy-sticks is displaced from its neutral position.

Tool Circuit Diverter/Relief Valve

This diverter/relief valve is plumbed into the crane’sswing cricuit between the pump and the radio remotesystem inlet valve. The block houses a 4-way, 2-posi-tion solenoid operated spool valve used to direct flowfrom the pump to the hydraulic Tool Circuit. Alsohoused in the block is a relief valve that limits the maxi-mum working pressure available to the Tool Circuit to2000 psi.

The solenoid is energized only when the crane is set-upfor remote control operation and the Tool CircuitSwitch on the radio remote transmitter is placed in theON position. Pump flow is diverted from the radio re-mote inlet valve and the crane’s swing circuit to thehigh pressure hose on the hose reel leading up to thecouplers at the boom or jib point. Bypassing the radioremote inlet valve eliminates the hydraulic pilot signalto the actuators necessary to respond to transmitterjoystick movements.


7600012-013 February 2002

The solenoid is de-energized when the crane is set-upfor normal operation from the control console or opera-tor station.

The solenoid is also de-energized when the crane isset-up for radio remote operation and the Tool CircuitSwitch is set to OFF>

INSTALLATION

Installation of the Radio Remote Control system maybe performed only by Manitowoc Boom Trucks Inc. atthe factory or by any of our authorized dealers.

The installation is done per drawing 6000815-XXX (thedash number will vary depending on the crane model).

The installation drawing covers the following items:� Bill of Material.� Installation of linear actuators & linkage.� Installation of engine hi-throttle solenoid.� Installation of swing limit switches.� Installation of receiver.� Electrical installation.� Hydraulic installation.� Installation of boom angle indicators on the

main boom and jib point.

A copy of the installation drawings are located in theparts section at the end of this publication.

PRE-OPERATION CHECKS

Perform the crane’s pre-operation and functionalchecks described in Daily Checks in the MaintenanceSection of the Owner’s and Operator’s Manual. Then,complete the following inspections.

Visual Inspection� Verify that all electrical connections shown in the

Radio Remote Control Installation drawing arepresent and properly connected.

� Verify that the engine/crane throttle linkage (if ap-plicable) operates freely without binding.

� Check the transmitter for any physical damage tosafety features. Check for broken parts on thetransmitter damaged rubber caps around joy-sticks. If any damage is evident, do not operatethe crane with the remote until the transmitterhas been repaired.

Functional TestThe Radio Remote Controls are adapted to existingcrane function controls, which are tested during theDaily Checks. The following checks are performed toverify that the Remote Control System operates thecrane controls properly.

� Move the crane to a location where there is ampleroom to operate the Boom Hoist, Swing, Tele-scope and Winch crane functions.

� Locate the radio remote selector switch inside thepedestal and set to “LOCAL” if not already set.

� Ensure that the Radio Remote TRANSMITTERPOWER SWITCH (key), is OFF (set to position“0”) and that the Key switch is removed.

� Set the EMERGENCY BUTTON to off (pull out).

� At the selected site, start truck engine and set-upthe crane for normal operation, i.e. outriggers ex-tended and crane level in all directions.

� Shut down the truck engine using theSTART/STOP SWITCH at the crane operator sta-tion.

� Re-START the truck engine using theSTART/STOP SWITCH on the crane operator sta-tion, allow engine to run momentarily, then STOPengine. If engine does not start and stop properlyfrom the crane operator station, troubleshoot andrepair start/stop feature before continuing.

� Using the crane controls at the operator stationraise the retracted boom to 65°and raise the hooksafely above the boom rest. Be sure to leaveenough room between the hook and theAnti-Two-Block weight. Shut down the truck en-gine.

� When finished, leave the engine ignition key in-side the truck cab in the RUN position, activate thePTO Switch, do not start the engine.

Testing The Radio Remote Control Transmitter

� Locate the radio remote selector switch inside thepedestal and set to “REMOTE”.

NOTE If the truck’s engine was left running, this ac-tion will shut it down. The Receiver will sensethe lack of signal from the transmitter andplace the crane in emergency shut-downmode.

� Using the BLACK capped Transmitter key, TurnON the TRANSMITTER POWER SWITCH, set toposition “I”. Listen for a short acoustical signal fol-lowed by a second signal about 3 seconds later.The POWER INDICATOR LIGHT on the transmit-ter should be flashing. If the light is steady or off,check the battery.

� Press the START BUTTON to establish transmitterto receiver communication.

� Activate the engine START function of theENGINE START/STOP SWITCH. The truck en-gine should turn on. Release the switch as soonas the engine starts.

� Activate the engine STOP function of the ENGINESTART/STOP SWITCH. The truck engine shouldshut off, communication to the receiver should re-main enabled.

� Restart engine and set the THROTTLE KNOB toHIGH. The truck engine should speed up.

� Set the THROTTLE KNOB to LOW. The truck en-gine should slow down.

� Test the EMERGENCY STOP button. Press thebutton DOWN, the truck engine should shut offand all control signals from the transmitter to thereceiver should be blocked. To re-start the truckengine, lift the EMERGENCY STOP BUTTON, re-store communication by pressing the STARTBUTTON (twice), then use the ENGINE STARTSWITCH.


February 2002 7600012-013

Testing Joystick Functionality

NOTE Testing joystick controls for the crane BoomHoist, Boom Telescope, Swing and Winchfunctions will consist of operating the Joystickat the transmitter and observing the control le-ver movement at the crane operator station(s).

To perform the following test,it is necessary to operate allfour crane functions. There-

fore, to prevent personal injury or damage tocrane or property, ensure that the crane is prop-erly set-up for operation and that the operatingarea selected is adequate to perform this proce-dure .

� Test the MECHANICAL INTERLOCK at each joy-stick control. When the switch is in the normal po-sition, the lock should hold and prevent joystickmovement.

� Slowly operate each JOYSTICK individually For-ward, Back, Left And Right. Each action shouldmove the corresponding control lever on thecrane operator station(s) and in accordance withthe function described on the decal of the corre-sponding control knob. When the joystick ismoved back to the neutral position, the corre-sponding lever should also return to neutral. Thecontrol lever should move smoothly throughoutthe operating range, sudden or intermittent move-ments can be smoothed out through proper sig-nal calibration.

� Operate each JOYSTICK individually, slowly me-ter into each function, as soon as the crane be-gins to move release abruptly, both the joystickand the corresponding control lever on the craneoperator station(s) should spring back to neutral.Test both joysticks in each direction to test all fourcrane functions.

� Test WINCH ENABLE/DISABLE SWITCH. Set theswitch on the DISABLE position. Operate theWinch Function joystick, the corresponding con-trol lever on the crane operator station(s) shouldnot move and remain in the neutral position.

� Set the switch on the ENABLE position. Operatethe Winch Function joystick, the correspondingcontrol lever on the crane operator station(s)should move as described on the decal on thecontrol knob.

� Set Tool Circuit Switch to OFF; pressure in thehigh pressure hose should drop to zero, the fourbasic crane functions should respond to joy-stick movements.

To perform the HI/LO switchtest, it is necessary to operateeach crane function at full

stroke. Therefore, to prevent personal injury ordamage to crane or property, be aware of thecranes’ beginning position and operate in thesafest direction only.

Operate at full stroke only as long as necessaryto determine if the function is properly cali-brated.

� Test HIGH range position on the HIGH/LORANGE switch. First, set the THROTTLE switch toLO. Next, position the RANGE switch on HIGHand operate any of the Joystick functions to itsmaximum position. Observe the correspondingcontrol lever and control valve linkage. A properlycalibrated joystick, when operated at full stroke,should match the full stroke of the spool at thevalve. Check both joysticks in each direction totest all four functions.

� Test LO range position on the HIGH/LO RANGEswitch. Position the switch on LO and operateany of the Joystick functions to its maximum posi-tion. The control levers should move to the cus-tomer preset reduced stroke position. Checkboth joysticks in each direction to test all fourfunctions.

NOTE Refer to the Appendix at the end of this docu-ment for information regarding calibration pro-cedures.

Testing Swing Limit System

The SWING LIMIT SYSTEM is a standard feature on allManitowoc Boom Trucks cranes except on thoseequipped with continuous rotation.

NOTE All S-Series cranes built after March 1999 areequipped with continuous rotation as stan-dard.

� With crane set-up as described in the previousstep, lift the boom off the boom rest directly overthe rear and raise to 75°. Slowly operate theSwing Function Joystick on the transmitter in theCLOCKWISE (CW) direction. When the boom isswung approximately 180° the crane should stopswinging and prevent further operation in theclockwise direction.

� Next, operate the Joystick in the COUNTER-CLOCKWISE (CCW) direction, the crane shouldswing approximately 372° and then come to acomplete stop again.

Testing the Tool Circuit Switch/System

� Set Tool Circuit switch to ON; pressure shouldbe present on the high pressure hose leadingup to the boom point.

� If necessary to confirm pressure, connect a3000 psi gauge to the high pressure coupler.The system should develop 2000 psi at the cou-pler when the Tool Circuit is selected.

� Operate any of the joysticks at the transmitter,when the Tool Circuit is on, there should be noresponse from any of the four crane functions,Boom Hoist, Boom Telescope, Winch or Swing.


7600012-013 February 2002

Should any of the functions not operate properly, verifythe installation of the Remote Controls System perdrawing provided, the crane Owner Manual, or contactyour local Manitowoc Boom Trucks dealer.


February 2002 7600012-013

APPENDIX

Calibration Procedure

IMPORTANT Do not operate the crane with the RadioRemote Control system unless the system has beencalibrated at the factory or by a qualified ManitowocBoom Trucks authorized dealer technician.

Checking Control Console Linkage

� Before installing the four (4) linear actuators(servo motors) as shown on the radio remote con-trol installation drawing check the control consolelinkage for binding.

� Manually move each control rod handle back andforth through it’s entire stroke. Make sure that,when released, the control levers are free to returnto their neutral position from both directions.

� If they don’t return freely to their neutral positionwhen released, the control rod is binding. Repairthe controls rod(s) and/or valve linkage(s) that arebinding before proceeding with the linear actua-tor installation.

Checking Actuator linkage

� After installing the four (4) linear actuators asshown on the radio remote control installationdrawing and before applying power to the craneor the linear actuators check the actuator linkagefor binding.

� Manually move each control lever back and forththrough it’s entire stroke. Make sure that, whenreleased, the control levers are free to return totheir neutral position from both directions.

� The crane control valve spring should be able tocenter the control rods and the linear actuators.

� If the control levers do not return freely to theirneutral position when released, inspect the link-age between the control rods and the linear actu-ators and make sure it is free to move.

� If the control rods continue to bind, remove the lin-ear actuator and manually pull and push the actu-ator’s rod end. If you cannot move the rodmanually, replace the actuator.

IMPORTANT Do not proceed with the installation untilall control rods return freely to their neutral positionwhen attached to the linear actuators.

Set-up of Crane for Linear Actuator Calibration

� Move the crane to a location where there is ampleroom to operate the Boom Hoist, Swing, Tele-scope and Winch crane functions.

Until the Radio Remote Sys-tem is properly calibrated,some functions may initially

operate erratically during this procedure. There-fore, ensure that an ample operating area is se-lected to perform this procedure to preventpersonal injury or property damage.

� Locate the radio remote selector switch inside thepedestal and set to “LOCAL” if not already set.

� Ensure that the Radio Remote TRANSMITTERPOWER SWITCH (key), is OFF (set to position“0”) and that the Key switch is removed.

� Once a site has been selected, start truck engineand set-up the crane for normal operation, i.e.outriggers extended and crane level in all direc-tions.

� Shut down the truck engine.

Turning the radio remote control system “ON”

� Locate the radio remote selector switch inside thepedestal and set to “REMOTE”.

� Verify that the Emergency Stop button is pulled“OUT” (up position).

NOTE This adjustment procedure requires that theRed capped programming key be used on theTransmitter Power Switch.

For normal operation use only the Blackcapped key to ensure the system is not re-ad-justed inadvertently.

7600012-013 February 2002


View inside Control Console

Control leverShown in centerneutral position

Linkage adjusted soconnectors areloose to touch whenpower is applied tothe actuators.

Actuator rod end

Existing tabs oncontrol consolelevers

Use REDcapped keywhencalibrating

PROGRAM

0

I

Transmitter Key “ON”

� Turn ON the TRANSMITTER POWER SWITCH(key), set to position “I”. Listen for a short acousti-cal signal followed by a second signal about 3seconds later. The POWER INDICATOR LIGHTon the transmitter should be flashing. If the light issteady or off, check the battery.

� Press the START BUTTON to establish transmitterto receiver communication.

� Start the engine using the START function of theENGINE START/STOP SWITCH. Release theswitch as soon as the engine starts.

Verifying Electrical connections

IMPORTANT Do not move the joysticks to their maxi-mum position before calibration, doing so could causethe linear actuator to exceed the valve stroke and possi-bly damage the linkage or linear actuator.

To prevent personal injury ordamage to crane and prop-erty, be aware of crane posi-

tion and movements throughout the calibrationprocedure.

� Check to see if each receiver plug is attached tothe correct actuator by moving each radio remotecontrol joystick slightly.

� Make sure that the joystick label and movementcorrespond to the correct crane function, use thelabel located on each control lever knob as refer-ence.

� If the incorrect control lever moves, identify thecorresponding receiver plug and plug it onto thecorrect actuator. Repeat for all four (4) cranefunctions.

� Proceed to calibration of initial crane functionspeed.

Calibrating Initial Crane Function Speed

When a joystick is activated, hydraulic pressure fromthe radio remote inlet valve is directed to the propor-tional valves in the actuator. This is accomplished via apulse-width modulated electrical signal to the coils onthe proportional valves. The actuator delivers variablepressure in response to the pulse-width modulated sig-nal to position the servo piston which in turn actuatesthe corresponding spool in the crane’s control valve.

As the servo piston in the actuator moves, a positiontransducer generates a feed-back signal to ensure re-peatability of function response to a given joystick posi-tion.

This procedure is performed to set the initial cranefunction response desired when the joystick’s initialsignal engages the corresponding actuator.

In this procedure we will move the joystick until we cansense hydraulic pressure in the inlet hose on the actua-tor manifold and then set the crane’s function responseto the desired initial speed using the Speed AdjustmentSwitch (Engine START/STOP switch when in program-ming mode).

To begin:� Make sure you have access to the pilot pressure

hose attached to the manifold on the radio remoteactuators.

� Set the Throttle High/Low Switch and the RANGEHigh/Low switch on the radio remote transmitterto the “HIGH” position.


February 2002 7600012-013

ENGINE

HIGH

TELESCOPE IN

LOW

ENGINE SPEED

L

Speed Adjustment Switch

To increase speedbump switch towards(+) position

To decrease speedbump switch towards( -- ) position

Actuators in C-Series Control Console

Pilot pressure hose

Sense initial pres-sure manually to ver-ify actuator isactivated in eitherdirection

Actuator in controlconsole C-Series

EMERGENCYENGINE

SW

HIGH

TELESCOPE IN

LOW

ENGINE SPEED

HIGHLOW

RANGE

CW

OVERLOAD

OVERRIDESTOP DISA

BO

Throttle and Range HIGH/LOW Controls

Set to HIGH

� Next, turn the Transmitter Power Switch to the“PROGRAM” mode by turning the key a ¼ turn inthe clockwise direction. The Hetronic system isnow in calibration mode.



� Place hand on the pilot pressure hose on the actu-ator manifold, slowly move the desired joystick indesired direction until you sense pressure in thehose and hold joystick position.

� Observe crane function, at this point that the se-lected function will either operate too fast or not atall.

If crane function does not move

� At the transmitter, bump the speed adjustmentswitch towards the ( + ) sign to increase func-tion speed. Ideally, it should be set to where thecrane function begins to creep when the actua-tor initially engages the crane function.

If crane function moves too quickly

� At the transmitter, bump the speed adjustmentswitch towards the ( -- ) sign to decrease func-tion speed. Ideally, it should be set to where thecrane function begins to creep when the actua-tor initially engages the crane function.

� Using this procedure, calibrate both joysticks forall four (4) directions.

� Proceed to calibrate the maximum crane functionspeed.

Calibrating The Maximum Crane Function Speed

This procedure is similar to the “initial crane functionspeed” procedure outlined above, except, you will nextcalibrate the joystick to match the crane’s valve maxi-mum spool position for each function.

To perform the following pro-cedure, it is necessary to op-erate each crane function at

full stroke. Therefore, to prevent personal injuryor damage to crane or property, be aware of thecranes’ beginning position and operate in thesafest direction only.Be aware of crane response and position at alltimes during this procedure.

To begin:� At the radio remote transmitter, set the Throttle

High/Low Switch to “LOW” position and theRANGE High/Low switch to the “HIGH” position.

� Looking at the crane control valve, observe theexposed end of the spool of the function you willcalibrate next. Look for a ring mark which indi-cates how far the spool travels into the valve sec-tion. This will give you an indication of spool travelduring calibration.

� Gradually move the desired joystick to the itsmaximum position and observe the response ofthe crane function.

NOTE If the actuator over-shoots the range of thecrane’s valve spool, the function will operateuntil the valve’s spool bottoms out, thefeed-back signal will then shut-off the actuator,and stop the crane function.

If crane function stops before the joystickreaches maximum position

� Continue holding the Joystick at the maximumstroke position.

NOTE Do not operate the speed adjustment switchuntil the joystick is at it’s maximum position.Otherwise you may affect the settings cali-brated previously.

� At the transmitter, bump the speed adjustmentswitch towards the ( -- ) sign until the functionbegins to move again, release.

� Move the same joystick back to neutral andre-test. If the function stops prematurely again,re-adjust as stated above.

� Ideally, when the joystick is at its maximumtravel, the valve’s spool should be fully stroked.Observe markings around the neck of the spoolas an approximate indicator of spool position.

If the joystick stops first, crane functionappears slow

� Using the visual marks on the valve’s spool forthe function being calibrated, try to determine ifthe spool is bottomed out when the joystick isplaced at its maximum position. When in neu-tral, the spool should move an equal distance toeach direction.


7600012-013 February 2002

I

PROGRAM

0

Transmitter Key in“PROGRAM” position

Use RED capped keywhen calibrating EENGINE

LOW HIGHLOW HIGH

ENGINE SPEED

TELESCOPE IN

RANGE


Set to HIGH

Set to LOW

� If the spool is not stroked completely, move thejoystick in the same direction once again andhold.

NOTE Do not operate the speed adjustment switchuntil the joystick is at it’s maximum position.Otherwise you may affect the settings cali-brated previously.

� At the transmitter, bump the speed adjustmentswitch towards the ( + ) sign, this will stoke thespool and increase function speed. Increasethe signal until the spool is fully stroked toachieve maximum function speed. Again, ob-serve markings around the neck of the spool asan approximate indicator of spool position.

� It is possible to over stroke the actuator duringthis procedure, if this happens re-calibrate us-ing the technique for “crane function stops be-fore the joystick reaches maximum position”.

� Using this procedure, calibrate both joysticks forall four (4) crane functions

� If desired, proceed to Low Range Calibration pro-cedure.

Linear Actuator “Low Range” Calibration

The “low range” operating mode allows the operator toselect a slower mode of operation. The “low range” op-erating mode will decrease the maximum stroke of thelinear actuators to a second preset level. This “lowrange” calibration allows you to establish a secondmaximum out position which can be adjusted from20% to 70% of the original linear actuator’s maximumposition.

This second preset value may be different for eachcrane function as determined by the crane operator.

By default, the “Low Range” setting is set at theHetronic factory to be 70% slower than the “HighRange”. If the High setting is re-calibrated this relation-ship is lost. However, when operating the system withthe Range switch placed on the low setting, internalelectronics limit the maximum throw to be equal or lessthan the High setting.

The “Low Range” signal is never calibrated byManitowoc Boom Trucks.

The crane owner/operator may elect to calibrate anyfunction to operate at a slower speed, if so desired,perform the following procedure.



To begin:� At the radio remote transmitter, set the Throttle

and the RANGE High/Low switch to the “LOW”position.

� Gradually move the desired joystick to it’s maxi-mum position and hold. Observe the response ofthe crane function.

� At the transmitter, bump the speed adjustmentswitch towards the ( -- ) sign until the functionslows down to the desired speed.

� If after testing the function you find that the cali-brated max speed does not yield the desired ef-fect, perform the procedure again.

� While holding the joystick at it’s maximum posi-tion bump the speed adjustment switch to in-crease ( + ) or decrease ( -- ) the function’soperating speed to the desired setting.

� Use this procedure to limit the maximum speed ofany other crane function as necessary.

Placing the Transmitter in normal operation mode

After all joystick functions have been calibrated turnOFF the TRANSMITTER POWER SWITCH (key), set toposition “0”.

Remove the RED capped programming key and storein a secure place. This key should only be used to cali-brate the transmitter joystick signals. To operate theRadio Remote System under normal operating condi-tions use only the BLACK capped key to power on thetransmitter.


February 2002 7600012-013

EM

TELESCOPE IN

ENGINE RANGETHROTTLE

HIGHLOW LOW HIGH


Set to LOW

Set to LOW

FrontTa ble of Con tentsIN TRO DUC TION 1SAFETY 1Warn ings 1Safe Op er ating Prac tices 2Area of op er a tion when crane is equipped with a man bas ket. 2Man bas ket on the Main Boom point. 2Man bas ket on the Jib point. 2

SYS TEM COM PO NENTS 3SYS TEM DE SCRIP TION 4Ra dio Re mote Trans mit ter 4Ra dio Re mote Re ceiver 4Ra dio Re mote Elec tri cal Har ness 4

Pro por tional Ac tu a tor Sys tem 4In let Valve (con sists of the fol low ing) 4Boom Hoist/Tele Pump Un loader Valve 5Swing Limits 5Pro por tional Elec tro-Hy drau lic Ac tu a tors 5Elec tri cal Har ness for Elec tro-Hy drau lic Ac tu a tors 5Pi lot Un loader Valve (EV9) 5Swing Un loader Valve (EV49) 5Lo cal/Re mote Key-Switch 5

Tool Cir cuit Di verter/Re lief Valve 5IN STAL LA TION 6PRE-OP ER A TION CHECKS 6Vi sual In spec tion 6Func tional Test 6Testing The Ra dio Re mote Con trol Trans mit ter 6Testing Joy stick Func tion al ity 7Testing Swing Limit Sys tem 7Testing the Tool Cir cuit Switch/Sys tem 7

AP PEN DIX 9Cal i bra tion Pro ce dure 9Check ing Con trol Con sole Link age 9Check ing Ac tu a tor link age 9Set-up of Crane for Lin ear Ac tu a tor Cal i bra tion 9Turn ing the ra dio re mote con trol sys tem fiONfl 9Ver ifying Elec tri cal con nec tions 10Cal i brating Ini tial Crane Func tion Speed 10If crane func tion does not move 11If crane func tion moves too quickly 11

Cal i brating The Max i mum Crane Func tion Speed 11If crane func tion stops be fore the joy stick reaches max i mum po si tion 11If the joy stick stops first, crane func tion ap pears slow 11

Lin ear Ac tu a tor fiLow Rangefl Cal i bra tion 12Placing the Trans mit ter in nor mal op er a tion mode 12

For Accessories 11A & 11B - Manitex€¦ · lined in ASME B30.23-1998; this standard explains in...

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Transcript of For Accessories 11A & 11B - Manitex€¦ · lined in ASME B30.23-1998; this standard explains in...