LOAD/ANTI TWO-BLOCK INDICATOR INSTALLATION MANUAL

LOHD -985 SYSTEM LOAD INDICATOR 10400 35400 4 400 8100 1 LOAD/ANTI TWO-BLOCK INDICATOR INSTALLATION MANUAL 1

WARNING The LOHD 985 System servicing hydraulic and lattice cranes is designed to aid the fully trained and experienced crane operator in safe crane operation. This Manual will assist in the installation of these Systems. At no time may these Systems be used as a substitute for the usual safety practices and precautions required for the safe setup and operation of the crane. 2

INSTALLATION PROCEDURES LOHD 985 SERIES HYDRAULIC & LATTICE CRANES LOHD 985 System... 5 System Features and Components... 5 Load Indicator (meter)... 6 Cable Storage Reel (lattice)... 10 Extension Reel (hydraulic)... 12 Swing-Arm Mounted Tensiometer (lattice)... 15 Tensiometer at Boom Head (hydraulic)... 19 Swing-Arm Mounted Tensiometer (hydraulic)... 22 Anti Two-Block Switch (main)... 25 Anti Two-Block Switch (jib)... 27 Anti Two-Block Switch (rooster/auxiliary)... 28 Dimensional Drawings... 31 DRAWINGS System Layout #13446, #13447 (lattice) & 13447A (hydraulic)... 7-9 Angle Sensor/Cable Storage Reel (lattice) #13391... 11 Extension Reel (hydraulic) #13278... 13 Swing Arm Mounted Tensiometer Single or Dual Load Channels (lattice) #13194 & #12148... 16 & 18 Tensiometer at the Boom Head Single or Dual Load Channels (hydraulic) #12145... 20 3

Solid Mount Single Load Channel (hydraulic) #12147... 24 Anti Two-Block Switch #13392... 26 Motion Cuts #11815 & #11816...29-30 Two-Block Switches, Cable Storage Reel, and Extension Reel Dimensional Drawing - #12149... 32 Tensiometers -Dimensional Drawing - #13403... 33 4

LOHD -985 SYSTEM Refer to LOHD System Drawings: #13446, #13447 (lattice) & 13447A (hydraulic), pages 7 & 8. The LOHD -985 SYSTEM is designed to aid in preventing overload and/or a Two-Block condition. The System provides visual and audible alarms as well as operator-settable alarms. All boom movements (hoist up, boom down, extend out) are halted when a Two-Block condition develops. This System can be used with a wide variety of hydraulic and lattice boom cranes. SYSTEM FEATURES Display of Actual Load (main & whip) Anti Two-Block Function Operator Settable Alarms SYSTEM COMPONENTS LOHD -985 Load Indicator (meter) Extension Reel Assembly, Two-Block Only (hydraulic) Cable Storage Reel (lattice) Tensiometer(s) Main Two-Block Switch Jib and Rooster Two-Block Switch(es) 5

LOHD 985 LOAD INDICATOR (meter) Refer to System Layout #13446, #13447 (lattice) & 13447A (hydraulic), pages 7 & 8. 1. CHOOSE A LOCATION FOR THE LOAD INDICATOR INSIDE THE CAB THAT ALLOWS THE SCREEN TO BE EASILY VIEWED BY THE OPERATOR WITHOUT OBSTRUCTING THE VISUAL FIELD THROUGH THE CAB WINDOW. 2. SECURELY MOUNT THE BRACKET FOR THE LOAD INDICATOR IN THE LOCATION CHOSEN INSIDE THE CAB. 3. SECURE THE LOAD INDICATOR TO THE BRACKET. 4. ROUTE THE POWER CABLE TO A 12 OR 24 VOLT DC BUSS. (POWER IS TURNED OFF WHEN THE IGNITION IS TURNED OFF.) 5. CHECK THE VOLTAGE (12 OR 24 VOLTS). 6. CONNECT THE BLACK WIRE TO "GROUND" (BAT NEG) AND THE RED WIRE TO THE 12 OR 24 VOLT DC BUSS (BAT POS). NOTE: THIS CONNECTION PERMITS THE LOAD INDICATOR TO BE EITHER ENERGIZED OR DEENERGIZED BY TURNING THE IGNITION SWITCH ON OR OFF. NOTE: IF NO MOTION CUT VALVES ARE TO BE INSTALLED, INSULATE THE ORANGE MOTION CUT WIRE. IT WILL BE "HOT" WHEN THE DISPLAY CONSOLE IS OPERATING. 7. TIE OFF AND STORE EXCESS CABLE IN A PROTECTED LOCATION. 6

JIB SWITCH A250023 CHAIN & WEIGHT A300103 CAB DISPLAY A251000 MAIN SWITCH A250003 JIB CABLE A048000-XX LOHD 985 DISPLAY CONSOLE (meter) CHAIN & WEIGHT J-BOX A260004 A048010-XX A230000-XX A048050-30 LOAD CELL LOAD CELL CABLE A048010-XX LOAD CELL A235200-0XXK A240105 REEL WITH A048050-XX FEET OF CABLE Drawing #13446 System Layout (lattice) 7

JIB SWITCH A250023 CHAIN & WEIGHT JIB CABLE CABLE STORAGE REEL A240105-XX FEET OF CABLE A300103 CAB DISPLAY A251000 MAIN SWITCH A250003 A048000-XX LOHD 985 DISPLAY CONSOLE (meter) CHAIN & WEIGHT JIB CABLE A048010-XX A230000-XX J-BOX A260004 A048050-30 LOAD CELL TENSIOMETER Drawing #13447 System Layout (lattice) 8

A300103 CAB DISPLAY LOW PROFILE LOHD 985 DISPLAY CONSOLE (meter) A230000-XX A048010-XX LOAD CELLL TENSIOMETER A040001 CABLE Drawing # 13447A System Layout (hydraulic) 9

CABLE STORAGE REEL (lattice) Refer to Drawing #13391 (page 11). The Cable Storage Reel is a hand-cranked Extension Reel that can accommodate enough cable for maximum boom length. Excess load cell or Anti Two-Block cable for shorter boom lengths can be stored there. 1. CLAMP THE CABLE STORAGE REEL TO THE LATTICE ON THE INSIDE OF THE BASE SECTION OF THE BOOM. NOTE: THE HOLE PATTERN ON THE BASE OF THE REEL WILL ACCOMMODATE CLAMPS OF VARYING SIZES. 2. TIGHTEN THE WING-NUT ON THE FRONT OF THE EXTENSION REEL. THE WING-NUT KEEPS THE REEL FROM TURNING. 10

CABLE STORAGE REEL ANGLE SENSOR ENSURE THAT AT HIGH BOOM ANGLES, THE CABLE IS NOT STRETCHED OR PINCHED TOP VIEW INSIDE RIGHT ANGLE SENSORS TO TENSIOMETER OUTSIDE LEFT TO METER Drawing #13391 Angle Sensor/Cable Storage Reel 11

EXTENSION REEL (hydraulic) The Extension Reel has 130 ft of shielded 2-wire cable, which terminates in a 3-pin connector. This cable cannot be shortened to accommodate varying boom lengths. Refer to Drawing #13278 (page 13). 1. FULLY RETRACT THE BOOM AND LOWER TO A HORIZONTAL POSITION. 2. SELECT A MOUNTING PLACE FOR THE EXTENSION REEL ON THE LEFT OR RIGHT (OPERATOR'S LEFT OR RIGHT WHEN SEATED IN THE CRANE) SIDE PANEL OF THE NON- TELESCOPING BASE SECTION OF THE BOOM. POSITION SHOULD BE PARALLEL TO THE BOOM AND FAR ENOUGH FORWARD TO AVOID OBSTRUCTION, E.G., THE CRANE CAB. 3. MOUNT THE EXTENSION REEL IN RELATION TO THE TIE-OFF POST. (SEE STEP #7 BELOW AND DRAWING #13278). NOTE: USE 3/8" DIAMETER BOLTS WELDED TO THE BOOM. IF THE BOOM IS NOT BOX SHAPED, LONGER BOLTS ARE REQUIRED ON THE TOP OR BOTTOM TO ENSURE THAT THE REEL REMAINS VERTICAL. 4. REMOVE THE FOUR ¼" - 20 TRUSS HEAD SCREWS SECURING THE COVER OF THE EXTENSION REEL. REMOVE COVER AND SET ASIDE SCREWS. 5. REMOVE THE NYLON CORDS, BLOCKS, AND PACKING USED TO LOCK THE EXTENSION REEL DURING SHIPMENT. 6. UNCOIL THE CABLE AHEAD OF THE CABLE CLAMP, BUT DO NOT REMOVE THE CABLE CLAMP FROM THE EXTENSION REEL CABLE AT THIS TIME. 7. DETERMINE THE POSITION OF THE TIE-OFF POST ON THE BOOM HEAD, ENSURING THAT WHEN THE CABLE IS CLAMPED TO THE TIE-OFF POST, ONE CABLE GUIDE (EYE BOLT) AT THE END OF EACH BOOM SECTION WILL BE VISIBLE FROM THE TIE-OFF POST. 8. WELD THE TIE-OFF POST TO THE BOOM HEAD. 9. AFTER THE TIE-OFF POST COOLS, PULL THE EXTENSION REEL-OFF CABLE TO THE BOOM HEAD AND TEMPORARILY ATTACH THE EXTENSION REEL CABLE TO THE TIE-OFF POST. ENSURE THAT THERE IS SOME TENSION IN THE CABLE. 10. INSTALL THE GUIDES, FORMING A STRAIGHT LINE FROM THE EXTENSION REEL TO THE TIE-OFF POST. ADJUST THE HEIGHT OF EACH GUIDE SO THAT THE CABLE WILL RUN THROUGH THE CENTER OF THE GUIDE HOLE. SMALL SQUARE WELD-TABS AND JAM NUTS ARE PROVIDED. (Continued on page 14) 12

CABLE ANCHOR CABLE GUIDE REEL MOUNTING 3/8" BOLT CABLE CLAMP A A THE BACK PLATE OF THE REEL SHOULD BE VERTICAL. USE LONGER 3/8" BOLTS, AS REQUIRED. SECTION A A BOOM HARDWARE KIT KO56003 Drawing #13278 Extension Reel (hydraulic) 13

(Continued from page 12) 11. WITH THE MAIN BOOM FULLY RETRACTED, GRIP THE EXTENSION REEL CABLE FIRMLY AND REMOVE THE CABLE FROM THE TIE-OFF POST; SLOWLY REWIND THE EXTENSION REEL CABLE ONTO THE EXTENSION REEL TO THE POINT OF NO TENSION. 12. CONTINUE TO REWIND THE EXTENSION REEL BY HAND UNTIL THE DISTANCE BETWEEN THE BOOM HEAD AND THE EXTENSION REEL CABLE CONNECTOR IS APPROXIMATELY 12 FT. 13. PULL THE EXTENSION REEL CABLE TOWARD THE BOOM HEAD THREADING IT THROUGH THE CABLE GUIDES. 14. SECURE THE CABLE TO THE TIE-OFF POST LEAVING 3 FT OF CABLE BEYOND THE BOOM HEAD TIE-OFF POST FOR CONNECTION TO THE ANTI TWO-BLOCK SWITCH. 15. PRE-SET THE EXTENSION POTENTIOMETER AS FOLLOWS: a) MANUALLY TURN THE LARGE GEAR, LOCATED ON THE "TRIANGLE PLATE" INSIDE THE EXTENSION REEL, FULLY COUNTER-CLOCKWISE. b) TURN THE LARGE GEAR CLOCKWISE FOR THREE "CLICKS." 16. REPLACE THE COVER ON THE EXTENSION REEL AND SECURE IT WITH THE FOUR ¼" - 20 TRUSS HEAD SCREWS. 17. CAREFULLY ROUTE THE SIGNAL CABLE FROM THE EXTENSION REEL TO THE COMPUTER BEHIND THE BOOM PIVOT SO THAT LOWERING THE BOOM DOES NOT STRETCH, PINCH, OR ABRADE THE SIGNAL CABLE. SMALL SQUARE WELD BLOCKS AND CABLE CLAMPS ARE PROVIDED. ENSURE THAT THE CABLE IS CAREFULLY SECURED TO THE PATH. 14

SWING ARM MOUNTED TENSIOMETER SINGLE OR DUAL LOAD CHANNELS (lattice) Refer to Drawings #13194 & #12148 (pages 16 & 18). 1. MOUNT THE TENSIOMETER(S) EITHER AT THE TOP OF THE TIP SECTION OR AT THE TOP OF THE BASE SECTION OF THE BOOM. NOTE: THIS POSITION IS DETERMINED BY THE NUMBER OF TENSIOMETERS TO BE INSTALLED AND WHETHER OR NOT THE WINCHES ARE SIDE-BY-SIDE OR TANDEM. THE METHOD OF INSTALLATION IS SAME FOR EITHER TIP OR BASE MOUNT. 2. WITH THE BOOM LOWERED TO THE GROUND: a. LAY THE SWING ARM BRACKET ON THE TOP OF THE BOOM. b. POSITION THE BRACKET AND LOOSELY INSTALL THE CLAMPS WITHOUT INTERFERING WITH THE LATTICE. c. MOUNT THE SWING ARM TO THE BRACKET WITH THE BOLT AND NUT SUPPLIED. 3. PLACE THE LANDING PAD BRACKET ONTO THE TOP OF THE BOOM SO THAT THE CENTER OF THE BRACKET IS APPROXIMATELY 7 INCHES FROM THE END OF THE SWING ARM: a. LOOSELY INSTALL THE CLAMPS. b. PLACE THE TENSIOMETER ON TOP OF THE LANDING PAD WITH THE LOAD CELL CABLE TOWARD THE SWING ARM. c. BOLT THE TENSIOMETER TO THE SWING ARM WITH THE BOLT AND NUT SUPPLIED. 4. BEFORE TIGHTENING THE CLAMPS ON THE SWING ARM BRACKET AND LANDING PAD, ENSURE THAT THE CENTER OF THE TENSIOMETER IS OVER THE CENTER OF THE LANDING PAD. NOTE: IF TWO TENSIOMETERS ARE TO BE INSTALLED MOUNT THE SECOND TENSIOMETER BEFORE TIGHTENING THE CLAMPS. CHECK FOR FREEDOM OF MOVEMENT OF THE JOINTS ON BOTH ENDS OF THE SWING ARM. 5. REMOVE THE BOLT THAT SECURES THE ROCKER-ARM/CENTER ROLLER ASSEMBLY DURING SHIPPING. FEED THE HOIST CABLE UNDER THE BACK OF THE END ROLLER, OVER THE TOP OF THE CENTER ROLLER, AND UNDER THE FRONT ROLLER TO THE HEAD SHEAVES. (Continued on page 17) 15

LAYDOWN INSTALLATION STANDUP INSTALLATION LANDING PAD TENSIOMETER SWING ARM MOUNTING BRACKET 13194 NOTE: THIS METHOD CAN ALSO BE USED WHEN MOUNTING THE TENSIOMETER ON THE BUTT BOOM SECTION. Drawing #13194 Swing-Arm Mounted Tensiometers Single or Dual Load Channels (lattice) 16

(Continued from page 15) IF IT IS INCONVENIENT TO UN-REEVE THE BLOCK, INSTALL THE CABLE ON THE TENSIOMETER AS FOLLOWS: a. REMOVE THE TWO END ROLLERS AND BOTH TOP SPACERS. b. SET THE HOIST CABLE INTO THE TENSIOMETER ON THE CENTER ROLLER. c. REPLACE THE END ROLLERS AND SPACERS. d. GREASE THE FOUR ZERK FITTINGS ON THE TENSIOMETER BEFORE OPERATING. 6. CLAMP THE CABLE TO THE FRAME OF THE TENSIOMETER FOR STRAIN RELIEF. 7. ENSURE THAT THE LOAD LINES WILL NOT RUB ON THE CABLE. SECURE THE CABLE ABOUT EVERY 12 INCHES ALONG THE SWING ARM. 8. LEAVE ENOUGH SLACK SO THAT THE TENSIOMETER CAN SWING TO THE STOPS IN ALL DIRECTIONS WITHOUT PULLING ON THE LOAD CELL PLUG. 9. AT THE LOWER UNIVERSAL JOINT OF THE SWING ARM, LEAVE ENOUGH SLACK FOR FREE SWING ARM MOVEMENT. 10. ROUTE THE CABLE DOWN THE BOOM TO THE LOAD INDICATOR BOX. 17

LOAD CELL CABLE LACED INSIDE BOOM TO BOOM PIVOT ENSURE THAT THERE IS ENOUGH SLACK TO ALLOW FULL MOTION OF THE SWING ARM ENSURE THAT THERE IS ENOUGH SLACK TO ALLOW FULL MOTION OF THE SWING ARM SWING ARM ASSEMBLY. SLACK CABLE AROUND HINGE AREA CLAMP TO CHORDS USING MOUNTING BRACKETS LANDING PAD CLAMP TO CHORDS USING MOUNTING BRACKETS CLAMP TO CHORDS USING MOUNTING BRACKETS. SWING ARM ASSEMBLY LANDING PAD CLAMP TO CHORDS USING MOUNTING BRACKETS MOUNT DISPLAY CONSOLE (METER) FOR EASY VIEWING BY OPERATOR. ENSURE THAT OPERATOR'S VIEW THROUGH THE CAB WINDOW IS NOT OBSTRUCTED. 12148 Drawing #12148 Swing-Arm Mounted Tensiometers Single or Dual Load Channels (lattice) 18

TENSIOMETER AT BOOM HEAD (hydraulic) SOLID MOUNT SINGLE OR DUAL LOAD CHANNELS Refer to Drawing #12145 (page 20). VERTICAL MOUNT HRT 186 ONLY - FOR CABLE WITH 3/4" DIAMETER AND UNDER The tensiometer with weld-on brackets is mounted near the tip of the non-telescoping section of the boom. Note: Cranes with only one winch that use an "A" frame or gantry for the jib (where the load line runs to a separate sheave above the boom) will need to use a swing arm arrangement to mount the tensiometer. 1. LOWER THE BOOM TO A HORIZONTAL POSITION. 2. SET THE TENSIOMETER WITH ATTACHED WELD-ON BRACKETS AT THE TIP OF THE NON-TELESCOPING SECTION OF THE BOOM. 3. ALIGN THE ROLLERS OF THE TENSIOMETER WITH THE HEAD SHEAVE (USED FOR THAT LOAD LINE) AND THE CENTER OF THE WINCH. 4. POSITION THE WELD-BRACKETS ON A SOLID, FLAT SECTION OF THE BOOM, AND TACK-WELD THE BRACKETS TO THE BOOM. DO NOT BURN THE LOAD CELL CABLE. 5. REMOVE THE TENSIOMETER FROM THE WELD-ON BRACKETS AND WELD THE BRACKETS SOLIDLY TO THE BOOM. 6. AFTER ALLOWING THE BRACKETS TO COOL, CLEAN AND PAINT THE BRACKETS. 7. REPLACE THE TENSIOMETER AND SECURE IT TO THE BRACKETS. NOTE: IF TWO TENSIOMETERS ARE TO BE MOUNTED ON THE BOOM, THE SECOND TENSIOMETER MAY HAVE TO BE SET BACK FROM THE FIRST, DEPENDING ON THE WIDTH OF THE BOOM. ENSURE THAT THE ROLLERS OF THE TENSIOMETER LINE UP WITH THE HEAD SHEAVES AND THE CENTER OF THE WINCH. 8. REMOVE THE BOLT THAT SECURES THE ROCKER-ARM/CENTER ROLLER ASSEMBLY DURING SHIPPING. FEED THE HOIST CABLE UNDER THE BACK OF THE END ROLLER, OVER THE TOP OF THE CENTER ROLLER, AND UNDER THE FRONT ROLLER TO THE HEAD SHEAVES. IF IT IS INCONVENIENT TO UN-REEVE THE BLOCK, INSTALL THE TENSIOMETER AS FOLLOWS: (Continued on page 21) 19

LOAD CELL CABLE TO METER PLACE TENSIOMETER AT TIP OF NON- TELESCOPING SECTION OF BOOM MOUNT DISPLAY CONSOLE (METER) FOR EASY VIEWING BY OPERATOR WITHOUT OBSTRUCTING OPERATOR'S VIEW THROUGH CAB WINDOW CLAMP CABLE TO SIDE OF BOOM EVERY 3 TO 4 FEET 7.5 REF 25.3 REF WELD BRACKET 4.35 REF ROUTE CABLE BEHIND BOOM PIVOT AND CLAMP SO THAT LOWERING THE BOOM DOES NOT STRETCH, PINCH, OR ABRADE THE CABLE CABLE GUARD, IF NECESSARY 12145 DUAL TENSIOMETER INSTALLATION SOLID MOUNT BOOM TOP VIEW POSITION TENSIOMETERON THE TIP OF THE NON-TELESCOPING SECTION OF THE BOOM AND MOUNT DIRECTLY ON THE NATURAL LINE OF THE ROPE WHEN THE ROPE IS ON THE CENTER OF IT'S HOIST DRUM Drawing #12145 Solid Mount Single or Dual Load Channels (hydraulic) 20

(Continued from page 19) a. REMOVE THE TWO END ROLLERS AND BOTH TOP SPACERS. b. SET THE HOIST CABLE INTO THE TENSIOMETER ON THE CENTER ROLLER. c. REPLACE THE END ROLLERS AND SPACERS. 9. GREASE THE FOUR ZERK FITTINGS ON THE TENSIOMETER BEFORE OPERATING. 10. CLAMP THE CABLE TO THE FRAME OF THE TENSIOMETER FOR STRAIN RELIEF. NOTE: ENSURE THAT THE LOAD LINES WILL NOT RUB ON THE CABLE. IF THIS HAPPENS, ADD SOME STEEL GUARDS OR GUIDES AS NECESSARY. 11. SECURE THE CABLE PATH FROM THE TENSIOMETER AND ALONG THE SIDE OF THE BOOM AND BEHIND THE BOOM PIVOT TO THE COMPUTER EVERY 3 TO 4 FEET. NOTE: ENSURE THAT THE CABLE IS NOT STRETCHED, PINCHED, OR ABRADED WHEN THE BOOM IS LOWERED. 21

SWING ARM MOUNTED TENSIOMETER (hydraulic) SINGLE LOAD CHANNEL HORIZONTAL MOUNTED HRT 181 ONLY FOR CABLES WITH 1 INCH DIAMETER AND UNDER Refer to Drawing #12147 (page 24). 1. ASSEMBLE THE SWING ARM TO THE TENSIOMETER AND PLACE IT ON THE BOOM WITH THE LOWER END OF THE SWING ARM AT THE TIP OF THE NON-TELESCOPING BOOM SECTION. NOTE: FOR CRANES WITH TWO WINCHES, MOUNT THE TENSIOMETER SO THAT THE LOAD LINE FROM THE FRONT WINCH WILL BE USED. TO PROTECT THE TENSIOMETER FROM THE REAR WINCH LINE, ENSURE THAT NO CABLE GUARDS ARE MOUNTED TO THE TOP OF THE TENSIOMETER. 2. MOUNT THE TENSIOMETER WITH THE PLASTIC SKID PADS CONTACTING THE BOOM. 3. ALIGN THE ROLLERS OF THE TENSIOMETER WITH THE SHEAVE USED FOR THE FRONT LOAD LINE AND THE CENTER OF THE WINCH. 4. POSITION THE SWING ARM PARALLEL TO THE BOOM AND WELD THE 3" BRACKETS TO THE BOOM AROUND THE OUTSIDE EDGES. 5. AFTER ALLOWING THE BRACKETS TO COOL, CLEAN AND PAINT THE BRACKETS. 6. REMOVE THE SWING ARM FROM THE 3" BRACKETS AND SET SWING ARM UPRIGHT. 7. REMOVE THE BOLT THAT SECURES THE ROCKER-ARM/CENTER ROLLER ASSEMBLY DURING SHIPPING. 8. FEED THE HOIST CABLE UNDER THE BACK OF THE END ROLLER, OVER THE TOP OF THE CENTER ROLLER, AND UNDER THE FRONT ROLLER TO THE HEAD SHEAVES. IF IT IS INCONVENIENT TO UNREEVE THE BLOCK, THE CABLE CAN BE INSTALLED ON THE TENSIOMETER AS FOLLOWS: a. REMOVE THE TWO END ROLLERS AND BOTH SPACERS. b. SET THE HOIST CABLE INTO THE TENSIOMETER ON THE CENTER ROLLER. c. REPLACE THE END ROLLERS AND SPACERS, ENSURING THAT WASHERS ARE ON EACH SIDE OF THE ROLLER. 9. GREASE THE FOUR ZERK FITTINGS ON THE TENSIOMETER BEFORE OPERATING. 10. LAY THE SWING ARM DOWN AND REATTACH ARM TO 3" BRACKETS. 22

11.CLAMP THE CABLE TO THE FRAME OF THE TENSIOMETER FOR STRAIN RELIEF. NOTE: ENSURE THAT THE LOAD LINES WILL NOT RUB ON THE CABLE. 12. SECURE THE CABLE ABOUT EVERY 12 INCHES ALONG THE SWING ARM. LEAVE ENOUGH SLACK SO THAT THE TENSIOMETER CAN SWING TO THE STOPS IN ALL DIRECTIONS WITHOUT PULLING ON THE LOAD CELL PLUG. 13. AT THE LOWER UNIVERSAL JOINT OF THE SWING ARM, LEAVE ENOUGH SLACK FOR FREE SWING ARM MOVEMENT, AND THEN ROUTE THE CABLE DOWN TO THE LOWER EDGE OF THE BOOM. 14. SECURE THE CABLE PATH FROM THE TENSIOMETER AND ALONG THE SIDE OF THE BOOM AND BEHIND THE BOOM PIVOT TO THE COMPUTER EVERY 3 TO 4 FEET. NOTE: ENSURE THAT THE CABLE IS NOT STRETCHED, PINCHED, OR ABRADED WHEN THE BOOM IS LOWERED. 23

MOUNTING BRACKET CABLE GUARD LOAD CELL CABLE TO DISPLAY CONSOLE (METER) PLASTIC SKID PADS MOUNT DISPLAY CONSOLE (METER) FOR EASY VIEWING BY OPERATOR WITHOUT OBSTRUCTING OPERATOR'S VIEW THROUGH CAB WINDOW CLAMP CABLE TO SIDE OF BOOM EVERY 3 TO 4 FEET ROUTE CABLE BEHIND BOOM PIVOT AND CLAMP SO THAT LOWERING THE BOOM DOES NOT PINCH, STRETCH, OR ABRADE THE CABLE WELD MOUNTING BRACKET ON OUTSIDE EDGE ONLY 12147 CLAMP LOAD CELL CABLE TO PIPE OF SWING ARM. ANCHOR WITH TIE-WRAPS Drawing #12147 Swing Arm Mounted Tensiometer Single Load Channel (hydraulic) 24

ANTI TWO-BLOCK SWITCH (main) The mounting method used for installing the Main Anti Two-Block switch is dependent on the identification number on the switch arm. Refer to Drawing #13392 (page 26). 1. REMOVE THE TWO 1/4 20" TRUSS HEAD SCREWS FROM THE SWITCH COVER AND SET THE COVER ASIDE. 2. LOOK AT THE PIVOTING SWITCH ARM. IF THE ARM IS CAST WITH THE NUMBER 10767, USE METHOD 1 (THE ARM WILL ALSO HAVE A G.L.G. CAST INTO IT). IF THE ARM IS CAST WITH THE NUMBER 11826, USE METHOD 2. METHOD 1 1. LOWER THE BOOM TO ZERO DEGREES. 2. FIND AND MARK A LOCATION ON THE BOOM HEAD WHERE THE SWITCH CAN BE MOUNTED AT ABOUT A 30 DEGREE ANGLE TO THE BOOM (THE ANGLE IS MEASURED FROM THE BOTTOM FRONT EDGE OF THE SWITCH). 3. ENSURE THAT THE SWITCH WILL NOT INTERFERE WITH ANY OF THE ATTACHMENTS WHEN FITTED. 4. REMOVE THE BACK WELD PLATE FROM THE SWITCH. WELD THE PLATE TO THE BOOM. ALLOW IT TO COOL, THEN CLEAN AND PAINT THE PLATE. 5. MOUNT THE SWITCH TO THE PLATE AND REPLACE THE COVER. 6. ATTACH THE CHAIN AND WEIGHT ASSEMBLY TO THE SWITCH SWING ARM. METHOD 2 1. LOWER THE BOOM TO ZERO DEGREES. 2. FIND AND MARK A LOCATION ON THE BOOM HEAD WHERE THE SWITCH CAN BE MOUNTED PARALLEL TO THE BOOM. 3. ENSURE THAT THE SWITCH WILL NOT INTERFERE WITH ANY OF THE ATTACHMENTS WHEN FITTED. 4. REMOVE THE BACK WELD PLATE FROM THE SWITCH AND WELD THE PLATE TO THE BOOM. ALLOW IT TO COOL, THEN CLEAN AND PAINT THE PLATE. 5. MOUNT THE SWITCH TO THE PLATE; REPLACE THE COVER. (Continued on page 27) 25

METHOD 1 FOR SWITCHES WITH THE NUMBER10767 CAST INTO THE SWITCH ARM (G.L.G. WILL ALSO APPEAR CAST IN THE SWITCH ARM). METHOD 2 FOR SWITCHES WITH THE NUMBER11826 CAST INTO THE SWITCH ARM CABLE FROM EXTENSION REEL MS310-1A-10SL-3P MS3101A-10SL-3P MS3106A-10SL-3S MS3106A-10SL-3S CABLE FROM EXTENSION REEL CABLE ANCHOR CABLE ANCHOR MS3101A-10SL-3P RECEPTACLE FOR JIB SWITCH MS3101A-10SL-3P (RECEPTACLE FOR JIB CABLE) MAIN TWO-BLOCK SWITCH APPROXIMATELY 30º MAIN TWO-BLOCK SWITCH WEIGHT CHAIN CHAIN HOIST ROPE WEIGHT HOIST ROPE Drawing #13392 Boom Head Anti Two-Block Switch 26

6. ATTACH THE CHAIN AND WEIGHT ASSEMBLY TO THE SWITCH SWING ARM. ANTI TWO BLOCK SWITCH (jib) The mounting method used depends on the model number of the Jib Anti Two Block switch. Remove the two 1/4-20 truss head screws from the switch cover; set cover aside. If the pivoting switch arm is cast with the number 10767 use method 1 above. If the arm is cast with the number 11826, use method 2 above. Note: The arm will also have a G.L.G. cast into it. In some cases, the Anti Two Block switch will have to be mounted behind the jib sheave. The Jib switch is connected to the main Anti Two Block switch with a cable. 1. CONNECT THE JIB CABLE TO THE JIB SWITCH, AND LACE THE CABLE INSIDE THE JIB WHERE IT CANNOT BE PINCHED OR DAMAGED. 2. SECURE CABLE EVERY 3 TO 4 FEET. A SMALL LOOP, WHICH CAN BE COILED UP WHEN NOT IN USE, WILL BE REQUIRED TO CONNECT THE CABLE TO THE MAIN SWITCH. 27

ANTI TWO-BLOCK SWITCH (rooster/auxiliary) The rooster/auxiliary Anti Two-Block switch is installed the same way as the jib switch but in most cases the cable from the switch will be long enough to connect straight to the main Anti Two-Block switch. Clamp the cable to the boom head to prevent damage. MOTION CUT SINGLE SIGNAL Refer to Drawing #11815 & #11816 (pages 29 & 30). The single orange wire (if installed on the Load Indicator), controls the motion cut signal. When not in alarm mode, the meter allows this wire to carry the positive voltage of your crane which is 12 or 24 volts DC. When an alarm occurs, the positive voltage is shut off. 1. CONNECT THE ORANGE WIRE TO ALL CUTOUT MECHANISMS; TIE THE OTHER TERMINAL OF ANY CUTOUT MECHANISM TO THE CRANE "GROUND." The motion cut valves on a hydraulic crane must be the type that open when their solenoids are energized. 2. INSTALLTHE MOTION CUT VALVES ON THE HYDRAULIC LINES FEEDING MAIN AND WHIP HOIST UP, BOOM DOWN, AND TELESCOPE OUT. 28

ANTI TWO-BLOCK MOTION CUT SYSTEM (MULTI-VALVE 4) - - - - - - - - - TWO CONDUCTOR CABLE ANTI TWO-BLOCK INSTRUMENT HYDRAULIC LINE MAIN WINCH V+ 2 CONDUCTOR 16 GUAGE 1 TELESCOPING CYLINDER AUX WINCH TELESCOPE OUT PRESSURE LINE 4 3 BOOM DOWN PRESSURE LINE 2 BOOM HOIST CYLINDER HOIST UP PRESSURE LINE CRANE CONTROL VALVE GC 11815 HYDRAULIC SCHEMATIC DRAWING Drawing #11815 Motion Cuts 29

40 GPM P/N 10773-1 C.W. ENGAGE 70 GPM P/N 10773-2 C.C.W. OVERRIDE A 6.38 A 6.81 3.00 3.00 IN 3.50 IN OIL FLOW FROM A TO B OUT B 3.00 1.75 THESE VALVES ARE TO BE PLUMBED INTO THE HYDRAULIC CIRCUITRY AT A CONVENIENT LOCATION BETWEEN THE CONTROL VALVES AND THE CYLINDERS AND/OR THE WINCH. 12V POS. OR NEG. - THEY ARE ENERGIZED FOR NORMAL OPERATION & DE-ENERGIZED WHEN A TWO-BLOCK CONDITION OCCURS. B OUT 3.50 PORTS ARE TAPPED FEMALE "O" RING S.A.E. T-16 FOR P/N 10773-1 T-20 FOR P/N 10773-2 2.25 VALVE INSTALLATION INSTRUCTIONS Drawing #11816 Motion Cuts 30

DIMENSIONAL DRAWINGS 31

MAIN TWO-BLOCK SWITCH (TYPE 1) 2.06 7.50 4.50 9.38 Ø11.00 CABLE STORAGE REEL 11.00 7.50 EXTENSION REEL 20.00 19.20 JIB TWO-BLOCK SWITCH (TYPE 1) 2.06 7.50 Ø4.75 4.26 4.50 8.52 12.00 9.38 4.13 MAIN TWO-BLOCK SWITCH (TYPE 2) 1.88 6.85 ANGLE SENSOR 3.56 4.75 UP 6.27 JIB TWO-BLOCK SWITCH (TYPE 2) 5.88 5.38 6.50 1.88 3.56 4.75 6.85 MODEL DIMENSIONS 12149 4.50 2.88 Drawing #12149 Dimensional Drawing Two-Block Switches, Cable Storage Reel, Angle Sensor, and Extension Reel 32

HRT 186 4.35 MOUNTING BRACKETS FOR STAND UP INSTALLATION ONLY HRT 181 7.50 4.31 5.34 25.38 25.38 22.00 HRT 179 26.00 10.25 8.25 13403 11.13 Drawing #13403 Dimensional Drawing Tensiometers - 33

GREER COMPANY 34

1918 East Glenwood Place Santa Ana, CA 92705 Telephone: (714) 259-9702 Fax: (714) 259-7626 35