M/D Totco: Instruction Manual

M/D TOTCO
INSTRUCTION MANUAL
INSTALLATION, OPERATION, MAINTENANCE
AND
ILLUSTRATED PARTS BREAKDOWN
LOAD-WATCH SYSTEM
Manufacturers of Precision Instruments
Printed in U.S.A. March 18,1994

List of Effective Pages
Manual 70-20 Contains 104 Pages as Follows:
Cover ................................ Mar 1994

A through C ............................ Mar 1994
ithroughvi .......................... ..Mar199 4
l-l through l-2 ......................... Mar 1994
2-1 through 2-8. ........................ Mar 1994
3-l through 3-22. ....................... Mar 1994
4-1 through 4-l 4. ....................... Mar 1994
5-1 through 5-22. ....................... Mar 1994
6-1 through 6-14 ........................ Mar 1994
7-1 through 7-8. ........................ Mar 1994
A-l through A-2 ........................ Mar 1994
B-l through B-4 ........................ Mar 1994
All product, brand, or trade names used in this publication are the trademarks or
registered trademarks of their respective owners.
Information in this manual is subject to change without notice.
A March 18,1994
M/D TOTCO
IMPORTANT SAFETY NOTICE
Proper service and repair is important to the safe, reliable operation of all M/D TOTCO equipment.
The service procedures recommended by M/D TOTCO and described in the technical manuals
are recommended methods of performing service operations. When these service operations
require the use of tools specially designed for the purpose, those special tools should be used as
recommended. Warnings against the use of specific service methods that can damage equipment
or render it unsafe are stated in the manuals. These warnings are not exclusive, as M/D TOTCO
could not possibly know, evaluate and advise service people of all conceivable ways in which ser-
vice might be done or of all possible associated hazardous consequences. Accordingly, anyone
who uses service procedures or tools which are not recommended by M/D TOTCO must first sat-
isfy themselves thoroughly that neither personnel safety nor equipment safety will be jeopardized
by the method selected.
March 18,1994 B
M/D TOTCO
LIMITED PRODUCT WARRANTY
THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES,

WHETHER EXPRESS, IMPLIED OR STATUTORY INCLUDING, BUT NOT BY WAY OF LIMITA-
TION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PUR-
POSE.
M/D TOTCO warrants to Buyer (‘Purchaser”) of new products manufactured or supplied by M/D
TOTCO that such products are, at the time of delivery to the Purchaser, free of material and work-
manship defects, subject to the following exceptions: (a) Any product that has been repaired or
altered in such a way, in M/D TOTCO’s judgment, as to affect the product adversely, including any
repairs, rebuilding, welding or heat treating outside of an M/D TOTCO-authorized facility, (b) Any
product that has, in M/D TOTCO’s judgment, been subject to negligence, accident or improper
storage, (c) Any product that has not been installed, operated and maintained in accordance with
normal practices and within the recommendations of M/D TOTCO, (d) For all items of special
order by Purchaser that are not manufactured by M/D TOTCO, Purchaser should submit warranty
claims directly to the manufacturer thereof.
M/D TOTCO’s obligation under this warranty is limited to repairing or, at its option, replacing any
products which, in its judgement, proved not to be as warranted within the applicable warranty
period. All costs of transportation of products claimed not to be as warranted and of repaired or
replacement products to or from authorized M/D TOTCO service facility shall be borne by Pur-
chaser. M/D TOTCO may, at its sole option, elect to refund the purchase price of the products,
and M/D TOTCO shall have no further obligation under the Sales Agreement.
The cost of labor for installing a repaired or replacement part shall be borne by Purchaser.
Replacement parts provided under the terms of this warranty are warranted for the remainder of
the warranty period of the product upon which installed to the same extent as if such parts were
original components thereof.
The warranty periods for various products are: a) Hydraulics and Mechanical Equipment: one (1)
year from date of installation or fifteen (15) months from date of shipment from M/D TOTCO,
whichever occurs first, b) All Elastomer Diaphragms: six (6) months from date of shipment from
M/D TOTCO, c) Electronic Equipment: six (6) months from date of shipment from Y/D TOTCO.
C March 18,1994
M/D TOTCO
Paragraph/Title Page
l-1 INTRODUCTION ............................................................... .1-l

1-2 SCOPE OF MANUAL ........................................................... .1-l
l-3 INTENDED AUDIENCE. ......................................................... .1-l
l-4 PERSONNEL QUALIFICATIONS .................................................. .1-l
l-5 NOTES, CAUTIONS AND WARNINGS ............................................. .1-l
CHAPTER 2 - DESCRIPTION
2-l INTRODUCTION ............................................................... .2-l

2-2 DESCRIPTION ................................................................ .2-l
2-2-l Data Display. ............................................................ .2-l
2-2-2 Processing Electronics Unit. ................................................ .2-4
2-2-3 Boom Angle Sensor ....................................................... .2-4
2-2-4 Transducer Assembly ..................................................... .2-4
2-2-5 Alarm Horn. ............................................................. .2-4
2-2-6 Hydraulic Load Cell ....................................................... .2-4
2-3 SPECIFICATIONS. ............................................................. .2-5
CHAPTER 3 - INSTALLATION
3-l INTRODUCTION ............................................................... .3-l

3-2 COMPONENT INSTALLATION. ................................................... .3-l
3-2-l Installation Guidelines ..................................................... .3-2
3-2-2 Data Display. ............................................................ .3-2
3-2-3 Processing Electronics Unit ................................................. .3-2
3-2-4 Boom Angle Sensor. ...................................................... .3-4
3-2-4-l Boom Angle Sensor Modification. ..................................... .3-4
3-2-5 Transducer Assembly ..................................................... .3-6
3-2-6 Alarm Horn. ............................................................. .3-7
3-2-7 Hydraulic Load Cell ....................................................... .3-7
3-3 CABLE CONNECTIONS ........................................................ .3-l 0
3-4 HYDRAULIC HOSE CONNECTIONS .............................................. .3-l 0
3-5 PEU CONFIGURATION SWITCHES .............................................. .3-l 7
3-6 PEU INTERFACE RELAYS. ..................................................... .3-l 8
3-7 JUMPERS ................................................................... .3-l 6
3-8 SYSTEM CONFIGURATION REPORT. ............................................ .3-21
CHAPTER 4 - OPERATION
4-l INTRODUCTION. .............................................................. .4-l

4-2 CONTROLS AND INDICATORS. .................................................. .4-l
4-2-l Data Display, ............................................................ .4-l
4-2-2 Power Supply. ........................................................... .4-4
March 18,1994 i
M/D TOTCO
LOAD-WATCH SYSTEM
TABLE OF CONTENTS MANUAL 70-20
4-3 OPERATING MODES ........................................................... .4-s
4-3-i System Power-Up ........................................................ .4-S
4-3-2 System Power-Down ...................................................... .4-s
4-3-3 Normal Operation. ........................................................ .4-s
4-3-4 Set Offset (Tare) ......................................................... .4-7
4-3-5 Net/Gross Select ......................................................... .4-7
4-3-6 Cradle Position. .......................................................... 4-7
4-3-7 Undefined Positions l-2 in Operate Mode. ..................................... .4-8
4-3-8 Undefined Positions l-3 in Programming Mode. ................................. .4-8
4-3-9 Parts Line Selection ....................................................... .4-8
4-3-l 0 Boom Length Selection .................................................... .4-8
4-3-l 1 Display Negative Selection ................................................. .4-8
4-3-l 2 Broken Wire Detector Feature ............................................... .4-8
4-4 SYSTEM CONFIGURATION. .................................................... .4-12
4-4-l Parameter Selection. ..................................................... .4-l 2
4-5 RESETS .................................................................... .4-l 3
4-6 INTERFACE RELAYS. ......................................................... .4-13
CHAPTER 5 - SYSTEM CALIBRATION
5-l INTRODUCTION. .............................................................. .5-l

5-2 PRE-CALIBRATION CHECKS .................................................... .5-l
5-2-l Primary ac Power Check ................................................... .5-l
5-2-2 Primary dc Power Check ................................................... .5-l
5-3 OUTPUT VOLTAGE CHECKS .................................................... .5-4
5-3-l Power Supplies .......................................................... .5-4
5-3-2 Microcomputer/Interface Board .............................................. .5-4
5-4 GENERAL CALIBRATION INFORMATION .......................................... .5-S
5-5 FACTORY LEVEL CALIBRATION PROCEDURE ..................................... 5-6
5-5-l Potentiometer Voltage Adjustments. .......................................... .5-6
5-5-2 Boom Angle Low and High Calibration ........................................ .5-7
5-5-3 Main Fall Zero and Span Calibration .......................................... .5-7
5-5-4 Whip Fall Zero and Span Calibration .......................................... .5-8
5-5-5 Aux Fall Zero and Span Calibration. .......................................... .5-8
5-6 FIELD CALIBRATION PROCEDURE ............................................... .5-9
5-6-l Field Calibration Using 935747 Series Current Simulator .......................... .5-9
5-6-2 Signal Output Voltage Check. ............................................... .5-9
5-8-3 Boom Angle Calibration ................................................... .5-l 0
5-6-3-l Boom Angle Low and High Calibration Using a Known Boom Angle ......... .5-10
5-6-3-2 Boom Angle Low and High Calibration Using a Know Radius. .............. .5-l 0
5-6-4 Inter-Fall Radius Verification ............................................... 5-l 1
5-6-5 Main Fall Zero and Span Calibration ......................................... .5-l 1
5-6-6 Whip Fall Zero and Span Calibration ......................................... .5-l 2
5-6-7 Aux Fall Zero and Span Calibration. ......................................... .5-l 3
5-6-8 Negative Numbers Displayed. .............................................. .5-l 4
5-6-8-l Negative Numbers Displayed Activation ............................... .5-l 5
5-6-8-2 Negative Numbers Displayed Deactivated ............................. .5-l 5
5-6-9 Selecting Median Value ................................................... .5-l 5
5-6-l 0 Post Calibration Checks. .................................................. .5-l 8
5-6-l 1 Calibration Completion Check .............................................. .5-l 6
5-7 LOAD CALIBRATION USING TEST WEIGHTS ...................................... .5-l 7
ii March 18,1884
M/D TOTCO
LOAD-WATCH SYSTEM
MANUAL 70-20 TABLE OF CONTENTS
5-8 LOAD CELL GAP ADJUSTMENT. ................................................ .5-16
5-8-l Adding Hydraulic Fluid .................................................... .5-l 9
5-8-2 Reducing Hydraulic Fluid. ................................................. .5-l 9
5-9 FORMULAS...................................................................5-2 0
5-9-l Single Line Load ........................................................ .5-20
5-9-2 Effective Pressure at Maximum Capacity ..................................... .5-20
5-9-3 Full Scale Calibration (Not Corrected for Offset Pressure at No Load) ............... .5-20
5-9-4 Full Scale Calibration (Corrected for Offset Pressure at No Load) .................. .5-20
5-9-5 Pounds/mA Constant. .................................................... .5-21
5-9-6 Displayed Weight Value. .................................................. .5-21
CHAPTER 6 - MAINTENANCE
6-1 INTRODUCTION ............................................................... .6-l

6-2 RECOMMENDED INSPECTIONS ................................................. .6-l
6-3 TROUBLESHOOTING. .......................................................... .6-l
6-3-l System Error Indications ................................................... .6-2
6-3-2 General Troubleshooting Tests .............................................. .6-2
6-3-3 Troubleshooting Table ..................................................... .6-3
6-4 REMOVAL AND REPLACEMENT. ................................................. .6-S
6-4-l System Resets. .......................................................... .6-S
6-4-2 Data Display PCB Assemblies. .............................................. .8-S
6-4-2-l Data Display EPROM Replacement ................................... .6-7
6-4-3 Processing Electronics Unit ................................................. .6-7
6-4-3-l AC Primary Power Supply Module. .................................... .6-7
6-4-3-2 Relay PC Board. .................................................. .6-8
6-4-3-3 Microcomputer/Interface Board ....................................... .6-8
6-4-4 PEU Microcomputer EPROM Replacement. ................................... .6-l 1
6-4-5 Boom Angle Sensor Board. ................................................ .6-l 2
6-4-6 Hydraulic Transducer Replacement. ......................................... .6-l 3
CHAPTER 7 - DRAWINGS AND PARTS LISTS
7-l INTRODUCTION ............................................................... .7-l

7-2 RECOMMENDED SPARE PARTS INVENTORY ...................................... .7-7
7-3 LOAD CELLS. ................................................................. .7-7
APPENDIX A - OPERATIONAL EXAMPLES
A-l EXAMPLES ................................................................... A-l

A-l -1 Overload Relay Cutout. .................................................... A-l
A-l-2 Auto Fall Select .......................................................... A-l
A-l-3 Auto Flash .............................................................. A-l
A-l-4 System Error ............................................................ A-2
APPENDIX B - CONVERSION DATA
B-l INTRODUCTION. .............................................................. B-l

B-2 TEMPERATURE CONVERSIONS ................................................. B-l
B-3 CONVERSION FACTORS ....................................................... B-l
. ..
March 18,1994 III
M/D TOTCO
LIST OF FIGURES
Figure/Title Page
2-l Block Diagram : Industrial Two-Fall System ......................................... .2-2

2-2 Block Diagram: Intrinsically Safe Three-Fall system. .................................. .2-3
3-1 Typical Crane Parameters and Terms ............................................. .3-l

3-2 LOAD-WATCH Component Locations on a Typical Crane. ............................. .3-2
3-3 Data Display Installation Dimensions .............................................. .3-3
3-4 Processing Electronics Unit Installation Dimensions .................................. .3-3
3-5 Boom Angle Sensor Dimensions and Recommended Installation ........................ .3-S
3-6 Transducer Assembly Installation Dimensions ....................................... .3-6
3-7 Typical Alarm Horn Installation Dimensions ......................................... .3-7
3-8 Typical Hydraulic Load Cell Installations (1 of 2) ..................................... .3-8
Typical Hydraulic Load Cell Installations (2 of 2) ..................................... .3-9
3-9 LOAD-WATCH System Connections ............................................. .3-l 1
3-10 LOAD-WATCH System Wiring Diagram: ac Primary Power. ........................... .3-12
3-l 1 LOAD-WATCH System Wiring Diagram: ac Primary Power with Safety Barriers. ........... .3-13
3-12 LOAD-WATCH System Wiring Diagram: dc Primary Power. ........................... .3-14
3-13 LOAD-WATCH System Wiring Diagram: dc Primary Power with Safety Barriers. ........... .3-15
3-14 Primary Power Connections .................................................... .3-l 6
3-15 PEU Interface Board Configuration Switches. ...................................... .3-l 7
3-16 Relay Interface Plug-In Circuit Board ............................................. .3-l 8
3-17 Relay Interface Wiring Diagram ................................................. .3-l 9
4-l Data Display Controls and Indicators .............................................. .4-3

4-2 Primary Power Supply. ......................................................... .4-4
4-3 LOAD-WATCH Operation Display Examples (1 of 3) .................................. .4-9
LOAD-WATCH Operation Display Examples (2 of 3) ................................. .4-l 0
LOAD-WATCH Operation Display Examples (3 of 3) ................................. .4-l 1
5-1 Location of PEU Interface Board and Power Supply .................................. -5-2
5-2 PEU Interface Board Test Points, Jumpers, Switches and Calibration Potentiometer ......... .5-3
5-3 Load Cell Detail .............................................................. .5-18
6-1 Data Display PCB/EPROM Replacement. .......................................... .8-6

6-2 AC Module/Relay Board Replacement ............................................. .6-9
6-3 PEU Interface Board Removal and Replacement. ................................... .6-l 0
6-4 PEU EPROM Removal and Replacement ......................................... .8-l 1
6-5 Boom Angle Sensor Board Replacement .......................................... .6-l 2
6-6 Transducer Assembly Removal and Replacement, .................................. .6-l 3
7-l Data Display (1 of 2). .......................................................... .7-l

Data Display (2 of 2). .......................................................... .7-2
7-2 Processing Electronics Unit (PEU) ................................................ .7-4
7-3 Boom Angle Sensor ........................................................... .7-S
7-4 Transducer Assembly .......................................................... .7-6
March 18,1994 iv
M/D TOTCO
Table/Title Page
2-l LOAD-WATCH System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-S
3-1 Boom Angle Potentiometer Wiring. ................................................. .3-4

3-2 LOAD-WATCH Cables ......................................................... .3-l 0
3-3 PEU Interface Board Configuration Switches ........................................ .3-l 7
3-4 PEU Interface Board Jumpers. ................................................... .3-20
4-1 Data Display Controls and Indicators ............................................... .4-l

4-2 Rotary Switch Settings for Pedestal Crane ........................................... .4-2
5-1 dc Voltage Test Points. .......................................................... .5-4

5-2 Microcomputer/Interface Board Voltage Test Points .................................... .5-4
5-3 Zero and Span Adjustment Test Points. ............................................. .5-7
6-1 Recommended Inspections. ...................................................... .6-l

6-2 List of System Errors. ........................................................... .6-2
6-3 Troubleshooting Table. .......................................................... .6-3
7-l Recommended Spare Parts Inventory. .............................................. .7-7

7-2 Non-Spin Load Cells ............................................................ .7-7
B-l Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
March 18,1994 V
M/D TOTCO
LOAD-WATCH SYSTEM
TABLE OF CONTENTS MANUAL 70-20
vi March 18,1994
M/D TOTCO
CHAPTER 1
INTRODUCTION
l-l INTRODUCTION
This manual contains installation, operation, calibration, maintenance and parts information for the
LOAD-WATCH system manufactured by M/D TOTCO. Information in this manual should enable
qualified personnel to install, operate, calibrate and maintain the LOAD-WATCH system.
l-2 SCOPE OF MANUAL
This manual is divided into the following chapters:

0 Chapter 1 - Introduction to manual
Q Chapter 2 - Description of system and main components; list of system specifications
Q Chapter 3 - Installation
D Chapter 4 - Operation
Q Chapter 5 - Calibration
0 Chapter 8 - Maintenance and troubleshooting
0 Chapter 7 - Drawings, parts lists and recommended spare parts inventory
D Appendix A - Operational examples
Cl Appendix B - Conversion data
l-3 INTENDED AUDIENCE
This manual is intended for use by field engineering, maintenance, operation and repair personnel.
l-4 PERSONNEL QUALIFICATIONS
The procedures described in this manual should be performed only by persons who have read the
safety notice on Page B of this manual and who are fully qualified and trained to perform the pro-
cedures herein.
l-8 NOTES, CAUTIONS AND WARNINGS
Notes, cautions and warnings are presented, when applicable, to aid in understanding and operat-
ing the equipment or to protect personnel and equipment. Examples and explanations follow.
NOTE
Provides additional information about the current topic.
March 18,1994 Page l-l

M/D TOTCO
Chapter 1 LOAD-WATCH SYSTEM
INTRODUCTION MANUAL 70-20
CAUTION
Provides information to prevent equipment malfunction or damage that
could result in interruption of service.
I Provides information to prevent equipment malfunction or damage that

could result in serious or fatal injury to personnel or major property loss.
Page 1-2 March 18,1994

M/D TOTCO
CHAPTER 2
DESCRIPTION
2-1 INTRODUCTION
This chapter describes the LOAD-WATCH system and its main components. System specifications
are listed in Table 2-1.
2-2 DESCRIPTION
LOAD-WATCH provides accurate and constant monitoring of vital crane functions and loads,
ensuring safe and efficient operation, especially in offshore operations. Data is displayed numeri-
cally on a display mounted in the crane cab. A two-fall industrial system is shown in Figure 2-1 and
a three-fall intrinsically safe system is shown in Figure 2-2. Available LOAD-WATCHconfigurations
are listed below.
0 ac-powered, industrial
0 ac-powered, intrinsically safe
0 dc-powered, industrial
0 dc-powered, intrinsically safe
0 Standard one-, two-, or three-fall systems (Additional falls are special order.)
The main components of a LOAD-WATCHsystem are listed below and described in the paragraphs
that follow:
0 Data Display
0 Processing Electronics Unit
0 Boom Angle Sensor
0 Transducer Assembly
0 Hydraulic Load Cell
0 Alarm Horn
2-2-1 Data Display

The data display is mounted in the crane cab. It displays the following data numerically using liquid
crystal displays (LCDs):
0 Fall in use: Main, Whip, Auxl , or Aux2
0 Boom load
0 Maximum load
0 Net or Gross load indications
0 Astern (optional)
l Application specific information (optional)
0 Boom angle
0 Percent of maximum allowed load (supplemented by bar graph display)
0 Parts line (for fall selected)
0 Load radius (reach)
0 Cradle or Run mode selected
Backlighted displays are also available.
March 18,1994 Page 2-I

M/D TOTCO
DESCRIPTION MANUAL 70-20
<
TRANSDUCER
HYDRAULICLOAD
ASENBLY,
CELLS(lW@FALL)
H1225.M
<
V
GGDMANGLE
SMSOR,
H11028A
NPUTPOWER
PROCESGlNG
05102MVAC,
ELECTRGNCS
47To44oHz
ORllTO4OVDC - w PJb
H11021B
(~@'w
) CUTOUTS
LOAD-WATCH”
DATADW'LAY,H12264A
Figure 2-1. Block Diagram: Industrial Two-Fall System

M/D TOTCO
LOAD-WATCH SYSTEM Chapter 2
MANUAL 70-20 DESCRIPTION
WHIP
<
TRANSDUCER
ASSEMBLY
MAIN
BOOM ANGLE
PROCESSING ELECTRONICS
INPUT POWER l UNIT (PEU)
86-264 Vat
47-440 HZ
or 11-4oVdc
(OPTIONAL)
v
I I
DATA DISPLAY
Figure 2-2. Block Diagram: Intrinsically Safe Three-Fall System
March 18,1994 Page 2-3

M/D TOTCO
2-2-2 Processing Electronics Unit

The Processing Electronics Unit (PEU) is the common point for all input and output signals and
primary input power for the system. The PEU contains the following components.
l Microcomputer/Interface Board
0 Relay Board
0 Power Supply
The microcomputer/interface board provides processing and signal conditioning for analog inputs,
which can include boom angle and main, whip, and auxiliary loads. It is controlled by a microcom-
puter that contains controlling programs and crane data.
The eight-channel relay board provides contact closures for alarm signals and cutout equipment.
The switch-mode power supply uses 85 to 284 Vat, 47 to 440Hz, as primary power. Optional power
supply is available for 11 to 40 Vdc primary power.
2-2-3 Boom Angle Sensor

The boom angle sensor is composed of a pendulum potentiometer mounted on a terminal board
assembly. The potentiometer senses the boom angle and develops an analog output proportional
to the main boom angle. The angular range is O-90degrees. The terminal board contains a S-volt
regulator which generates a stable reference voltage for the potentiometer.
2-24 Transducer Assembly

The transducer assembly can contain up to two transducers, one for each fall. Each transducer
produces a linear dc electrical output of 4 to 20 mA, depending on the hydraulic inputs from the load
cells.
2-2-5 Alarm Horn

The alarm horn is a standard, audible alarm device used to signal when certain predetermined
parameters of the crane are exceeded.
2-2-8 Hydraulic Load Cell

The load cell is connected to the transducer assembly with hydraulic hose. The load cell provides
different hydraulic pressure outputs that correlate with the crane load.

M/D TOTCO
MANUAL 70-20 DESCRlPTlON
2-3 SPECIFICATIONS
Specifications for the LOAD-WATCH system are listed in Table 2-1.
Table 2-I. LOAD-WATCH System Specifications
Parameter Requirements/Limits
Primary Power 85 to 264 Vat, 47 to 440 Hz (11 to 40 Vdc - optional)

Ambient Operating Temperature -2OOFto +l 40°F (-29OCto +60°C)
Standard Input Signals 0 to 5.0 volts, 4 to 20 ma
*System Accuracy Weight il% of full-scale, static system
Display Accuracy:
Boom Load Six digits in Ibs
Max Load Six digits in Ibs
Boom Angle Two digits, 0’ to 90° in increments of lo
% Max Load Three digits
Parts Line Two digits
Radius Three digits, feet or meters
Housing Dimensions
Data Display 8.4”Lx 10.2”Wx4.4” H (259.lmmx213.4mmx 111.7mm)
PEU 14.0” L x 16.0” W x 6.2” H (406.4mm x 355.6mm x 157.5mm)
Boom Angle Sensor 6.0” L x 6.0” W x 4.0” H (152.4mm x 152.4mm x 101.6mm)
Transducer Assembly 6.0” L x 6.0” W x 4.0” H (152.4mm x 152.4mm x 101.6mm)
Hydraulic Load Cell Refer to Chapter 7
Alarm Horn Refer to Chapter 7
Weight
Data Display 11 Ibs (4.99 kg)
PEU 36Ibs (16.33 kg)
Boom Angle Sensor 5 Ibs (2.27 kg)
Transducer Assembly 5 Ibs (2.27 kg)
Hydraulic Load Cell Refer to Chapter 7
Alarm Horn 6 Ibs. (2.72 kg)
(Continued)

M/D TOTCO
Table 2-l. LOAD-WATCH System Specifications (Continued)
Parameter Requirements/Limits
Alarms
Approaching Maximum Flashing display and intermittent horn at 80-l 00% of rated load
Safe Load (factory programmable only)
Exceeds Maximum Safe Flashing display and continuous horn at 100-l 10% of rated load
Load (factory programmable only)
High Boom Angle Limit Flashing display and continuous horn
Low Boom Angle Limit Flashing display and continuous horn
l This does not take into account sheave friction or acceleration factors.

M/D TOTCO
CHAPTER 3
INSTALLATION
3-I INTRODUCTION
This chapter contains information for installing LOAD-WATCH system components and connecting
the cables and hydraulic hoses.
3-2 COMPONENT INSTALLATION

Procedures for installing LOAD-WATCH system components are presented in the following para-
graphs. Figure 3-l identifies typical crane parameters and terms. Figure 3-2 identifies approximate
locations of LOAD-WATCH components on a typical crane.
Figure 3-1. Typical Crane Parameters and Terms
March 18,1994 Page 3-I

M/D TOTCO
INSTALLATION MANUAL 70-20
Transducer
Electronics
Unit(PEU)
Figure 3-2. LOAD-WATCH Component Locations on a Typical Crane
3-2-l Installation Guidelines

Follow the guidelines below during installation.
1. Always allow adequate space for cable and hose connections.
2. Mounting locations may vary according to space available in each crane application.
3. Allow room for access to enclosures (PEU, Boom Angle Sensor).
3-2-2 Data Display

Refer to Figure 3-3 and select a location for mounting the data display in the crane cab. Ensure
that the display will not restrict the crane operator’s view. A mounting bracket is included with the
display.

Refer to Figure 34 and select a location for mounting the processing electronics unit (PEU). If space
permits, it is best to mount the PEU in the cab area or in close proximity to the cab and away from
any heat-generating devices, such as motors or engines. However, if the PEU cannot be mounted
in the cab, it may be mounted at the heel pin, which centralizes the wiring, or in the winch room for
maximum physical protection to the PEU.

M/D TOTCO
MANUAL 70-20 INSTALLATION
0 0 0 0 0 0
e l
Mounting
Bracket e l
LocatedonRwof
a12
DisplayUnit e l
5.12 e e
l l
4 ixLl 0 0 0 0
Figure 3-3. Data Display Installation Dimensions
0412Dlameter
,(4PI-4
0.75NPT
f-
Figure 3-4. Processing Electronics Unit Installation Dimensions

M/D TOTCO
3-24 Boom Angle Sensor

Follow the steps below and refer to Figure 35 to install the boom angle sensor.
1. Mount the boom angle sensor assembly on the inside left of the boom, as close as possible
to the foot pin (see Top View, Figure 3-5). Ensure that the center-line of the sensor
assembly is parallel to the center-line of the boom, or is within 0.5’ of being parallel to
the boom (see Side View, Figure 3-5).
CAUTION
If the boom angle sensor assembly is not mounted parallel to the boom or within
0.5’ of being parallel to the boom, the system might not operate correctly.
2. Fabricate a mounting bracket. Make sure that the four mounting holes are large enough
toallow the mounting bolts to fit loosely,which permitsslight rotation of the entire assembly
for accurate boom center-line alignment.
3. Lower the crane boom to its lowest safe horizontal position.
4. Open the cover of the sensor assembly enclosure and note the direction of the arrows.
The sensor assembly must be mounted with these arrows pointing to the boom tip and top.
5. Align the sensor assembly and mounting bracket to the selected boom location.
6. Secure the sensor assembly to the mounting bracket; then secure the mounting bracket
to the boom.
3-24-l Boom Angle Sensor Modification

If the boom angle sensor assembly must be mounted on the right side of the boom instead of on the left,
it must be modified. Follow the steps below and refer to Figure 6-5 to modify the sensor assembly IF
AND ONLY IF the sensor assembly is mounted on the right side of the boom.
1. Loosen the retaining screws to the sensor assembly cover and remove boom angle
sensor board.
2. Remove the four screws retaining the pendulum potentiometer.
3. While viewing the front of the sensor board, rotate the potentiometer 90’ counter-
clockwise; then reinstall the four retaining screws.
4. Desolder and disconnect the red and black wires.
5. Connect and resolder the red and black wires in opposite positions (Table 3-l).
6. Reinstall sensor board; then replace the sensor assembly cover.
Table 3-1. Boom Angle Potentiometer Wirlng
Pot Pin No. if Mounted Pot Pin No. If Mounted

Wire Color
on Left Side of Boom on Right Side of Boom
Black 1 3
White 2 2
Red 3 1
Page 34 March 18,1884

M/D TOTCO
0.75NPT
- _ Bracket
Fabricated
e by Customer
Top
view
, lower BoomWon
Side
View - RoomCenterLine
-
+I- 0.5O
Figure 3-5. Boom Angle Sensor Dimensions and Recommended Installation

MID TOTCO
3-2-6 Transducer Assembly

Mounting dimensions for the transducer assembly are shown in Figure 3-6. Mount the assembly on
the boom as close as possible to the hydraulic load cell(s) to minimize possible hydrostatic head
pressure differential.
- K- 4.75 ----ii
.75
JI
---
,312Diameter
(4 Places)
I 4lz:__
(0 ---
-
‘\\\ \
Tl
6.50
7.50
0
6.75
: :
6.00 -+ pA.375
Figure 3-6. Transducer Assembly Installation Dimensions

M/D TOTCO
MANUAL 70-20 INSTALLAnON
3-2-6 Alarm Horn

The alarm horn is available in a variety of configurations. Mounting dimensions for a typical horn
are shown in Figure 3-7. Mount the horn under the cab and aimed at the boom to ensure good
audibility.
HornrhownbH126&2.
Dlmensbnsvary
dependlngonhom
selected.
Figure 3-7. Typical Alarm Horn Installation Dimensions
3-2-7 Hydraulic Load Cell

The hydraulic load cell is available in a variety of configurations (Table 7-2). Installation examples
of typical hydraulic load cells are shown in Figure 3-3. Install the load cell at the dead end or cable
end, as shown.
CAUTION
To ensure proper load cell operation, verify that the load cell hangs free and
completely clear of all obstructions at all operating angles.
March 18, 1994 Page 3-7

M/D TOTCO
DeadEndPd DadEndPad IbdEndPad

EYE EP Ev,
Cbvb Exten8bnPlate Ph
Ph ShEkOl
LoadCell
w8dgmd
wedgesocht SW@l
Wh Rope Wedp md
CIP wad@ socket
WhRap,
Clip
DeadEndW
eye
shackel
lmd call
wedgeand Wh Rop8
W8d@soclnt Clip
~whRope WWd
cm wedgesocht
DeadEndPad Lad cdl1

m
Loadcell
WdPd
w*-
WireRope WhfW
WMlpmd Clip Clip
wedp socket
Wh Rope
CM
Figure 3-8. Typical Hydraulic Load Cell Installations (1 of 2)

M/D TOTCO
MANUAL 70-20 INSTALLATlON
load Cellatdead Loadcellatdsadendon Loadcellsuspendedbylink

endinsideboom undersideof boom or pendant
whendeadend
locatsdontopof boom
Loadcellsuspended Loadcellatdeadendon Loadcellatdeadend

betweenboomand undersideof boom belowupperblock
Loadcellatdsadends Loadcellatdeadend
onundersideandinsideof in boombutt
Todrum
Leverwithsheaveandload
cell(loadcellbeneath
heave)
Figure 3-8. Typical Hydraulic Load Cell Installations (2 of 2)
March 18, 1994 Page 3-9

M/D TOTCO
INSTALLATlON MANUAL 70-20
3-3 CABLE CONNECTIONS

The cables used in LOAD-WATCH are listed in Table 3-2. Armor-jacketed cable is standard; non-
armor-jacketed is optional. The number of conductors required depends on the number of fall
transducers.
Refer to Figure 3-9 to connect these cables. Refer to Figures 3-10 through 3-14 for interface wiring
hookups for ac and dc primary power systems.
CAUTION
Connect and isolate grounds and shields per the appropriate wiring
diagram. Improper connections could result in electrical interference, short
circuits and/or ground loops.
Table 3-2. LOAD-WATCH Cables
Cable No. of Conductors Part No.
Input Power/PEU 4 H1091OA-4AJ

Horn 4 H1091OA-4AJ
Boom Angle Sensor 12 H10910A-12AJ
I Transducer H1091OA-7AJ
1 Data Display H1091OA-7AJ
3-4 HYDRAULIC HOSE CONNECTIONS

Hydraulic hose connects each transducer assembly to the appropriate hydraulic load cell. The hose
is 0.25” (6.35mm) inside diameter and available in lengths of 1’ to 50’ (0.3m to 15.24m). Hydraulic
hose connections are shown in Figure 3-9.
CAUTION
Make sure each hydraulic hose is connected to the correct transducer, as
labeled on the terminal block inside the transducer assembly.
If bleeding or load cell gas adjustment is required, refer to Chapter 6.
Page 3-10 March 18,1884

M/D TOTCO
Hydraulic Hoses
\
: : ... .: ., .... .,. .,. ,_ ..
: .. .: ..:;;:: ~+.,‘:,)+);: ..:,..::.:j:.;::::j :... :;
i ..:.. :: ;.. ,. ..:’ :.:“, ..
“’ 3..
.:.:::.“‘:.:.::.
.:::,j;:<:..::, J234 ’
:‘:
” ‘:--i~~~~~:i~~
...::
..:>.: :..:. .: .:,:
,.,.
..::,:.:.:
:.
.._.. :.:...:.,:. .:...,. ,,.:,j

..j...::... ...:.
...::.::.::
..:,:::.
...)...
:. .:I.;::
j.:... j.,:..,.,:.:
:::::.:.:.
i.:..
j.:::::.
:.::ji::l:i.;:i::.:.i
ii;.fW&. p+&i;ijjj Hydraulic Load
~~:i:~~ ,,,,, ,..91~-:i-iii:I:;sj:~~~~~ . ‘.‘.’ ” _ Cells (Three-Fall)
,...: ..:.;.: .,_,...........
.i..
,.,.:.
.
::i:li;ii:~~~~~~~~,-il . .,..:::.:.:.:‘.:,:,::::_‘:::‘:::
.:::.:::::.z:
.. ..::. . .,.,_. ‘,....:.:.:.:,(:
:,:,: :,.;
::::,:
..:,::;.;...
..../
.....:.::::
.....:.:.:
..::.::x:,;::.:
..,.,.
.,
.
:::.:::.:.:. .:. ......,,,.:(.):...,....:.
.,.,.,_,_,...::
..,;;
...,.,.:::.::: .
:., :.:,::
.,:,:,:,:
::,:::/:::: . I.E.1
::)::::)::,::.:
,\....._........
....::
.:. ::.: :,j:I’:j~:~:.:‘::..~::..:::j:j:.\.
..:.,.......
..:... ...::y:,:
.c.:.:...:_ ::::y:~.:.:
.....::::::.:~‘..:::: ..:::,:.,
:......,.,.,.:
.,...:
: ::.__::‘:::::‘:~:.: :‘.:;,,
:;:::~:.::,~.‘::~:::~~.:;::::::j-;:::::~.:.~,~
.,,,:
:.:.:.:
:.j.
.,.,
,.::.
.A....
::.:.: ......:..
.:.,I.:..
.,...
.....I ...A....
..........:..:...j...
:..,.,.
:.:.:.:.:.;.:. :.....:....,.
.,::.:I:.?.
_, .::.
.,:.:..:.y.:.,,..::,
.,.,
:.y.:. .\.:,:,.
;::. :.:,.:...>;
.../......(
(i..,,.. ,._
:‘(‘:‘;:,:
.:.))):.,
.,.
:._.:...
:,:,:,..
.,...
I I
HlO91OA4AJ for
Two-Fall Configura-
tion
-.-
c H1091OA-7AJ
HlO91OA-4AJ
H 1091 OA-7AJ for

Two-Fall Conflgura-
/ tion
’ Data Display
H12264A
Figure 3-9. LOAD-WATCH System Connections
March 18,1994 Page 3-11

M/D TOTCO
Figure 3-10. LOAD-WATCH System Wiring Diagram: ac Primary Power
f
J
Figure 3-11. LOAD-WATCH System Wiring Diagram: ac Primary Power with Safety Barriers
March 18, 1994 Page 3-13

M/D TOTCO
Figure 3-12. LOAD-WATCH System Wiring Diagram: dc Primary Power
Figure 3-l 3. LOAD-WATCH System Wiring Diagram: dc Primary Power with Safety Barriers
March 18, 1994 Page 3-15

M/D TOTCO
INSTALLATION MANUAL 70-20.
FUSE
1 AMP SLOW
AC INPUT
I
AC Primary Power DC Primary Power
Terminal Block Terminal Block
NOTE:
Wire colors conform to National Electrical Code
Specification NFPA 70
AC Primary Wire Color I DC Primary 1’ Wire Color I

Ground * Green
Neutral (N) White
1 Line (L)
Figure 3-14. Primary Power Connections
Page 3-16 March 18,19Q4

M/D TOTCO
3-5 PEU CONFIGURATION SWITCHES

The PEU microprocessor/interface board contains switches for configuring LOAD-WATCH. These
switches are identified in Figure 3-l 5. Table 3-3 lists the switch types and functions.
PUSHSUllON
OFF 4-b ON
10 Sl
s4
I@ I 62
lo I s3
Figure 3-l 5. PEU Interface Board Configuration Switches
Table 3-3. PEU Interface board Configuration Switches
Switch Type Function
Sl Push-button Resets the system without affecting current variables

s2 Push-button Not used
s3 Push-button Resets the system and reloads initial system tables from EPROM when
S3 and Sl are pressed simultaneously
s4 Toggle Selects auto fall mode when set to ON. Selects manual fall mode when
set to OFF.
s5 Toggle Enables auto-flash when set to ON. Disables auto-flash when set to OFF.
March 18,19Q4 Page 3-17

M/D TOTCO
3-6 PEUINTERFACERELAYS
Relays are used to activate alarms, cutouts and optional, customer-specified functions. Relay Kl
is the alarm relay; relays K2 and K3 are identical overload relays. Relays K4 through K8 can be
added to meet customer requirements, such as lights for alarms or external lights to indicate
overload.
The relays plug into positions Kl through K8 of the relay circuit board (Figure 3-18), located in the
PEU. The relay interface diagram is shown in Figure 3-17.
Iml
ASSY. NO. PCE312A fw.m !ERALNa-
lrn
Figure 3-l 8. Relay Interface Plug-In Circuit Board
3-7 JUMPERS
Table 3-4 lists the function and configuration of each jumper on the PEU microprocessor/interface
board.
Page 3-18 March 18,1994

M/D TOTCO
Plug-In Relays
IL
T61
1 NC
NO
CON
NC
Inputs
No
CON
NC
No
CON
NC
NO
NC
NO
I1
2 y7
Inputs 311 yz T7 26 NO
Ka 1 I I
Figure 3-17. Relay Interface Wiring Diagram
March 18, 1994 Page 3-19

M/D TOTCO
INSTALLATION MANUAL 7429
Table 3-4. PEU Interface Board Jumpers
Jumper Purpose Configuration
JPl Add or remove transmit current Installed when barrier used in current loop between
loop 150 ohm resistor PEU and display. Removed when barrier not used.
JP2 Used with transmit current loop When installed between JP2-1 and JP2-2, current
loop is sourced by 12 V from PEU. When installed
between JP2-3 and JP2-4, current loop is sunk to
ground by PEU (normal LOAD-WATCH applica-
tions). When installed between JP2-2 and JP2-4,
current loop is sourced and sunk external to PEU.
JP3 Used with receive current loop When installed between JP4-1 and JP4-2, current
loop is sourced by 12 V from PEU (normal LOAD-
WATCH applications). When installed between
JP4-3 and JP4-4, current loop is sunk to ground by
PEU (normal LOAD-WATCH applications). When
installed between JP4-2 and JP4-4, current loop is
sourced and sunk external to PEU.
JP4 Add or remove receive current Installed when barrier used in current loop between
loop 150 ohm resistor PEU and display. Removed when barrier not used.
JP5 Connects analog and digital Hard-wired
ground
JP8 Controls voltage output and When installed, V-out at TB3-1 is 10 V and current
current limiting of the voltage limit is 100 mA (industrial). When not installed, V-
regulator circuit that powers the out at TB3-1 is 18 V and current limit is 50 mA (I.S.).
display (3 x 2 pin jumper) I.S. configuration used when display is powered
through MTL 788P dual barrier. With barrier, a
second voltage regulator with 18 Vand 50 mA isalso
used. TB3-1 and TB2-1 are each connected to an
MTL 788P barrier on the safe side. Hazardous side
of each barrier is tied together and connected to
display power input.
JP7 Testing Normally installed
JP8 Future communication applica- Installed between pins 2 & 3, 5 & 8, 8 & 9, 11 & 12
tions. Configured at factory. Do
not change in field.
JP9 Same as JP8 Installed between pins 1 & 2, 5 & 8, 7 & 8, 10 & 11
JPlO Installed at factory, if required
JPll Determines size of EPROM Installed between pins 2 & 4 for 84k x 8
Installed between pins 1 & 3 for 32k x 8
JP12,14, 18, Not required
18,21,23,
25,27
JP13, 15, Specifies sensor input type Current input: pins 1 & 3,2 & 4, 5 & 8
17, 19, 20, Single-ended voltage input: pins 3 & 4, 5 & 8
22, 24,28 Differential voltage input: pins 3 & 4
Page 3-20 March 18,1994

M/D TOTCO
3-8 SYSTEM CONFIGURATION REPORT

Each system ships with a unique system configuration report, consisting of the following sections:
SECTION 1 - Summary of the application. Provides general information about system power,
number of falls, specific load cells, pressure transducers, EPROM part number and revision.
SECTION 2 - Provides crane geometry details and lists each table programmed into the EPROM.
These are typically identified by boom lengths and parts line, but may be referenced by dynamic
factors, list, or astern specifications.
I 1
The tables must be reviewed to ensure they match the load radius chart in
the crane cab.
SECTION 3 - Block diagram grouping cable lengths, placement of enclosures and system bill of
materials.
March 18,1994 Page 3-21

M/D TOTCO
Page 3-22 March 18,1994

M/D TOTCO
CHAPTER 4
OPERATION
4-1 INTRODUCTION
This chapter describes the following:
l Operating controls and indicators for the data display and PEU power supply
. Normal and special operating modes of the LOAD-WATCH system
l System configuration
4-2 CONTROLS AND INDICATORS

Controls and indicators for the LOAD-WATCH data display and PEU power supply are presented
in the following paragraphs.
4-2-l Data Display

The data display controls and indicators are described in Table 4-1 and shown in Figure 4-1.
Table 4-1. Data Display Controls and Indicators
Control/Indicator Function
BOOM LOAD Displays the following: 1) either gross or net load of active fall in normal
operate mode, 2) fall load during calibration, 3) messages during cradle mode
in conjunction with MAX LOAD display, 4) parts line or boom length selection
during programming mode, and 5) features in programming mode
MAX LOAD Displays the following: 1) maximum load limit in normal operate mode, 2)
messages during cradle mode in conjunction with BOOM LOAD display, 3)
current parts line or boom length numbers in conjunction with BOOM LOAD
display in programming mode, and 5) features status
MAIN Lights up to indicate main fall is selected in normal operating mode.
WHIP Lights up to indicate whip fall is selected in normal operating mode
AUXl If available, lights up to indicate auxiliary 1 fall is selected in normal operating
mode
AUX2 If available, lights up to indicate auxiliary 2 fall is selected in normal operating
mode (special order)
GROSS Lights up to indicate gross load is selected by rotary and push-button switches
in normal operating mode
NET Lights up to indicate net load is selected by rotary and push-button switches
in normal operating mode
(Continued)
March 18, 1994 Page 4-l

M/D TOTCO
OPERATION MANUAL 70-20
Table 4-l. Data Display Controls and Indicators (Continued)
Control/Indicator Function
BOOM ANGLE Displays boom angle of active fall, in degrees

% MAX LOAD Displays percent of maximum load limit of active fall shown in %MAX LOAD
display and in conjunction with bar graph display
PARTS LINE Displays current parts line of active fall in normal operate mode
RADIUS Displays load radius of active fall in normal operate mode (calculated from
boom angle sensor)
Two-Position Key Used to select Operating or Programming mode. In OFF position (key can
Switch be removed from display), selects Operating Mode. In ON position (key
cannot be removed from display, selects Programming Mode.
Six-Position Rotary Selects one of six operating functions in either normal operating or
Switch programming modes (Table 4-2).
Fall Select/Test Push- When momentarily pressed while key switch and rotary switch are in normal
Button Switch operating mode, selects any of the currently available falls if there is no load
on them. Also selects between GROSS and NET if rotary switch is in gross/
net mode. In programming mode, sequentially enters current data for boom
length or parts line as selected by rotary switch. When weight is below 5%
capacity for each fall, pressing and holding push-button switch places system
into test mode; all LCD segments flashing. Releasing places system back
into normal operating mode.
Table 4-2. Rotary Switch Settings for Pedestal Crane
Rotary Switch Key Switch Off - Operating Mode Key Switch On - Programming Mode
Position (Key can be removed from display) (Key cannot be removed from display)
1 Normal Mode Parts line programming
2 Set Offset Boom length programming
3 Net/gross Select ‘Display Negative
4 Cradle Mode Undefined 1
5 Undefined 1 Undefined 2
8 Undefined 2 Undefined 3
* Use only during calibration

M/D TOTCO
MANUAL 70-20 OPERATION
LCD IN DICATOR
PANEL
.A
FALL SELECT/TEST
PUSHBUTTON SWITCH \
ROTARY SWITCH
(NORMAL - FULL
COUNTERCLOCKWISE)
KEYSWITCH (NORMAL
POSITION)
Figure 4-1. Data Display Controls and Indicators
March 18, 1994 Page 4-3

M/D TOTCO
4-2-2 Power Supply

The ac primary power supply is located in the PEU. Figure 4-2 shows the approximate location of
the power supply and identifies the controls on its front panel.
PllmluyPowr
f /On/OlfSwltch
I’
1
OFF
m . 0 FUSE
2 AMP SLOW
Figure 4-2. Primary Power Supply

M/D TOTCO
4-3 OPERATING MODES

The primary power switch to the LOAD-WATCH system is usually in the ON position during normal
crane operation. However, during maintenance or when performing special checks, the system
might have to be powered-down. The following paragraphs explain how to power-up and power-
down the system.
4-3-l System Power-Up

Follow the steps below to power-up the LOAD-WATCH system.
1. Turn primary crane power on to PEU.
2. Open PEU door.
3. Set power supply ON/OFF switch to ON position.
4. Re-secure PEU door. If performing calibration, maintenance, or troubleshooting,
disregard this step.
4-3-2 System Power-Down
Follow the steps below to power-down the LOAD-WATCH system.
1.Open PEU door.
2. Set power supply ON/OFF switch to OFF position.
3. Re-secure door.
NOTE
The alarm system will sound if power is applied to the horn when the PEU
is turned off.
4-3-3 Normal Operation

During normal crane operation, the data display key switch and six-position rotary switch should be
in their normal positions (Figure 4-l). A square lights next to one of the falls (MAIN, WHIP, etc).
Several LOAD-WATCH features are enabled or disabled based upon whether each fall is ACTIVE
or INACTIVE. The system considers a fall active if either:
l The boom angle is in the legal range for that fall and the boom load is
greater than 5% of that fall’s maximum capacity, or
l The boom angle is outside the legal range for that fall and the boom
load is greater than 2% of that fall’s maximum capacity.
Selections and operating conditions in this mode are as follows:

a. A short press of the fall select/test push-button selects any of the currently available
falls if there is no load on them. Selection is sequential with each press of the push-
button. The example in Figure 4-3a shows the main fall selected. If another fall is
selected, the LCD square next to the new selection activates and the MAX LOAD
and PARTS LINE indicators change accordingly. Only falls with crane tables in the
EPROM can be selected. Those without crane tables are locked out.
b. If a selected fall is inoperative due to an out-of-range signal from its sensor, an alarm
sounds and cutouts are activated. BOOM LOAD displays “INOP” and MAX LOAD
displays “LOAD” (Figure 4-3b). No other indicators are affected. Crane operation is
not permitted until an operative fall is selected.
March 18, 1994 Page 4-5

M/D TOTCO
c. If the BOOM ANGLE is inoperative due to an out-of-ran e signal from the sensor, an
alarm sounds and cutouts are activated. BOOM LOA#displays “INOP” and MAX
LOAD displays “ANGLE” (Figure 4-3c).
d. A press and hold (over one second) of the push-button laces the system into test
mode. All indicator segments of the data display Ii ht, t1en flash for 10 seconds.
This feature is only available when all falls are INA8 TIVE.
e. AUTO-FALL SELECT - This feature is enabled when switch S4 on the
microcomputer/interface board (Figure 3-12), is pushed to the right side, or ON
position. When enabled, the fall that is automatically displayed will be the first fall
with weight above 5% of that fall’s maximum capacity, provided the radius is in the
legal range (i.e., the fall is ACTIVE). If the radius is outside the legal range, then the
fall displayed will be the first fall with weight above 2% of that fall’s maximum
As Ion as this fall is ACTIVE, it will be dis layed. When the fall is no longerT”kA TIV ,
any oR er fall that becomes ACTIVE will 1e displayed; the change is automatic.
The displayed fall can be determined by observing the fall status lights on the left
side of the display or by reading the PARTS LINE window. In practice, this feature
allows the operator “hands-free” control of the instrument, as typically onl one fall
has weight on it at one time. This feature should be turned off during caliii ration.
Note that manual fall than ing is not allowed when AUTO-FALL SELECT is enabled
and only one fall is ACTIV%. However, manual fall changing is always allowed
between any ACTIVE falls, should more than one fall become active at the same
time. Once all falls are INACTIVE, manual fall changin is a ain allowed between
any fall. The AUTO-FALL SELECT feature is disabled w\ en 8 4 is pushed to the left,
or OFF position. The falls can then be selected manually by pressing the FALL
SELECT/TEST push-button, located on the bottom of the display; each time this
button is pressed, the next fall is displayed.
f. AUTO-FLASH - This feature is enabled when switch S5 on the microcom uter;
interface board (Figure 3-12) is pushed to the right side, or ON position. !I
enabled, this feature causes alarm checking on all falls that become ACTIVE. If
AUTO-FALL SELECT is enabled, the first ACTIVE fall will be displayed. If AUTO-
FALL SELECT is disabled, the currently displayed fall will remain displayed until a
manual change is made.
AUTO-FLASH should always be enabled. If AUTO-FLASH is disabled, only

the displayed fall will be checked for alarms.
AUTO-FLASH causes the second ACTIVE fall’s status window to flash (Figure 4-3d).
This indicates that either it has weight over 5% of its capacity if the boom is in the
legal range or 2% of its capacity if the boom is outside the legal range. This is to alert
the operator that a problem has developed. If the third fall becomes ACTIVE, its
status window will also flash. If the load increases on any fall to the point that the
fall’s caution or overload alarm point is reached, the system horn will sound
accordingly. AUTO-FLASH is disabled when S5 is pushed to the left, or OFF position.
NOTE
Switches S4 and S5 are only read when:

The system is turned on
l
Immediately after switch Sl (reset) is pressed.

l
Press and release Sl each time S4 or S5 is changed.

M/D TOTCO
4-34 Set Offset (Tare)

Selection of this mode displays “OFFSET” in the BOOM LOAD indicator and a number representing
the current offset weight in the MAX LOAD indicator as shown in Figure 4-3e. All other indicators
continue to display information as in normal operate mode. Pressing the push-button alters the
offset to the current weight for that fall. This mode allows the operator to adjust for the weight of the
wire rope, blocks, and slings providing a tare-like function when used with the net/gross mode.
4-3-S Net/Gross Select

Selection of this mode causes the appearance of either “NET” or “GROSS” in the BOOM LOAD
indicator as shown in Figures 4-3f and g. The MAX LOAD indicator blanks out. However, all other
indicators continue to display information as in the normal operate mode. This mode allows the
operator to select whether to display the gross weight or, in conjunction with the offset option mode,
the net weight. Pressing the push-button switches between net and gross.
NOTE
The system always performs alarm and overload checks based on gross
mode regardless of which mode, gross or net, is displayed.
4-3-8 Cradle Position

Cradle mode allows operation of the crane beyond the legal maximum radius, so that the boom can
be lowered into its cradle without activating the alarm horn and overload relays. Cradle mode should
be selected while the crane is in the legal radius range. All falls must be below 2% of maximum
capacity before entering Cradle mode.
When the operator selects this switch position, BOOM LOAD displays “CRADLE” for approximately
one second (Figure 4-3m). If all falls are below 2% of capacity and if the radius is in the legal radius
range, BOOM LOAD and MAX LOAD displays “run or crAdlE” (Figure 4-3n), indicating that the
operator may either begin to lower the boom into its cradle position without activating the alarm horn
and overload relays, or the operator may switch back to normal operating position.
Note that the PARTS LINE, BOOM ANGLE and RADIUS displays continue to function as during
normal operating mode. The %MAX LOAD display and bar graph will not display percent of
maximum capacity for the fall while in Cradle mode. Instead, they will display the percentage of the
2% allowable load for cradle operation.
As the boom is lowered past the maximum legal radius, the message “crAdlE POSn” is displayed
in BOOM LOAD and MAX LOAD (Figure 4-30). This message is displayed as long as the radius is
beyond the legal maximum, indicating to the operator that, although the crane is outside the legal
radius operating range, he may safely continue lowering the boom into its cradle.
During Cradle mode operation, the alarm scanning for legal radius is effectively turned off, but the
system continues to scan all falls for weight. If at any time during Cradle mode weight exceeds 2%
of maximum capacity for any of the falls, BOOM LOAD and MAX LOAD display “rEdUCE LOAd”
and BOOM ANGLE flashes its current value (Figure 4-3~)
If the boom is beyond the maximum legal radius when the YEdUCE LOAd” message is displayed,
the alarm horn will sound and the overload relays will activate. The operator must remove weight
that is on the fall until it is below the 2% allowable value to clear the VEdUCE LOAd” message and
end the alarm condition.
March 18, 1994 Page 4-7

M/D TOTCO
If the boom is sti!l within the legal working radius when the “rEdUCE LOAd” message is displayed,
the operator may either reduce load to below 2% of maximum capacity or switch back to the normal
operating position. Note that an alarm state may not exist because the crane is within the working
legal radius and may still be within the load limits for that particular radius.
To remove the crane from its “CrAdlE POSn” and return to normal operating mode, the operator
must raise the boom up to a legal working radius, as indicated by the “run or crAdlE” message, and
then turn the rotary switch back to the normal operating position. If the rotary switch is turned from
the Cradle mode position before the boom is returned to a legal working value, the display will not
change from the “CrAdlE POSn” message.
4-3-7 Undefined Positions l-2 in Operate Mode

Undefined l-2 positions of the rotary switch should not be used during normal operation. Figure
4-3h shows the display in the ‘undefined 1’ mode. The first position from operate may be used to
display application-specific information, such as “sea state” or “list” tables.
4-3-8 Undefined Positions l-3 in Programming Mode
The undefined l-3 rotary switch positions cause the data display indicators to blank out when key
switch is in programming mode (key cannot be removed). Figure 4-3h shows the display in the
‘undefined 1’ mode. Undefined positions may be used for application-specific function selection,
such as ‘sea state” or “list” tables.
4-3-9 Parts Line Selection

Selection of this mode displays “P.LINE” in the BOOM LOAD indicator and a number representing
the current parts line in the MAX LOAD indicator as shown in Figure 4-3j. All other indicators blank
out. Each subsequent press of the fall select/test push-button steps through the list of valid parts
lines. This function is available only when the key switch is in the programming mode and none of
the falls are ACTIVE.
4-3-10 Boom Length Selection

Selection of this mode displays “B.LEN” in the BOOM LOAD indicator and a number representing
the current boom length in the MAX LOAD indicator as shown in Figure 4-4k. All other indicators
blank out. Each subsequent press of the fall select/test push-button steps through a list of valid
boom lengths. This function is only available when the key switch is in the programming mode and
none of the falls are ACTIVE.
4-3-l 1 Display Negative Selection

Selection of this mode displays ‘dS NEg” in the BOOM LOAD indicator and either ‘YES” or “NO” in
the MAX LOAD indicator (Fig 4-4i). All other indicators blank out. A press of the fall select/test
push-button toggles YES to NO or NO to YES. See Paragraph 5-5-9 for an explanation of this
feature.
4-3-12 Broken Wire Detector Feature

LOAD-WATCH will cause a SYSTEM ERROR (alarm horn and cutouts activate) if any fall’s weight
signal falls below a factory-set limit (2mVdc), as measured at that fall’s span test point. This value
will occur if a dc current load transducer’s wiring becomes broken. This is indicated on the display
by the message “INOP LOAD”.

M/D TOTCO
MANUAL 70-20 OPERATiON
a) Main Fail Selected b) inoperative Load
c) inoperative Boom Angie d) Auto-Flash
e) Weight Offset Selected f) Net/Gross Selected
Figure 4-3. LOAD-WATCH Operation Display Examples (1 of 3)

M/D TOTCO
g) Net Weight Selected h) Operation Mode Undefined
i) Display Negative Seieted J) Parts Line Selected
k) Boom Length Selected
Page 4-10 March 18,1994

M/D TOTCO
m) Cradle
o) Cradle Position p) Reduce Load
March 18,1994 Page 4-11

MID TOTCO
44 SYSTEM CONFIGURATION
This section describes how to configure LOAD-WATCH. This must be done at initial installation,
after initialization reset, or if boom length or parts line is changed.
4-4-l Parameter Selection

Selection of the following operating parameters is accomplished in the steps that follow:
l Boom Length
l Main Parts Line
l Whip Parts Line
. Aux Parts Line
Perform the following steps with no weight on any fall:
1. Turn key switch to normal operate mode (key can be removed).

2. Press fall select/test push-button switch until MAIN fall indicator lights (no fall can be
active).
3. Turn key switch to programming mode (key cannot be removed).
4. Turn rotary switch until boom length function is displayed in BOOM LOAD indicator.
5. Press push-button until required boom length is displayed in MAX LOAD indicator.
6. Turn rotary switch until parts line function is displayed in BOOM LOAD indicator.
7. Press push-button until main fall parts line is displayed in MAX LOAD indicator.
8. Turn key switch to normal operate mode.
9. Press push-button until WHIP fall indicator lights.
10. Turn key switch to programming mode.
12. Press push-button until required parts line for WHIP fall is displayed in the MAX LOAD
indicator.
13. Turn key switch to normal operate mode.
14. Press push-button until AUXl fall indicator lights.
15. Turn key switch to programming mode.
17. Press push-button until required parts line for AUXl fall is displayed in the MAX LOAD
indicator.
18. Turn key switch to normal-operate mode.
The operating parameters are set. The system retains these selections even if the PEU is shut off.
If the ‘initialization reset’ is used, reselection of operating parameters is

necessary. ‘Initialization reset’ causes all entered variables to be set to
default values and system indication may not be valid until parameter
selection is accomplished per Paragraph 44-l.
Page 4-12 March 18,1994

M/D TOTCO
4-5 RESETS
If the ‘initialization reset’ is used, reselection of operating parameters is

necessary. ‘Initialization reset’ causes all entered variables to be set to
default values and system indication may not be valid until parameter
selection is accomplished per Paragraph 44-1.
When switch Sl is pressed, the system is reset without disturbing any system variables currently in
use. With S3 held down and Sl pressed, an ‘initialization reset’ is invoked and initial system tables
are reloaded from the EPROM to the battery backed static RAM. Current variables are ovewritten
with the default values. Parameter selection is required (Paragraph 4-4-l). Refer to Figure 3-15
for switch locations.
4-8 INTERFACE RELAYS

The alarm relay activates at 80-l 00% of a customer-specified capacity. This cycles the alarm horn
on and off to indicate the approach, i.e., caution alarm point has been reached. At 100-l 10% of
capacity, the alarm relay activates and turns the alarm horn on to signal that the overload alarm
point has been reached. The horn remains on until the overload has been reduced. The overload
relays activate at 100-i 10% of capacity. Refer to Paragraph 3-6 for relay circuit board description
and related schematic.
March 18,1994 Page 4-13

M/D TOTCO
Page 4-14 March 18,1994

M/D TOTCO
CHAPTER 5
SYSTEM CALIBRATION
5-1 INTRODUCTION
This chapter contains procedures to verify that the system is operating within design limits. Perform
these procedures with all system components installed and properly interconnected. Calibration
should be performed during installation, when operating conditions change, or after components
have been repaired or replaced.
5-2 PRE-CALIBRATION CHECKS

Perform the following checks with no load on falls and at zero degrees, or minimum boom angle.
Figure 5-1 identifies the power supply in the PEU and the microcomputer/interface board, and Figure
5-2 identifies test points, adjustment potentiometers, switches, and indicators on that board.
5-2-l Primary ac Power Check

Follow the steps below to verify that the primary ac power is at the correct level.
1. Turn off crane power to LOAD-WATCH system.
2. Open PEU cover door and remove protective cover from power supply terminal block
labeled AC INPUT.
3. Turn on crane power to LOAD-WATCH system.
4. Set voltmeter to ac scale. Connect ac voltmeter across terminals Land N. Voltmeter
should indicate 85 to 284 Vat.
NOTE
Although system power may be any stable value between 85 to 284 Vat,
the horn selected for any particular system will restrict the ac power to the
horn nominal power rating.
S-2-2 Primary dc Power Check

Follow the steps below to verify that the dc primary power is at the correct level.
1. Turn off crane power to LOAD-WATCH system.
2. 0 en PEU cover door and remove protective cover from power supply terminal block
latLieled DC INPUT.
3. Turn on crane power to LOAD-WATCH system.
4. Set voltmeter to dc scale. Connect voltmeter positive lead to (+) terminal and common
lead to (-) terminal. Voltmeter should indicate 11-40 Vdc.

M/D TOTCO
SYSTEM CALIBRATION MANUAL 70-28
POWER SUPPLY
(AC SHOWN)
MICROCOMPUTEW
INTERFACE BOARD
Figure 5-l. Location of PEU Interface Board and Power Supply

M/D TOTCO
-C
L
38 3
Ah
JP17
YY
32 =:
JPlS
YY
Ml
II0
-
J
Figure 5-2. PEU Interface Board Test Points, Jumpers, Switches and Calibration Potentiometer
5-3 OUTPUT VOLTAGE CHECKS

Afterverifyingthatprimarypoweriswithintheprescribed limits, perform thefollowingvoltagechecks.
5-3-l Power Supplies

Refer to Table 5-l and check the dc output voltage as follows.
1. Ensure power supply ON/OFF switch is set to ON position.
2. Set voltmeter to dc scale.
3. Connect common (-) lead, to power supply COM terminal.
4. Using positive (+) lead, probe each test point listed in Table 5-l for required voltage
reading.
Table 5-1. dc Voltage Test Points

j
+5 4.90 to 5.20 Vdc

+12 11.64 to 12.36 Vdc
-12 -11.64 to -12.36 Vdc
+24 22.80 to 26.40 Vdc
5-3-2 Microcomputer/Interface Board

Refer to Table 5-2 and perform the test point output voltage checks as follows.
1. Ensure power supply ON/OFF switch is set to ON position.
2. Set voltmeter to dc scale.
3. Connect common (-) lead to TP4 (see Figure 5-2).
4. Using positive (+) lead, measure voltage at each test point listed in Table 5-2 for
required reading.
Table 5-2. MicrocomputerRntertace Board Voltage Test Points
Test Voltage Voltage Source

Point
TP2 11.64 to 12.36 Vdc J2-3,5,11

TP3 I 22.80 to 28.40 Vdc 1 J2-7,lO I
TP5 I -11.64 to -12.36 Vdc 1 J2-1 I
TP8 I ~~4.90 to 5.20 Vdc -1 J2-8
~~__ 1

M/D TOTCO
MANUAL 70-20 SYSTEM CALlBRATlON
54 GENERAL CALIBRATION INFORMATION

Because of the many different types of cranes, installing the LOAD-WATCH instrument with a rigid
calibration procedure is not practical. With this in mind, the following general rules should be
observed when performing calibration on any crane.
0 The radius calibration must occur first so the instrument can indicate the correct
maximum capacities for the given radius during the load calibration.
l All cranes are classified as being ‘gross on the hook’ or ‘net on the hook’. This
must be known to properly calibrate the system. As the definition for these two
classes vary among crane vendors, the class must be verified by examining the crane
load chart which is generally kept in the crane’s cab.
0 Typically, crawler cranes are ‘gross on the hook’. All load at the boom tip is counted as
weight. This includes blocks, wire rope, etc. During calibration the crane has the zero
calibration adjusted to display the combined weight of the blocks and suspended wire
rope. For example:
Block weighs 9,000 Ibs.
40 feet of 1.5 inch wire rope IWRC is suspended.
1.5 inch weighs @ 4.18 M/foot.
Eight parts line.
Weight of block and wire rope is 9,000 + (4.16 x 40 x 8) = 10331 Ibs.
If count-by is set at 1,000, the display is adjusted to read 10,000 pounds by the
zero pot.
With the crane radius set at the appropriate (usually minimum radius), the weight of the
block and suspended wire rope produce a hydraulic signal from the load cell which
generates pressure at the pressure transducer. This pressure is called the offset
pressure at no load which is allowed for ‘gross on the hook’ applications and must be
indicated on the display.
The span calibration, when using a simulator, is adjusted for the maximum capacity at
a given radius. No offsets for the block or wire rope are allowed. When a test weight
is used, the weight of the test weight, blocks, wire rope, and slings all count as live
weight and must be displayed.
0 The other cranes are typically ‘net on the hook’ and all boom tip weight (blocks and wire
rope, etc.) are usually zeroed out (display reads zero). During simulator calibration, the
offset pressure at no load is measured and recorded from the pressure transducer for
use during the span calibration. The span calibration, when using the simulator, is
adjusted for the maximum capacity at a given radius. The injected signal value during
simulator calibration makes use of the offset pressure with no load. When a test weight
is used, the weight of the test weight and slings should be displayed as ‘live’ weight with
the blocks and wire rope weights not included. Be aware that some crane tables define
‘net’ with the weight of the wire rope zeroed and not the block.

M/D TOTCO
0 The recommendation is that the radius be set at the minimum legal value (maximum
legal boom angle) when any load calibration zero adjustment is made. The blocks
should be placed at a height the same as when the test weights are lifted. This height
should be convenient for the operator to verify the instrument still reads zero. This
position should be checked periodically.
0 The recommendation is that the radius also beset at the minimum legal value (maximum
legal boom angle) when any load calibration, span adjustment is made. This is
necessary to achieve the required capacity for a calibration lift. The blocks should be at
the same height they were during the zero calibration.
5-5 FACTORY LEVEL CALIBRATION PROCEDURE

The following procedures calibrate the LOAD-WATCH system to the original factory specifications.
Perform the procedures in sequential order and in the manner prescribed. Verify all
preceding primary and output voltages are within prescribed limits. The following are required:
0 All voltage measurements referenced to PEU interface board, TP4 (ground).

0 Hydraulic test bench and test gauges. Test gauges must match the main, whip, and
aux falls single line load capacity.
0 Boom angle sensor test stand. Precisely mounts the boom angle sensor and provides a
readout in degrees accurate to 0.5 degrees.
0 System configuration report.
0 Ensure all channel type configuration jumpers are in place. See Chapter 3 for
jumper installation requirements. Boom angle channel is a voltage type channel. All
other channels including unused channels are current type channels.
5-5-l Potentiometer Voltage Adjustments

This procedure verifies that each fall is wired correctly and ensures that all unused falls are adjusted
to zero span. If not, these could bias readings on other falls. Set up for voltage adjustments as
follows:
1. Mount boom angle sensor.
2. Position test stand at zero degrees.
3. Ensure each fall has no pressure applied to its transducer.
4. On PEU interface board, set switch S4 to OFF position (Figure 3-15).
5. Unused voltage inputs should be shorted to ground.
NOTE
Follow instructions in Chapter 4 to ensure LOAD-WATCH is configured for
boom length and parts line required by the system configuration report.
6. Adjust interface board potentiometers (Figure 5-2) for the test point voltages listed in
Table 5-3. Connect negative to TPl .
7. Repeat Step 6 until no further adjustments are required.
8. In programming mode, select “NEGATIVE NUMBERS DISPLAYED” is ‘YES”
(Paragraph 5-6-8).

M/D TOTCO
Table 5-3. Zero and Span Adjustment Test Points
* Test Points are Blue

** Test Points are Yellow
S-5-2 Boom Angle Low And High Calibration

Follow the steps below to calibrate the boom angle in both the low ‘zero’position and the high (highest
normal working angle) position. All adjustments are on the PEU interface board. Refer to Figure
5-2 for locations of adjustment potentiometers.
1. Set boom angle test stand to zero degrees.
2. Adjust R32 for data dis lay an le reading of one degree, then back-off adjustment
until display angle reaBs zero $ egrees.
3. At TP7, measure for -0.2 vdc or less.
4. Position boom angle test stand to 90 degrees.
5. Adjust R44 to indicate a display angle of 90 degrees.
6. At TP8 measure for a positive voltage. A negative signal indicates a fault. Check
sensor configuration and connections.
7. Repeat Steps 1 through 8 until no further adjustments are required.
S-5-3 Main Fall Zero and Span Calibration

The procedure for calibrating the main fall zero and span is as follows:
1. Consult crane load chart supplied with load-watch specification sheets.
2. Determine a high boom angle that gives maximum lift capacity for main fall below
high boom alarm angle.
3. Position boom angle test stand to read angle determined in Step 2.
4. Install hydraulic test stand to main fall pressure transducer.
5. Follow instructions in Chapter 4 to ensure LOAD-WATCH is configured for boom
length and parts line required on specification sheets. Ensure main fall is displayed
on data display.
6. Withzero ressurea ied, adjust R35for boom load reading of minimumcount used
by this falP, then bat P-off pot until zero weight is displayed.
March 18, 1994 Page 5-7

M/D TOTCO
8. Apply pressure to system to give main fall full scale calibration PSI as indicated on
specrfication sheet.
9. Adjust R45 for boom load weight of system’s main fall capacity.
10. At TPl 0, measure for a sitive voltage. A negative signal indicates a fault. Check
sensor configuration anr connections.
S-5-4 Whip Fall Zero and Span Calibration

The procedure for calibrating the whip fall zero and span is as follows:
1. Consult crane load chart supplied with load-watch specification sheets.
2. Determine a high boom angle that gives maximum lift capacity for whip fall below
high boom alarm angle.
3. Position boom angle test stand to read above angle.
4. Install hydraulic test stand to whip fall pressure transducer.
5. Follow instructions in Chapter 4 to ensure LOAD-WATCH is configured for,boom
length and parts line required on specification sheets. Ensure whip fall is displayed
on data display.
6. With zero pressure applied, adjust R38 for boom load reading of minimum count-by
used by this fall, then back-off pot until zero weight is displayed.
7. At TPl 1, measure for -0.5 vdc or less.
8. Apply pressure to system to give whip fall full scale calibration PSI as indicated on
specification sheet
9. Adjust R48 for boom load weight of system’s whip fall capacity.
10. At TP12, measure for positive voltage. A negative signal indicates a fault. Check
5-5-5 Aux Fall Zero and Span Calibration
The procedure for calibrating the Aux fall zero and span potentiometers is as follows:
1. Consult crane load chart supplied with LOAD-WATCH specification sheets.
2. Determine a high boom angle that gives maximum lift capacity for aux fall below high
boom alarm angle.
3. Position boom angle test stand to read above angle.
4. Install hydraulic test stand to aux fall pressure transducer.
5. Follow instructions in Chapter 4 to ensure LOAD-WATCH is configured for boom
length and parts line required on specification sheets. Ensure aux fall is displayed
on data display.
6. With zero pressure applied, adjust R41 for boom load reading of minimumcount used
by this fall, then back-off pot until zero weight is displayed.
8. Apply pressure to system to give aux fall full scale calibration PSI as indicated on
specification sheet.
9. Adjust R47 for boom load weight of system’s aux fall capacity.

M/D TOTCO
5-6 FIELD CALlBRATlON PROCEDURE

A field calibration of the LOAD-WATCH system is presented in the following paragraphs. The
following criteria is required to perform these procedures:
0 All voltage measurements referenced to PEU interface board, TPl ground.
l System installed with load cells hung and hydraulic system filled with W15/16 fluid and
purged of air
0 Load cell gap set
5-6-l Field Calibration Using 935747 Series Current Simulator

Using the current simulator allows field calibration by first determining the offset pressure at no load
in mAdc that may be zeroed out during calibration. This is detected by the transducer as weight but
is ignored during operation. The value is used in a formula to determine the correct value of the
simulated full scale mAdc signal injected during span calibration. This applies to ‘net on the hook
cranes.
Although use of the simulator allows calibration without the traditional certified weights, certified
weights should still be used to verify that the complete system consisting of the load cell, associated
hose, and pressure transducer is operating normally.
5-6-2 Signal Output Voltage Check

The LOAD-WATCH system is pre-calibrated at the factory prior to delivery but may require minor
calibration adjustments following installation. If the PEU interface board is replaced, adjustments
must also be made using these procedures. Complete the following pre-calibration checks.
, d
NOTE
LOAD-WATCH is usually connected to audible alarms and/or cutouts that
stop the crane if a boom overload or system error is detected. lf the crane
owner permits, the audible alarm can be temporarily disconnected and the
cutouts bypassed. Notify crane operator if these systems are bypassed.
I I
To disable the alarm horn:

1.Disconnect power to system by opening circuit breakers.
2. On the power supply input power strip, remove the wire from the ‘L’ terminal that goes
to the relay board.
3. Reapply power to system.
4. Notify operator that audible alarm has been bypassed.
To check output voltages:

1. On PEU interface board (Figure 3-l 5) set manual/auto fall select switch S4 to OFF
position (manual).
NOTE
Follow instructions in Chapter 4 to ensure LOAD-WATCH is configured for
boom length and parts line required on the specification sheet.
I I
2. Check all test point voltages listed in Table 5-2.

M/D TOTCO
5-6-3 Boom Angle Calibration

Boom Angle can be calibrated using two different methods:
Method 1 - If the boom angle can be accurately measured at both the high and low
extremes of boom travel, follow the procedure in Paragraph 5-6-3-l.
Method 2 - If the boom angle cannot be accurately measured at the high and low extremes
of boom travel, follow the procedure in Paragraph 5-6-3-2. This procedure can be
used because LOAD-WATCH senses the boom angle position via an angle
potentiometer and calculates the radius based upon boom angle. Thus, the boom
angle zero and span adjustments can be made based on a measurement of radius
feet.
5-6-3-l Boom Angle Low and High Calibration Using a Known Boom Angle
Perform the boom angle low and high calibration using a known boom angle as follows:
1. Move boom to a low boom angle of 20 degrees or less. The boom should not be
lowered more than zero degrees.
2. Adjust R32 for display angle reading to match position of boom plus one de ree; then
back off adjustment until display angle reads position of boom. Refer to ! igure 5-2
for locations of test points and adjustment potentiometers.
3. Move boom to high boom angle of 70 degrees or higher.
4. Adjust R44 for display angle reading matching boom position.
5. At TP6, Measure for positive voltage. A negative signal indicates a fault. Check
6 Repeat Steps 1 through 5 until no further adjustments are required.
5-6-3-2 Boom Angle Low and High Calibration Using a Known Radius
The precise center of rotation must be known. All radius measurements are made from this center
of rotation to the center line of the suspended block for the fall being measured. If the king pin is
not accessible, the heel pin may be used as the start of the measurement, provided the king pin to
heel pin distance is added to each radius measurement. Generally, the fall with the greatest distance
from the king pin is used for calibration. Follow the steps below using a known radius.
1. Measure from king pin for the maximum distance (lowest boom angle) found in the
load tables supplied with the system configuration report. Have boom lowered until
the center line of the fall is over the tape at this measurement. Mark the ground as
these points are used more than once.
2. Select fall for these measurements using data display push-button switch.
3. Adjust R32 for display radius reading matching measured radius. Refer to Figure
5-2 for locations of test points and adjustment potentiometers.
4. Move boom to minimum radius (highest boom angle) indicated on system
configuration report for selected fall. Mark ground.
5. Adjust R44 for display radius reading to match measured radius.
Page 5-10 March 18,1994

M/D TOTCO
MANUAL 70-20 SYSTEM CALIBRATION
5-6-4 Inter-Fall Radius Verification

If actual boom angle is used to calibrate the boom angle position, read paragraph 5-6-3-2 and make
the radius marks as indicated before proceeding. If radius was used, then proceed as follows:
1. Move boom to maximum radius which appears in common on each load table.
2. Select each fall in turn and verify radius is correctly indicated for displayed boom
angle and the fall under test as noted on system configuration report. Note radius
readings and boom angle indicated on data display.
3. Move boom to minimum radius which appears in common on each load table.
4. Select each fall in turn and verify radius is correctly indicated for the displayed boom
angle and fall under test as noted on system configuration report. Note radius
readings and the boom angle displayed.
5-6-5 Main Fall Zero and Span Calibration
Follow the steps below to calibrate main fall zero and span for ‘net on the hook’ cranes.
For safety reasons, zeroing of block weight must be based on

manufacturer’s crane load chart and not on customer’s preference. In a
critical operating situation where a boom is lowered to minimum lift capacity,
additional weight of block and wire rope becomes a significant component
of load as seen by the boom tip. Therefore, use the LOAD-WATCHsystem
gross/net function to zero the suspended weight, if required.
1. In the PEU, remove field wiring from TB3-6.

2. Connect red lead from current simulator (935747series) to disconnected wire.
Connect black lead from simulator to TB3-6.
3. On simulator, set left switch to READ. Move top slide switch to O-20mAdc position.
Position of right switch does not matter.
4. Have crane operator do the following:
a. In programming mode, select ‘NEGATIVE NUMBERS DISPLAYED’ is
‘YES’ (see paragraph 5-6-8).
b. Verify main fall is being viewed.
c. Move boom to minimum legal radius as indicated on the system
configuration report position.
d. Move main block to position equal to a standard lift block position.
5. Record reading on simulator. This value is the offset pressure at no load in mAdc.
6. Attach positive lead of DVM to TP9 (main fall zero test point) and negative lead toTP1.
7. Adjust R35 until boom load window display indicates zero. Use procedure in
Paragraph 5-6-9, Selecting Median Value, to precisely set zero. This application is
‘net on the hook’. The weight of block and suspended wire rope are to be zeroed out.
8. Set simulator to OFF by moving slide top switch to center position.
9. Disconnect both test leads from PEU wiring.
10. Disconnect field wiring side of TB3-18 (sensor excitation).
11. Connect simulator red lead to TB3-18 and black lead to TB3-8.
12. Set simulator left switch to 2 WIRE position. Adjust knob to full CW position. Position
right switch to DIAL position. Move slide switch to O-20 mAdc position.
March 18,1994 Page 5-l 1
M/D TOTCO
13. Connect DVM red lead to TPlO (main fall span test point). Measure for positive
voltage. If negative voltage (indicates fault), verify connections are correct.
14. Using the offset pressure at no load in mAdc recorded in Step 5, calculate the full
scale calibration in mAdc, corrected for offset pressure at no load offset (See
Paragraph 5-9-4)
15. Adjust simulator knob until display reads exact calculated value from step n.
16. Adjust R45 until the BOOM LOAD window displays full-scale maximum capacity.
Refer to paragraph 5-6-9, under ‘Selecting the Median Value’ to precisely set this
value.
17. Readjust simulator for offset pressure at no load in mAdc as measured in Step 5.
Verify that display reads zero. If not, repeat Step 7 to readjust to zero.
16. If an adjustment was made in Step 17, repeat Steps 15 and 16.
19. Repeat Steps 17 and 18 until no further adjustments are required.
20. Move simulator slide switch to OFF (center) position. Disconnect simulator and DVM
test leads.
21. Reconnect field wiring to TB3-8 and TB3-18.
5-6-6 Whip Fall Zero and Span Calibration
Calibrate whip fall for “net on the hook” cranes as follows:

1. Open PEU and disconnect field wiring from TB3-9.

2. Connect red lead from 935747series current simulator to just disconnected wire.
Connect black lead to TB3-9.
3. Set left simulator switch to READ. Move top slide switch to O-20 mAdc position.
a. In ro ramming mode, select ‘NEGATIVE NUMBERS DISPLAYED’ is
Y El!S’ Paragraph 5-6-8).
b. Verify whip fall is being viewed.
c. Move boom to minimum legal radius position as indicated on system
configuration report.
d. Move whip block to position equal to standard lift block position.
5. Record reading on simulator. This value is the offset pressure at no load in mAdc.
6. ;;yh positive lead of DVM to TPl 1 (whip fall zero test point) and negative lead to
Paragraph 5-8-9, Selecting Median Value, to precisely set zero. This application is
‘net on the hook’. The weight of block and suspended wire rope are to be zeroed
out. Note that the whip fall might not display a negative weight for all applications,
due to the size of the count-by relative to the full-scale capacity. If so, from first count-
by, back-off pot to read zero.
Page 5-12 March 18,1994
M/D TOTCO
8. Set simulator to OFF by moving slide top switch to center position.

9. Disconnect both test leads from the PEU.
12. Set simulator left switch to 2 WIRE position. Adjust knob to full CW position. Position
right switch to DIAL position. Move slide switch to O-20 mAdc position.
13. Connect DVM red lead to TP12 (whip fall s n test point). Measure for positive
voltage. If negative voltage (indicates faultp”, verify connections are correct.
14. Using the offset pressure at no load in mAdc recorded in Step 5, calculate the full-
scale calibration in mAdc, corrected for offset pressure at no load offset (see
Paragraph 5-9-4).
15. Adjust simulator knob until display reads exact calculated value from Step 14.
16. Adjust R48 until the LOAD-WATCH, BOOM LOAD displays full scale maximum
capacity. Refer to paragraph 5-8-9, under ‘Selecting the Median Value’ to precisely
set this value.
test leads.
5-6-7 Aux Fall Zero and Span Callbratlon

Calibrate aux fall for “net on the hook” cranes as follows:
I

1. Open PEU and disconnect field wiring from TB3-11.

2. Connect red lead from current simulator (935747series) to just disconnected wire.
Connect black lead to TB3-11.
3. Set left simulator switch to READ. Move top slide switch to O-20 mAdc position.
a. In r ramming mode, select ‘NEGATIVE NUMBERS DISPLAYED’ is
Y R!S’ Paragraph 5-6-8).
b. Verify aux fall is being viewed.
c. Move boom to minimum legal radius position as indicated for system
configuration report.
d. Move aux block to position equal to standard lift block position.
March 18,1994 Page 5-13

M/D TOTCO
5. Record reading on simulator. This is offset pressure at no load in mAdc.

6. Attach positive lead of DVM to TP13 (aux fall zero test point) and negative lead toTP1.
Paragr h 5-6-9, Selecting Median Value, to precisely set zero. This application is
‘net on “R
t e hook’. The weight of block and suspended wire rope are to be zeroed out.
8. Set simulator to OFF by moving slide switch to center position.
9. Disconnect both test leads from PEU.
12. Set simulator left switch to 2 WIRE position. Ad’ust knob to full CW position. Position
right switch to DIAL position. Move slide switcil to O-20 mAdc position.
13. Connect DVM red lead toTPl4 (aux fall n test point). Measure for positive voltage.
If negative voltage (indicates fault), veri“p”y connections are correct.
14. Using the offset pressure at no load in mAdc recorded in Step 5, calculate the full
~l~)calrbratron In mAdc, corrected for offset pressure at no load: (see Paragraph
- _
15. Adjust simulator knob until display reads exact calculated value from Step 14.
16. Adjust R47 until the BOOM LOAD window displays full scale maximum capacity.
Refer to paragraph 5-6-9, ‘Selecting the Median Value’ to precisely set this value.
test leads.
5-6-8 Negative Numbers Displayed

The ‘Negative Numbers Displayed’ feature is used during calibration of any fall to indicate the level
above absolute zero input.
The load cell produces a pressure output proportional to the single line load on the fall. This pressure
is sensed by a pressure transducer that outputs a proportional 4-20 mAdc signal, which is scaled
and displayed as boom load. Calibration sets up the scale used to convert signals to engineering
units for display.
To ensure that a stable value can be displayed, a ‘dead band’ exists around the absolute zero input.
In normal operation, a zero is displayed. When “Negative Numbers Displayed” is active, the display
indicates where the scaled zero is in relationship to the absolute zero. Values below the scaled zero
are indicated by negative numbers.
NOTE
As this feature is not intended for normal operation, it is turned off each
time the system power is turned on or reset switch Sl is pressed.
During calibration process this feature should be YES’. This allows the setting of the zero loads
exactly in the middle of the zero range. Also, see paragraph 5-8-9, Selecting the Median Value.
Page 5-14 March 18,1994

M/D TOTCO
5-6-6-l Negative Numbers Displayed Activation

Activate the negative numbers displayed feature as follows:
NOTE
Activation from any fall affects all falls.
1. Ensure no fall is active.

2. Turn key to programming mode (key cannot be removed).
3. Rotate selection knob until ‘dlS NEg” is displayed in BOOM LOAD window.
4. Press push-button until MAX LOAD window displays YES’. Push-button toggles
between YES’ and ‘NO’.
5. Rotate selection knob until P.LINE is displayed in BOOM LOAD window.
6. Turn key to operating mode (key can be removed).
5-6-8-2 Negative Numbers Displayed Deactivated

There are two ways to deactivate the “Negative Numbers Displayed” feature:
l Power cycle the system or press PEU interface board reset switch Sl , or
* Perform Step 4 in Paragraph 5-8-8-l) but select ‘NO’ with push-button switch.
5-6-9 Selecting Median Value

Select the median value as follows:
1. Adjust DVM to read mV if a zero adjustment is being made or volta e if a s
adjustment is being made. Connect negative lead to PEU Interface%oard, #and
positive lead to associated fall zero or span test point.
2. Observe BOOM LOAD dis la and rotate adjustment pot slowly from zero, or desired
span value, towards next f:iig er count-by increment. Repeat this several times so
that value just changes to next count-by. Record voltage.
3. Rotate adjustment pot slowly from zero, or desired value, towards next lower count-
by increment. Repeat this several times so that value just changes to next count-by.
Since ‘Display Negative Numbers’ is enabled, displayed number will be a negative
when setting zero. Record voltage.
4. Use calculations that follow to determine proper pot adjustment value for setting zero,
or desired span value:
a. Ignore any polarity and subtract smaller number from larger number.
b. Divide result by two.
c. Add result to smaller number (ignore polarity of smaller number).
Example: Setting Zero
Step 1: The next higher count-by occurs at 250 and DVM reads -32 mVdc.
Step 2: The next lower count-by occurs at -250 and DVM reads -10 mVdc.
Step 3: 32-10 = 22
Step 4: 22/2 = 11
Step5: 11 + lo-21
Result: The center of zero adjust occurs at -21 mVdc.
March 18,1994 Page 5-15

M/D TOTCO
5. Adjust zero pot so DVM reads value just calculated.

Example: Setting a Desired Value of 14.17 mVdc from Slmulator for a
Display of 38,066 Ibs.
Step 1: The next higher count-by occurs at 38,250 and DVM reads 1.940 Vdc.
Step 2: The next lower count-by occurs at 37,750 and DVM reads 1.920 Vdc.
Step 3: 1.940-l .920 = 0.020
Step 4: 0.020/2 = 0.010
Step 5: 1.920 + 0.010 = 1.930
Result: The center of desired value occurs at 1.930 Vdc.
6. Adjust span pot so DVM reads value calculated. Verify display reads ‘O’,or desired
span value.
5-6-l 0 Post Cali bration Checks

After the above calibration, the following checks must be made to ensure correct and safe operation.
1. Enable alarms or cutoffs that were disabled for calibration.

2. Select main fall.
3. Have operator move boom through all legal radii and all boom angles required for
maintenance and/or booming down to the cradle position. Adjust block weight by
moving blocks so that boom load is always less than 5% of capacity for fall selected,
while in radius and less than 2% of capacity while out of radius. Use Cradle mode.
4. During boom movement, alarm may sound at boom alarm set point. However, cutoffs
should not activate unless load exceeds 2% of fall’s capacity.
5. Repeat movement for each working fall.
NOTE
Hydraulic fluid W15 has a pressure gradient of 0.376 psi per foot of head.
A 15-foot hose run could produce a pressure change of approximately 5.5
psi as the crane booms down from minimum to maximum radius. For
example, with a 1000 psi, 4 to 20 mAdc transducer, a 0.09 mAdc change
is produced.
5-6-l 1 Calibration Completlon Check

Upon completion of calibration procedure, ensure the auto/manual fall select S4 on PEU interface
board (Figure 3-15) is set to the ON (right) position (auto), if required for this application.
Page 5-16 March 18,1994

M/D TOTCO
5-7 LOAD CALIBRATION USING TEST WEIGHTS

If desired, the system can be calibrated using certified test weights. Customers provide a wide
variety of test weights and, although government-certified test weights may occasionally be
available, it is more likely a concrete or iron weight with a lifting hook will be used. The weight is
painted on the side. All test weights should be -O/+5% of the stated weight.
Also, remember to add the weights of all slings, shackles, and any other devices used to test weights.
The test weights can be verified at a public scale by first weighing the truck empty, then with the test
weight. The difference between the two weighings is the weight of the test weight.
Listed below are procedural modifications to Main Fall Zero and Span Calibration (Paragraph 5-6-
5) when test weights are used instead of a simulator. Although only the Main Fall is described, the
same changes apply to Whip Fall Calibration (Paragraph 5-6-8) and Auxiliary Fall Calibration
(Paragraph 5-6-7).
NOTE
Only those steps listed below are affected. Skip all steps in Paragraphs
5-8-7 that are not mentioned below.
1. Start with Step 4, then perform Steps 8 and 7. Then do Step 13.
2. Move boom to minimum legal radius.
3. Attach certified test weights to make a lift of 100% capacity. Remember that the
weight of the lifting hoists, shackles, etc., must be accounted for. The weight of the
suspended wire rope and block is not counted.
4. Lift the weights and hoist them 20 feet. Lower the weights to within one foot of the
ground. After the load has stopped moving, perform the adjustment per Step 18,
adjusting the span pot to match the combined weights of the test weights, lifting hoists,
shackles, etc.
5. Lower the weights and perform Step 7, if required. If adjustment was required, repeat
Step 4 above.
6. Repeat Steps 4 and 5 above, as required.
7. Disconnect DVM test leads.
8. Complete sections 5-6-l 0 and 5-6-l 1.
March 18,1994 Page 5-17

M/D TOTCO
5-6 LOAD CELL GAP ADJUSTMENT

The load cell system must be filled with hydraulic fluid at all times to accurately indicate hoisted
weight. A quick way to check for adequate fluid is to check the gap between the load cell load plate
and retainer ring (Figure 5-3). Load cell gap adjustment involves either adding or occasionally
reducing the amount of hydraulic fluid in the system.
NOTE
The procedure below details calibrating a hydraulic system that uses
disconnects on each component. If these hydraulic components do not
match the installation, then only follow the intent of these procedures.
Figure 5-3. Load Cell Detail
Page 5-18 March 16,1994

M/D TOTCO
5-8-l Adding Hydraulic Fluid

Add hydraulic fluid to the system as follows:
1. Remove all weight from load cell.
2. Ensure that weight hose is free of kinks and sharp bends.
3. Open disconnect at transducer box.
4. Attach a Jl OgOOA-20male disconnect to a J998 0.25 inch nipple. Attach nipple to a
M/D TOTCO YA2 hand pump. Fill pump bowl with W15/18 fluid. Keep hand pump
bowl at least half full at all times to avoid introduction of air into system.
5. Purge YA2 assembly by connecting a Jl OgOOA-02female disconnect to male
disconnect and pump fluid through hand pump until no bubbles appear. Disconnect
female disconnect.
6. Attach YA2 male disconnect to female disconnect of hose removed in Step 3.
7. Loosen load cell plug (or check valve) on load cell.
8. Pump fluid into system and bleed at load cell plug until air bubbles cease to appear.
9. Tighten load cell plug (or check valve).
10. Pump enough fluid into system to achieve correct load cell gap (Table 7-2).
11. Disengage hand pump from hose.
12. Reattach hose to transducer assembly box.
5-8-2 Reducing Hydraulic Fluid

Reduce the hydraulic fluid as follows:
NOTE
Use rags or a container to trap escaping fluid.
1. Using an appropriate wrench, loosen pipe plug (or check valve) on load cell until fluid
begins to escape from fitting.
2. Check load cell for proper gap (Table 7-2).
3. When load cell gap is correct, securely tighten pipe plug (or check valve).
March 18,1994 Page 5-19

M/D TOTCO
5-9 FORMULAS
Formulas used to calculate calibration measurements are presented in the following paragraphs,
accompanied by examples.
5-9-l Single Line Load

Single line load = maximum capacity/parts line
Example:
If maximum capacity is 38,000 Ibs and parts line is 2,
then
Single line load is 38,000/2 = 19,000 Ibs
5-9-2 Effective Pressure at Maximum Capacity

Effective pressure = single line load /effective area of load cell
Example:
If single line load is 19,000 Ibs and effective area of load cell is 18.0 sq in
then
Effective pressure = 19,000/l 8.0 = 1187.5 psi
5-9-3 Full Scale Calibration (Not Corrected for Offset Pressure at No Load)
Full Scale Cal in mAdc = [(effective pressure at maximum capacity/transducer FS in psi)
x transducer FS range in mAdc] + transducer offset from ‘0’ mAdc
Example:
If: effective pressure at maximum capacity is 1187.5 psi, and
transducer FS is 2,000 psi, and
transducer FS range is 20-4 = 16 mAdc, and
transducer offset from ‘0’ mAdc is 4 mAdc
Full Scale Cal in mAdc = [(1187.5/2,000) x 161+ 4 = 13.5 mAdc
5-94 Full Scale Calibration (Corrected for Offset Pressure at No Load)

Full Scale Cal in mAdc = [(effective pressure at maximum capacity/transducer FS in psi) x
transducer FS range in mAdc] + transducer offset from ‘0’ mAdc’ +
(offset pressure at no load in mAdc - transducer offset from ‘0’ mAdc*)
*Typically 4 mA for a 4-20 mA transducer, but transducers that test at 3.85 mA may be used.
Example:
If: effective pressure at maximum capacity is 1187.5 psi, and
transducer FS is 2,000 psi, and
transducer FS range is 20-4 = 18 mAdc, and
transducer offset from ‘0’ mAdc is 4 mAdc, and
offset pressure at no load is 4.87 mAdc
then
Full Scale Cal in mAdc (corrected) = [(1187.5/2,000) X 181+ 4 + 4.67 - 4 = 14.17
mAdc.
Page 5-20 March 18,1994

M/D TOTCO
5-9-5 Pounds/ mA Constant

Pounds per mA = Full Scale capacity/(Full Scale Cal in mAdc - transducer offset from 0 mAdc)
Example:
If: Full Scale capacity is 38,000 Ibs., and
Full Scale Cal is 13.5 mAdc, and
Transducer offset from 0 mAdc is 4,
then
Pounds/mA = 38,000/( 13.5 - 4) = 4,000 Ibs/mAdc
5-9-8 Displayed Weight Value

Displayed weight = (reading in mAdc - offset pressure at no load in mAdc) x pounds/mA for this fall.
Example:
If: Reading in mAdc is 18.50, and
Offset pressure at no load is 4.87 mAdc, and
Pounds per mA is 4,000 Ibs,
then
Displayed weight = (18.50 - 4.87) X 4,000 = 47,320 Ibs
NOTE
The displayed weight rounds based on count-by, with a count-by of 250,
the display will read 47,500 Ibs.
March 18,1994 Page 5-21

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Page 5-22 March 18,1884

M/D TOTCO
CHAPTER SIX
MAINTENANCE
6-1 INTRODUCTION
Maintenance checks should be performed periodically to maintain the high level of performance
provided by the LOAD-WATCHsystem. This chapter describes the general inspections that should
be performed depending on the usage of the system.
6-2 RECOMMENDED INSPECTlONS

Table 8-l lists the recommended inspections to be performed.
Table 6-1. Recommended Inspections
Item Action
Verify calibration and adjustments. Calibration should be

performed whenever operating conditions change or parts have
been repaired or replaced.
Check all hydraulic hose connections for leaks; repair as
required. Check load cell gap and recharge hydraulic system,
as required.
I Electrical Cables Check cables for fraying, cuts, or other damage; replace as
required.
Check wiring connections for loose or broken leads; repair as
required.
Checkall system component mounting bolts; tighten as required.
Check inside each enclosure for moisture ingression; correct as
necessary. Replace corrosion inhibitors every six months.
6-3 TROUBLESHOOTING
The paragraphs that follow provide troubleshooting procedures for isolating malfunctions and
providing corrective action. The paragraphs that follow provide a list of system error indications,
general troubleshooting tests, and a troubleshooting table for use in isolating specific problems.
Refer to Paragraph 8-4, Removal and Replacement Procedures for removal and replacement of
components found to be defective.
March 18, 1994 Page 6-1

M/D TOTCO
MAINTENANCE MANUAL 70-20
6-3-l System Error Indications

Table 6-2 provides a list of system error indications, definitions, and suggested corrective action.
Table 6-2. List of System Errors
Error Deflnitlon/Correctlve Action
Display shows all dashes Indicates display is functioning, but is not receiving
information from PEU. Refer to Table 6-3.
Display test (all segments blink on and off) Occurs during power on sequence and when display
push-button switch is held in. All falls must be
INACTIVE.
Display indicates El $2 Error message indicates internal calculation error.
Perform initialization reset (Paragraph 4-5). If error
still occurs, replace EPROM U12 on PEU interface
board (Paragraph 6-44).
Display shows UNDEF 1,2, .. . Display selector switch is in undefined position. Place
switch in normal setting.
PEU interface board LED flashing, When LED is on PEU interface board is not running.
Perform initialization reset (Paragraph 4-5). Replace
either EPROM U12 or interface board.
Display indicates ‘or’ Display over-rangeerror. The number to be displayed
exceeds the size of the display window. Check
calibration.
BOOM LOAD and MAX LOAD show Weight signal from load cell is out of range. Check
“INOP LOAD” calibration and installation.
BOOM LOAD and MAX LOAD show Boom angle signal is out of range. Check calibration
“INOP ANGLE” and installation.
Active fall status indicator flashing Load cells from multiple falls are detecting active
loads.
6-3-2 General Troubleshooting Tests

Field experience has proven that minor repairs can correct 90% of all electronic equipment failures,
avoiding the replacement of major assemblies. The following steps should always be completed
prior to performing more extensive repairs.
1. Verify primary power is supplied to the system and that power is as specified for the
system being serviced (see Chapter 5).
2. Check dc voltages (see Chapter 5).
3. Check for loose, crushed, cut, or otherwise damaged cables.
4. Verify all system components are properly connected (Chapter 3).
5. Verify all integrated circuits and plug-in components are properly seated in mating
connector or socket.
6. Check for pro r load cell gap and for hydraulic signal from the load cell to the
transducers. Fensure hydraulrc system is properly charged.

M/D TOTCO
MANUAL 70-20 MAlNTENANCE
6-3-3 Troubleshooting Table

Table 8-3 lists specific malfunctions, probable causes, and corrective actions.
Table 6-3. Troubleshooting Table
Malfunction Probable Cause Corrective Action
System inoperative No power to system Check and correct power

(display is blank) source
Blown power supply fuse Replace fuse(s)
Display not connected Connect display
Broken wire to display Repair broken wire
Defective power supply module Replace power supply module
Faulty display controller board Replace board
Faulty Wiring Check/Correct
Erratic display Mode switch improperly set Verify mode switch on display is
in normal setting (Chapter 4).
Poor connections within display Verify connections
assembly
Faulty display board Replace board
Display shows dashes Broken wire to display Repair wire
Faulty converter board Replace board
Faulty microprocessor board Replace board
Faulty Display Controller Board Replace board
All display segments on, not Display controller not Check IC and other
flashing functioning connections in display or
replace controller board
No boom angle indication Boom angle sensor assembly Recheck installation. Ensure
not properly installed boom angle sensor is facing
proper direction
Incorrect calibration settings Repeat boom angle calibration
Pendulum potentiometer Replace boom angle sensor
defective PCB
Defective microprocessor Replace PEU interface board
(Continued)

M/D TOTCO
Table 6-3. Troubleshooting Table (continued)
Boom angle erratic Loose boom angle sensor Tighten boom angle sensor
assembly mounting
Incorrect calibration Repeat boom angle calibration
Defective boom angle sensor Replace PCB assembly
PCB assembly
Faulty PEU interface board Replace board
Boom angle does not calibrate Boom angle sensor assembly Recheck installation and
improperly installed voltages
Pendulum potentiometer Ensure pendulum
improperly installed potentiometer is properly
assembled on PCB
Defective pendulum Replace PCB
potentiometer
Defective PEU interface board Replace board
No load Indication Load cell to transducer Tighten or repair connections,
hydraulic connections leak check for faulty wiring, check
load current
Load cell improperly charged Charge system
Defective transducer Replace transducer
Defective PEU interface board Replace board
Faulty Wiring Check/Correct
Erratic load Indication Load cell binding or interfering Reposition load cell
with reeving
Faulty transducer Replace transducer
Load cell will not calibrate Lever ratio (compression type Verify and correct ratio as
load cell) incorrect for system required
Load cell gap incorrect Service system
Defective transducer Replace transducer
No radius indication or No boom angle input to the Refer to “boom angle
improper reading of radius system malfunction” section of this
table.
(Continued)

M/D TOTCO
MANUAL 70-20 MAINTENANCE
Table 6-3. Troubleshooting Table (continued)
Audible alarm (horn) does not Horn assembly incorrectly Check horn wiring and correct
operate wired during installation as required
Faulty relay (Kl ) Replace relay
Faulty horn Replace horn
Audible alarm (horn) sounds System out of calibration Recalibrate system
continuously
System turned off Turn on system
Defective relay (Kl) Replace relay
64 REMOVAL AND REPLACEMENT

The paragraphs that follow describe the removal and replacement of LOAD-WATCHsystem
components that require service due to malfunctions detected during troubleshooting.
Disconnect primary power input before servicing any internal parts of the
LOAD-WATCH system.
6-4-l System Resets

After removal and replacement of PCBs or EPROMS in these procedures, the LOAD-WATCH
system must be reinitialized to clear the memories and invoke the changes Depending on the
particular component changed, this is accomplished in either one of two ways as follows:
1. Press Sl to reset the system without disturbing any system variables currently in use.
2. Press and hold S3 and press Sl to ON for a minimum of two seconds. Release Sl
and S3. An initialization reset is invoked and initial system tables are reloaded from
the EPROM to RAM without any current variables.
6-4-2 Data Display PCB Assemblies

Remove and replace data display PCB assembly(ies) shown in Figure 6-l as follows:
1. Observe WARNING in Paragraph 6-4.
2. Remove thumbwheel screw from each side of indicator enclosure.
3. ;;3kiracket away from indicator to clear mounting studs and remove indicator from
4. Remove screws retaining indicator assembly back cover. Remove cover.

M/D TOTCO
Controller,
PCB285A
Converter,
Controller,
EPROM, U5
Dlsplay,
PCB288A
Figure 6-l. Data Display PCB/EPROM Replacement

M/D TOTCO
5. Disconnect connectors from circuit boards.

6. Remove six screws securing indicator assembly. Remove boards from enclosure.
7. Install replacement board(s).
8. Reinstall indicator assembly circuit boards in reverse order. Calibration is not
required.
6-4-2-l Data Display EPROM Replacement

Remove and replace the data display EPROM shown in Figure 6-l as follows:
2. Perform paragraph 6-4-2, Steps 2 through 6.
3. Remove four screws securing converter PCB. Lift off board and set aside.
4. The data display memory EPROM (U5) is the 28 pin IC with a white tag on its top.
Remove and replace EPROM as follows:
CAUTION
STATIC DISCHARGE CAN DAMAGE INTEGRATED CIRCUITS. Do not
handle integrated circuits or component boards unless grounding wrist
strap is properly worn and grounded. Do not let clothing or plain plastic
materials contact or come close to these static-sensitive devices.
Carefully remove chip from socket using an IC extractor tool.

a.
b. Carefully install replacement chip. Make sure the notch in the chip is facing in
the same direction as the chip just removed.
5. Reposition converter PCB over controller board and reinstall in reverse order.

The procedures that follow explain the removal and replacement of all serviceable components
within the PEU.
6-4-3-l AC Primary Power Supply Module

Remove and replace power supply module as shown in Figure 6-2 as follows:
2. Remove and tag input power wires.
3. Disconnect power supply connector at PEU microcomputer/interface board.
4. Remove four screws securing power supply assembly to PEU frame.
5. Remove four screws securing relay assembly to power supply assembly. Set relay
assembly to side.
6. Remove four screws holding heat sink to power supply bracket.
7. Remove four screws securing power supply to mounting bracket.
8. Replace power supply.
9. Reinstall in reverse order.

M/D TOTCO
6-4-3-2 Relay PC Board

Remove and replace relay PC board shown in Figure 6-2 as follows:
2. Disconnect ribbon cable connector and any wiring on terminal block.
3. Pull ac power supply as in paragraph 6-4-3-1, Steps 2 through 4.
4. Remove four mounting screws securing board to enclosure and remove board.
5. Install replacement board in reverse order.
6-4-3-3 Microcomputer/Interface Board

Remove and replace the PEU interface board shown in Figure 6-3 as follows:
2. Disconnect and tag interface connectors.
3. Remove six screws retaining board.
4. Remove board.
5. Install replacement board.
6. Reconnect cables.
7. Install new corrosion inhibitor before securing lid of enclosure.
8. Check system for correct operation.

M/D TOTCO
Power Supply and /a

0
Relay Board Mounting t
Bracket , 1 * 0’
- - b 0 0’
A
I
.’ 0
0
0 0 0 0 0 /)
53 0
,o;’ 0,
‘-;i!
I 0’
‘0 “niver Supply
Module
/-
0
/ 0’
Power Supply
Module
Processing Electronks y
Untt (PEU)
Figure 6-2. AC Module/Relay Board Replacement

M/D TOTCO
--- .--- --- ---*
= = = = 1 --
--------- -- ---Q
__------- m
--- ---- _--- --- -----Q
Figure 6-3. PEU Interface Board Removal and Replacement

6-44 PEU Microcomputer EPROM Replacement

Remove and replace microcomputer EPROM(s) shown in Figure 6-4 as follows:
2. The EPROM U12 is the IC with a white tag on its top, near center of board. Remove
and replace 2 PR4 M as follows:
CAUTION
STATIC DISCHARGE CAN DAMAGE INTEGRATED CIRCUITS. Do not
handle integrated circuits or component boards unless grounding wrist
strap is properly worn and grounded. Do not let clothing or plain plastic
materials contact or come close to these static-sensitive devices.
a.Carefully remove chip from socket using an IC extractor tool.

b.Carefully install replacement chip. Make sure notch in chip is facing in
same direction as chip just removed.
3. Power-up system and perform system reset (Paragraph 6-4-l).
EPROM
U12
Figure 6-4. PEU EPROM Removal and Replacement

M/D TOTCO
6-4-5 Boom Angle Sensor Board

Remove and replace the boom angle sensor board (Figure 6-5) as follows:
2. Open cover by loosening three clamp assemblies.
3. Remove wires from TBl and TB2.
4. Remove four screws that secure PC board to enclosure.
5. Install replacement PCB, observing proper orientation of board.
6. Reconnect wires to TBl and TB2.
7. Install new corrosion inhibitor.
8. Secure lid of enclosure.
9. Recalibrate boom angle as described in Chapter 5.
Pendulum
Potentiometer
Sensor
Board,
PC831 1A
Figure 6-5. Boom Angle Sensor Board Replacement
Page 6-l 2 March 18,1994

M/D TOTCO
6-4-6 Hydraulic Transducer Replacement

Remove and replace any one of the transducers shown in Figure 6-6 as follows:
2. Open transducer assembly box cover.
3. Disconnect hydraulic hose to transducer.
4. Disconnect electrical wiring between transducer and terminal board.
5. Unscrew transducer counterclockwise to remove from box.
6. Coat threads of replacement transducer with liquid teflon.
7. Reinstall in reverse order.
8. Add new corrosion inhibitor.
9. Bleed hydraulic system and adjust load cell gas as described in Chapter 5.
H12354ASeties
PressureTransducer
Figure 6-6. Transducer Assembly Removal and Replacement

M/D TOTCO
CHAPTER 7
DRAWINGS AND PARTS LISTS
7-1 INTRODUCTION
This chapter contains parts lists and accompanying illustrations for LOAD-WATCH system compo-
nents. Table 7-1 is a recommended spare parts inventory and Table 7-2 is a list of available load
cells for use with LOAD-WATCH.
Detail ‘A’
Figure 7-1. Data Display (1 of 2)
March 18,1994 Page 7-l

M/D TOTCO
DRAWINGS AND PARTS LISTS MANUAL 70-M
Figure 7-l. Data Display (2 of 2)

M/D TOTCO
MANUAL 70-20 DRAWINGS AND PARTS LISTS
FIGURE UNITS
& PART PER
ITEM NO. NUMBER DESCRIPTION ASSY
7-1- H12284A Data Display ................................................................................. N/A

1 H12262A-01 . ENCLOSURE, Fab ......................................................................1
2 H12261A-01 . BEZEL .........................................................................................1
3 Al 1454A-series . FACEPLATE ................................................................................1
4 B10532A . COVER, Rear ..............................................................................1
5 B10525A . GASKET, Bezel ...........................................................................1
6 B10526A . GASKET, Rear Cover ..................................................................1
7 PCB266A-02 . PCB, Display, Digital, type 2 ........................................................1
6 PCB295A . PCB, Display, Control Board ........................................................1
9 H11069Aseries . PROGRAM, EPROM (not shown) ...............................................1
10 PCB350A-02 . PCB, Current Loop-to-CMOS Converter .....................................1
11 B10526A . SPACER/MOUNT, Display Board ................................................2
12 H12263A-series . CONDUIT, 90’ Conduit Hub ........................................................1
13 H11045B-01 . SWITCH ASSEMBLY, Rotary, PCB, cable.. .................................1
14 Al 1261A-03 . BRACKET, Mounting ...................................................................1
15 SA1212 . KNOB, Mounting Adjustment .......................................................2
16 G16OA-04643 . WASHER, Flat, sst, 0.312” ..........................................................2
17 999449-066 . SCREW, Sst, pan head, 6-32 x 0.375”. .......................................6
16 J613-3NS . SCREW, Sst, pan head, 8-32 x 0.38”. ......................................... 10
19 999449-l 20 . SCREW, Sst, pan head, 6-32 x 0.50” ..........................................22
20 999449-l 26 . SCREW, Sst, pan head, 6-32 x 0.75”. .........................................12
21 G176-8NS . WASHER, No. 6, lock internal tooth, 6-22.. .................................44
22 G 16OA-05443 . WASHER, Flat, 0.375 cres ..........................................................1
23 999216-066 . WASHER, Nylon, flat, no. 6 .........................................................6
25 G176-13FS . WASHER, Lock Internal Tooth.....................................................1
26 H1573-4 . COMPOUND, Sealer, RTV ..........................................................AR
27 Xl 0092-001 . LOCTITE .....................................................................................AR
t M 10073A-140304 . STANDOFF, 4-40 x 0.87, 0.25 Hex, nylon.. .................................3
l
100766 . CORROSION INHIBITOR ...........................................................1

M/D TOTCO
-_-~..--.---.
Figure 7-2. Processing Electronics Unit (PEU)

,_.-
~.._
_____.-.
FIGURE UNITS USE

al PART PER ON
INDEX # NUMBER DESCRIPTION ASSY CODE
7-2- H11031 B-01 PROCESSING ELECTRONICS UNIT, Ind, ac ..... .N/A A
H11031 B-02 PROCESSING ELECTRONICS UNIT, I.S., ac ..... .N/A B
H11031B-03 PROCESSING ELECTRONICS UNIT, Ind, dc ..... .N/A C
H11031B-04 PROCESSING ELECTRONICS UNIT, I.S., dc ..... .N/A D
Al 1251A-01 . BOX, Assembly ............................. .l A,B,W
H12328A-01 . POWER SUPPLY, ac, p/o H12329A-01 assy ...... .l A,B
H12331A . POWER SUPPLY, dc (optional). ................ .l CD
Al 1424A-02 . TRACK, Mounting ........................... .l BD
Al 1436A . STAND, Mounting, busbar. .................... .2 B,D
220236-001 . PCB, Microcomputer/Interface. ................. .l A,B,W
B10516A . NAMEPLATE, ID ............................ .2 A,B,C,D
6 Al 1250A-01 . LID, Fab ................................... .l AM3
9 B10425A-02 .GASKET ................................... .l A,W,D
10 H1573 SEALANT. .................................. AR A&W
11 991701-002 . CORROSION INHIBITOR ..................... .l A,B,W
12 H11027A-01 . BUSBAR, Barrier Grounding ................... .l B,D
14 H10397A-000020 . BLOCK, Terminal. ........................... .l A,C
15 Al 1437A . BRACKET, Mounting, earth rail ................. .2 W
16 Al 1442A-01 .RAIL,Earth ................................ ..l B,D
17 H12246A-01 . STRIP, Tagging ............................. .l B,D
16 H12249A . SEAL, Tagging Strip. ......................... .l W
19 H1225OA . TERMINAL, Earth. ........................... 12 B,D
20 H10992A-766P . BARRIER, Display Power ..................... .l B,D
21 H10992A-767s P . BARRIER. ................................. .3 W
22 J812-3NS .SCREW, 10-32x 0.375 ....................... .4 AC
............................................ 6 B,D
23 G16OA-02942 . WASHER .................................. .2 BJ
24 J6144PS .SCREW,6-32x0.5 ........................... . A,C
27 H12267A-01 .CABLEASSY,Signal,I/S.. .................... .l W
26 H12267A-02 . CABLE ASSY, Display Link, I/S ................. .l B,D
29 H1062OA RELAY, 12V ................................. .3 A&W
30 PCB312A . PCB, Relay Control .......................... .l A,B,W
31 H12267A-06 .CABLEASSY ............................... .l B,D
32 H12267A-05 .CABLEASSY ............................... .l W
l Not shown

M/D TOTCO
DRAWINGS AND PARTS LISTS MANUAL 70-20
Figure 7-3. Boom Angle Sensor
FIGURE UNITS
& PART PER
INDEX NO. NUMBER DESCRIPTION ASSY
7-3- H11028A Boom Angle Sensor .................................................................... N/A

1 Al 1331B-01 . BOX, Stainless, NEMA 4X.. .........................................................1
2 PCB311A . PCB, Boom Angle Sensor ...........................................................1
3 J 10461A-02 . HUB, Conduit, 0.75 ......................................................................2
5 B10425A-01 . GASKET ......................................................................................1
6 H1573 SEALANT, RTV..............................................................................AR
6 J613-3NS . SCREW, 8-32 x 0.36 ...................................................................4
11 BlO514A . LABEL .........................................................................................
2
12 100766 . CORROSION INHIBITOR ...........................................................1
Page 7-6 March 18,lffl

M/D TOTCO
Figure 7-4. Transducer Assembly
FIGURE UNITS
& PART PER
INDEX NO. NUMBER DESCRIPTION ASSY
7-4- H12353A Transducer Assembly ................................................................. N/A

1 Al 1331B-03 . BOX, Assy ...................................................................................1
2 J 10481A-02 . CONDUIT, 0.75.. ..........................................................................1
3 B10425A-01 . GASKET.. ....................................................................................1
4 H1573 SEALANT, RI-V..............................................................................AR
6 B10516A . NAMEPLATE, ID..........................................................................2
7 100768 . CORROSION INHIBITOR ...........................................................1
8 H10397A-000006 . BLOCK, Terminal.........................................................................1
9 H1057-6 . STRIP, Marker .............................................................................1
10 999334-536 . SCREW, 6-32 x 0.50 long.. ..........................................................2
11 J10553A-4S . CAP, Pipe, 0.25.. ..........................................................................1
12 Xl 0092A-027 SEALANT, Thread .........................................................................AR
13 Hi 2354Aseries . TRANSDUCER, Pressure, 4-20 mAdc.. ......................................AR
15 H10406A-000002 . LUG, Terminal, #6.. ......................................................................12
t H11099A-02 SLEEVE, Insulating .......................................................................AR
17 Cl 0018A-000001 TIE, Cable.. ....................................................................................AR
18 947645-002 . MOUNT, Cable Tie.. .....................................................................2
t 9895 15-031 . CAPLUG, #13.. ............................................................................ 1

M/D TOTCO
DRAWINGS AND PARTS LISTS MANUAL 70-20

M/D TOTCO
APPENDIX A
OPERATIONAL EXAMPLES
A-l EXAMPLES
The following LOAD-WATCH system setup is assumed for the following examples of system
operation:
d Gross mode selected.

J Auto/manual fall select switch (S4) on interface board set to auto fall select
position (ON).
J Auto Flash switch (S5) on interface board in auto flash position (ON).
J 5% of Main is 11,000 Ibs., 5% of Aux is 2,000 Ibs., 5% of Whip is 600 Ibs.
A-l-l Overload Relay Cutout

The boom relay cutout activates when any of the following conditions exist:
4 Maximum boom load is exceeded.

4 High boom angle is exceeded.
J Low boom angle is exceeded when any fall is loaded in excess of 2% of
maximum capacity.
4 System error is detected. (Sensor failure is detected only for a fall which is
currently selected).
A-l-2 Auto Fall Select

The LOAD-WATCH automatically selects the fall with the highest percentage of maximum load
should the load indicated for the currently selected fall be reduced below 5% of maximum load for
that fall when in legal radius, 2% of maximum load for that fall out of radius.
Assume that boom angle is in its normal range, main fall is selected, and both main and whip are
loaded in excess of 5% of maximum load. Reducing load on the main fall below 5% of maximum
load activates auto fall select. Whip fall is selected automatically. Cutouts do not activate.
A-l-3 Auto Flash

Indication of active fall is accomplished with a lighted indicator on the LOAD-WATCHdisplay. Should
a fall that is not selected be loaded to more than 5% in radius or 2% out of radius of its maximum
load, the active indicator for that fall flashes.
Assume that boom angle is in its normal range, main fall is selected and loaded, and whip fall is not
in use. Whip fall then tangles and begins to indicate weight in excess of 5% of maximum load. The
active indicator for the whip fall flashes to indicate this condition. lf the whip load exceeds the caution
alarm setpoint, the horn sounds on and off to indicate this condition. If the whip load reaches
maximum safe load, the horn sounds continuously and cutouts activate.
March 18,1994 A-l

Y/D TOTCO
Appendix A LOAD-WATCH SYSTEM
MANUAL 70-m
A-1-4 System Error

LOAD-WATCH is designed to provide specific messages upon detection of certain system failures.
Failures that do not affect the current indication might not be detected.
Assume that boom angle is in its normal range, main fall is selected and loaded, and whip fail is not
in use. lf the whip fall load sensor has a detectable failure, LOAD-WATCHwill provide no indication
of the failure. Assume load is then removed from the main fall and whip fall is selected. BOOM
LOAD displays “INOP” and MAX LOAD displays “LOAD”, the horn sounds continuously, and cutouts
activate to indicate the failure. The system resumes operation if the main fall is selected; the horn
turns off and the cutouts release.
A-2 March 18,1994

M/D TOTCO
APPENDIX B
CONVERSION DATA
B-l INTRODUCTION
This chapter contains the following conversion information:

. Methods for converting temperature from degrees Fahrenheit (OF)to
degrees Centigrade (OC)and vice versa
l Conversion factors for commonly used units
B-2 TEMPERATURE CONVERSIONS
To convert from degrees Fahrenheit (OF)to degrees Centigrade (OC),subtract 32 from the degrees
Fahrenheit, then multiply by 0.556, as shown below:
OC = [OF - 321 x 0.556
To convert from degrees Centigrade (OC)to degrees Fahrenheit (OF),multiply the degrees Centi-
grade by 1.7985, then add 32, as shown below:
OF = [OC x 1.81 + 32
B-3 CONVERSION FACTORS
Conversion factors for commonly used units are presented in Table B-l.
March 18,1884 Page B-l

M/D TOTCO
APPENDIX B LOAD-WATCH SYSTEM
CONVERSION DATA MANUAL 70-20
Table B-l. Conversion Factors
MULTlPLY BY TO OBTAlN
atmospheres (atm) 101.325 kiloPascal (kPa) absolute
atmospheres (atm) 14.7059 pounds per square inch (psi)
barrels (bbl) of petroleum 5.615 cubic feet (fts)
barrels (bbl) of petroleum 0.159 cubic meters (m3)
barrels (bbl) of petroleum 42 gallons, U.S. liquid
barrels of petroleum per inch (bbl/in) 0.628 cubic meters per centimeter (m3/cm)
bars 14.5138 pounds per square inch (psi)
centimeters 0.394 inches (in)
centimeters per second (cm/set) 0.0328 feet per second (ftIsec)
cubic feet (fts) 7.4805 gallons, U.S. liquid
cubic feet (fts) 28.32 liters
cubic feet (f?) 0.178 barrels (bbl) of petroleum
cubic meters (m3) 6.289 barrels (bbl) of petroleum
cubic meters (m3) 264.2 gallons, U.S. liquid
cubic meters per centimeter (m3/cm) 1.597 barrels of petroleum per inch (bbl/in)
decaNewtons (daN) 2.248 pounds
feet (ft) 0.3048 meter(m)
feet per hour (ftlhr) 0.3048 meters per hour (m/hr)
feet per minute (fvmin) 0.01829 kilometers per hour (km/hr)
feet per minute (ft/min) 0.3048 meters per minute (m/min)
feet per second (ft/sec) 30.48 centimeters per second (cm&c)
feet per second (ft/sec) 18.29 meters per minute (m/min)
foot-pound 1.4882 kilogram-meter (kg-m)
foot-pound 1.3558 Newton-meter
gallons, U.S. liquid 0.0238 barrels (bbl) of petroleum
gallons, US. liquid 0.13368 cubic feet (fts)
gallons, U.S. liquid 0.003785 cubic meters (m3)
gallons, U.S. liquid 3.7854 liter
grams per cubic centimeter (g/cm3) 8.345 pounds per U.S. liquid gallon (lb/gal)
inch (in) 2.54 centimeter (cm)
inches Hg (Mercury) 0.4912 pounds per square inch (psi)
inches H20 (Water) 0.0361 pounds per square inch (psi)
kilograms (kg) 2.2046 pounds
kilogram-meters (kg-m) 0.67196 foot-pound
kilograms per cubic meter (kg/m3) 0.00835 pounds per U.S. liquid gallon (lb/gal)
kilograms per meter (kg/m) 0.672 pounds per foot
kilograms per square centimeter (kg/cm3) 14.2227 pounds per square inch (psi)
(Continued)
Page B-2 March 18,1884

M/D TOTCO
LOAD-WATCH SYSTEM APPENDIX B
MANUAL 70-20 CONVERSION DATA
MULTlPLY BY TO OBTAIN
kilometers (km) 0.6215 miles
kilometers per hour (km/hr) 54.6747 feet per minute (ft/min)
kiloPascals (kPa) 0.0099 atmospheres (atm)
kiloPascals (kPa) absolute 0.145 pounds per square inch (psi)
liters (I) 0.0353 cubic feet (fts)
liters (I) 0.2642 gallon, U.S. liquid
liters per minute (Ipm) 2.1186 standard cubic feet per hour (scfh)
meters 3.281 feet (ft)
meters per hour (m/hr) 3.2808 feet per hour (fUhr)
meters per minute (m/min) 3.2808 feet per minute (ft/min)
meters per minute 0.0547 feet per second (fVsec)
miles 1.609 kilometers (km)
Newtons 0.2284 pounds
Newton-meters 0.7376 foot-pounds
pounds (lb) 0.4448 decaNewtons (daN)
pounds (lb) 0.4536 kilograms (kg)
pounds (lb) 0.000454 metric tons
pounds (lb) 4.448 Newtons (N)
pounds (lb) 0.0005 U.S. tons
pounds per foot (Ib/ft) 1.488 kilograms per meter (kg/m)
pounds per gallon (lb/gal) 0.119826 grams per cubic centimeter (g/cm3)
pounds per gallon (lb/gal) 119.826 kilograms per cubic meter (kgIm3)
pounds per square inch (psi) 0.0680 atmospheres (atm)
pounds per square inch (psi) 0.0689 bars
pounds per square inch (psi) 2.0358 inches of Hg (Mercury)
pounds per square inch (psi) 27.6778 inches of H20 (Water)
pounds per square inch (psi) 0.0703 kilograms per square centimeter (kg/cm2)
pounds per square inch (psi) 6.895 kiloPascals (kPa)
square centimeters (cm2) 0.155 square inch (in2)
square feet (ft2) 0.0929 square meter (m2)
square inch (in2) 6.4516 square centimeter (cm2)
square meter (m2) 10.764 square feet (f+)
standard cubic feet per hour (scfh) 0.472 liters per minute (Ipm)
tons, metric 2205 pounds
tons, metric 1.1025 U.S. tons
tons, U.S. 0.907 metric tons
tons, U.S. 2000 pounds
metric ton-kilometers (tonne-km) 0.6853 U.S.ton-miles
U.S.ton-miles 1.4593 metric ton-kilometers (tonne-km)
March 18,19Q4 Page B-3

M/D TOTCO
APPENDIX B LOAD-WATCH SYSTEM
CONVERSION DATA MANUAL 70-20
Page B-4 March 18,19Q4

M/D TOTCO

M/D Totco: Instruction Manual

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M/D TOTCO

Manufacturers of Precision Instruments

Printed in U.S.A. March 18,1994

Cover ................................ Mar 1994

Information in this manual is subject to change without notice.

THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES,

l-1 INTRODUCTION ............................................................... .1-l

2-l INTRODUCTION ............................................................... .2-l

3-l INTRODUCTION ............................................................... .3-l

4-l INTRODUCTION. .............................................................. .4-l

CHAPTER 5 - SYSTEM CALIBRATION

5-l INTRODUCTION. .............................................................. .5-l

6-1 INTRODUCTION ............................................................... .6-l

CHAPTER 7 - DRAWINGS AND PARTS LISTS

7-l INTRODUCTION ............................................................... .7-l

APPENDIX A - OPERATIONAL EXAMPLES

A-l EXAMPLES ................................................................... A-l

APPENDIX B - CONVERSION DATA

B-l INTRODUCTION. .............................................................. B-l

2-l Block Diagram : Industrial Two-Fall System ......................................... .2-2

3-1 Typical Crane Parameters and Terms ............................................. .3-l

4-l Data Display Controls and Indicators .............................................. .4-3

6-1 Data Display PCB/EPROM Replacement. .......................................... .8-6

7-l Data Display (1 of 2). .......................................................... .7-l

2-l LOAD-WATCH System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-S

3-1 Boom Angle Potentiometer Wiring. ................................................. .3-4

4-1 Data Display Controls and Indicators ............................................... .4-l

5-1 dc Voltage Test Points. .......................................................... .5-4

6-1 Recommended Inspections. ...................................................... .6-l

7-l Recommended Spare Parts Inventory. .............................................. .7-7

B-l Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

l-2 SCOPE OF MANUAL

This manual is divided into the following chapters:

l-3 INTENDED AUDIENCE

l-4 PERSONNEL QUALIFICATIONS

l-8 NOTES, CAUTIONS AND WARNINGS

Provides additional information about the current topic.

March 18,1994 Page l-l

I Provides information to prevent equipment malfunction or damage that

Page 1-2 March 18,1994

2-2-1 Data Display

March 18,1994 Page 2-I

Figure 2-1. Block Diagram: Industrial Two-Fall System

Page 2-2 March 18,1994

Figure 2-2. Block Diagram: Intrinsically Safe Three-Fall System

March 18,1994 Page 2-3

2-2-2 Processing Electronics Unit

2-2-3 Boom Angle Sensor

2-24 Transducer Assembly

2-2-5 Alarm Horn

2-2-8 Hydraulic Load Cell

Page 2-4 March 18,1994

Table 2-I. LOAD-WATCH System Specifications

Primary Power 85 to 264 Vat, 47 to 440 Hz (11 to 40 Vdc - optional)

March 18,1994 Page 2-5

Table 2-l. LOAD-WATCH System Specifications (Continued)

Page 2-6 March 18,1994

3-2 COMPONENT INSTALLATION

Figure 3-1. Typical Crane Parameters and Terms

March 18,1994 Page 3-I

Figure 3-2. LOAD-WATCH Component Locations on a Typical Crane

3-2-l Installation Guidelines

3-2-2 Data Display