PSR PAT ANTI-TWO-BLOCK Specifiche

INSTALLATION, OPERATOR’S & TROUBLESHOOTING

MANUAL

PAT ANTI-TWO-BLOCK

TABLE OF CONTENTS

GENERAL INFORMATION.........................................................................................................1

WARNINGS.................................................................................................................................1

OPERATION ...............................................................................................................................2

SYSTEMDESCRIPTION.........................................................................................................2

CONTROL IDENTIFICATION ..................................................................................................2

PRE-OPERATION INSPECTION.............................................................................................4

OPERATIONAL TESTS...........................................................................................................6

INSTALLATION ..........................................................................................................................7

SYSTEMKITS.........................................................................................................................7

INSTALLATION, HYDRAULIC CRANE....................................................................................7

DRAWING 1. 031-300-060-653 A2B CONSOLE INSTALLATION KIT - PARTS LIST..................8

DRAWING 1. 031-300-060-654 A2B MAIN BOOM INSTALLATION KIT - PARTS LIST...............9

DRAWING 3. 031-300-100-443 A2B MOUNTING KIT - PARTS LIST........................................11

DRAWING 4. 031-300-060-653 A2B CONSOLE INSTALLATION KIT - ELECTRICAL

DIAGRAM..................................................................................................................................12

DRAWING 5. 031-300-100-654 A2B MAIN BOOM INSTALLATION KIT - ELECTRICAL

DIAGRAM..................................................................................................................................13

INSTALLATION, LATTICE CRANE........................................................................................14

DRAWING 6. 031-300-101-224 KIT, A2B MAIN BOOM LATTICE RETROFIT - PARTS LIST....14

031-300-101-225 KIT, A2B JIB LATTICE RETROFIT - PARTS LIST.........................................14

DRAWING 7. 031-300-101-224 KIT, A2B MAIN BOOM LATTICE RETROFIT - ELECTRICAL

DIAGRAM AND 031-300-101-225 KIT, A2B JIB LATTICE RETROFIT - ELECTRICAL

DIAGRAM..................................................................................................................................15

DRAWING 8. CONSOLE, A2B, W/LOCKOUT KEY SWITCH PARTS LIST................................16

DRAWING 9. 006-820-006-002 CABLE REEL, KT200 PARTS LIST..........................................17

LENGTH CABLEREPLACEMENT PROCEDURE .................................................................18

SLIP RINGREPLACEMENT PROCEDURE...........................................................................19

TROUBLESHOOTING ..............................................................................................................20

ANTI-TWO-BLOCK PROBLEM..............................................................................................20

ANTI-TWO-BLOCK THEORY..........................................................................................................................23

INSTALLATION, OPERATOR’S & TROUBLESHOOTING MANUAL

ANTI-TWO-BLOCK

GENERAL INFORMATION 1

GENERAL INFORMATION

The PAT Anti–Two-block System has been designed to warn the crane operator of a two-blocking

condition of the crane. If a two-blocking condition is approached, the system will warn the operator by

sounding an audible alarm, lighting a warning light and locking out those functions which may

aggravate the crane's condition, whenever applicable.

NOTE: The term "two-block" is a crane term that refers to a condition when the load handling device

comes in contact with the boom head. This condition, if not prevented, may cause the wire rope to

break, allowing the load to fall. Either raising the load into the boom head, or telescoping the boom

without paying out hoist line can cause a "two- block" condition.

WARNINGS

The PAT Anti-Two- Block System is an operational aid, which warns a crane operator of approaching

two-block conditions, which could cause damage to equipment and personal injury.

This device is not, and shall not be a substitute for good, sound operator judgment, experience and

use of accepted safe crane operating procedures.

The responsibility for the safe operation of the crane remains with the crane operator who shall ensure

that all warnings and instructions supplied are fully understood and observed.

Prior to operating the crane, the operator must carefully and thoroughly read and understand the

information in this manual to ensure that he or she knows the operation and limitations of the system

and the crane.

Proper functioning is dependent upon proper daily inspection and observations of the operating

instructions set forth in this manual. Refer to Section 4 of this manual.

OPERATION

SYSTEM DESCRIPTION

The PAT Anti-Two-block System consists of an operating console, a cable reel, two-block switches

and all applicable wiring.

The anti-two-block switch(es) is (are) mounted at the head of the boom and boom extensions if

available. When the hook block contacts the weight, which means a two-block condition is

approaching, the hoist limit switch contacts open sending a signal that locks out the hoist up, boom up,

and tele out functions.

The cable reel, which is mounted on the boom base section, serves as an electrical conductor for the

anti-two-block switch signal.

The operating console is located in the operator's cab in front of the operator. This unit contains

different controls, which are described in the following picture.

Buzzer

Alarm light button

By-pass key switch

CONTROL

IDENTIFICATION

Figure 1 illustrates the controls of the PAT Anti-two-block System. The numbers of the illustration

correspond to the numbers in the following list, which describes the function of each control.

1. Buzzer: The BUZZER (1) is an audible alarm that sounds during an approaching two-block

condition of the crane. At the same time, the Anti-two-block Alarm Light (2) illuminates. The

following crane movements will be stopped concurrently; hoist up, telescope out and boom down.

(Whenever applicable) The audible alarm can be silenced temporarily by pushing the Alarm light

button (2).

INSTALLATION, OPERATOR’S & TROUBLESHOOTING MANUAL

ANTI-TWO-BLOCK

Since this switch deactivates the cut-off function of the anti-two-block system, the

following instructions shall be adhered to:

The by-pass key shall be used with discretion, because unwarranted use to

override the control lever lockout system can result in harm to the crane

and endanger property and/or person.

Never use the by-pass key to either overload or operate the crane in a

range that is not permissible.

PRE-OPERATION INSPECTION 3

2. Anti-Two-block Alarm Light and Alarm Stop Button: The ALARM LIGHT BUTTON serves a

dual purpose. First, a red warning light illuminates when the anti-two-block limit switch contact

opens. This indicates that a two-blocking condition is approaching. At the same time, the BUZZER

(1)

will sound and the following crane movements will be stopped concurrently: hoist up, telescope

out and boom down. (Whenever applicable) Second, it acts as an alarm stop button, which allows

the buzzer to be silenced temporarily.

3. By-Pass Key Switch: The BY-PASS KEY SWITCH (3) can deactivate the cut off function of the

anti-two-block momentarily to allow the crane operator to override the control lever lockout. This

function can only be engaged by using the matching key. The BY-PASS SWITCH has 2 positions,

which are more specifically described as follows:



The neutral position is engaged when the plunger is out and the key can be removed, as

shown below. In this position, the by-pass key switch does not influence the anti-two-block

control lever lockout.



This position bypasses the anti-two-block control lever lockout. This function can only be

engaged by using the matching key. In this position, the cut off function of the system is

deactivated. To activate the switch, the key has to be turned clockwise for about 45 degrees

and plunger push in, then turned back to the middle position to lock it in place (as shown

below). After activating the by-pass key switch, the alarm light will constantly blink, indicating

that the cutoff function has been deactivated. During this operation, with the anti-two-block

switch activated, the alarm light will blink with a higher frequency. The BUZZER (1) for

approaching two-block conditions will be illuminated at all times.

Failure to re-position the anti-two-block switch weight will prevent the system from functioning

properly. No weight shall be on the main hoist anti-two-block switch when the boom extension

is being used.

PRE-OPERATION INSPECTION

Prior to operating the crane, the following checks must be made:

Check the cabling connections to the various parts of the system for physical damage.

Check the spring-loaded cable reel to ensure it is free to rotate, has proper tension and is spooled

properly.

Check the anti-two-block switches and weights for freedom of movement.

Check the anti-two-block switch weight for proper installation on the hoist load line. The hoist line

runs through the A2B weight. With even parts of hoisting line, the weight shall be attached to the

dead-end line. With odd parts of hoisting line, the weight shall be attached to the line of lowest

speed.

Check the A2B conditions for main/auxiliary hoist operation with the following instructions:

If the crane works with only the main boom, the by-pass plug must be installed in the main

boom junction box.

If the crane works with an extension:

If the boom extension is not in the operating position, the by-pass plug must be installed in

the main boom junction box. The weight shall be installed on the main hoist anti-two-block

switch.

If the boom extension is in the operating position and the load line is being used on the main

boom, the connecting cable must be installed between the junction boxes on the main boom

and extension. Weights must also be attached to the anti-two-block switches on both the

main boom and boom extension.

If the boom extension is in the operating position and no load line is being used on main

boom, to prevent injury or damage to equipment, the weight shall be removed from main

boom switch. In that case the anti-two-block switch has to be locked with the red Anti-two-

block Retainer (See number 6 in this section).

INSTALLATION, OPERATOR’S & TROUBLESHOOTING MANUAL

ANTI-TWO-BLOCK

Fig. 1: Setting of Anti-two-block Retainer in

Locking Position

Fig. 2: Retainer in Locking Position

PRE-OPERATION INSPECTION 5

Check the installation of the A2B retainer when applicable. - See Numbers 4 and 5 of Pre-

Operation Inspection, above.

Installation of Anti-two-block Retainer in Locking Position (Figures 1 and 2)

Pull the cable out of the switch and bend back parallel to the boom and hold .

Slide the retainer from left side with its slot over the cable between the crimped stop and the switch

. Push it firmly straight onto the cable guide of the Anti-two-block switch .

Straighten the cable completely into the slot and release the cable.

Turn the flag of the retainer for the operator’s best visibility. .

Removal and Storage of Anti-two-block Retainer (Figures. 3 and 4)

Pull the cable out of the switch and bend back parallel to the boom and hold .

Move the retainer down and then left to remove it from the Anti-two-block switch. Release the

cable.

For storage, slide the retainer from the right side over the Anti-two-block switch until the clips (A)

lock into the holes (B).

Fig. 3: Removal of the Anti-two-block

Retainer

Fig. 4: Retainer in Storage Position

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