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Manual The Load & A-2 Mod 737
Manual The Load & A-2 Mod 737
**Please note:
This system DOES NOT require calibration out of the box.
Table of Contents
Foreword, System components, Installation guidelines, Tools required 2
Sandwich link stabilization pin installation instructions (Male/male load cells only) 5
System specifications 12
© The LOAD & A-2-B Company Inc. – 737 Manual / last revised January 2002 / specifications subject to change
1
Foreword
The Model 737 Radio Load Indicating System is a two component wireless load indicating system.
It is designed to provide a digital indication of the total load on the hook. The system also provides an
indication of the load as a percentage of an operator set maximum capacity.
System components
Check to be sure that you have received the following components:
• Load Cell link (with sandwich link attachment if 40,000 S. L. P.)
• Display panel, panel cover & mounting bracket
• Power cord
• Antenna assembly (either rubber or metal – see page 6 of this manual for details)
• Pins, washers, cotter pins
• Calibration screw driver
• This manual
Installation guidelines
• Read all of these instructions completely prior to beginning
• Plan the installation
• Have the necessary tools available
• Mount the load cells first
• Mount the display panel second
• Test the system
Tools required
• Step ladder – to reach the boom, rooster sheave and or jib tip
• Pliers for removing and bending cotter pins
• Electric drill with 3/16th inch drill bit
• Wire crimping tools – for the display power and ground connections
• Screw drivers and or socket set
• Clear silicone
© The LOAD & A-2-B Company Inc. – 737 Manual / last revised January 2002 / specifications subject to change
2
Load cell
Installation instructions FRONT VIEW OF
SHEAVES AND
BOOM TIP
PINS
For even parts-of-line, the load cell link is simply pinned between
LOAD
the wire rope socket (becket) and the dead end on the boom tip. CELL
LINK
BECKET
OR WIRE
ROPE
SOCKET
BECKET
OR WIRE
ROPE
SOCKET
DEAD END /
TOP OF SWIVEL BEARING
Important Service Note: The colored blocks on the load cells contain
transmitters, lithiuon ion battery packs, internal strain guages in addition
to various modern technology electronics. Visually inspect the seals
where the colored blocks attach to the load cell. If a seal is broken due
to mis-use, and even if it continues to work, ship the system in for service
immediately. This will prevent moisture from turning a $100 repair into a
$700 repair.
© The LOAD & A-2-B Company Inc. – 737 Manual / last revised January 2002 / specifications subject to change
3
737 Load cell installation and placement guide
for load cell links
Figure ‘A’ Pin the load cell between the wire rope socket (becket) and the dead end on the main boom of the crane.
MAIN
Figure ‘B’ Pin the load cell between the wire rope socket (becket) and the headache ball on the auxiliary sheave
(rooster) on the cranes boom tip. AUX 1
Figure ‘C’ Pin the load cell between the wire rope socket (becket) and the headache ball on the jib extension. AUX 2
Figure ‘D’ Location of external magnetic mount antenna on operator cab of crane.
JIB EXTENSION
DEAD END
Rooster sheave
Figure ‘B’
© The LOAD & A-2-B Company Inc. – 737 Manual / last revised January 2002 / specifications subject to change
4
Load cell - sandwich link installation instructions
> Male/Male - Load Cell Link
Placement on BOOM TIP DEAD END
Even part-of-line
ATTENTION: THIS PIN PREVENTS DAMAGE TO THE LOAD CELL BY KEEPING THE SANDWICH LINK FROM
FOLDING AGAINST THE LOAD CELL IN A TWO BLOCK SITUATION. SUCH DAMAGE WILL NOT BE COVERED
UNDER WARRANTY. CHECK THIS PIN REGULARLY TO ENSURE THAT IT IS SECURE & IN PLACE.
Load Cell
© The LOAD & A-2-B Company Inc. – 737 Manual / last revised January 2002 / specifications subject to change
5
Display panel installation
> Display panel mounting: The installation of the display panel consists of drilling two holes for mounting in
the operator cab and connecting two wires (red to +12VDC and black to ground). First find a suitable
location on the dash where the crane operator has an unobstructed view of the display. Using the removable
bottom portion of the mounting bracket align, mark and drill two holes in the cab of the crane. Securely
attach the bottom portion of the mounting bracket assembly to the dash. Insert the blue display panel into the
carriage holes of the lower mounting bracket and with the two fluted knobs and star washers, securely
attach panel with the front of the display facing the operator.
> Display panel power: is provided to the panel using the two conductor cable included. Connect the red
wire to a positive (+12VDC) terminal and the black wire to a solid ground on the crane.
ATTENTION: Ensure that a continuous +12VDC (10V minimum) is available to the panel at all times.
Otherwise the system will not operate correctly. When attaching power cable to panel gently push
male end of plug into female receptacle on side of panel. Slide plug neck back towards panel and
tighten clockwise ½ turn.
Antenna installation
Depending on the length or type of boom, three antenna installations and placements are possible.
With your system you may have received:
(A) One ten inch rubber antenna.
(B) One ten inch rubber antenna with an external magnetic mount base, attachment cable and plug.
(C) One metal whip antenna with an external magnetic mount base, attachment cable and plug.
(A) Outside operator cab – up to 150 feet of boom: Where the receiver panel is installed outside a cab
simply install the 10 inch rubber antenna directly onto the blue receiver panel. Attach the base of the
rubber antenna to the side of the receiver panel by inserting it GENTLY with a simple half turn. Ensure
that the line of sight between the load cell and the antenna is unobstructed. It is important that the
receiver antenna not be touching glass or metal.
(B) Inside operator cab – up to 150 feet of boom: For installations inside the operator cab and where your
boom does not exceed 150 feet of length, place the magnetic mount base with the 10 inch rubber
antenna on the top of the operator cab on the crane. (see Figure D, page 4) Ensure that the line of sight
between the load cell and the antenna is unobstructed. Drill a small hole in the side of the cab to allow
the black antenna lead to enter the cab. Use a small amount of clear silicone to seal around the hole
when complete. Install the chrome metal plug at the end of the antenna cable directly on to the blue
receiver panel.
(C) Inside operator cab – more than 150 feet of boom: For installations inside the operator cab and where
your boom EXCEEDS 150 feet of length, place the magnetic mount base with the metal whip antenna on the
top of the operator cab on the crane. (Figure D, page 4) Please ensure the small allen screw for holding the
whip antenna to the magnetic base is firmly tightened. Ensure that the line of sight between the load cell and
the antenna is unobstructed. Drill a small hole in the side of the cab to allow the black antenna lead to enter
the cab. Use a small amount of clear silicone to seal around the hole when complete. Install the chrome
metal plug directly on the side of the blue receiver panel by inserting with a simple half turn while pressing
down GENTLY.
Start up
Upon power up, the blue receiver panel runs through an initialization sequence. After power up the last line
used, the weight of the last load on the hook and parts-of-line of the last load cell used will be displayed.
Parts-of-line adjustment
Parts of line: The operator must ensure that the panel part-of-line adjustment knob is set to the actual num-
ber of parts-of-line in use on the crane. The number of parts-of-line can be changed by turning the knob lo-
cated on the top of the right side of the panel. Standard systems are constructed for a maximum setting of
12 for the parts-of-line.
© The LOAD & A-2-B Company Inc. – 737 Manual / last revised January 2002 / specifications subject to change
6
Option for 24 part of line adjustment:
When more than twelve parts-of-line are required, an optional toggle switch can be installed behind the parts
of line knob. With the toggle switch in the lower position, the P.O.L. knob will select a number from 1
through 12. When the toggle is in the upper position, the knob will select numbers from 13 through 24.
Calibration
THIS SYSTEM DOES NOT NEED TO BE CALIBRATED OUT OF THE BOX…
THE SYSTEM IS CALIBRATED TO +/- 1% FROM FACTORY. Calibration should be checked on a
bi-annual basis by lifting a known weight, and comparing the known weight with the weight indicated on the
display panel. One criterion for determining if the system is properly calibrated is SAE Recommended
practice SAE J376, section 4.2 that reads: "The accuracy of the load indicating system is to be such that the
indicated load is not less than 100% of the actual load, no more than 110% of the actual load...."
© The LOAD & A-2-B Company Inc. – 737 Manual / last revised January 2002 / specifications subject to change
7
737 Radio load monitor - panel functions
1 2
3
X 1000 X 100 PARTS OF LINE
5
15
14
6
13
% LOAD
7
THE 8
12
11
9
10
1. Digital Display – Displays the weight of the load in 100 pound increments (200 pound increments for the
40,000 S. L. P load cells) e.g. 7.8 = 7,800 pounds. Numbers to the left of the decimal represent thousands
of pounds, number the right of the decimal represent hundreds of pounds.
2. Parts-of-Line (POL) Indicator – Displays the parts of line is use.
3. Parts-of-Line (POL) Selector – Operator selectable for the parts-of-line.
4. Battery Warning Light – Illuminates when a low battery is detected in the load cell. If it is illuminated please
refer to troubleshooting guide.
5. System Warning Light – Illuminates to alert the operator of a problem so that he does not rely on a faulty
system. If it is flashing please refer to troubleshooting guide.
6. Fuse Holder.
7. Over Limit Indicator – Indicates when 100% of the user selectable Max Load has been reached. For
instructions on setting the Max Load refer to operating instructions, Max Load.
8. Power Connector.
9. Fluted Knob.
10. Lower portion of Mounting Bracket
11. Max Load Knob – Use to set the Max Load. Please refer to operating instructions for detailed instructions on
use.
12. Antenna Connector
13. Calibration Pot Adjustment – IMPORTANT – This system comes calibrated from the factory – re-calibration
is not necessary. Please read calibration instructions completely before performing any changes.
14. Zero Pot Adjustment – Please read zero instructions completely before performing any changes.
15. Max Load Bar Graph – Gives the operator a visual indication of the percentage of the operator preset Max
Load being lifted. The percentage of load is simply the actual load divided by the maximum load value
assigned by the operator.
© The LOAD & A-2-B Company Inc. – 737 Manual / last revised January 2002 / specifications subject to change
8
Troubleshooting guide
Please do not attempt to open the load cell or the receiver panel
before reading this section completely and then contacting
The Load & A-2-B Company service department at 1-888-562-3222.
2. Panel powers up but does not A. Verify that there is +12VDC going to the panel.
run through the full start up B. Power the panel directly with +12VDC from the cranes battery by
sequence – e.g. Lights burnt passing any fuse panels and connections or on a separate 12 volt
out, missing numbers, etc. battery to ensure that it is not a crane power problem.
C. Call the service department at 1-888-562-3222.
3. Panel gets extremely hot to the A. If the panel is installed in a cab remove the black dust cover and
touch improve the air circulation around the panel.
B. Change the power to the panel so that it runs on +12VDC. If you
need assistance in doing this contact the service department.
4. Battery warning light is on A. Battery needs to be replaced. Please refer to the Battery
steady Replacement section of this manual.
5. System warning light is flashing A. Loss of communication with load cell. Refer to the
No Communication section at the end of this troubleshooting guide.
6. Dashed lines on the display A. Loss of communication with load cell. Refer to the No
Communication section at the end of this troubleshooting guide.
B. Interference from other radio frequency sources in the area.
(e.g. radio towers, high power TV antennae, satellite transmissions,
etc.)
7. Display always shows the same A. Loss of communication with load cell. The panel will display the last
weight or stuck on same weight weight picked if communication is lost and it will look like the weight
even after turning the power on is stuck. Refer to the No Communication section at the end of this
and off troubleshooting guide.
8. Display is slow to update weight A. Intermittent communication with load cell. Refer to the No
changes Communication section at the end of this troubleshooting guide.
B. Interference from other radio frequency sources in the area.
(e.g. radio towers, high power TV antennae, satellite transmissions,
etc.)
9. Fluctuating weights Boom & load need to be stabilized. Try the following steps if you are
still having problems;
A. Raise the load as high as possible and stop until the motion of the
load is minimized. Note if the fluctuation on the readout stops or is
reduced.
B. Lower the load & release. The readout should go back to indicating
the block weight.
C. If fluctuation is reduced in step A and the readout returns to the block
weight in step B, the sheaves on the rigging may require cleaning and
lubrication. If fluctuation is not reduced in step a or readout does not
return to block weight in step B, contact the service department of
The Load & A-2-B Company.
© The LOAD & A-2-B Company Inc. – 737 Manual / last revised January 2002 / specifications subject to change
9
No communication between load cell and blue receiver panel
If you suspect a communication problem between the load cell
and the receiver panel, please use the following steps in troubleshooting.
3. Damage to Load Cell A. If the cell has been damaged please call our service department
immediately.
B. If the plastic cases are mis-aligned, broken or cracked call our service
department immediately.
C. If the gasket seal has been damaged or broken it will allow moisture to
damage the electronics and strain gages. Please call the service
department immediately.
Important: Both components of the system, the load cells and the blue receiver panel
must be shipped together for any service work.
Check serial numbers to ensure matched system components are shipped together.
© The LOAD & A-2-B Company Inc. – 737 Manual / last revised September 2000 / specifications subject to change
10
Battery replacement
Before attempting to replace the batteries we suggest that you read over the troubleshooting guide and then
call the service department @ 1-888-562-3222.
Once you have verified that it is a battery problem then read the following instructions before beginning.
1 Battery replacement kit (contact The Load & A-2-B Co. to purchase)
Contents of kit: 1 load cell battery pack – 7.2V Lithium Ion Pack P/N DCS001BP
1 battery cover gasket
1 tube of RTV silicone
1 Allen Key 5/32”
It is suggested that you remove the load cell from the winch line, but the replacement can be done with the cell
in line if need be.
1. Locate the battery compartment of the load cell. The battery compartment is on the same side as the serial
number tag. There should be 4 hex head bolts visible.
2. NOTE: If the holes are filed with silicone then this is the transmitter side of the cell. Do not open the
transmitter side of the unit, it has no user serviceable parts. The warranty may be void if the transmitter
electronics section has been opened.
3. Remove the 4 hex head bolts using an allen key. Note – Do not use a power drill/screw driver to remove or
tighten the bolts, you may easily damage the threads on the aluminum plate.
4. Disconnect the battery from the cell at the connector.
5. Remove the old gasket material from both sides of the compartment.
6. Make sure the surfaces of the battery compartment are clean, then install the new gasket on the aluminum plate.
7. Install the new battery making sure to route the wires so as not to pinch them when reinstalling the cover.
8. Using the RTV silicone put a bead all the way around the edge of the plastic cover and on any surfaces
touching the gasket.
9. Place the plastic cover over the battery pack taking care not to wipe off the silicone or pinch the wires.
10. Replace the screws and tighten until the gasket is squished to about 1/16” (half of it’s thickness). You will
also notice that silicone will be squeezed out while tightening. If no excess silicone then you did not put
enough on.
11. Clean off excess silicone.
12. The battery replacement procedure is now complete.
13. Re-install the load cell and test for correct operation.
Important Service Note: The colored blocks on the load cells contain
transmitters, lithium ion battery packs, internal strain gauges in addition
to various modern technology electronics. Visually inspect the seals
where the colored blocks attach to the load cell. If a seal is broken due
to mis-use, and even if it continues to work, ship the system in for service
immediately. This will prevent moisture from turning a $100 repair into a
$700 repair.
© The LOAD & A-2-B Company Inc. – 737 Manual / last revised January 2002 / specifications subject to change
11
Technical component specifications
Receiver panel
reception range minimum of 150 feet
power supply 12 VDC standard
weight 3½ pounds
length 9 inches
height 6 inches
width 2 ½ inches
antenna rubber or metal
oper. temp in ºF -40 to 122 (-40 to 50 ºC)
Load cell (15,000 and 25,000 S.L.P.) - female / male cell design
transmit range minimum of 150 feet
response time 0.1 second
weight 14 pounds
length 14 inches
width 5 inches by 5 inches
antenna inner coil
oper. temp in ºF -40 to 122 (-40 to 50 ºC)
battery lithium ion
battery life two years
These specifications for the 40,000 S.L.P. include the sandwich link attachment rigging
© The LOAD & A-2-B Company Inc. – 737 Manual / last revised January 2002 / specifications subject to change
12
FCC compliance
FCC ID: NFB LAB 737
This device complies with part 15 of the FCC Rules. Operation is subject to the following two
conditions: (1) This device may not cause harmful interference, and (2) This device must accept any
interference received, including interference that may cause undesired operation.
Unauthorized changes or modifications to the Model 737 Radio Load Monitoring System are expressly
prohibited by the Load & A-2-B Company. Unauthorized changes or modifications could void the operator’s
authority to operate the equipment.
If you require any modifications, please contact The Load & A-2-B Company toll free at 1-888-562-3222.
Warranty
The Load & A-2-B Company Inc. warrants to the purchaser of each new Radio Load Indicating System
that any part thereof which proves to be defective in material or workmanship within one (1) year from date of
delivery will be repaired or replaced at no charge, if the system is returned to us in Edmonton, Alberta with all
freight charges prepaid.
If a performance problem should occur, contact our office in Edmonton, Alberta at 1-888-562-3222.
This warranty does not cover defects resulting from accident, alteration, improper use, or failure of the
purchaser to follow normal operating procedures as outlined in this instruction manual.
THIS WARRANTY IS IN LIEU OF ANY WARRANTY OR MERCHANTABILITY AND OF ALL OTHER
WARRANTIES, EXPRESSED OR IMPLIED, ALL OF WHICH ARE HEREBY EXCLUDED.
The Load & A-2-B Company Inc. shall in no event be liable for any special, indirect, or consequential
damages whatsoever and neither assumes nor authorizes any person to assume for it any other obligation or liability.
© The LOAD & A-2-B Company Inc. – 737 Manual / last revised January 2002 / specifications subject to change
13