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HAC-WJ-200T Crane Moment Limiter

Operation Manual

(Applied for Crawler Crane)


Preface
This manual is a debugging and operating manual for Puyuan Crawler crane moment
limiter.
The crane moment limiter is an auxiliary device for safety operation of crane. But this
device can’t replace the actual experience of excellent operator, can’t replace the on-side
actual circumstances. Moreover, it can’t replace the safety operating regulation of
crane.
When crane moment limiter judges that the crane is in overloading state it will
automatically send out the stopping control signal. This control signal can only be
realized through the electrical circuit and hydraulic system of crane itself to cut off the
dangerous action.
One point must be pointed especially here: if fault happens on the crane moment
limiter, its displaying data is incorrect before solving the fault problem. So the
displaying data can’t be used as reference for operation. Under this circumstance, you
must strictly operate it according to safety operating regulation and crane characteristic
table.
Thank you very much for choosing our company’s product.
If you have any problem in operating process, please call +86 731 5667249 or 5316732
(fax) to get technical support.
Content
1 Operating interface.................................................................................................................................. 1
1.1 Self-check interface..................................................................................................................... 1
1.2 Main interface ............................................................................................................................. 2
1.3 Small keyboard............................................................................................................................ 3
2 Setup of operating state ........................................................................................................................... 3
2.1 Select boom and setup the ratio and hook ................................................................................... 4
2.2 Choose sensors ............................................................................................................................ 5
2.3 Check and diagnose..................................................................................................................... 5
2.3.1 Communication Test........................................................................................................ 6
2.3.2 Control Test ..................................................................................................................... 7
2.3.3 Sensors Check ................................................................................................................. 8
2.4 Touch screen Calibration............................................................................................................. 8
3 System adjustment................................................................................................................................... 9
3.1 Adjust boom angle .................................................................................................................... 11
3.1.1 Adjust minimal derricking angle ................................................................................... 11
3.1.2 Adjust maximal derricking angle .................................................................................. 12
3.2 Adjust tower jib angle ............................................................................................................... 12
3.2.1 Adjust minimal angle .................................................................................................... 14
3.2.2 Adjust maximal angle.................................................................................................... 14
3.3 Adjust boom tensile force.......................................................................................................... 15
3.4 Adjust tower jib tensile force .................................................................................................... 16
4 Fine adjustment of parameter ................................................................................................................ 17
4.1 Fine adjustment for radius......................................................................................................... 18
4.2 Fine adjustment for load............................................................................................................ 19
4.3 Fine adjustment for fixed jib load ............................................................................................. 20
4.4 Fine adjustment for tower jib load ............................................................................................ 22
4.5 Weight check for different operating state................................................................................. 23
4.6 Check of rated lifting capacities ................................................................................................ 23
4.7 Test of overload control............................................................................................................. 23
5 Connecting mode................................................................................................................................... 24
5.1 Connecting way of signal wire in control box of QUY200 boom............................................. 24
5.2 Connecting way of signal wire in control box of QUY200 tower jib........................................ 25

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1 Operating interface

1.1 Self-check interface

On Every Booting, the system can Self-check every control module automatically. The

self-checking result will be displayed on the screen (System check interface). If the

self-check of equipment (1), equipment (2), equipment (32) fails, the system will stop

running. Consumer should get on touch with manufacturer on time to solve the problem.

System check interface:

Three buttons at lower part of the screen: “Communication Test”, “Control Test”,
“Sensors Check” are used to check whether the communication system, control system and
acquisition of sensor signal is normal or not.

The “Advanced Mode” button on top-right of the screen are only provided for
professional personnel and password must be provided when using it.

When the self-check finishes, the system will close the self-check window automatically
in 7 seconds and show the main interface of the system.

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1.2 Main interface

2.Operating parameter display area


3.Operating state display area

1.Menu Display Area

4.Working State Indicator Lamps

6.Operation State Diagram Area

5.Load Percentage

The Main Interface is divided into 6 display areas:


(1) Menu Display Area(Left of the screen):Contains some instructions of system;
(2) Operating parameter display area (Top of screen, blue area): Display the current setup of
operating state, including magnification, hook, working jib etc;
(3) Operating state display area (Top of screen, black, yellow area): Display the current
operating parameters, including boom length, lifting angle, working radius, height,
calculated load (actual lifting capacity), rated load (rated lifting capacity);
(4) Working State Indicator Lamps (top-right of screen): From top to bottom, the green,
yellow, red indicator lamps separately indicate the normal, pre-warning, alarm working
states. Under pre-warning state, the buzzer begins sounding. Under alarm state, the buzzer
chirps rapidly;
(5) Load Percentage (bottom-right of screen), displays the percent value of calculated load to
rated load;
(6) Operation State Diagram Area (Middle of screen): display the lifting operation state and
lifting loads directly and visually with diagram.

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1.3 Small keyboard

The system provides a small touching keyboard and used for inputting data. Under
normal circumstances the small keyboard is not displayed. When it needs to input characters,
the small keyboard will be displayed automatically.
In the small keyboard, “E” is used for inputting float data. “←”、“→”are used for
controlling the inputting position of characters. “Bksp” is used for delete the front one
character before current position. “←”shows moving the inputting position left. “→”
shows moving the inputting position right. “Inc”is used for increasing “1” continuously.
“Dec” is used for decreasing “1” continuously. “Copy”, “Paste” are used for copying and
pasting data.

2 Setup of operating state

When the actual operating state doesn’t accord with the operating state shown on screen,
must setup the operating state. The detail operating steps are: Click the “Choose Job Case”
menu in menu display area and make corresponding setup in the listed instructions. The
interface is shown as the following figure:

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2.1 Select boom and setup the ratio and hook

In main interface, click the “Select boom” item of “Choose Job Case” in menu
display area. An interface is shown as the following figure:

Select the boom and some type of jib according to actual circumstance, then click “save”,
and “Close” to return to main interface.

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◆ Input the magnification value of boom hook and make the display
magnification be same as the actual magnification;
◆ Select the weight of boom hook and make the displaying weight be same as the
actual weight;
◆ If jib hook is used, then choose the magnification and weight of jib hook to be
the same as the actual value;
◆ After choosing magnification and weight, click “Save” and then click “Close”
to quit and return to main interface.

2.2 Choose sensors

All sensors should be chosen in normal operation, shown in following figure:

2.3 Check and diagnose

The check and diagnose is used to check whether the system operates normally or
not. In general circumstance this function will not be used. In main interface click “Check
& diagnose” item in “Choose Job Case” menu in menu displaying area and an interface is
shown as the following figure:

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2.3.1 Communication Test

Click “Communication Test” and a dialog box is displayed in operation state diagram
area in main interface as shown in following figure:

The communication testing result will be displayed in dialog box. If there is no


communication fault, PASS is displayed, if there is fault, FAILURE is displayed.
Check whether the CAN-H and CAN-L signal wire is open or not referring to
connecting way of sockets in section 5.1. If there is connecting fault, please overhaul it and
guarantee that the signal wire is working.
Click “Close” to quit after testing.
Attention: During “Communication test” operation, the overload control system is
in pausing state.

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2.3.2 Control Test

Click “Control Test” button and a dialog box is displayed in operation state diagram area
in main interface as shown in following figure:

On this state, all control signals are simulated and output by moment limiter, so
they have nothing to do with the actual state.
◆ Click “Normal” and the green indicating lamp on screen is on;
◆ Click “Pre-warning” and the yellow indicating lamp on screen is on;
◆ Click “Alarm” and the red indicating lamp on screen is on;
◆ Click “Overload”, “Boom over-depression”, the red indicating lamp on screen
flickers rapidly and send out overload control signal simultaneously.
Click “Close” to quit after testing.

Attention: During “Control test” operation, the displayed information of overload


control on screen is simulated and outputted by moment limiter. The outputting part
of control signal of overload control system is in pausing state.

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2.3.3 Sensors Check

Click “Sensors Check” and Check for Sensors dialog box is displayed in operating
state diagram area in main interface. The current collected values of angle sensor, tensile
force sensor will be displayed in this dialog box. If the current collected value of one
sensor is 0 or 32767, which means that this sensor or the wire connected to the sensor goes
wrong. We must check the connecting wire by referring the connecting way of sensors in
section 5.1. If the connecting wire has no fault, please replace the corresponding sensor.

Click “Close” to quit after checking.

Attention: During “Sensors Check” operation, the overload control system is in


pausing state.

2.4 Touch screen Calibration

When there is deviation between touching position of figure on touch screen and the
actual cursor position, we must calibrate the touch screen.
Click “touch screen calibration” item in “Choose Job Case” menu in menu displaying
area and a window is displayed as following figure:

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Then click “OK” key, the calibrated interface of touch screen is shown as the following
figure:

According to the prompt on the screen, click the circle in drawing with a finger. When
the color of circle changes from blue to red and a beep is heard, then calibrate the next point
according to the prompt on the screen until all four points are calibrated. Then it will quit the
calibrating interface automatically and return to main interface.

3 System adjustment

When there is much deviation between displaying value and actual value of boom angle,
calculating lifting capacitance, we must adjust the moment limiter. This adjustment is done
in “System adjustment” and “Fine adjustment of parameters”.

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Attention: All instructions listed in “System adjustment” and “Fine adjustment of
parameters” menu are provided for professional personnel and password must be provided
before operating these instructions.
When inputting password is needed, the small keyboard will popup automatically and
input password “1234”. Click “OK” key to enter into each adjusting menu in “System
adjustment” menu.

Click “System adjustment” arrow in main interface and one window is displayed as the
following figure:

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3.1 Adjust boom angle

The function of adjusting angle is used to adjust the collected value of angle sensor
when boom is in minimal and maximal lifting angle.
Object of reference: angle indicating index mark or a level instrument.
In main interface, click the “Adjust boom angle” item in “System adjustment” menu
in menu displaying area and a window is displayed as shown in following figure:

3.1.1 Adjust minimal derricking angle

Place the boom horizontally, the angle showing on index mark or the level instrument
indicates 00, click the “Emend” key at the bottom of “Adjust minimal derricking angle: 00 ”.
A dialog box is displayed as shown in following figure:

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After confirming that the boom is placed to horizontal position, i.e., the angle is 00, click
“OK” to emend (Viz, adjust the minimal derricking angle according to the prompt on screen).

3.1.2 Adjust maximal derricking angle

Lift the boom and the angle showing on index mark or indicates 800, click the “Emend”
key at the bottom of “Adjust maximal derricking angle: 800 ”. A dialog box is displayed as
shown in following figure:

Lift the boom and confirm that the boom is placed at 80o angle. Click “OK” to emend
(Viz, adjust the maximal derricking angle according to prompt on screen).
After adjusting derricking angle, click “Save” then click “Quit” key to return to main
interface.

3.2 Adjust tower jib angle

The function of adjusting tower jib angle is used to adjust the collected value of angle
sensor when tower jib is at angle of 20o and 60o.
In main interface, click the “Adjust tower jib angle” item in “System adjustment”
menu in menu displaying area and a window is displayed as shown in following figure:

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The calculated R (radius) of all kinds of tower jib length at an angle of adjusted zero
point (20o) and adjusted full point (60 o) are listed in following table:

luffing jib length(m) Zero adjusting point Full adjusting point


o o
(20 )R(m) (60 )R(m)

27 25.4 13.5

30 28.2 15

33 31 16.5

36 33.8 18

39 36.6 19.5

42 39.5 21

45 42.3 22.5

48 45.1 24

51 47.9 25.5

18.29 17.2 9.1

24.38 22.9 12.2

27.43 25.8 13.7

30.48 28.6 15.2

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33.53 31.5 16.8

36.58 34.4 18.3

39.62 37.2 19.8

42.67 40.1 21.3

45.72 43 22.9

48.77 45.8 24.4

51.82 48.7 25.9

3.2.1 Adjust minimal angle

Confirm the tower jib length and refer to data of zero adjustment (20o), measure the actual
operating radius and compare it with the referring value in table. Click “Adjust” key and a
dialog box is displayed as shown in following figure:

Confirm that the tower jib is at 20o angle, click “OK” key to make minimal angle
adjustment (adjust it according to prompt on screen)

3.2.2 Adjust maximal angle

Lift the tower jib length and refer to data of zero adjustment (60o), measure the actual
operating radius and compare it with the referring value in table. Click “Adjust” key and a
dialog box is displayed as shown in following figure:

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Lift the tower jib and confirm that the tower jib is at 60o angle, click “OK” key to make
maximal angle adjustment (adjust it according to prompt on screen).
After adjusting tower jib angle, click “Save” and then “Close” key to return to main
interface.

3.3 Adjust boom tensile force

On operating state of boom working, when the displayed length and angle are
consistent with the actual values, if there is difference between the displayed weight and
actual weight, we must adjust the weight of moment limiter. Before adjusting it, please check
the data of tensile force sensor first and then do fine adjustment of weight parameter.

In main interface, click the “Adjust boom tensile force” item in “System adjustment”
menu in menu displaying area and a window is displayed as shown in following figure:

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The zero point of Force I and Force II is 30 and the magnification is 1000. These data is
constant and can’t be modified randomly. If it is changed please resume it. After confirm
that the zero point and magnification of Force I and Force II are correct, then observe the
collected value of Force I and Force II, Confirm that these data changes obviously during
changing radius process. Click “Save” and then “Close” to quit the “Adjust boom tensile
force” interface and return to main interface.

3.4 Adjust luffing jib tensile force

On operating state of tower jib working, when the displayed length and angle are
consistent with the actual value, if there is difference between the displayed weight and
actual weight, we must adjust the weight of moment limiter. Before adjusting it please
check the data of tensile force sensor first and then do fine adjustment of weight
parameter.
In main interface, click the “Adjust tower jib tensile force” item in “System
adjustment” menu in menu displaying area and a window is displayed as shown in
following figure:

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The zero point of Force I and Force II is 30 and the magnification is 1000. These data is
constant and can’t be modified randomly. If it is changed please resume it. After confirm that
the zero point and magnification of Force I and Force II are correct, then observe the
collected values of Force I and Force II, Confirm that these data changes obviously during
changing radius process. Click “Save” and then “Close” to quit the “Adjust tower jib tensile
force” interface and return to main interface.

4 Fine adjustment of parameter

When displayed length and angle are consistent with the actual value, and the parameter
of pressure sensor is normal too, if there is any difference between the displayed weight,
radius and actual weight, radius, the fine adjustment of parameters must be done.
In main interface, click “Parameter fine adjustment” and the following window will be
displayed:

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4.1 Fine adjustment for radius

Before fine adjustment of radius please make sure whether the boom length
and boom angle are correct or not. Then continue the fine adjustment for radius. If
there is deviation between displayed radius and actual radius, the radius must be adjusted.
Click “fine adjustment for radius” item in “Parameter adjustment” menu and the
following window will be displayed:

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The measuring method of actual radius: Measure the horizontal distance between
revolving center and boom hook center with tape measure.

 Zero Point setting


Make the main boom in the second stage extending, measure the radius with the
tape. Adjust the “zero position” in window of fine adjustment for radius and make:
Calculated Working radius = Measured Working radius

 Adjust Slope
Make the main boom in its full length and measure the radius with the tape. Adjust
the “Slope” in window of fine adjustment for radius and make:
Calculated Working radius = Measured Working radius
After adjusting, click “Save” and “Close” to quit the interface of fine adjustment
for radius.

4.2 Fine adjustment for load

If there is deviation when using boom load, please adjust the boom parameters in
interface of “Fine adjustment for load” and make:
Calculated weight ≈ object weight + lifting tool weight + hook weight
Click “fine adjustment for load” item under the “Parameter fine adjustment” menu in
main interface, and the following window will be displayed:

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Object of reference: object with known weight
 Lift a object as heavier as possible, adjust the slope in interface of “Fine adjustment
for boom load” and make:
Calculated weight ≈ object weight + lifting tool weight + hook weight
 Put down the object, adjust the zero position in interface of “Fine adjustment for
boom load” and make:
Calculated weight ≈ lifting tool weight + hook weight
 Repeat the above two steps several times and make the display weights consistent
After adjustment, click “Save” and then click “Close” to exit the interface of “Fine
adjustment for boom load” (Please pay attention to whether the position of chosen
parameter is correct or not).

4.3 Fine adjustment for fixed jib load

If there is deviation when using fixed jib load, please adjust the fixed jib parameters that
is in interface of “Fine adjustment for load”, and make:
Calculated weight ≈ object weight + lifting tool weight + hook weight
In main interface, click “Fine adjustment for fixed jib load” in “Parameter fine
adjustment” menu and the following interface will be displayed:

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Object of reference: object with known weight.

 Lift a object as heavier as possible, adjust the slope in interface of “Fine adjustment
for fixed jib load” and make:
Calculated weight ≈ object weight + lifting tool weight + hook weight

 Put down the object, adjust the zero position in interface of “Fine adjustment for
fixed jib load” and make:
Calculated weight ≈ lifting tool weight + hook weight

 Repeat the above two steps several times and make the display weights consistent.

After adjustment, click “Save” and then click “Close” to exit the interface of “Fine
adjustment for fixed jib load” (Please pay attention to whether the position of chosen
parameter is correct or not).

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4.4 Fine adjustment for tower jib load

If there is deviation when using tower jib load, please adjust the tower jib parameters
that is in interface of “Fine adjustment for load”, and make:
Calculated weight ≈ object weight + lifting tool weight + hook weight
In main interface, click “Fine adjustment for tower jib load” in “Parameter fine
adjustment” menu and the following interface will be displayed:

Object of reference: object with known weight


 Lift a object as heavier as possible, adjust the slope in interface of “Fine adjustment
for tower jib load” and make:
Calculated weight ≈ object weight + lifting tool weight + hook weight
 Put down the object, adjust the zero position in interface of “Fine adjustment for
tower jib load” and make:
Calculated weight ≈ lifting tool weight + hook weight
 Repeat the above two steps several times and make the display weights consistent
After adjustment, click “Save” and then click “Close” to exit the interface of “Fine
adjustment for tower jib load” (Please pay attention to whether the position of chosen
parameter is correct or not).

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4.5 Weight check for different operating state

According to the requirement of crane characteristic, check whether the displaying load
of other operating state is consistent or not. If there is much difference please repeat
adjusting it according above steps.

4.6 Check of rated lifting capacities

According to the requirement of crane characteristic, check whether the rated lifting
capacities is correct or not (the magnification should be full magnification).

4.7 Test of overload control

Firstly the overloading state must be gotten by some methods, such as: lift a heavier load
which weight is larger than the permitted value in crane characteristic table, or decrease the
magnification and decrease the rated lifting capacity manually, or set the magnification to be
minimal and lift a heavier object. Then check whether the crane acts or not when lifting load
or change radius downward. If there is no cutting action: 1) Check whether the control
interface of computer is access correctly or not. 2) Check whether there is output of overload
control signal. If there is no overload control signal output or no cutting action, the electrical
system or hydraulic system must go wrong.

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2

5 Wire Connecting mode

5.1 Connecting way of signal wire in control box of Crawler Crane boom
2 3

J2
DC24V
1
MGND
2 J4
CANH
3
CANL ANGER2+
4 1
ANGER2
5 2
PRESS1+ GND
6 3
PRESS1 IN4
7 4
GND IN5
8 5
9 IN6
PRESS2+ 6
10
PRESS2 PIN6
11
GND
12
13
ANGER1+
14
ANGER1
15
GND
16
PIN16

J3
IN0
1
IN1
2
IN2
3
IN3
4
O-FMQ
5
CAOZAI
6
BOOM-UP
7
BOOM-DOWN
8
FB-UP
9
FB-DOWN
10
CZ7
11
CZ8
12
O-DC24V
13
MGND
14
O-CANH
15
O-CANL
16
PIN16

2 24
3
5.2 Connecting way of signal wire in control box of Crawler Crane tower jib

J2
DC24V
1
MGND
2
CANH
3
CANL
4
5
PRESS1+
6
PRESS1
7
GND
8
9
PRESS2+
10
PRESS2
11
GND
12
13
ANGER1+
14
ANGER1
15
GND
16
PIN16

1 2

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