gc MG 500 Manual

Rated capacity indicator system

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MG 500

Rated Capacity Indicator System

Prototype Calibration and Testing for:

Machine Model

Serial Number

Tester

Date

MG434/500 Prototype Commissioning Manual

PN W453101Rev- Nov-02-1998

Table of Contents

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Page 1 MG 500 Rated Capacity Indicator System Prototype Calibration and Testing for: Machine Model Serial Number Tester Date MG434/500 Prototype Commissioning Manual PN W453101Rev- Nov-02-1998...
Page 2: Tools Required
Page 2 of 28 Introduction This document describes the process by which MicroGuard systems using the “Supercal” concept are set up for use on a new crane model. If correctly followed, this procedure will ensure accurate and fast calibrations of subsequent calibrations on the same model machine. Procedures within this document are intentionally written as a step-by-step guide to enable the calibrating engineer to correctly determine the characteristics of the machine.
Page 3: Preliminary Checks
Page 3 of 28 Preliminary checks Before commencing calibration, it is important that certain checks of the machine geometry be made. Geometric values have been previously entered into the capacity chip from the crane application data sheet filled out by the crane manufacturers engineering department. Measure the following dimensions and check against the values specified within the capacity chip file entered into the 5-charts program.
Page 4: Boom Hoist Geometry
Page 4 of 28 Boom Hoist Geometry Measure each dimension shown using a tape. It is at best, a difficult exercise to measure these dimensions, but still a necessary check. It is recommended that two people carry out this task and that care is taken to ensure that clear references are used to measure from.
Page 5: Front Winch Geometry
Page 5 of 28 Front Winch Geometry Measure each dimension shown using a tape. It is at best, a difficult exercise to measure these dimensions, but still a necessary check. It is recommended that two people carry out this task and that care is taken to ensure that clear references are used to measure from.
Page 6: Rear Winch Geometry
Page 6 of 28 Rear Winch Geometry Measure each dimension shown using a tape. It is at best, a difficult exercise to measure these dimensions, but still a necessary check. It is recommended that two people carry out this task and that care is taken to ensure that clear references are used to measure from.
Page 7 Page 7 of 28 Miscellaneous Data The following checks are for Main Boom Head Sheave Radius and Swing Offset. Swing Offset is negative when the boom pivot is behind the center of rotation. Enter the measured values into the gray boxes provided. Top Sheave Boom Pivot Boom...
Page 8: Zero Angle Sensor
Page 8 of 28 Reset Crane Data ‘Reset Crane Personality Data’ Reset the systems crane data using the routine in the calibration ‘Crane Data’ menu selection. This process uses some of the geometric data entered in the capacity chip to prepare the system for calibration. See the calibration manual for instructions on how to use the routine.
Page 9: Set Zero And Direction Of Swing Pot
Page 9 of 28 Set Zero and Direction of Swing Pot. Set the machine to the over front swing area and zero the swing pot. Swing the machine in a clockwise direction (to the right) and set the direction indicator to ‘+’. Check the swing angle shown increments as you swing the crane to the right, at 360 degrees the angle indicator will roll over to zero degrees and you should be back over the front of the machine again.
Page 10 Page 10 of 28 Calibrate Radius/Moment Up to seven points may be calibrated for each boom-telescoping mode. These points must include fully retracted and fully extended. Intermediate points should be chosen to be where individual sections of the boom start to telescope and/or other sections stop telescoping as the boom is extended. For booms that exhibit an appreciable amount of flexibility or droop, it may be necessary to include an extra point to improve accuracy, especially if there is a long distance between obvious points of calibration.
Page 11 Page 11 of 28 Boom ________ Boom Boom Boom Boom Boom Boom Boom Extension 0 Extension 1 Extension 2 Extension 3 Extension 4 Extension 5 Extnsion 6 EXTN LEN_S Boom ________ Boom Boom Boom Boom Boom Boom Boom Extension 0 Extension 1 Extension 2 Extension 3...
Page 12 Page 12 of 28 Calibrate Boom deflection Fully extend the boom at a high angle of greater than 60 degrees and lift the same load used to calibrate the pressure. Calibrate the boom deflection by following the instructions in the calibration manual. It is a good idea to add 0.1ft or 0.1m to the radius when entering the radius in the calibration for boom deflection.
Page 13 Page 13 of 28 Calibrate Boom Head Offset The boom head offset is required to aid the computer to correctly calculate the radius of flys/jibs. During the process of checking and recording the boom head angle the boom will need to be fully telescoped at zero degrees.
Page 14 Page 14 of 28 Boom ________ Boom Extension Boom Angle Boom Head Angle Difference Boom ________ Boom Extension Boom Angle Boom Head Angle Difference NOTES: M434/500 Prototype Commissioning Manual PN W453101Rev- Nov-02-1998...
Page 15 Page 15 of 28 Test Main Boom Following each main boom calibration perform a series of tests that will sufficiently show the accuracy of the calibration in all working areas of the main boom. Test the unladen boom, two different loads at three different lengths and three different angles for each length of main boom.
Page 16 Page 16 of 28 Boom ________ Displayed Displayed Displayed Measur’d Radius Displayed Actual Load Notes Length Angle Radius Radius Error Load Load Error M434/500 Prototype Commissioning Manual PN W453101Rev- Nov-02-1998...
Page 17 Page 17 of 28 Boom ________ Displayed Displayed Displayed Measur’d Radius Displayed Actual Load Notes Length Angle Radius Radius Error Load Load Error M434/500 Prototype Commissioning Manual PN W453101Rev- Nov-02-1998...
Page 18: Test Auxiliary Head
Page 18 of 28 Test Auxiliary Head The auxiliary head should be checked for radius accuracy as a minimum. Load testing is optional since the attachment is only a short extension to the main boom. Check that the auxiliary head dimensions specified in the capacity chip file either specify an effective vertical and horizontal offset or length and angular offset only.
Page 19: Test Attachments
Page 19 of 28 Test Attachments There is little calibration required to set up fly’s and jibs. The most likely requirement is for a deflection correction. The deflection correction may be applied to each attachment by calibrating with the bdc command.
Page 20 Page 20 of 28 Attachment Tests Attachment & Offset Main Boom Test # Test Displayed Displayed Displayed Measur’d Radius Displayed Actual Load Error Length Angle Radius Radius Error Load Load M434/500 Prototype Commissioning Manual PN W453101Rev- Nov-02-1998...
Page 21 Page 21 of 28 Attachment Tests Attachment & Offset Main Boom Test # Test Displayed Displayed Displayed Measur’d Radius Displayed Actual Load Error Length Angle Radius Radius Error Load Load M434/500 Prototype Commissioning Manual PN W453101Rev- Nov-02-1998...
Page 22 Page 22 of 28 Attachment Tests Attachment & Offset Main Boom Test # Test Displayed Displayed Displayed Measur’d Radius Displayed Actual Load Error Length Angle Radius Radius Error Load Load M434/500 Prototype Commissioning Manual PN W453101Rev- Nov-02-1998...
Page 23 Page 23 of 28 Attachment Tests Attachment & Offset Main Boom Test # Test Displayed Displayed Displayed Measur’d Radius Displayed Actual Load Error Length Angle Radius Radius Error Load Load M434/500 Prototype Commissioning Manual PN W453101Rev- Nov-02-1998...
Page 24 Page 24 of 28 Attachment Tests Attachment & Offset Main Boom Test # Test Displayed Displayed Displayed Measur’d Radius Displayed Actual Load Error Length Angle Radius Radius Error Load Load M434/500 Prototype Commissioning Manual PN W453101Rev- Nov-02-1998...
Page 25 Page 25 of 28 Attachment Tests Attachment & Offset Main Boom Test # Test Displayed Displayed Displayed Measur’d Radius Displayed Actual Load Error Length Angle Radius Radius Error Load Load M434/500 Prototype Commissioning Manual PN W453101Rev- Nov-02-1998...
Page 26 Page 26 of 28 Attachment Tests Attachment & Offset Main Boom Test # Test Displayed Displayed Displayed Measur’d Radius Displayed Actual Load Error Length Angle Radius Radius Error Load Load M434/500 Prototype Commissioning Manual PN W453101Rev- Nov-02-1998...
Page 27 Page 27 of 28 Attachment Tests Attachment & Offset Main Boom Test # Test Displayed Displayed Displayed Measur’d Radius Displayed Actual Load Error Length Angle Radius Radius Error Load Load M434/500 Prototype Commissioning Manual PN W453101Rev- Nov-02-1998...
Page 28 Page 28 of 28 Completion Before finishing, thoroughly check that all data from the calibration that needs to entered into the capacity chip has been and that the latest copy of the chip is installed in the system computer. This will ensure that in the event of a future calibration, initialize will not cause calibration problems for this machine.