PAT America, Inc.

1665 Orchard Drive Chambersburg, PA 17201

KRUGER

MARK H OPERATOR'S MANUAL

Anti-Two Block System

. .

PART NO. 031-300-190-103
REV - 6/27/00

INDEX

FOREWORD

1

INTRODUCTION

2

WARRANTY

3

SYSTEM COMPONENTS

4

Control Panel

4

Cable Reel - Spring Operated

5

Cable Reel - Mechanical

5

Junction Box

5

Anti-2-Block Switch

5

CRANE FUNCTION SHUT OFF SYSTEM

6

SYSTEM COMPONENT LOCATION

7

SYSTEM OPERATION

8

Function Test

8

Physical Check

9

Normal Operating Conditions

9

Two-Block During Operation

1 0

PREVENTIVE MAINTENANCE

1 1

Mark "H" Operators Manual (RE899)

PAT America, Inc.

1665 Orchard Drive Chambersbur, PA 17201

Phone:[phone] Fax: [phone]

PART NO. 031-300-190-103 REV - 6/27/00

Mark "H" Operators Manual (RE899)

Page 1

PAT America, Inc.

FOREWORD

The purpose of this handbook is to provide the operator with instructions on the proper use and
operation of the MARK “H” Indicating System.

The MARK “H” Indicating System is designed to provide an audible and visual warning of an
approaching two-block condition. The MARK “H” Indicating System can actuate an optional
shut off system.

WARNING

DO NOT CONSIDER THIS SYSTEM A SUBSTITUTE FOR GOOD
JUDGEMENT, EXPERIENCE AND ACCEPTED SAFE CRANE
OPERATIONAL PRACTICES.

THE CONTENTS OF THE MARK “H” OPERATORS HANDBOOK
AND THE CRANE MANUFACTURERS HANDBOOKS SHOULD BE
READ AND THOROUGHLY UNDERSTOOD BEFORE ATTEMPTING
TO OPERATE THE CRANE.

NOTE

This system utilizes a series of electrical and mechanical components and
cannot be 100% fail safe.

This system should only be serviced by qualified individuals, either PAT America, Inc. service
technicians or those who have received special training from Krüger GmbH or their authorized
representatives.

To avoid damage and loss of warranty consideration, we recommend repair only be attempted
by individuals with a strong electrical/electronic background.

Translated and reprinted by PAT America, Inc. with approval of Krüger GMBH & Co. KG.

Mark "H" Operators Manual (RE899)

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PAT America, Inc.

INTRODUCTION

The system MARK “H” is the simpliest Operators Aid Device of the new Mark series of
Operating Aids.

The basic system warns the crane operator of a pending two- block condition with a red light
and audible warning.

When installed in conjunction with a function shut off system, this system prevents the hook
block of a crane from coming into physical contact with the sheaves in the boom head.

The system consists of:

* An Operating/Indicating panel
* A Junction Box with shut off relay

* A Cable Reel (where required)

* An Anti-Two-Block Switch with counterweight

The Operating Panel features a Function Test Button, to comply with current SAE standard
J1305 JUN87, and a push button to shut off the horn. The horn is automatically reset when the
two-block condition is corrected.

TECHNICAL SPECIFICATIONS

Power Supply:

12 VDC/24 VDC ± 20 %

Current draw:

100 mA (max. 180 mA)

Working Temperature:

-30

0

C to +70

0

C (-22

0

F to +160

0

F)

Relative Humidity:

95%/ 40

0

C

Enclousure:

IP 65

Fuse:

10 AMP Slowblow

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PAT America, Inc.

WARRANTY

THERE ARE NO WARRANTIES EXPRESS OR IMPLIED, MADE BY EITHER THE
DISTRIBUTOR OR THE MANUFACTURER ON NEW KRÜGER EQUIPMENT, EXCEPT
THE MANUFACTURER’S WARRANTY AGAINST DEFECTS IN MATERIAL AND
WORKMANSHIP SET OUT BELOW.

NEW EQUIPMENT WARRANTY

The manufacturer warrants each new product made by the manufacturer to be free from defects
in material and workmanship. At its option, all obligation and liability under this warranty is
limited to free of charge replacement, repair or reconditioning, at its factory, of any part proven
defective under normal use and service within twelve (12) months from the date of delivery.
The system or component must be on record with the manufacturer as being delivered by the
distributor. If the system or component is not on record as being delivered by the distributor,
the warranty period will commence on the date of shipment from the factory. This warranty
shall not include any transportation, customs or other charges or the cost of installation or any
liability for the cost of installation or any other liability for direct, indirect or consequential
damage or delay resulting from the defect. The manufacturer is not responsible for, and makes
no warranties in connection with, the installation or servicing, use or operation of the product.
Any repair, alteration or adjustment of the product or any substitution of parts without the
express written consent of the manufacturer shall void this warranty. This warranty covers only
the products of KRÜGER including products replaced, repaired or reconditioned by KRÜGER.
The products of other manufacturers are covered only by such warranties as are made by their
manufacturers.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS
OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE, AND OF THE OBLIGATIONS OR
LIABILITY ON THE PART OF THE MANUFACTURER, AND KRÜGER NEITHER
ASSUMES NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR IT ANY
OTHER LIABILITY IN CONNECTION WITH SUCH EQUIPMENT!

Mark "H" Operators Manual (RE899)

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PAT America, Inc.

SYSTEM COMPONENTS

This section will identify and describe each component used in the MARK “H” Anti-Two-
Block System. Where necessary operational instructions are provided to acquaint the operator
with the function of push-buttons, warning lights and key switches.

CONTROL PANEL
This unit is located in the operators cab. It includes a by- pass key switch, if used in conjunction
with a Crane Function Shut Off System.

The following describes the functions of the various buttons and switches on the panel.

1. HORN/A-2-B (RED BUTTON)

This button is lit when a Two-Block condition occurs. When pushed this button silences the
audible alarm.

NOTE

The horn is automatically reset when the Two-Block condition is corrected.

2. FUNCTION TEST BUTTON (BLUE BUTTON)

When pushed this button activates a System Function check cycle, as required by SAE standard
J1305 JUN87.

3. BY-PASS KEY SWITCH

This key allows the operator to override the A-2-B shut off for boom rigging or when placing
the boom in the boom rest for travel. The key switch is also used to perform a Function test
of the Crane Function Shut Off System, as required by SAE standard J1305 JUN87.

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PAT America, Inc.

WARNING

THE A-2-B BY-PASS KEY SWITCH SHOULD NOT BE USED TO LIFT
LOADS HIGHER THAN PERMITTED BY THE COUNTERWEIGHT
ATTACHED TO THE A-2-B SWITCH. THE BY-PASS KEY SWITCH
MUST BE USED WITH DISCRETION AS UNWARRANTED USE OF IT
TO OVERRIDE THE CRANE FUNCTION SHUT OFF SYSTEM COULD
RESULT IN LOSS OF LIFE, DESTRUCTION OF PROPERTY AND
IRREPARABLE DAMAGE TO THE CRANE.

SOUND JUDGEMENT MUST BE USED , WHEN USING THE A-2-B
BY-PASS KEY SWITCH.

NOTE

A by-pass key switch is NOT provided if the machine is not equipped with
a Crane Function Shut Off System.

CABLE REEL - SPRING OPERATED
The spring operated cable reel is used on hydraulic machine installations and is located on the
boom base section. The two conductor cable carries the electrical signal for the A-2-B switch,
mounted at the boom tip.

CABLE REEL - MECHANICAL
A mechanical reel of either rubber or steel construction is used on lattice machine installations and is
mounted in the boom base section near the boom foot. The two conductor cable carries the electrical
signal for the A-2-B switch, mounted at the boom tip.

JUNCTION BOX
This unit is located on the crane structure. It can be either inside or outside of the crane cab.
This box contains terminals for connection of the various system components , the relays used
for by-pass and the fuse for system protection.

ANTI-2-BLOCK SWITCH
This switch is mounted on the main boom tip and on all other boom attachments, where a load
line is used. The switch is activated by a counterweight, suspended by chains. When the
counterweight is lifted by the hook block the audible/visual warning on the control panel is
activated. If the crane is equipped with a crane function shut off system the shut off system is
activated.

Mark "H" Operators Manual (RE899)

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PAT America, Inc.

CAUTION

THE LENGTH OF THE CHAIN IS IN ACCORDANCE WITH HOOK
SPEED AND SENSITIVITY OF THE OPTIONAL CRANE FUNCTION
SHUT OFF SYSTEM AND SHOULD NOT BE SHORTENED OR A
POSSIBLE TWO-BLOCK CONDITION COULD RESULT PRIOR TO
THE ACTUAL FUNCTION SHUT OFF.

NOTE

With even parts of hoist line, the counterweight should be attached to the
dead end line.

With odd parts of hoist line, the counterweight should be attached to the
slowest speed line.

CRANE FUNCTION SHUT OFF SYSTEM
This is an optional system. It can be of Crane Manufacturer design or operate through the use
of Krüger Magnet Valves.

The basic function of a Shut Off System is to disable the following crane functions:

MAIN HOIST UP
AUXILIARY HOIST UP (IF MACHINE IS SO EQUIPPED)
BOOM DOWN
TELESCOPE OUT (FOR HYDRAULIC MACHINES ONLY)

CAUTION

EVEN THOUGH THE MACHINE IS EQUIPPED WITH A MARK “H”
ANTI-TWO-BLOCK SYSTEM AND CRANE FUNCTION SHUT OFF
SYSTEM, WE DO “NOT” CONSIDER THEM AS SAFETY SYSTEMS.
BE AWARE THAT ALL SYSTEMS ARE ONLY A “BACK UP” SYSTEM
FOR THE CRANE OPERATOR. THESE SYSTEMS ARE NOT A
SUBSTITUTE FOR GOOD JUDGEMENT, EXPERIENCE AND ACCEPTED
SAFE CRANE OPERATIONAL PRACTICES. THEY SHOULD “NEVER”
BE USED AS AN OPERATING CONTROL.

Mark "H" Operators Manual (RE899)

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PAT America, Inc.

ANTI-2-BLOCK
SWITCH LOCATIONS

SPRING
OPERATED
CABLE REEL

MECHANICAL
CABLE REEL

CONTROL PANEL

JUNCTION BOX

SYSTEM COMPONENT LOCATION

Mark "H" Operators Manual (RE899)

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PAT America, Inc.

SYSTEM OPERATION

This section will provided a step by step sequence of start up and operation of the Mark “H”
Anti-Two-Block System.

1. Install jumper cable or dummy plug in the appropriate receptacles at the boom tip and

attachment(s) for the machine configuration being used.

NOTE

The dummy plug is only used if the machine is equipped with two (2)
winches and two (2) or more A-2-B switches.

Install the dummy plug only if a single A-2-B switch is being employed,
with this type machine configuration.

2. Install counterweight(s) on A-2-B switches to be checked.

CAUTION

THE LENGTH OF THE CHAIN IS IN ACCORDANCE WITH HOOK
SPEED AND SENSITIVITY OF THE OPTIONAL SHUT OFF SYSTEM
AND SHOULD NOT BE SHORTENED OR A POSSIBLE TWO-BLOCK
CONDITION COULD RESULT PRIOR TO ACTUAL FUNCTION SHUT
OFF.

NOTE

With even parts of hoist line, the counterweight should be attached to the
dead end line.

With odd parts of hoist line, the counterweight should be attached to the
slowest speed line.

3. Start the crane according to the crane manufacturer instructions.

4. At start up the MARK “H” system automatically begins a system self test.

FUNCTION TEST
5. Press and hold the BLUE “TEST” button. The following should occur:

* The RED “HORN/A-2-B” light is ON.

* The audible horn sounds. It cannot be silenced by pushing the RED “HORN/A-2-B”

button.

Mark "H" Operators Manual (RE899)

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PAT America, Inc.

6. Release the TEST button. The RED light should be OFF and the HORN silent.

7. If the system is equipped with a by-pass key switch, turn and hold the key to simulate a by-

passcondition. The following should occur:

* The RED “HORN/A-2-B” light is ON.

* The audible alarm sounds. It cannot be silenced by pushing the “HORN/A-2-B”

button.

* The optional shut off system is deactivate. All crane functions are operational.

8. Release the key switch. The RED light should be OFF and the horn silent.

9. If the system does not operate as described:

* Check all wiring and connections for proper installation.
* Refer to Troubleshooting Section of the Installation and Check Out Manual.

PHYSICAL CHECK
This portion of the check out must be performed with extreme care and can be by passed if the
operator is sure that the shut off system is operational.

10. With the boom at a low angle, lift the A-2-B counterweight by hand to simulate a two-block

condition. The following should occur:

* RED “HORN/A-2-B” light is ON.
* Audible alarm sounds. Push “HORN/A-2-B” button to shut off horn.

* If so equipped, the optional shut off system is activated. The following functions are

inoperative:

* Hoist up both main and auxiliary
* Boom lowering

* Telescope out (Hydraulic Machine Only)

11. If the system does not operate as described:

* Check all wiring and connections for proper installation.
* Refer to Troubleshooting Section of the Installation and Check Out Manual.

Begin Safe operation of the crane. PROCEED WITH APPROPRIATE CARE.

NORMAL OPERATING CONDITIONS
During normal crane operation the Operating Panel will:

* Have the RED “Horn/A-2-B” light OFF.

* Have the audible alarm SILENT.
* If equipped with Crane Function Shut Off System, the system is deactivated. All crane

functions are operational.

Mark "H" Operators Manual (RE899)

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PAT America, Inc.

NOTE

If the RED "Horn/A-2-B" light is ON and the audible alarm is SOUNDING
when NO Two - Block conditions exists check the 10 Amp. fuse located
in the junction box. Replace as necessary with a 10 Amp. Slowblow fuse.

TWO-BLOCK DURING OPERATION
When a two-block condition occurs during operation the panel will display the following:

* The RED “Horn/A-2-B” light is ON.

* The audible alarm SOUNDS. It can be silenced by pushing the RED “Horn/A-2-B”

button.

* If so equipped, the Crane Function Shut Off System is activated. the following crane

functions are inoperative:

* Hoist up, both main and auxiliary
* Boom Down

* Telescope Out (Hydraulic Machines Only)

TO CORRECT:

Lower the load, Raise the boom or Retract the boom. Use the crane function
which best suits the immediate situation and job site conditions.

When the two-block condition has been corrected:

* The RED “Horn/A-2-B” light is OFF.

* The audible alarm is silent.

* The horn is reset if it had been silenced previously.

Return to normal crane operation. PROCEED WITH APPROPRIATE CARE.

Mark "H" Operators Manual (RE899)

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PAT America, Inc.

PREVENTIVE MAINTENANCE

The MARK “H” Anti-Two-Block System uses electronic, electrical and mechanical components.
The system should only be serviced by PAT America, Inc. Service Technicians or those who
have received special training from Krüger GmbH or their authorized representatives.

The operator retains the responsibility for inspection of the system components. To insure that
no external damage will affect proper system operation inspections should include:

DAILY INSPECTION
1. Inspect all Anti-Two-Block switches for free movement of the lever arm that supports the

counterweight.

2. Counterweights should be free of obstructions in the operating position and installed on all

switches where a load line is being used for a lift.

3. Insure that the Anti-Two-Block portion of the system is properly wired at the boom nose.

A. Install JUMPER CABLE from auxiliary attachment to the boom nose receptacle, if

used.

B. Install DUMMY PLUG in the boom nose receptacle, if the machine is equipped with

two (2) winches and NO auxiliary attachment is being used.

4. Check Anti-Two-Block System operation as described in the System Operation - Function

Test and Physical Check sections of this manual.

5. For Lattice Machines, inspect the 2 conductor cable between the mechanical cable reel and

the boom tip Anti-two- block switch for cuts, abrasions or other physical damage.

6. For Hydraulic Machines, EXTEND the boom and check the cable from the spring operated

cable reel to the boom nose for cuts, abrasions or other physical damage.

7. For Hydraulic Machines, while RETRACTING the boom check the spring operated cable

reel for proper spooling of the cable and spring tension.

8. Report all damage to your supervisor for appropriate action