SIGALARM

MODEL 210

LOHD 975/977
LOAD AND HOOK SYSTEM

INSTALLATION AND CALIBRATION MANUAL

 Load and Hook Systems – LOHD 975/977

NOTICE
SkyAzúl makes no warranty of any kind with regard to this material, including, but not limited to,
the implied warranties of merchantability and/or its fitness for a particular purpose.

SkyAzúl will not be liable for errors contained in this manual or for incidental or consequential
damages in connection with the furnishing, performance, or use of this manual. This document
contains proprietary information, which is protected by copyright, and all rights are reserved.

No part of this document may be photocopied, reproduced, or translated to another language

without the prior written consent of SkyAzúl.

SkyAzúl reserves proprietary rights to all drawings, photos and the data contained therein. The
drawings, photos and data are confidential and cannot be used or reproduced without the
written consent of Hirschmann. The drawings and/or photos are subject to technical
modification without prior notice.

All information in this document is subject to change without notice.

MANUAL REVISIONS

REV DATE NAME DESCRIPTION

- 05/03/11 SC 975/977 Load and Hook System (SkyAzúl) – Rev 10/99

SkyAzúl, Inc.
16 Walnut Street
Middletown, MD 21769
Fax 301-371-0029
info@skyazul.com

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126

4 Load and Hook Systems – LOHD 975/977

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Installation and Calibration Manual LOHD 975/977 Load and Hook Systems

TABLE OF CONTENTS

LOHD 975/977™
LOAD ON HOOK SYSTEMS
INSTALLATION AND CALIBRATION ......................................................................................................... 3

DISPLAY INSTALLATION.........................................................................................................................3-4

INSTALLING A SWING ARM MOUNTED TENSIOMETER (lattice crane) .................................................. 4

SINGLE OR DUAL LOAD CHANNEL ...................................................................................................... 4-6

INSTALLING A TENSIOMETER AT THE BOOM HEAD (hydraulic crane).................................................. 6

SOLID MOUNT SINGLE OR DUAL LOAD CHANNELS ......................................................................... 6-7

INSTALLING A SWING-ARM MOUNTED TENSIOMETER (hydraulic crane) ............................................. 8

SINGLE LOAD CHANNEL ........................................................................................................................8-9

CALIBRATION INSTRUCTIONS............................................................................................................ 9-10

OPERATING INSTRUCTIONS .................................................................................................................10

TENSIOMETER DIMENSIONAL DRAWING .............................................................................................11

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Installation and Calibration Manual LOHD 975/977 Load and Hook Systems

LOHDTM -975/977
LOAD ON HOOK SYSTEMS (HYDRAULIC CRANES)

INSTALLATION AND CALIBRATION

The LOHDTM- 975/977 Load On Hook Systems have three major components: a
hoist rope tensiometer, a digital display (meter), and an interconnecting cable.

• The hoist rope tensiometer measures the tension in the hoist rope with a
roller deflection system and a precision strain-gauge load cell. The load cell
is powered by the display circuitry.

• The LOHDTM-975 Display identifies loads up to 199,000 pounds. (Refer to

Drawing 10991.)The LOHDTM-977 Display identifies loads up to 500,000
pounds.

• The interconnect cable is a four-wire shielded cable made especially for

this application. It is covered with a specially designed and durable
polyurethane jacket that can withstand severe abrasion without damage.

DISPLAY INSTALLATION

Refer to Drawing # 10991 below.

1. Mount the display inside the cab in a position for easy viewing by the operator
with all controls within reach. Calibration controls on the front of the display
must be accessible. The display mounting bracket can be repositioned and
tilted to permit mounting the display near the top window in the cab.

2. Bolt the tilt bracket with two 1/4-20 bolts in the location selected.

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Installation and Calibration Manual LOHD 975/977 Load and Hook Systems

3. Route the power cable to a 12 or 24 volt DC buss, which is turned off when the
ignition is turned off.

4. Connect the white wire to the +12 VDC or +24VDC and the black wire to the
same ground used for other instruments. On some displays, red and black
wires are supplied. In this case, connect RED to + and BLACK to - .

INSTALLING A SWING ARM MOUNTED TENSIOMETER (LATTICE CRANES)

SINGLE OR DUAL LOAD CHANNEL

Refer to Drawing 13194 (above) & 12148 (next page).

1. Mount the tensiometer at either the top of the tip section or the top of the
butt section of the boom. The method is the same for either installation.
Note: The setup chosen depends on the number of tensiometers to be
installed and whether or not the winch reels are side-by-side or tandem.

2. Lower the boom to the ground, lay the swing-arm bracket on the top of the
boom, and position the bracket so that the clamps can be loosely installed
without interfering with the lattice.

3. Mount the swing-arm to the bracket with the bolt and nut supplied.
4. Place the landing pad bracket on the top of the boom. The center of the bracket
should be approximately 7” from the end of the swing arm. Loosely install the
clamps. Place the tensiometer on top of the landing pad with the load cell cable

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Installation and Calibration Manual LOHD 975/977 Load and Hook Systems

toward the swing arm; bolt the cable to the swing arm with the nut and bolt
supplied.

5. Before tightening the clamps on the swing arm bracket and landing pad, ensure
that the center of the tensiometer is over the center of the landing pad. If two
tensiometers are to be installed, mount the second tensiometer before
tightening the clamps. Ensure that the joints on both ends of the swing arm
move freely.

6. Remove the bolt that secures the rocker-arm/center roller assembly during
shipping. Feed the hoist cable under the back end of the roller, over the top of
the center roller, and under the front roller to the head sheaves.

7. If it is inconvenient to un-reeve the block, install the cable on the

tensiometer as follows:

a Remove the cotter pins from the shafts of the two end rollers.

b With a drift, punch, or bolt, slowly remove the shafts.

c Catch the washers and rollers.

d Set the hoist cable into the tensiometer on the center roller.

e Replace the end rollers (with a washer on each side of each roller).

8. Before operating, grease the rollers via the 4 zerk fittings on the tensiometer.

9. Clamp the cable to the frame of the tensiometer for strain relief. Ensure that the
load lines will not rub on the cable.

10.Install cable clamps approximately every 12” along the swing arm. Leave
enough slack so that the tensiometer can swing to the stops in all directions
without pulling on the load cell plug.

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Installation and Calibration Manual LOHD 975/977 Load and Hook Systems

11.Leave enough slack at the lower universal joint of the swing arm to allow free
swing arm movement; then, route the cable down to the lower edge of the
boom.

INSTALLING A TENSIOMETER AT THE BOOM HEAD (HYDRAULIC CRANES)

SOLID MOUNT, SINGLE OR DUAL LOAD CHANNELS

Refer to Drawing #12145 above.

1. Using the weld-on brackets supplied, mount the tensiometer near the tip of the
non-telescoping boom section.

Note: Cranes with one winch that use an “A” frame or gantry for the jib (where
the load line runs to a separate sheave above the boom) will need to use a
swing-arm arrangement to mount the tensiometer.

2. Lower the boom to a horizontal position and set the tensiometer, with weld-on
brackets attached, at the tip of the non-telescoping boom section.

3. Align the rollers of the tensiometer with the head sheave used for that load line
and the center of the winch reel.

4. Ensure that the weld-brackets are on a solid, flat section of the boom. Tack-
weld the brackets to the boom taking care not to burn the load cell cable.

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Installation and Calibration Manual LOHD 975/977 Load and Hook Systems

5. Remove the tensiometer from the weld-on brackets and weld the brackets
solidly to the boom.

6. After allowing the brackets to cool, clean and paint the brackets.
7. Replace the tensiometer and secure it to the brackets

Note: If two tensiometers are to be mounted on the boom, the second

tensiometer may have to be set back from the first, depending on the width of
the boom. Ensure that the rollers of the tensiometer line up with the head
sheaves and the center of the winch reel.

8. Remove the bolt that secures the rocker-arm/center roller assembly during
shipping. Feed the hoist cable under the back end of the roller, over the top of
the center roller and under the front roller to the head sheaves.

9. If it is inconvenient to un-reeve the block, install the cable on the

tensiometer as follows:

a Remove the cotter pins from the shafts of the two end rollers.

b With a drift, punch, or bolt, slowly remove the shafts.

c Catch the washers and rollers.

d Set the hoist cable into the tensiometer on the center roller.

e Replace the end rollers (with a washer on each side of each roller).

10.Before operating, grease the rollers via the 4 zerk fittings on the tensiometer.

11.Clamp the cable to the frame of the tensiometer for strain relief.

Note: Ensure that the load lines will not rub the cable. Add some steel guards
or guides, as needed, to prevent this condition.

12.Secure the cable from the tensiometer to the meter every 3 to 4 feet along the
side of the boom and behind the boom pivot.

Note: Lowering the boom should not stretch, pinch, or abrade the cable.

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Installation and Calibration Manual LOHD 975/977 Load and Hook Systems

INSTALLING A SWING ARM MOUNTED TENSIOMETER (HYDRAULIC CRANE)

SINGLE LOAD CHANNEL

Refer to Drawing 12147 below.

1. Assemble the swing arm to the tensiometer and place it on the boom with the
lower end of the swing arm at the tip of the non-telescoping boom section.

Note: For cranes with two winches, mount the tensiometer so that the load line
from the front reel will be used. To protect the tensiometer from the rear winch
line, ensure that the cable guards are mounted to the top of the tensiometer.

2. Mount the tensiometer with the plastic skid pads next to the boom, aligning the
rollers of the tensiometer with the sheave used for the front load line and the
center of the winch reel.

3. Position the swing arm parallel to the boom and weld the side brackets to the
boom around the outside edges.

4. After allowing the brackets to cool, clean and paint the brackets.

5. Replace the tensiometer and secure it to the brackets.

6. Remove the bolt that secures the rocker-arm/center roller assembly during
shipping.

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Installation and Calibration Manual LOHD 975/977 Load and Hook Systems

7. Feed the hoist cable under the back end of the roller, over the top of the center
roller and under the front roller to the head sheaves.

8. If it is inconvenient to un-reeve the block, install the cable on the

tensiometer as follows:

a Remove the cotter pins from the shafts of the two end rollers.

b With a drift, punch, or bolt, slowly remove the shafts.

c Catch the washers and rollers.

d Set the hoist cable into the tensiometer on the center roller.

e Replace the end rollers (with a washer on each side of each roller).

9. Before operating, grease the rollers via the 4 zerk fittings on the tensiometer.

10.Camp the cable to the frame of the tensiometer for strain relief.

Note: Ensure that the load lines will not rub on the cable. Install cable clamps
every 12” along the swing arm. Leave enough slack to permit the tensiometer
to swing to the stops in all directions without pulling on the load cell plug. Leave
enough slack at the lower universal joint of the swing arm for free swing arm
movement.

11.Route the cable down to the lower edge of the boom. Secure the cable
between the tensiometer and the display every 3 to 4 feet along the side of the
boom and behind the boom pivot.

Note: Lowering the boom should not stretch, pinch, or abrade the cable.

CALIBRATION INSTRUCTIONS
1. Select a weight for calibration which is about 50% of the capacity for the
‘PARTS OF LINE’ reeved. Add the weight of the rope below the head sheaves,
hook block, slings, and rigging to the known test weight. The total weight
should be known to 1% accuracy.

2. Set the hook and all other rigging on the ground so that the line is slacked.

3. Set PARTS OF LINE switch to 12.

4. Adjust ‘ZERO’ on LOHD-975/977 front panel until the display indicates +00.0

5. Set PARTS OF LINE switch to the number of Parts of Line rigged on the crane.

6. Lift the known weight and stop smoothly. Adjust ‘SPAN’ on LOHDTM 975/977
front panel until the display indicates the total weight being lifted (known weight
plus the hook block, rope, slings and rigging or any other rigging on the
line).See example on next page.

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Installation and Calibration Manual LOHD 975/977 Load and Hook Systems

Table 1:

EXAMPLE
KNOWN WEIGHT = 19,400 Pounds

HOOK BLOCK, ROPE,

SLINGS and
RIGGING= 900 Pounds

TOTAL= 20,300 Pounds

7. Adjust SPAN until the display indicates +20.3

8. Lift the load several inches, stop smoothly, and check the weight again.

9. Repeat steps 3 through 8 and adjust the ZERO and SPAN controls, if
necessary.

OPERATING INSTRUCTIONS
1. Ensure that the system has been recently calibrated or that the calibration has
been checked.

2. Set the PARTS OF LINE switch to match the number of PARTS OF LINE
actually reaved on the crane.

3. Lift the load and stop smoothly.

4. On the display, observe the total weight being lifted. Measurement is in

thousands of pounds.

5. Total weight includes the rope, hook block, slings, rigging, and load.

EXAMPLES
1. +123.4 pounds x 1000 = 123,400 pounds

2. +12.3 pounds x 1000 = 12,300 pounds

3. +0..5.9 pounds x 1000 = 5,900 pounds

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Installation and Calibration Manual LOHD 975/977 Load and Hook Systems

TENSIOMETER DIMENSIONAL DRAWING

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SkyAzúl, Soluciones de Equipos www.skyazul.com 301-371-6126
 SkyAzúl, Inc.
16 Walnut Street
Middletown, MD 21769
Phone 301-371-6126
Fax 301-371-0029
www.skyazul.com info@skyazul.com

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126