Installation Guide & User 'S Manual: The ACS-600 Load Moment Limiter

Intelligent Safe Control Solutions of Cranes
Installation Guide & User’s Manual
The ACS-600 Load Moment Limiter

（ACS Model：ACS-600-WY-QUY-300T）
(QUY70 Crawler Cranes)
Precise Technology (Beijing) Co., Ltd.

(Manufactured by Changsha Huizhi Technology Co., Ltd.)
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ACS-600 (QUY70)
Respectful users:
We welcome you to use the ACS-600 type load moment limiter. We look forward to
providing you with a safe experience and create greater value for your work through the
usage of our quality products and services.
Precise Technology (Beijing) Co., Ltd. is a high-technology enterprise located at the hearth
of the Zhongguancun Science Park, which provides technical solutions for safe operation of
engineering machinery depending on Zhongguancun human and technological advances;
Changsha Huizhi Technology Co., Ltd. is an industry leader with over ten years of
experience in production, service and maintenance of safe control products in the area of
engineering machinery in China. The ACS series load moment limiter is a new generation of
load moment limiters under the co-development and cooperation between the two
companies, which has made breakthroughs in product precision, ease of installation and
maintenance.
This manual provides you with basic knowledge concerning daily operation, calibration,
installation, maintenance of the ACS-600 type load moment limiter. Read this manual
carefully before operation.
Precise Technology (Beijing) Co., Ltd. and Changsha Huizhi Technology Co., Ltd. will put
continuous effort into improving the product and we invite you to inquire about the latest
updates on our products through mail, telephone, fax and internet.
Mail address:
Rm. 303A, Building No.2, Fuhai, Daliushu Rd. Haidian Dist., Beijing, China
Beijing Precise Technology Co.,Ltd.
Zip code: 100081
Phone: (86)-010-62122771/62150300 13911073285
Fax: (86)-010-62120663
http://www.canadapti.com
Due to modification and technical improvements of the vehicle, Precise Technology (Beijing)
Co., Ltd. and Changsha Huizhi Technology Co., Ltd. have the right to modify the
Installation Guide & User Manual at any time. Regarding these modifactions, the user
should always refer to the actual vehicle. The interpretation right of Installation Guide &
User Manual belongs to Precise Technology (Beijing) Co., Ltd.
Copyright © 2003-2007 Precise Technology (Beijing) Co., Ltd. All Rights Reserved.
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The ACS-600 (QUY70)
Table of Contents
Cautions .................................................................................. 4
Maintenance Instructions ........................................................5
Executive Standards.................................................................5
Technical Parameters ..............................................................5
Glossary .................................................................................. 6
Key-Press ................................................................................ 6
Routine Check ..........................................................................7
General Use Method................................................................ 8
Startup.............................................................................................................................. 8
Normal Operation ........................................................................................................... 8
Choosing Operating Conditions......................................................................................9
Choose Boom Operation ........................................................................................................................ 9
Choose Operating Status........................................................................................................................ 9
Choose Falls ....................................................................................................................10
System Setup...........................................................................11
Parameters Setting .........................................................................................................12
Radius (R0)........................................................................................................................................... 12
Single Wire Pulling Force .................................................................................................................... 12
Setup Measurement (Angle, Force Sensor) ........................................................................................ 13
Precision Calibration...................................................................................................... 15
Weight Calibration ............................................................................................................................... 16
Fast Calibration...................................................................... 19
Radius Calibration..........................................................................................................19
Preparation ........................................................................................................................................... 19
Calibration Steps .................................................................................................................................. 19
Weight Calibration ........................................................................................................ 20
Time Calibration............................................................................................................ 22
Reading Overload Data................................................................................................. 22
Instructions On Installation ...................................................24
System Composition ..................................................................................................... 24
Installation......................................................................................................................25
Central Unit ..........................................................................................................................................26
Pressure Sensor ....................................................................................................................................26
Angle Sensor .........................................................................................................................................28
Maintenance ......................................................................... 30
Breakdown Management ....................................................... 31
Support & Services .................................................................33
Appendix ................................................................................34
Signal List of Sockets on Central Unit ......................................................................... 34
Normal Voltage Value between Lines of the Central Unit External Socket...............35
Path Illustration of Function Menu of Host Machine.................................................35
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ACS-600 (QUY70)
Cautions
Before the first time you use this crane or when you have just altered the settings of it, for the
safety of the crane, please make sure to follow the guidance in this manual for the safe
settings and operations.
Please pay attention to whether the displaying values of length, angle, etc. are consistent with
the operating status used during daily operation of load moment limiter. Abnormity, such as
incorrect display of length, angle, etc. will lead to inaccurate working radius, height, rated
lifting capacity. Then please check whether pull box can work normally and calibrate
according to the rapid calibration guide for weight display attached on the side of computer
box. If precise calibration is required, please refer to relevant chapters of this manual for
rapid adjustment.
If it is mechanical abrasion of crane or other reason which leads to deviation, please refer to
relevant chapters of this manual for calibration.
For safety of lifting operation, follow the safe operation codes for crane unconditionally
during crane operation and for any consequence due to breach of regulation or incorrect
operation, the operation unit which breaches the regulation should bear all the
responsibilities.
If there is product quality problem due to dismantlement of this product and modification of
components (central unit and sensor) without permission, it is not in the scope of guarantee
by the manufacturer.
Attention:
² Do NOT put lit cigarette or objects with sparks or unwatchable fires onto the moment
limiter.
² Do NOT put objects with grease or volatile liquids onto the moment limiter.
² Do NOT wipe the moment limiter with cleaning agent, gasoline, thinner and diluents,
etc.
² Do NOT wash the moment limiter with water directly.
² Do NOT scratch on the plate of the moment limiter with sharp-pointed objects.
Conditions not Breakdowns of the Central unit:

² When the crane is in operation, the display of the moment limiter shows nothing. The
reason may be that there is no power supply for the moment limiter.
² If the angle reading is not accurate, the reason may be that unidentified factors have
changed the original installation position of the angle sensor.
² If the length reading is not accurate, the reason may be that the cable of the reel box is
stuck or cut off.
² If the weight reading is not accurate, the reason may be that the entered length or angle
value are not consistent with the actual number; or it may be that the selected operating
condition is not consistent with the actual one (e.g. the jib’s operating condition is
selected while it is the boom that is operating.)
² If the number demonstrated changes irregularly, or leaps dramatically, the reason may
be that the cable of the relevant sensor is crushed.
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The ACS-600 (QUY70)
² If the weight reading is not in line with the estimated weight, the reason may be that the
information out of the estimation is not exact.
Maintenance Instructions
² Wipe out the dirt on the moment limiter with clean and moist soft cloth. Do NOT wipe it
with cleaning agent, gasoline, thinner and diluents, etc.
² Remember to shut off the power switch of the moment limiter when work is over.
² Make sure that the power switch of the moment limiter is at the OFF position before
starting the engine.
² If there is suspect of breakdowns, please read the chapter “Conditions not Breakdowns”.
Executive Standards
² GB 12602-1990 Lifting Appliances-Safety Devices against Overloading-Safety
Technology Code
² GB 7950-1990 Boom Type Cranes-Load Moment Limiters-General Technical
Requirements
² GB/T 14560-1993 Technical Requirements for Cranes with Lifting Capacity up to 150
Tons
Technical Parameters
This product is demanded to satisfy the requirements in GB12602-1990 and GB7950-1990.
² Operating Life: ＞35,000 hrs
² Operation Voltage: DC+18～+36V
² Operation Temperature: -25～+70℃
² Storage Temperature: -55～+80℃
² Anti-impact: 30G
² Relative Humidity: ≤95% (25℃)
² Rated Power: 9W
² Comprehensive Precision: ±2%F.S
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ACS-600 (QUY70)
Glossary
Glossary Description
1 Length Distance from pivot point at the root of boom to the center of block at
the top end of boom
2 Angle Angle (elevation angle) between boom and level
3 Radius Distance from the gyration center of rotary table of crane to the center
of lifting hook
4 Rated Weight Maximum permissible lifting weight at certain boom length and angle
5 Actual weight Weight of actual load hoisted by the lifting hook of crane
6 Percentage Percentage between actual lifting moment and rated lifting moment
7 Multiple ratio Number of cable wire through traveling block set of lifting hook
8 Pulling force of Permissible lifting weight of single cable wire
single wire
9 R0 Distance from the pivot point at the root of main jib to the gyration
center
10 W Show value of actual weight (including weight of lifting hook)
11 W0 Weight of free hook
12 W1 Weight used to calibrate
13 Q Rated lifting capacity
Key-Press
Key Description
1 + Often used to add digit of number, once by 1
2 - Often used to decrease digit of number, once by 1
3 × Often used to move cursor or switch between Chinese & English
4 8 Confirmation key of backspace
5 ADJ Adjustment key used to set parameters and calibrate
6 RST Reset key
7 ▼ Down key
8 ▲ Up key
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The ACS-600 (QUY70)
Routine Check
1. Check of AML switch
Make sure that AML power of moment limiter is at shutoff state (OFF position).
2. Check of connection cable

Check whether the connection cables between central unit of moment limiter and sensor as
well as crane are fastened and there is loosening and falloff.
3. Check of pull box

Check whether the pull box is intact and the pull wire is broken and drops.
4. Check of central unit

Start engine and close force fetcher. Make sure hydraulic system begins to work. Switch on
AML (at ON position) and the central unit of moment limiter sends out a “di” sound and
automatically enters into normal working state. If there is abnormity, please press RST key
and you will enter into normal working state.
Notice:
If the engine goes out temporarily, please turn off the central unit; don’t start the engine
when the central unit is on.
5. Check of operating status

After the power is on, the central unit of moment limiter begins to work and will
automatically show the normal work interface according to the operating condition of crane.
Before lifting operation, please check whether the data of radius shown is normal.
a) Method of radius check and calibration

Change the elevation angle of main jib to about 60° and measure the current working
radius with tape. The radius value shown on the central unit should be basically
consistent with the measured value. If the deviation exceeds 1%, keep the angle of main
jib and loosen the fastening bolts of angle sensor with wrench. Rotate angle sensor
carefully to make the radius value shown on the screen equal to the measured radius
(deviation no more than ± 1%). Tighten the fastening bolts and complete the radius
calibration.
b) Check of length
Start and enter into the normal work interface. Check whether the displaying value of
length is consistent with the actual length of main jib, or the right length must be
selected again. Please refer to 8.1 for specific method.
6. Abnormity disposal
If abnormity is found, report it to equipment management department in time or call our
company for consultation.
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ACS-600 (QUY70)
General Use Method

Startup
After the central unit is turned on and a “di” sound is heard, the system display is as follows:
(Figure: Startup interface)
After the “di” sound, the system will wait for 6 seconds and then directly enter into the
default operating condition interface. Before entering into the default operating condition
interface, user can press: “×” key to switch between Chinese and English, “+” key to
select operating condition, and “-” key to select falls.
Press “ADJ” key, namely adjustment key, to enter into the main setup menu of this
system.
Normal Operation
After the central unit is turned on, if no key is pressed, after waiting for 6 seconds, the system
will automatically enter into the following default operating condition interface:
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The ACS-600 (QUY70)
(Figure: Default normal operating condition interface)
Notice:
During operation, observe whether the shown figures of angle, weight, length, radius, height,
percentage have a mark of “E”. If so, it is possibly because the signal line of sensor is broken
or the sensor fails. Stop work and check whether the connections of all sensors are broken
and report it to relevant management department for disposal; or it will be maintained and
calibrated by personnel with maintenance experience of this product or maintenance
personnel of manufacturer according to this training material and user’s manual.
Choosing Operating Conditions

If the crane needs to change the operating conditions of the boom or jib while n operation,
please choose the operating conditions for the boom or jib according to the following
methods.
After turning on the power switch of the central unit or pressing the RST button, and hearing
a beep while characters appearing on the display, press the “+” button and the display shows
the following interface:
(Figure: Selection interface of operating condition)
Choose Boom Operation

In the above menu, the cursor usually appears in the first row “【1】 Boom Operation”. Press
the 8 button to confirm and enter the normal operating interface. The central unit will
automatically memorize this choosing, and if the operating conditions do not change, it needs
not to input again the next time the engine is started. If the operating conditions do change, it
is to be chosen again.
Choose Operating Status

When it needs to use the jib for operation, use the same method to enter the menu above, and
press the + or - button to choose operation conditions of the jib among 【2】～【3】, press the
8 button to confirm. Some of cranes only have one length for one jib operation condition,
but some cranes have more than one. If one condition has more than one jib, it must be input
the length of jib. Press × to move the cursor to the digital place where it needs to input, press
+/- to input digits, then press × to move the cursor to the next digital place. With the process
going on like this, in the end press the 8 button to confirm, then it enters the normal
operating interface.
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ACS-600 (QUY70)
The central unit will automatically memorize the operating conditions chosen this time,
which remains unchanged the next the engine is started. If it needs to change the operating
conditions, it must be input again according to the above-mentioned method.
For example, according to the construction requirements, it needs to choose the jib’s
operating conditions as installation angle 30º and length 15 m. Press the × button to move
the cursor to Row 【3】 as in the menu shown in Graph 1, press the 8 button and the cursor
will automatically move rightwards to the digital places in “Jib 30 º __ __ .__ m”, and press
+/- and × buttons to input 15.0, then press 8 to confirm, thus completing the operating
conditions choosing process. After that, press the ▲ button to return to the daily interface.
The central unit will memorize this choosing: “Boom + Jib 30º 15.0 m”, and show this
operating conditions. The next time the engine starts, this choice will remain unchanged,
unless the choosing is updated.
(Figure: Selection interface of operating condition of auxiliary jib)
Choose Falls
Turn on the power switch of the central unit, or press the RST button once and hear the beep,
press the “-” button and the display will show the following interface:
(Figure: Input falls)
Press +/- to input digits, press × to move the cursor to the next digital place, in the end press
the 8 button to confirm.
The central unit will memorize the value chosen this time, and will show this one henceforth,
unless the choosing is updated.
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The ACS-600 (QUY70)
System Setup
In order to ensure the precision, during installation, the parameters of the ACS-200/600
moment limiter must be setup before delivery. End users don’t need to setup again. If it
needs to change components for the central unit or the sensors or the lines between sensors
and sensors are broken, it will be necessary to reset the parameters under the guidance of
professional maintenance personnel.
Attention:
Once the parameter settings are changed, it is required to re-conduct the precision
calibration.
While confirming that the parameters setting is needed, press the RST button, and after hear
a beep, press the ADJ button while the icons appear, and the display shows the following
menu:
(Figure: Password input of main setup menu)
With the correct password, press the ↵ button to confirm, and the following menu appears:
(Figure: Main setup menu)
Attention:
The option parameters of main setup menu can’t be modified easily, or it will lead to
computation deviation of the system and subsequently incorrect computation and display of
lifting weight. It must be strictly operated by personnel familiar with this system according to
the requirement of this manual.
The password of main setup menu will not be provided with this manual. Please ask it from
the crane equipment management personnel or directly call the crane manufacturer or the
service hotline of our company to get it.
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ACS-600 (QUY70)
Parameters Setting
Choose 【1】 Parameters Scale Setting in the above menu. Press the ↵ button to see the
following menu:
(Figure: Selection menu of parameter setup)

Radius (R0)
(Figure: Parameter setup menu of radius R0)
R0 = the distance from the base of the boom to the rotation center.
Press +, -, × to set the R0 value; press the ↵ button to confirm and store value. With the
setting completed, press the ▲ button to return to the subordinate menu.
Single Wire Pulling Force
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The ACS-600 (QUY70)
(Figure: Setup of pulling force of single wire)
Single wire pulling force =maximum rated lifting capacity of crane ÷ maximum multiple
factor × 110%. Example: maximum rated lifting capacity of QUY70 = 70 tons, maximum falls
= 12, the pulling force of single wire computed according to this is 6.42 tons.
Press +, -, × to set the R0 value; press the ↵ button to confirm and store value. With the
setting completed, press the ▲ button to return to the subordinate menu.
Setup Measurement (Angle, Force Sensor)
(Figure: Setup measurement menu)
ANGLE CALIBRATION
Choose 【1】 Setup the Range of Angel. Press the ↵ button to see the following interface:
(Figure: Setup the Range of Angel: zero point)
Draw the boom to 0 degree, double confirm again, and then press ↵ button to see the
following interface:
(Figure: Setup the Range of Angel: upper limit)
Lift boom to 80 degree, double confirm again, and then press ↵ button. Angel Calibration
completed, press the ▲ button to return to the subordinate menu.
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ACS-600 (QUY70)
(Figure: Completion of angle calibration)
After angle calibration completes, please recheck whether the angle shown is right. The angle
can be checked with the above angle check method or with angle meter. If deviation occurs,
then it is required to calibrate again.
FORCE SENSOR CALIBRATION

In Precision Calibration menu, choose 【3】 Force Sensor Calibration. Press the ↵ button to
see the following interface:
Select 【3】 force sensor calibration from the precise calibration interface and press ↵ key to
confirm. The screen shows:
(Figure: Force sensor calibration 1)
Change the radius under complete retraction of main jib to lower limit according to the hints
on the screen, keep the variable radius handle stationary and release accelerograph. After the
above operation completes, press 8 key to confirm the zero point of force sensor and the
screen shows the following figure:
(Figure: Force sensor calibration 2)
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The ACS-600 (QUY70)
Then stretch the main jib to full length. Change radius slowly to about 43° and upward to 45°
( ± 0.1°) and keep steady.
After a while when the main jib does not vibrate, press ↵ key to confirm the force sensor in
full range. The calibration of force sensor completes and press ▲ key to return to previous
menu.
Precision Calibration
The precise calibration of ACS-200/600 type load moment limiter is completed by crane
manufacturer before delivery for use and user is generally not required to perform precise
calibration during use. If the required display precision can’t be achieved by rapid calibration,
then precise calibration can be performed under the guidance of professional maintenance
personnel.
Preparation:
1. Prepare 20t, 10t, 3t, 2t, 1t weights for calibration.
2. Carefully check whether the operating conditions of main jib and auxiliary jib shown on
the display are consistent with the actual conditions. If not so, please input the current
actual operating conditions according to the instructions of “selection of operating
conditions of main jib and auxiliary jib”.
3. Make sure that the angle and length of main jib has been checked.
4. Make sure that the crane stops on solid ground and is in normal work state;
5. Select suitable weights according to the lifting capacity table, change radius to that equal
to the rated lifting capacity shown on the central unit, keep the main jib steady and put
the weight down on the ground.
After preparation of all above steps, Turning on the power switch of the central unit or
pressing the RST button, and hearing a beep while characters appearing on the display, press
the ADJ button and the display shows the following interface:
(Figure: Password input interface of setup menu)
With the correct password, press the ↵ button to confirm, and the following menu appears:
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ACS-600 (QUY70)
(Figure: Selection of operation menu)
Choose 【2】 High Precision Calibration. Press the ↵ button to see the following menu:
(Figure: Selection of parameter setup menu)
Weight Calibration
FREE HOOK CALIBRATION
Choose 【1】 W0 （Free Hook Weight） Calibration. Press the ↵ button to see the following
interface:
(Figure: Weight calibration – free hook calibration 1)
Confirm that there is no weight on the hook; lift boom to 15º, input weight of hook, press the
↵ button to confirm, and then to see the following interface:
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The ACS-600 (QUY70)
(Figure: Weight calibration – free hook calibration 2)
Lift boom at a very low speed to 79º, then reverse the action slowly. The central unit shows
the following interface, indicating it’s automatically executing precision calibration. With the
lifting and dropping activities finished and the lifting boom back to the original position, the
weight calibration is completed. Press the ↵ button to confirm, and then press the ▲ button
to return to the subordinate menu.
Special Tips:
Once the calibration procedure started, the lifting boom must maintain a slow and uniform
motion, where it can not stop or change speed suddenly.
ACTUAL WEIGHT CALIBRATION

After the free hook calibration, lift the boom to 20º, hoisting up the prepared weights; enter
the weight calibration menu with the same method cited above. Choose 【2】 W1 (Actual
Weight) Calibration, and press the ↵ button to see the following menu:
(Figure: Weight calibration – actual calibration)
Adjust boom to 20 º, add weight or load to lifting hook, and make sure that the sum of weight
of main hook and weight of load lifted is equal to W1. Change radius of main jib downward to
the position where W is equal to Q and press 8 key. The central unit shows the following
interface, which indicates that weight calibration is ready to be performed automatically.
Make sure that the weight of the primary hook plus that of the hoisted item equals to W1, and
drop the boom to the position where the value of W equals that of Q. While the lifting boom is
slowly lifting from the current angle, press the 8 button and the display shows the following
interface, indicating that the central unit is executing weight calibration automatically:
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ACS-600 (QUY70)
(Figure: Weight calibration – actual calibration 2)
Lift boom at a very low speed to 79º, then reverse the action slowly. The central unit shows
the following interface, indicating it’s automatically executing precision calibration. With the
lifting and dropping activities finished and the lifting boom back to the original position, the
weight calibration is completed. Press the ↵ button to confirm, and then press the ▲ button
to return to the subordinate menu.
Special Tips:
Once the calibration procedure started, the lifting jib must maintain a slow and uniform
Attention:
The calibration weights used for all boom/jib lengths should not be less than 1.5 tons, and
should be equal or slightly smaller than the min rated lifting capacity for a specific jib length.
While calibrating, the user needs to enter the accurate value of the actual weight of the
weights used and the hook for the specific jib length.
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The ACS-600 (QUY70)
Fast Calibration
Radius Calibration
Preparation
1. Calibration Equipment: one 30m tape measure
2. One 5 ton calibration weight
Calibration Steps
Press the ADJ button on the primary operation interface to see the following menu:
(Figure: Fast calibration: password input)
With the right password, the display shows the following interface:
(Figure: Fast calibration: menu selection)
Choose 【1】 radius calibration, and press the ↵ button to see the following menu
(Figure: Fast calibration: radius calibration 1)
Lift a 5-ton weight, retract main jib completely and change range to 150. Measure the range
value from gyration center of rotary table to the center of main hook with tape, press +, -, ×
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ACS-600 (QUY70)
keys to input the measured values to make the radius equal to the current measured radius
and press ↵ key to confirm. Then change range upward to increase the angle by 5 degrees.
Measure the radius value from gyration center of rotary table to the center of main hook with
tape, press +, -, × keys to input the current measured values and press ↵ key to confirm. Then
measure, input values and confirm for every 5 degrees until 75 degrees.
(Figure: Fast calibration: radius calibration 2)
After calibration of complete retraction of main jib completes, stretch the main jib to the next
length in the rated lifting capacity table and calibrate according to the above calibration
method until the main jib is fully stretched.
Weight Calibration
If it is found during use that the display deviation exceeds ± 5% or it is considered necessary
to calibrate the show value of weight (for example: routine check by Bureau of Quality and
Technical Supervision), observe the following steps for rapid calibration:
Confirm the weight of crane required to be calibrated and show the boom length for rapid
calibration. Mobile crane is calibrated according to the length in rated lifting capacity table
and crawler crane is calibrated according to the actual operating length.
Confirm that the crane is on solid horizontal ground, and in normal operating state; the
length, angle and radius reading values on the central unit are all identical with the actual
ones, with the deviation variance no more than ±1%;
Hoist up something or a weight with a known weight (10t for example), press the ADJ button
on the primary operation interface, enter the right password, choose 【2】 Weight calibration,
and press the ↵ button to see the following menu:
(Figure: Fast calibration: weight calibration 1)
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The ACS-600 (QUY70)
Enter the accurate weight value W, which includes the weight hoisted plus the weight of the
hook, and drop the boom to the position where the value of W equals that of Q. Press the 8
button while the lifting jib is lifting at a very low speed from the current angle, and the central
unit shows the following interface, indicating it is executing automatically the weight
calibration
(Figure: Fast calibration: weight calibration 2)
Change the upward lifting action into a slow downward one when the lifting jib lifts to 79º.
When the lifting and dropping actions are finished and the lifting jib is back at the original
position, the weight calibration is completed, then press the ▲ button to return to the
subordinate menu.
Special Tips:
Once the calibration procedure started, the lifting jib must maintain a slow and uniform
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ACS-600 (QUY70)
Time Calibration
Press the ADJ button on the primary operation interface, enter the right password, choose
【3】 Time calibration, and press the ↵ button to see the following menu:
(Figure: Time calibration)
Press +, -, × to set time; press the ↵ button to confirm and store value. With the setting
completed, press the ▲ button to return.
Reading Overload Data

Press the ADJ button on the primary operation interface, enter the right password, choose
【4】 Reading overload data, and press the ↵ button to see the following menu:
(Figure: Password input interface for reading overload data)
Enter the right password for reading overload data, then the displays shows the last recorded
overload data, and with each press of “+”, the displays shows the next page of data.
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The ACS-600 (QUY70)
(Figure: Interface for reading overload data, which shows overload data one by one)
When all overload data is showed, the display shows that:
(Figure: All overload data has been read)
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ACS-600 (QUY70)
Instructions On Installation
System Composition
ACS-600 type load moment limiter system, which applies to this vehicle type, is composed of
the following parts:
Name of article Quantity
Central unit of the moment limiter
Pressure sensor (including cable and plug)
Multi-core shielded cable and aeronautical plug-in

Three-core (hole) and seven-core (hole) plug 1
cable
Seven-core (pin) plug cable 1
Angle sensor
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The ACS-600 (QUY70)
The connection relation of each part is shown as follows:
(Figure: Composition and structure figure of ACS-600 type load moment limiter)
Installation
The central unit of ACS-600 type load moment limiter is installed in the operating cab of
crane. Pressure sensor is installed on the pipe connection of compensation valve or sucker.
Angle sensor is installed on the main jib of crane. Length sensor is not a product of our
company and is generally installed to the left or right of middle part of main jib of crane. The
sketch map of installation position is as follows:
(Figure: Sketch map of installation position of ACS-600 load moment limiter)
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ACS-600 (QUY70)
Central Unit
The central unit is installed in the electric appliance box of operating cab and is fastened in
the central unit mounting hole of electric appliance box with four screws.
Lead out power cord and signal input/output cable from the five aeronautical plugs behind
central unit. The following figure is the sketch map of leading wire of aeronautical plugs
behind central unit.
(Figure: Sketch map of illustration of sockets of central unit)
For the corresponding signals of each socket on the central unit, please refer to Annex “Signal
list of sockets on central unit”.
Pressure Sensor
This product has an associated pressure sensor installed, which was installed on the
motherboard of pressure sensor. The specific installation method is as follows:
Installation of pressure sensor:

Fix pressure sensor onto the base with the attached bolts.
(Figure: Sketch map of installation of pressure sensors and sensor base)
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The ACS-600 (QUY70)
Fix the pressure sensor and base tightened together onto the motherboard of crane where
pressure sensor is installed with bolts.
(Figure: Sketch map of installation of pressure sensor on the reserved sensor motherboard)
Connection to Central unit

After the sensor is installed, it is required to bind the cable of sensor along A-shape rack and
rotary table orderly and finally lead into electric cabinet through the floor of operating cab.
Enough length should be reserved during binding and wiring to prevent the cable from being
damaged or broken. Then connect the cable with four-core pin-type socket on the backboard
of host machine of moment limiter and tighten the retaining nuts of aeronautical plug to
prevent them from falling.
Page 28
ACS-600 (QUY70)
Angle Sensor
For this vehicle type, some products have a corresponding angle sensor installed. As the
bases used are different, the installation method is divided into two types.
1. Use the standard installation bracket of “Changsha Zoomlion Heavy Industry Science &
Technology Development Co., Ltd”.
a) Point “FRONT” arrow mark on the angle sensor horizontally to the head of main jib
and “UPPER” arrow mark upright;
b) Fix the angle sensor onto the bracket with three M10×25 or M8×25 bolts;
c) Screw the five-core aeronautical plug onto the five-core aeronautical socket of angle
sensor.
2. Use adjustable installation bracket equipped for angle sensor

a) Welding of base of installation bracket
b) First take out the round barrel type base of bracket associated with angle sensor and
weld the base end with thick inner wall onto the installation position of angle sensor
on the main jib.
(Figure: Sketch map of base and base welding)
c) Connection of installation bracket with angle sensor

d) Fix the triangle bracket onto the angle sensor by M10×25 or M8×25 screws for
future use.
(Figure: Sketch map of installation of angle sensor and triangle fixed mount)
e) Connection of angle sensor with bracket installed and bracket base

f) Connect the angle sensor with bracket installed with the bracket base already welded
on the main jib of crane and then adjust the angle.
Notice:
During the angle adjustment, make sure the crane stops on a level and flat ground and the
main jib of crane is at horizontal position.
g) Observe with naked eyes that the main jib is level. To guarantee the precision of
measured result, you can also use electronic angle meter or refer to the angle
indicator installed on the main jib after measurement and confirmation to check
whether the main jib is level.
Page 29
The ACS-600 (QUY70)
h) After the main jib is confirmed to be level, observe with naked eyes the UPPER and
FRONT arrows on the surface of angle sensor and rotate the angle sensor to the
position where it is relatively level to the main jib. Tighten the three screws on the
triangle bracket to ensure that the angle sensor can’t be rotated and shaked.
3. Connecting cable of angle sensor

After the angle sensor is installed, insert the connecting cable of angle sensor (five-core plug
end) into the five-core (pin) socket on the angle sensor and tighten it to prevent from falling.
(Figure: Sketch map of cable connection and installation)
Page 30
ACS-600 (QUY70)
Maintenance
² Before operating the crane, users should first conduct a visual check on the components
of the crane, central unit of the moment limiter and all the sensors, so as to timely find
out abnormalities if any. After starting the engine, users should pay attention to whether
the length and angle readings are normal or whether there are breakdowns shown on the
display. Once abnormalities or breakdown warnings are found, it’s needed to be properly
managed by professionals.
² Before finding out the real reasons, NEVER blindly dismantle the central unit,
components or sensors of the moment limiter, in order not to expend the breakdowns,
and induce further ones.
² In daily usage, pay attention to keeping the moment limiter clean. Keep rain, grease,
organic solvent, and other harmful liquid from dripping or splashing onto the central
unit of the moment limiter or into the sensors. Prevent heavy or sharp-pointed objects
from bumping against or scratching on the central unit, sensors and the connecting
wires.
² In hot summer, be aware to prevent the central unit of the moment limiter from being
exposed to the scorching sun, in order to prolong its service life. Due to the temperature
sensitive quality of the LCD, in relatively hot temperatures (＞35℃), the hue of the LCD
display of the central unit will be darker, and in low temperatures (＜10℃), the hue will
be lighter. Both situations are normal, and won’t affect its functions.
² Users should constantly pay attention to the operational status of the storage battery and
generator. Breakdowns in the storage battery and generator will affect the operating
performance of the moment limiter.
Page 31
The ACS-600 (QUY70)
Breakdown Management
1． Checking Method
When the moment limiter shows there are abnormalities, users should first check whether all
components are operating normally, whether the cables and their joints are intact, then
double-check against the breakdown conditions table. If the breakdown still can not be fixed,
please consult directly with our company and ask for services.
2． Conditions not Breakdowns of the Central unit

² When the crane is in operation, the display of the moment limiter shows nothing. The
reason may be that there is no power supply for the moment limiter.
² If the angle reading is not accurate, the reason may be that unidentified factors have
changed the original installation position of the angle sensor.
² If the length reading is not accurate, the reason may be that the cable of the reel box is
stuck or cut off.
² If the weight reading is not accurate, the reason may be that the entered length or angle
value are not consistent with the actual number; or it may be that the selected operating
condition is not consistent with the actual one (e.g. the jib’s operating condition is
selected while it is the boom that is operating.)
² If the number demonstrated changes irregularly, or leaps dramatically, the reason may
be that the cable of the relevant sensor is crushed.
² If the weight reading is not in line with the estimated weight, the reason may be that the
information out of the estimation is not exact.
Page 32
ACS-600 (QUY70)
3． Breakdown Status Table

The central unit of the ACS-200/600 moment limiter has self-diagnosis functions. It can
automatically demonstrate the breakdown information in text format when the connecting
wire is crushed and result in short or broken circuit, so as to warn the user.
On seeing breakdowns demonstrated, please refer to the checking methods in the following
table to fix them.
No Signal on the Display

Breakdown Description Reasons Checking and Fixing Method
Turn on the power supply Failures occur in the Double-check whether the power
and press the RST button, power supply of the supply of the upper structure is in the
without hearing the beep. upper structure. scope of 18～36V。
The power switch in Double-check whether the voltage
the electrical box of between the ① and ② sockets of the
the moment limiter aviation plug of the central unit’s
falls off. power supply is 18～36V.
Display failure. Contact our company.
Angle Signal Failure

It show “Angle Over Max The shielded cable Stop the boom at about 60º. Measure
Degree”, or “Angle Failure”. between the angle if the resistance between the ① and
sensor and the central ② of the angle aviation plug is about
unit is crushed and 5kΩ, and that between ② and ③ is
result in short/broken about 0.9kΩ.
circuit.
The angle reading is not The position of the Refer to the “Fast Angle Calibration”
consistent with the angle sensor is in the daily maintenance for
actuality. artificially changed. calibrating.
P1, P2 Signal Failure

P1, P2 over upper/lower The cable is crushed to The resistance between ① and ②, or
limits. result in short/broken ③ and ④ should be about 350～400
circuit. Ω.
Weight reading leaps The joint of shielded Check and fix the bad connection, lock
dramatically. cable or plugs/sockets well the aviation sockets.
not well connected.
Weight reading is zero or Sensor circuits Change sensors.
other symbols. shortened or damaged.
Page 33
The ACS-600 (QUY70)
Support & Services

1. The company has its own professional post-sales maintenance personnel. If breakdowns
occur, please contact the company directly, and we will respond to the customer’s
requirements immediately.
² Beijing: (010) 62122771

² Shanghai: (021) 56523529
² Changsha: (0731) 5597296
2. The maintenance period of the central unit of ACS-200/600 moment limiter is 24 months,
within which the company provides technical services gratis and free maintenance. The
following items are not included in the maintenance (services will be paid even if within the
maintenance period).
² Breakdowns and damages resulted from the inappropriate operation of the user.
² Breakdowns and damages resulted from the repairing, changing, dismantling and
maintenance by operators or maintenance personnel not authorized by the company.
² Breakdowns and damages resulted from the dismantling, repairing, and the installation
of the central unit, circuits and sensors by the users themselves without the authorization
of the company.
² Breakdowns and damages resulted from the adding, refitting, and changing of the central
unit, circuits and sensors by the users themselves without the authorization of the
company.
² The components that has a service life and need to be changed regularly.
² Breakdowns and damages resulted from the irresistible natural disasters including fires,
flood, earth quake and thunder, etc.
² Breakdowns and damages resulted from the unallowable voltage values, etc. of the
machine.
² Breakdowns and damages resulted from the inappropriate transportation and movement
of the machine.
3. For broken products out of the maintenance period, only under repairable circumstances,
the company repairs the product and charges the maintenance fee.
4. According to the requirements of the customers, the company will regularly hold the
moment limiter central unit adjustment and maintenance personnel training class. Please
directly contact and consult with us on the training issues, then you may come to the
company to enjoy favorable training services offered by us. For specific major customers or
under special circumstances, the company may provide on-the-scene training for the
customers. The customers have to pay for this kind of training, please contact us for specific
information.
The final interpretation right of the above service terms belongs to Precise
Technology (Beijing) Co., Ltd. and Changsha Huizhi Technology Co., Ltd.
Page 34
ACS-600 (QUY70)
Appendix
Signal List of Sockets on Central Unit
Pin Numb. Pin/Hole Note

3-Pin Plug（Pin） 1 24V
[Power] 2 Ground
3 connecting to engine starting button wire
7-Pin Plug（Pin） 1 Relay contact of control output of other functions
[Overload Cut-off, 2 Relay contact of control output of other functions
Moment Area 3 Overload Control Contact
Input] 4 Input signal
5 Relay contact of overloading output
6 Relay contact of alarm output of upper limit of angle
7 Relay contact of alarm output of upper limit of angle
7-Pin Plug (Hole） 1 N/A
[Angle, Length 2 Angle Power Supply +4V
Sensor] 3 N/A
4 N/A
5 Angle Power Supply - 0V
6 N/A
7 Angle Signal +0～1.8V
4-Pin Plug（Pin） 1 P1 Power Supply +
[P1 Sensor] 2 P1 Power Supply -
3 P1 Signal +
4 P1 Signal -
4-Pin Plug（Hole） 1 P2 Power Supply +
[P1 Sensor] 2 P2 Power Supply -
(Optional) 3 P2 Signal +
4 P2 Signal -
Page 35
The ACS-600 (QUY70)
Normal Voltage Value between Lines of the Central

Unit External Socket
Pin (Hole) No. 3-Pin 7-Pin Socket 7-Hole 4-Pin 4-Hole

Socket Socket Socket Socket
Normal 1～2 18～36 V 9~11V 9~11V
Normal 3～4 >20mV >20mV
Normal 1～2 Warning
Connection
Normal 3～4 Overload
Connection
Normal 6～7 ≥79°Connection
4 Input Signal
Normal 2～5 +4 V
Normal 2～5 >+ 7 V
Normal 5～7 + 0.1～1.8 V
Breakdown 5～7 0 or ﹥3 V
Notes:
1. Numbers in ? connect to the red pen of the digital multimeter; numbers in ? connect to
the black pen of the multimeter.
2. The length, angle, P1 and P2 power supplies are high-precision power supplies
independent from each other, and can not be exchanged or connected with each other,
still less with the 24V wire or the ground.
Path Illustration of Function Menu of Host Machine
(Figure: Menu path for crawler crane)

Installation Guide & User 'S Manual: The ACS-600 Load Moment Limiter

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What is the purpose of the ACS-600 load moment limiter?

What is the purpose of the ACS-600 load moment limiter?

What are the technical parameters and standards of the ACS-600?

What are the technical parameters and standards of the ACS-600?

Intelligent Safe Control Solutions of Cranes

Installation Guide & User’s Manual

The ACS-600 Load Moment Limiter

(QUY70 Crawler Cranes)

Precise Technology (Beijing) Co., Ltd.

Conditions not Breakdowns of the Central unit:

2. Check of connection cable

3. Check of pull box

4. Check of central unit

5. Check of operating status

a) Method of radius check and calibration

General Use Method

(Figure: Startup interface)

(Figure: Default normal operating condition interface)

Choosing Operating Conditions

(Figure: Selection interface of operating condition)

Choose Boom Operation

Choose Operating Status

(Figure: Selection interface of operating condition of auxiliary jib)

(Figure: Input falls)

(Figure: Password input of main setup menu)

(Figure: Main setup menu)

(Figure: Selection menu of parameter setup)

(Figure: Parameter setup menu of radius R0)

Single Wire Pulling Force

(Figure: Setup of pulling force of single wire)

Setup Measurement (Angle, Force Sensor)

(Figure: Setup measurement menu)

(Figure: Setup the Range of Angel: zero point)

(Figure: Setup the Range of Angel: upper limit)

(Figure: Completion of angle calibration)

FORCE SENSOR CALIBRATION

(Figure: Force sensor calibration 1)

(Figure: Force sensor calibration 2)

(Figure: Password input interface of setup menu)

(Figure: Selection of operation menu)

(Figure: Selection of parameter setup menu)

(Figure: Weight calibration – free hook calibration 1)

(Figure: Weight calibration – free hook calibration 2)

ACTUAL WEIGHT CALIBRATION

(Figure: Weight calibration – actual calibration)

(Figure: Weight calibration – actual calibration 2)

(Figure: Fast calibration: password input)

(Figure: Fast calibration: menu selection)

(Figure: Fast calibration: radius calibration 1)

(Figure: Fast calibration: radius calibration 2)

(Figure: Fast calibration: weight calibration 1)

(Figure: Fast calibration: weight calibration 2)

(Figure: Time calibration)

Reading Overload Data

(Figure: Password input interface for reading overload data)

When all overload data is showed, the display shows that:

(Figure: All overload data has been read)

Pressure sensor (including cable and plug)

Multi-core shielded cable and aeronautical plug-in