LOADWISE MODEL 503 RATED

503
503
CAPACITY INDICATOR SYSTEM

LOADWISE MODEL 503

RATEDCAPACITYINDICATORSYSTEM
OPERATORS MANUAL

Page 1
 LOADWISE MODEL 503 RATED
503 CAPACITY INDICATOR SYSTEM
Table of Contents
THERE ARE NO WARRANTIES, EXPRESS OR IMPLIED, MADE BY EITHER THE DISTRIBUTOR
WARRANTY OR THE MANUFACTURER ON NEW LOADWISE EQUIPMENT, EXCEPT THE MANUFACTURER
WARRANTY AGAINST DEFECT, MATERIAL AND WORKMANSHIP SET OUT BELOW.

The manufacturer warrants each new product made by the manufacturer to be free from defects in
material and workmanship, its obligation and liability under this warranty being limited to replacing free
of charge at its factory, any part proving defective under normal use and service within twelve (12)
months from the date of delivery, providing the equipment is on record with the manufacturer as being
installed by the distributor. If the machine is not on record as being installed by the distributor the
manufacturer will consider the date of shipment from the factory. This warranty is in lieu of all other
warranties, express or implied, and the obligation and liability of the manufacturer under this warranty
shall not include transportation or other charges of consequential damages or delay resulting from the
defect. Any operation beyond rated capacity or improper use or application of the product or the
substitution upon it of parts not approved by the manufacturer shall void this warranty. This warranty
covers only the products of Loadwise, Inc. 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 WARRANTIES, EXPRESS OR IMPLIED,

INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR AN INTENDED
PURPOSE, AND OF ANY OTHER OBLIGATIONS OR LIABILITY ON THE PART OF THE
MANUFACTURER, AND LOADWISE INC. NEITHER ASSUMES NOR AUTHORIZES ANY OTHER

TABLE OF CONTENTS

INTRODUCTION Page 3

SYSTEM DESCRIPTION Page 4

BILL OF MATERIAL Page 6

DISPLAY CONSOLE ILLUSTRATION Page 7

DISPLAY CONSOLE FUNCTIONS Page 8

DISPLAY MODES Page 9

CONTROL MODES Page 10

MESSAGES Page 11

FAULT CODES Page 13

Edition # 94595
Rev 00156

Page 2
 LOADWISE MODEL 503 RATED
503 CAPACITY INDICATOR SYSTEM
Introduction
INTRODUCTION
The Loadwise 500 Series Rated Capacity Indicator System provides the operator with a
continuous display of essential information, to enable the crane to be used within its
design parameters.
This information is on a large, easy to read liquid crystal display. Various sensing
devices are positioned on the crane to monitor boom angle, boom length and load, all of
which are displayed with rated capacity, boom tip height, percentage of load moment and
various warning messages. When approaching rated capacity or non-permitted areas of
operation, the operator will be warned by lights and audible alarm, and may be followed
by the cutting of crane motion.

WARNING
This operator’s manual describes the operation of the Loadwise 500 Series Rated
Capacity Indicator, which has been developed over many years of design and field
experience. While the indicator will display information and alert the operator to
impending conditions, it must always be remembered that the system utilizes a series of
electrical, mechanical and hydraulic components and cannot be 100% fail safe.
Therefore, operators are warned not to consider the system as a substitute for good
judgment, experience and accepted safe crane operating practice. The operator is solely
responsible for safe operation of the crane.
Certain program selections are necessary before performing each lift. If incorrectly
selected, the system may not alert the operator to an impending condition; therefore, this
manual should be read and thoroughly understood before operating the crane.
This system may be equipped with an override key. This key by-passes the motion -stop
function of the indicator. This switch should only be used by authorized personnel during
emergency situations.
During normal operations of the Loadwise 500 Series Rated Capacity Indicator, the rated
load of a crane should not be exceeded. Therefore the warning of overload should not
be used as a normal operating facility. Additionally, certain statutory requirements do not
permit the crane’s rated capacity to be exceeded except for the purpose of testing.
The indicator in its standard form is not protected for explosive atmospheres. For
applications up to ZONE 1 please consult the factory for modifications.
 LOADWISE MODEL 503 RATED
503 CAPACITY INDICATOR SYSTEM
Introduction
SYSTEM DESCRIPTION
WHAT IT IS

The LOADWISE 500 series is a automatic microprocessor controlled rated capacity

indicator that provides the operator with the essential information and vital approach and
overload warnings.

The system works on the principle of comparing STORED data with LIVE data detected
from the sensors.

The STORED data (which is in the memory chip) consists of capacity charts, crane boom
dimensions, together with the line pull limits, slew limits etc.

The LIVE data is sensed by the boom length and angle sensors for radius calculations and
by strain gauge loadcells located in in the derricking ropes for loading of the crane.

WHAT IT MEASURES

(1) The boom hoist (support) load.

(2) The boom angle with respect to the horizon

WHAT IT DOES

The system continually computes the radius (or any angle, on angle rated duties,) and
refers to the appropriate duty chart to establish the rated capacity for the working position.

The resultant moment caused by the boom hoist load is used in conjunction with the
radius to determine the hook load.

It compares the established hook load with the rated capacity, displaying the percentage
on a bar graph and tripping the alarms required and any lockout system connected.
 LOADWISE MODEL 503 RATED
503 CAPACITY INDICATOR SYSTEM
Introduction
WHAT IT CONSISTS OF
LOADPINS

Loadpins are installed in the hoist rope’s path, so that the hoist rope is held deflected over
three sheaves. The hoist rope causes a force to be applied to the loadpin. These
electronic loadcells transmit the rope tension signal to the computer, where it is used to
produce the weight indication on the display console.

ROPE DIRECTION SENSORS

Rope movement sensors are installed and electrically connected to the computer. This is
used to enable corrections to be made to the load signal to combat the change in apparent
load from hoisting and lowering.

INCLINOMETER (ANGLE SENSOR)

An angle sensor is located within an enclosure that is attached to the crane’s butt section.
This inclinometer is a potentiometer-driven pendulum that senses boom angle with respect
to the horizon.

DISPLAY CONSOLE AND JUNCTION BOX

All the electronics are in the Display Console and the Junction Box, which is installed
behind the Display Console.
 LOADWISE MODEL 503 RATED
503 CAPACITY INDICATOR SYSTEM
BILL OF MATERIAL
Qty Area Dwg # Description
1 Display 94335 Display Console
1 Display 94337 Junction Box
1 Display
1 Documents Duty Selection Plate (specify crane)
1 Documents 94570 Operator’s Manual
1 Documents 94599 Calibration Manual
1 Documents Drawings Package (specify crane)
1 Sensor 94385 M1 Angle Sensor
2 Sensor
2 Bracketry Sensor Bracketry
2 Bracketry Sensor Bracketry
6 Bracketry Sensor Bracketry
Wiring
Wiring Boom Tip Junction Box
Wiring Dual Loadcell Cable, (length of boom)
Wiring
Wiring
Wiring
Wiring :
Wiring
Wiring
Wiring
 LOADWISE MODEL 503 RATED
503 CAPACITY INDICATOR SYSTEM
SYSTEM OPERATION
DISPLAY CONSOLE
The Display Console is split into two sections. The center section is a four (4) line “alpha-
numeric” screen that displays information to the operator, and the right section is a keypad
used to change the display to alternative information modes, and is also used in the
calibration process. Here is a sketch of the Display Console showing its two sections.

F L/H ALT

+ TEST

TARE DEDUCT DUTY

LOADWISE 500
{
{
Display Section Keypad
Section
 LOADWISE MODEL 503 RATED
503 CAPACITY INDICATOR SYSTEM
SYSTEM OPERATION
LOAD PERCENTAGE RATED
WEIGHT OF CAPACITY CAPACITY

%
RADIUS
OF W MAX
LOAD
8 . 4 1 5 . 6 1
R = 1 1 . 0 F { R } A = 6 1 . 0
C U T O U T BOOM
ANGLE
D U T Y = 0 0 1 F 1 = 0 8 D = 0

VARIOUS WINCH SELECTED

MESSAGES DUTY 1=MAIN WINCH DEDUCT
SELECTED 2=AUX WINCH SELECTED

DISPLAY CONSOLE FUNCTIONS

The Display offers a variety of operational data to the crane operator, depending on the
application. The illustration below shows that data normally displayed. Additionally, a
keyboard, on the right-hand side of the Display Console, allows for the input of
information to the system, including: the ALTERNATE INFORMATION screen; the L/H
screen; the TEST screen; DUTY SELECTION; STOWED AND ERECTED DEDUCT
SELECTION; FALLS (Parts-of-Line) SELECTION; and TARE SELECTION.
 LOADWISE MODEL 503 RATED
503 CAPACITY INDICATOR SYSTEM
SYSTEM OPERATION
F L/H ALT

+ TEST

TARE DEDUCT DUTY

KEYBOARD

DISPLAY MODES (ACCESSED BY USING THE KEYBOARD)

L/H When pushed, causes the display location showing radius (R) to display main
boom length (L), and the display location for angle (A) shows boom head height
(H). A second push will restore the display to normal, or after a time delay, display
will be automatically restored to normal.
TEST When pushed, initiates a test routine, and will display the word TEST on the third
line of the display screen. After the test routine is completed, the TEST message
is removed. The test may be canceled by two pushes on the ALT button.
TARE When pushed, will deduct the existing load displayed from itself and any future
loads. It is canceled by a second push. When operating in the TARE mode, the
word TARE will be displayed on the third line of the display.
ALT When pushed, will show:
When pushed with a normal display showing, will show a description of the duty
selected. To return to the normal display screen, push ALT a second time.
When pushed while in the TEST routine, will display fault diagnosis information,
which can be used to confirm the system is operational, and also gives information
on optional input sensors. To return to the normal display while in the TEST and
fault diagnostic mode, press ALT a second time.
The above modes are display modes only and do not affect the operation of the system.
 LOADWISE MODEL 503 RATED
503 CAPACITY INDICATOR SYSTEM
SYSTEM OPERATION
CONTROL MODES (ACCESSED BY USING THE KEYBOARD)
The following modes are input instruction controls and are VERY IMPORTANT for the
correct operation of the system.
Prior to making a lift operation, the operator must consult the DUTY SELECTION CHART to
establish the correct duty number for the required configuration of the crane. (For example,
DUTY 001 = 100 Ft Main Boom Plus 32 Ft Jib @ 15º Offset.) Next, the operator must select
how many parts-of-line (“falls”) required to make the lift, and if any “Stowed or Erected
Deducts” are applicable. These duties, falls and deducts are entered into the system using
the following commands on the keyboard:
DUTY / F (“falls” or “parts-of-line”) / DEDUCT
These commands will only operate when the load is on the ground. Any attempt to change
these commands while lifting will cause the word INHIBITED to be displayed. This is to
prevent the operational instructions to the indicator from being changed during a lifting
operation.
DUTY When pushed, will flash the most significant digit. To change, push “+” or “-”.
A second push of the DUTY button will cause the second digit to flash and a third
push will cause the third digit to flash. A fourth push of the DUTY button will store
the duty selection made, (after a three (3) second pause).
F (Falls) The display will indicate by a “1” or a “2” which winch is in operation for the
duty selected. Press “F” to flash the most significant digit; the digit flashing may
be increased or decreased using the “+” or the “-” buttons. To select the next less
significant digit, press “F” again. A third push of the “F” button will store the parts-
of-line selected (for that winch only) , after a three (3) second pause.
D (DEDUCT) When pushed, will flash to indicate that a selection can be made (using the
“+” or the “-” buttons) in a range of 0 to 9. A selection of available deducts is
located on the Duty plate; typically these are deductions from the capacity of the
crane due to stowed or erected jibs, hook blocks, balls, etc. that are not in use for
a particular duty. A second push of the “DEDUCT” button will store the selection
made, after a three (3) second pause.
After a CONTROL MODE selection has been made, the ALT buttons should be pressed, to
give the operator an opportunity to check that the selections made are entered into the
system CHECK ALL DATA CAREFULLY.
 LOADWISE MODEL 503 RATED
503 CAPACITY INDICATOR SYSTEM
SYSTEM OPERATION
MESSAGES
The third line of the normal display is used to display a variety of messages. The line of
twenty (20) characters is divided into two sections; one section of thirteen (13) characters
and one section of seven (7) characters. Each of these two sections is totally independent
and are not to be read together. Within each section there are a number of possible
messages, some of much greater importance than others. Therefore, each section has a
priority rating, with the message at the top of the list taking priority. During normal operating
conditions, the third line will be blank.
The section of thirteen (13) characters is displayed on the left-hand portion of the third line,
and include the following messages:
OUT OF LEVEL if equipped with the necessary switch(es) and/or sensor(s)
RIGGING if equipped with the necessary switch(es) and/or sensor(s)
OVERRIDE if equipped with the necessary switch(es) and/or sensor(s)
OVERHOIST if equipped with the necessary switch(es) and/or sensor(s)
DUTY NUMBER indicates that a duty is being selected where no duty is possible. When
this is displayed, consult the DUTY SELECTION PLATE to make the
correct duty selection.
FAULT indicates the system has generated a fault code. Press “TEST” and
then press “ALT” to display the fault. This will display fault diagnosis
information, which can be used to confirm the system is operational, and
also gives information on optional input sensors. To return to the normal
display while in the TEST and fault diagnostic mode, press ALT a second
time.
HIGH ANGLE indicates that the max high angle has been exceeded.
LOW ANGLE indicates that the max low angle has been exceeded.
OUT OF RADIUS indicates that there is no rated capacity for the radius of the crane, for
the duty selected.
OUT OF ANGLE indicates that there is no rated capacity for the boom angle of the crane,
for the duty selected.
UNCALIBRATED indicates that a duty selection has been made for a duty configuration
that has not been calibrated.
CUT-OUT indicates that the crane’s (optional) “motion-cut” or “lever-lockout” has
been activated.
INHIBITED indicates an attempt to change a CONTROL MODE input while a load
is suspended.
 LOADWISE MODEL 503 RATED
503 CAPACITY INDICATOR SYSTEM
SYSTEM OPERATION
MESSAGES (continued)
The section of seven (7) characters is displayed on the right-hand portion of the third line,
and include the following messages:
ROPE indicates that the crane’s rated capacity is limited by the number of
parts-of-line selected. Additional capacity is available by re-reeving
the crane for additional parts-of-line and selecting the additional parts-
of-line in the CONTROL MODE.
FALLS indicates that a selection for the number of parts-of-line has been made
that exceeds the maximum number permitted by the crane’s rated
capacity chart(s) for the winch selected.
TEST indicates that the system is in its “self-test” mode. The system will, in
the event of a successful test, return to the normal, working display
upon completion of the self-test.
TARE indicates that the TARE function has been selected and is in operation.
Additionally, eight optional input switches are available, as necessary to a particular crane.
These can include swing switches, counterweight position switches, etc.

DISPLAY NOTES
1) Load and rated capacity are displayed to:
TWO decimal places, in the range from 0.00 to 9.99
ONE decimal place, in the range from 10.0 to 99.9
NO decimal place, in the range from 100 to 9999
2) The bar graph only shows from 0% to 120%. Any further excess will not be shown.
3) The rated capacity will display 0.00 if a correct rated capacity cannot be found, or if the
system detects a fault.
4) The angle display will normally show the main boom angle (Aº) but will show the luffing
jib angle (0º) when the system is fitted with such, and when that duty is selected.
5) The boom length display (L) refers only to the main boom and does not include any
extensions or jibs.
6) The height display refers only to the main boom.
7) F1 or F2 are normally displayed to indicate with which winch the duty is associated.
 LOADWISE MODEL 503 RATED
503 CAPACITY INDICATOR SYSTEM
FAULT CODES
When the word FAULT appears on the third line of the display, all the warning lamps will be
“ON” and the capacity is reduced to ZERO.

To access the fault listing, push the “TEST” button and then push the “ALT” button.

The display will then look like the illustration below.

F L/H ALT

+ TEST

TARE DEDUCT DUTY

LOADWISE 500

Lines 1 and 3 will display those switch inputs that are in use and whether they are open or
closed. To check which switches are programmed to be in service, consult the DUTY
SELECTION PLATE located in the crane cab. This plate will show, at the bottom, the
program number and the switch(es) used.

Lines 2 and 4 will display the sensor conditions. When the sensor is connected and is
within the range required by the system, a “check mark” will appear. An “X” means the
system is not receiving correct signals; in this case, the wiring to the applicable sensor, or
the sensor itself, must be checked out.

Standard sensor inputs include:

W1 (1st load sensor) A1 (main boom angle sensor) L1 (main boom length sensor)
W2 (2nd load sensor) A2 (luffing jib angle sensor) L2 (2nd boom length sensor)