1. On-Board Safety Systems
Lifting With Your SPYDERCRANE
KBT 5.2
Welcome to KBT 5.2, On-Board Safety Systems of your SPYDERCRANE Micro-Crawler

2. Topic Overview and Contents
This Topic (On-Board Safety Systems) is designed to provide you with an overview of the various safety systems and operator aids of your SPYDERCRANE
You will learn about:
The MINIMUM WIRE ROPE SAFETY
The ANTI-TWO BLOCK (A2B) SYSTEM
The BOOM STOW SAFETY
The VOICE WARNING SYSTEM (VWS)
The AUDIBLE ALERT SYSTEM (AAS)
The CRANE MANAGEMENT UNIT (CMU) CODE INDICATOR
The EMERGENCY STOP
The HOOK SAFETY LATCH
The SAFETY HORN
The Load Meter
The ENGINE HOUR METER
This Lesson Topic covers all of the various safety systems and operator aids your SPYDERCRANE Micro-Crawler is equipped with. This Lesson Topic specifically covers the 094-, 095- and 200-Series SPYDERCRANE.
It is YOUR RESPONSIBILITY to read and understand the user manuals included with your SPYDERCRANE and the warning decals posted on it
This Lesson Topic covers the 094-, 095- and 200-Series SPYDERCRANE

3. Learning Objective(s)
The learning objectives for this Lesson Topic are for each student to…
DLO 5.2.1: Explain the purposes of the MINIMUM WIRE ROPE SAFETY.
DLO 5.2.2: Explain the purpose of the ANTI-TWO BLOCK SAFETY.
DLO 5.2.3: Explain the purpose of the BOOM STOW SAFETY.
DLO 5.2.4: Explain the purpose of the VOICE WARNING SYSTEM.
DLO 5.2.5: Explain the purpose of the AUDIBLE ALERT SYSTEM.
DLO 5.2.6: Explain the purpose of the CRANE MANAGEMENT UNIT CODE INDICATOR.
The learning objectives for this lesson segment involve all of the onboard safeties and operator aids of the SPYDERCRANE Micro-Crawler.

4. Learning Objective(s)
The learning objectives for this Lesson Topic are for each student to…
DLO 5.2.7: Explain the purpose of the EMERGENCY STOP.
DLO 5.2.8: Explain the purpose of the HOOK SAFETY LATCH.
DLO 5.2.9: Explain the purpose of the SAFETY HORN.
DLO : Explain the purpose of the LOAD METER.
DLO : Explain the purpose of the ENGINE HOUR METER.
The learning objectives for this lesson segment involve all of the onboard safeties and operator aids of the SPYDERCRANE Micro-Crawler.

5. The Minimum Wire Rope Safety
The MINIMUM WIRE ROPE SAFETY is installed in the Boom Turret, forward of the Wire Rope Drum
It is designed to function kick-out the WINCH DOWN command when triggered
The safety is tripped when there is between 3 to 5 turns of wire rope left on the drum
The Minimum Wire Rope Safety has ONE purpose:
It prevents you from unspooling all of the wire rope when WINCHING DOWN
    The MINIMUM WIRE ROPE SAFETY is installed in the boom turret, forward of the wire rope drum.  It is designed to disable (function kick-out) the WINCH DOWN command when activated. The safety is composed of two components: the function kick-out switch and a spring-loaded spoon that presses against the spooled wire rope and trips the kick-out switch when the amount of wire rope spooled on the drum is reduced to a certain level.
    The safety activates when there are between 3-5 turns of wire rope remaining on the wire rope drum.  This prevents the wire rope from being completely un-spooled from the drum when the operator commands a WINCH DOWN.  
    The PURPOSE of the Minimum Wire Rope Safety is to prevent you from un-spooling all of the wire rope from the wire rope drum of your SPYDERCRANE when WINCHING DOWN.
The Minimum Wire Rope Safety can be bypassed via the Overwind Override Switch

6. The Anti-Two-Block (A2B) System
The A2B SYSTEM is designed to disconnect (function kick-out) the HOIST and BOOM OUT commands when activated
The A2B System is connected to the A2B BOOM Switch
A2B Switch Closed
A weight is hung from the end of the spring-loaded switch, holding it OPEN
When the hook is raised to within a couple of feet of the boom tip, it hits and lifts the weight up, which causes the A2B Switch to CLOSE, activating the system
Which disconnects the HOIST and BOOM OUT commands
   When you are commanding a crane (any crane) and you HOIST the hook to the point where it impacts the boom-tip, you are TWO-BLOCKING, where the hook represents one block and the tip of the boom represents the other block. Smashing the two blocks together, or two-blocking, can cause enormous damage to the crane and can lead to the hook separating from the wire rope and dropping both the hook (and the attached load). To prevent this, every crane, and related lifting system, is equipped with an ANTI-TWO BLOCK (A2B) SAFETY.       
    The A2B Safety is installed at the heart of the SPYDERCRANE. When the A2B Safety is ACTIVATED, the SPYDERCRANE's Crane Management Unit (CMU) disables the HOIST and BOOM OUT commands. 
    At the end of the SPYDERCRANE's boom-tip is the A2B SWITCH. The A2B Switch is spring-loaded and WHEN CLOSED it activates the A2B Safety. To hold the switch open, a small, hollow weight called the A2B WEIGHT is suspended from the switch by a 2 ft. lanyard. When the A2B Switch is held in the open position the A2B Safety is DEACTIVATED.
   As long as the SPYDERCRANE's hook is freely suspended BELOW the A2B Weight, the A2B Safety will remain deactivated. If you command a HOIST, the hook will strike and then lift the A2B Weight, which will release the A2B Switch, allowing it to close (and activated the A2B Safety). 
    The PURPOSE of the A2B System is to prevent two-blocking. 
A2B Switch Open
The A2B System has ONE purpose:
It prevents the hook from smashing into the boom tip with enough force to begin pulling apart the wire rope

7. The Boom Stow Safety
The BOOM STOW SAFETY is designed to disconnect (function kick-out) the SLEW command when activated
The Boom Stow Safety is a whisker switch attached to the back of the HYDRAULIC OIL TANK of the Micro-Crawler
You command a SLEW LEFT to lock the boom into the Boom Stow Safety as the final step in the HOOK AND BOOM STOWING PROCEDURE
This will place the boom in the Stowed Position and disconnect the SLEW commands
To UNSTOW the boom you must command a BOOM UP
    The BOOM STOW SAFETY is a whisker switch installed on the back of the SPYDERCRANE's hydraulic oil tank. When the Boom Stow Safety is ACTIVATED, the SLEW command is disabled. To activate the safety, the switch must be pressed. 
    When the SPYDERCRANE's boom is properly stowed, the LIFT CYLINDER GUARD will press against the switch and activate the safety. 
    The PURPOSE of the Boom Stow Safety is to prevent the boom from being SLEWED while it is in its stowage position AND to help you properly stow the SPYDERCRANE's boom when transitioning the SPYDERCRANE from Crane Mode to Travel Mode.  
The Boom Stow Safety has ONE purpose:
To prevent the boom from being slewed into the SPYDERCRANE or the operator when it is stowed

8. The Voice Warning System (VWS)
The VOICE WARNING SYSTEM (VWS) provides plain-English spoken warnings and operational status updates; it is part of the Crane Management Unit (CMU)
It’s purpose to communicate the SPYDERCRANE’s operational state to you, through nine specific messages
We will cover these Voice Warning Messages as they occur as part of normal lifting (and deploying) operations
“Crane Mode”
“Outrigger Mode, Outriggers Moving”
“Stop, Winch Up”
“Remote Control Ready”
“Check Error Code”
“Change Control Mode”
“Low Transmitter Battery”
“Service Remote Control”
“Secure Lifting Hook”
    The VOICE WARNING SYSTEM (VWS) provides plain-English spoken warnings and operational status updates; it is part of the Crane Management Unit (CMU).
    The PURPOSE of the VWS is to communicate the SPYDERCRANE's operational status to you through nine specific messages:
"Crane Mode, Crane Mode..."
The TCB has been lowered into the Crane Setting and the SPYDERCRANE is in Crane Mode.
"Outrigger Mode, Outriggers Moving..."
The SPYDERCRANE has been placed into Outrigger Mode.
"Stop; Winch Up..."
The A2B System has been activated
"Remote Control Ready..."
The SPYDERCRANE has been placed under Remote Control.
"Check Error Code..."
The CMU is reporting a specific error code; check the CMU CODE INDICATOR.
"Change Control Mode..."
For Micro-Crawlers, this is a general reporting phrase that is signaled when the operational status of the SPYDERCRANE has changed; not an error.
"Low Transmitter Battery..."
The batteries in the Radio Remote Controller have less than 10% power remaining and should be changed.
"Service Remote Control..."
The CMU is reporting an error in the Remote Control Group (RCG).
"Secure Lifting Hook..."
The SPYDERCRANE is storing the hook into its stowed position. 

9. The Audible Alert System (AAS)
The AUDIBLE ALERT SYSTEM (AAS) provides audible warning through single-, or multi-tone signals that communicate the SPYDERCRANE’s operational state; it is generated by the CMU
It’s purpose to communicate the SPYDERCRANE’s operational state to you, through five specific alerts
We will cover these Audible Alerts as they occur as part of normal lifting (and deploying) operations
Battery Engaged Alert
CMU POST Alert
A2B Alert
    The AUDIBLE ALERT SYSTEM (AAS) provides audible warning through single-, or multi-tone signals that communicate the SPYDERCRANE’s operational state; it is part of the CMU.
    The PURPOSE of the AAS is to communicate the SPYDERCRANE’s operational state to you, through five specific alerts:
BATTERY ENGAGED ALERT
A two-tone signal that the battery has been engaged.
CMU BOOT/POST ALERT
A two-tone signal that indicates that the CMU has completed its boot-up and Power-On-Self-Test sequence.
A2B ALERT
A two-tone alert that precedes the "Stop; Winch Up..." VWS message when the A2B System has been activated.
REMOTE CONTROL ALERT
A two-tone signal that the SPYDERCRANE is under Remote Control. 
OUTRIGGER MODE ALARM
A constant beeping sound that signals that the SPYDERCRANE is in Outrigger Mode.
Remote Control Alert
Outrigger Mode Alarm

10. The CMU Code Indicator
The CMU CODE INDICATOR is a visual operator-alerting system that generates two-digit numerical codes that correspond with an operational condition of the SPYDERCRANE
The CMU will ALWAYS generate a code as long as it is powered up and it uses a three-stage priority system to display the most important codes
In this example, there are no errors being reported and the SPYDERCRANE is in Crane Mode (Manual), so it is displaying the CMU Code of “01;” if the SPYDERCRANE were in Crane Mode (Remote) it would display “00”
For Micro-Crawlers, the Code Indicator is on the front half of the carrier, on the curbside
    The CRANE MANAGEMENT UNIT (CMU) is the SPYDERCRANE's central diagnostics and management computer. The CMU CODE INDICATOR is a visual operator aid that displays operational and error messages generated by the CMU. 
    The messages created by the CMU and displayed by the CMU Indicator are rendered as two-digit numerical codes that you can be interpret.  The CMU Code Indicator ALWAYS displays a code, but, uses a priority system to ensure that higher priority operational and error codes are displayed over routine codes.
    The PURPOSE of the CMU Code Indicator is to report the SPYDERCRANE's operational status without the use of audible alarms. In some cases, the CMU will report an error to you through the AAS and VWS ("Check Error Code") and you can get the specific error by reading the CMU Code Indicator.
The Code Indicator has ONE purpose:
To communicate the SPYDERCRANE’s operational status to the operator

11. The CMU Code Priority System
Since the Indicator can only display a single code at-a-time, a priority system ensures that more critical messages are shown instead of routine operating codes
In this case, the Micro-Crawler is in Crane Mode (Remote),which is a routine condition with a low-priority message
When the Tipover Prevention Device (TPD) signals a WARNING CONDITION it generates a higher-priority message of Code 16 (we will cover the TPD in a later lesson)
When the TPD signals a LOCKOUT CONDITION, the CMU generates a Code 15 which carries the second highest priority level
The CMU Code Indicator is ALWAYS displaying a code, and it uses a priority system to make sure that only the most important code is displayed at any given time.
As Code 15 has a higher priority than either 00 or 16, it is displayed on the Code Indicator

12. Example CMU Codes
A partial listing of the most common CMU Codes is posted as an informational decal next to the Code Indicator
A full listing of all the assigned CMU Codes (not all 99 possible codes are used) can be found in the UNIC Operator’s Manual or the SLS Quick-Start Guide
These are some example CMU Codes. A full listing of the CMU Codes can be found in the Operator’s Manual and Quick Start Guide for your SPYDERCRANE

13. The Emergency Stop
The EMERGENCY STOP is designed to stop the motor of the SPYDERCRANE during emergencies
The Emergency Stop (or, E-Stop) is located at the front of the SPYDERCRANE’s carrier, near the CCG and OCG
The E-Stop is a mechanical switch held in closed position (maintaining an electrical circuit with the motor)
When pushed, the E-Stop button collapses into the open position (disrupting the circuit) and the Emergency Stop is ACTIVE
While the E-Stop is active, the battery is still connected (the CMU remains powered, but, the engine CANNOT be re-started
    The EMERGENCY STOP (or E-STOP) is an over-sized, visually-unique slam-switch that, when pressed, shuts down the engine of the SPYDERCRANE. 
    When pressed, the E-Stop prevents the SPYDERCRANE's engine from running, or being re-started. With the engine off, the hydraulic system will lock the SPYDERCRANE in whatever configuration it was in when the E-Stop was activated. 
    The PURPOSE of the E-Stop is to safely shut down the SPYDERCRANE under emergency conditions.
The SPYDERCRANE will lock into the last position; the boom and outriggers are fixed in-position and WILL NOT collapse as the hydraulic oil flows back into the hydraulic oil tank
The Emergency Stop has ONE purpose:
To kill the motor of the SPYDERCRANE during an emergency; it should NEVER be used as on/off switch

14. The Hook Safety Latch
The HOOK SAFETY LATCH is a part of EVERY hook used by the SPYDERCRANE
It is a spring-loaded gate designed to close the hook and secure the rigging
The Hook Safety Latch is an inspectable item: if it is broken, the hook CANNOT be legally used
The Hook Safety Latch has ONE purpose:
To secure the rigging of the load when it is lifted by the hook
    The HOOK SAFETY LATCH is a part of EVERY hook used by the SPYDERCRANE and is an OSHA-required safety device for all hoisting hooks. The latch is a spring-loaded gate designed to prevent the rigging from slipping off of the hook. 
    The PURPOSE of the Hook Safety Latch is to secure the load when it is rigged to the hook.

15. The Safety Horn
There are two SAFETY HORNS on your SPYDERCRANE, one is part of the Travel Control Group (TCG) and the other is part of the Outrigger Control Group (OCG)
The Safety Horn is a basic audible alert system with a brightly marked button
The Safety Horn has ONE purpose:
To warn bystanders that the SPYDERCRANE is moving
The TCG Safety Horn
The OCG Safety Horn
    Another OSHA-required safety warning device, the SAFETY HORN emits a loud single-tone alarm when activated. You would use the Safety Horn to warn bystanders when you are using the SPYDERCRANE.
    Your SPYDERCRANE Micro-Crawler has TWO Safety Horn buttons. One is at the rear of the SPYDERCRANE, as part of the Travel Control Group (TCG). The other is at the front, as part of the Outrigger Control Group (OCG). The Remote Controller also has a Safety Horn button. 
    The PURPOSE of the Safety Horn is warn bystanders. 

16. The Load Meter
The Load Meter is located on the front of the SPYDERCRANE’s carrier, next to the E-Stop
The Load Meter measures the amount of hydraulic pressure (load) is being applied when HOISTING
Is only accurate when the operator is slowly applying power to the HOIST command
Just as the load is being lifted off of the ground, the Load Meter will provide the approximate weight
Difficult to use practically
    The LOAD METER (sometimes, referred to as a WEIGHT GAUGE) is located at the front of the SPYDERCRANE, near the Crane Control Group (CCG). It is a analog hydraulic strain gauge that measures the amount of hydraulic power being applied to the HOIST command. 
    To use the Load Meter, you must command a HOIST to remove the slack from the rigging to the load. Then, you must SLOWLY apply HOIST power incrementally while reading the gauge. Eventually, you will apply an amount of hydraulic power equivalent to the weight of the load (equilibrium).  When this occurs, the needle of the meter will point to the approximate weight of the attached load. 
    As a practical matter, the Load Meter is fairly difficult to use and is only equipped to the SPYDERCRANE for the rare instances when you don't know the weight of the load you must lift.
    The PURPOSE of the Load Meter is to give you an indication of the amount of hydraulic pressure being applied to the load in order to determine its approximate weight.
The Load Meter has ONE purpose:
To provide a general indication of how much hydraulic pressure is being applied at the lift

17. The Engine Hour Meter
The ENGINE HOUR METER is located on the front of the SPYDERCRANE’s carrier, below the OCG
The Engine Hour Meter is an analog meter that displays the amount of time that the battery is engaged
The Engine Hour Meter measures in hours and tenths of hours
The Engine Hour Meter has ONE purpose:
    Installed at the front of the SPYDERCRANE, next to the Hook Store and Overwind Override Switches, the ENGINE HOUR METER lists the number of hours and fractions of hours that the battery of the SPYDERCRANE's engine has been engaged. Like an odometer, the Engine Hour Meter is designed to provide you with metric for scheduling preventative maintenance and servicing for your SPYDERCRANE. 
    The PURPOSE of the Engine Hour Meter is provide you with an indication of the SPYDERCRANE's state-of-use in order to schedule servicing and preventative maintenance.
To display the SPYDERCRANE’s total running time, in order to schedule Preventative Maintenance