Crane Info Gr No

Crane Info
4 8 1
Page Date Product

1:22 08.97 BOSS

ES
MANUAL DE TALLER

BOSS
BASIC OVERLOAD SAFETY SYSTEM
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HIAB

BOSS MK II

Basic Overload Safety System

Contents:

1.0 System description

2.0 Components
2.1 Parts in the components

3.0 Function description.

4.0 Connection diagrams

5.0 Adjustment of BOSS MK II

6.0 Trouble shooting

BOSS MK II folder GB 04.09.96

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HIAB
1.0 System description

HIAB BOSS MK II system is a microprocessor based electronic/hydraulic overload

safety system, which is designed for the light cranes with a lifting capacity above
1000 kg. Included in the system is also an emergency stop function. The system will
warn the operator, and bystanders, as the crane reaches 90% of maximum lifting
capacity and block all dangerous crane movements as the crane reaches its maximum
capacity.

2.0 Components
U
HIAB BOSS system "Components" Appendix 1

Spool indicator
5/6
Spool switch

Dump valve
4

1
Control box I

2
Control box II

3
Pressure transducer
12/24 V DC

23.02.96

Pos. 1 Control box I, which is situated near the crane control valve.

Pos. 2 Control box II, which is situated near the cross control handles.
Control box II is only fitted to cranes with cross control.

Pos. 3 Pressure transducer, which is installed in the inner boom cylinder,

to sence the hydraulic pressure.

Pos. 4 Dump valve, which is installed on the control valve (only PTO
driven cranes).

Pos. 5 Spool indicators, which are mounted on the control valve

(articulated cranes only).
or
Spool switches, which are mounted on the control valve
(stiff boom cranes only).

BOSS MK II folder GB 04.09.96

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2.1 Parts in the components.
HIAB
Control box I, which is the heart of the BOSS system consist of the following
main parts:
1 2

5
3 2
4

Pos. 1 On/off and release button.

Pos. 2 Emergency stop button.

Pos. 3 Buzzer.

Pos. 4 Signal lamps.

Pos. 5 Fuse (3,15 amp.).

Pos. 6 Print board with microprocessor.

Control box II, which is an extra box for cranes which are controlled from both
sides of the vehicle, consist of the following main parts:
2
1

3 2
4

Pos. 1 On/off and release button.

Pos. 2 Emergency stop button.

Pos. 3 Buzzer.

Pos. 4 Signal lamps.

BOSS MK II folder GB 04.09.96

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HIAB
The pressure transducer, which is installed in the inner boom cylinder, is the
same transducer as in the MiniSPACE system. The pressure transducer
measure the hydraulic pressure in the inner boom cylinder and transfer that
information to the BOSS microprocessor.

The dump valve, which has two different executions, which is the build in type
and the external type.

Pos. 1 Solenoid.

Pos. 2 Hydraulic valve.

Build in type External type

1
2

Spool indicators/spool switches are mounted onto the inner boom and the
extension valve sections on the control valve.

Spool indicator
Spool switch
Spool switch

BOSS MK II folder GB 04.09.96

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3.0 Function description
HIAB
3.1 Use of crane

3.1.1. Start the truck and engage the PTO pump, or switch on the main switch for the
12/24V power pack.

3.1.2. Start the crane by pressing the on/off button on one of the control boxes.

3.1.3. The crane can now be operated normally until 90 % of maximum pressure is
reached in the inner boom cylinder. When the capacity exceed 90 % the nine
red signal lamps will flash intermittent and the buzzer will buzz intermittent.

3.1.4. If the load on the crane reaches maximum capacity, the nine red lamps will
light constantly and the buzzer will buzz constantly.

3.1.5.1. PTO driven pumps.

The power signal to the dump valve will now be switched off, allowing
the oil flow to circulate from the pump through the dump valve to the
tank, without circulating through the crane control valve.

3.1.5.2. 12/24V DC power packs.

The power to the 12/24 V DC motor will now be switch off so the oil
circulation is stopped.

3.1.6. To move the crane out of this locked position, you can now choose
between the following alternatives:
A. Retract the extension cylinder.
B. Lower or raise the inner boom. This can only be done with
within approx. 105 % of the normal capacity, and it can only be
done at a very slow speed.
C. Press the release button and move the crane in any direction
(extending the extension cylinder is not possible) for a period
of five seconds (no more is possible). This operation can be
repeated after thirty seconds.

3.1.7 When the job is finished, stop the crane by pressing the
on/off button. Switch off the 12/24V power pack or disengage
the PTO pump.

BOSS MK II folder GB 04.09.96

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HIAB
OR
OR

OR
OR

POWER PACK NOTE!

UNIT WITH THERMO FUSE

LEG 2 LEG 1 EXTEN LIFT SLEW OR

OR
OR
RELAY

OR

OR

OR MOUNTING DESCRIPTION
HIAB STIFF-BOOM WITH
ELECTRICAL POWERPACK
CABLES FROM BOSS
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HIAB

OR

OR

OR

NOTE!

EXTEN LIFT OR

OR OR
12 OR 24 V DC

OR

MOUNTING DESCRIPTION
HIAB STIFF-BOOM
PTO
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BLUE + BLACK TERMINALS IS OLP FUNCTION
PRESSURE SENSOR
HIAB
BROWN + YELLOW/GREEN IS ROPE END FUNCTION

1
DUMP-VALVE
OR

OR OR
3

4 3 2 1

OR OR 1 OR OR OR OR
12 OR 24 V DC
OR OR
2 OR

OR OR OR 2 OR
4

54 3 2 1 54 3 2 1

WINCH BOX
24 V DC

EXTEN
1 OR

WINCH

2 OR 3 OR EXTEN LIFT
OR OR OR OR
WINCH

2 1
WINCH

LIFT

DRAINHOLE DOWNWARDS

BOSS MK 2.1
WIRE CONNECTING DIAGRAM
HIAB 027/035/045/052
WINCH
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BLUE + BLACK TERMINALS IS OLP FUNCTION
BROWN + YELLOW/GREEN IS ROPE END FUNCTION PRESSURE SENSOR HIAB
DUMP-VALVE

OR

OR 12 OR 24 V DC
OR

OR

OR
OR

WINCH BOX
24 V DC

OR OR
EXTEN WINCH

WINCH

LIFT

DRAINHOLE DOWNWARDS

HIAB 027/035 WINCH

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HIAB

1
OR

2
OR

COLUMN
SEEN FROM ABOVE

OR

3
OR

4
CLOCKWISE SENSOR

OR

4 3 2 1
OR OR OR OR
12 OR 24 V DC
OR OR

OR

54 3 2 1 54 3 2 1

LIFT

SLEWING

1 OR EXTEN

2 OR 3 OR EXTEN

SLEWING

DRAINHOLE DOWNWARDS
LIFT

BOSS MK 2.1
WIRE CONNECTING DIAGRAM
HIAB 027/035/045/052
OLP STABILITY
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HIAB
OR

12 OR 24 V DC
OR OR

OR

NOTE!
54 3 2 1 54 3 2 1

1 OR

NOTE!
EXTEN

2 OR
EXTEN LIFT

3 OR OR

LIFT

DRAINHOLE DOWNWARDS

BOSS MK 2.1
WIRE CONNECTING DIAGRAM
HIAB 027/035/045/052
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HIAB
OR

12 OR 24 V DC
OR OR

OR

NOTE!
54 3 2 1 54 3 2 1

NOTE!

EXTEN

LIFT

DRAINHOLE DOWNWARDS

HIAB 027/035
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HIAB
OR

12 OR 24 V DC
OR OR OR

OR NOTE!
OR

NOTE!

NOTE!

DRAINHOLE FORWARDS

EXTEN

LIFT

HIAB 022/027/032/035 LT
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5.0 Adjustment of BOSS MK II system.
HIAB
The system has 2 multi-turn adjustments, where only"P" is in use (the"A"is a spare one for
additional functions).
Both are situated in the metal box close to the terminals 28 and 29.
Since the 90 % level automaticly follows the OLP level there is only one adjustment nessesary,
that is the OLP level (100 % ).
The multi-turn adjustment to be turned is the"P" which is farest away from the emergency stop
switch.

ADJUSTMENT:
There are two ways in which the system can be adjusted:

1) Exactly as the BOSS MK I system, that is by loading the crane and turning the
adjustment slowly until the OLP cuts you off.
2) When connecting the external power cable to the main box press the on/off button
simultanuously. This places the system in “adjustment mode”
removing all filters anddampers. This makes it possible
to adjust the system very exactly. After finishing
the adjustment just disconnect the power cable
and connect again. This brings the system back
to normal mode.

SELF TEST:
When the system is switched on it is automaticly
testing itself to see if there are any missing or faulty functions.
If there is any faults, the system will not start, and there is a quick intermittent warning
signal.

TEST FUNCTIONS:
If there is a fault on the system, it can easilly be located in the following way:
1) Press the emergency button.
2) Press or move any function containing switches or indicators (Including ON/OFF button)
The system will now make a quick “beep” when the function is activated/deactivated, if
the function is without faults.

RELEASE FUNCTION:
When using this function the crane can be operated in 5 sec. (Except function “extension out”)
The release function can only be used once. After that the operator has to wait 30 sec. if it is
nessesary to use the function a second time. During the waiting time the light in the green LED is
cut off to indicate that the crane can not be operated.

BOSS MK II folder GB 04.09.96

 HIAB BOSS system "Normal Working Position" Appendix 2

Green light

Less than 90 %
of
Max Load

= Possible to move in that direction.

= Possible to move in that direction

within approx. 105 % of max. capacity.
= Not possible to move in that direction.

23.02.96
= Possible to move in that direction for
5 sec.
 HIAB BOSS system "90 % Load Position" Appendix 3

Flashing red light

Buzz!Buzz!

90 %
of
Max Load

= Possible to move in that direction.

= Possible to move in that direction

within approx. 105 % of max. capacity.
= Not possible to move in that direction.

23.02.96
= Possible to move in that direction for
5 sec.
 HIAB BOSS system "Max Load Position" Appendix 4

Constant red light

Constant Buzz !

Max Load

= Possible to move in that direction.

= Possible to move in that direction

within approx. 105 % of max. capacity.
= Not possible to move in that direction.

23.02.96
= Possible to move in that direction for
5 sec.
 HIAB BOSS system "Release Position" Appendix 5

Flashing red light

Buzz!Buzz!

Max Load

= Possible to move in that direction.

= Possible to move in that direction

within approx. 105 % of max. capacity.
= Not possible to move in that direction.

23.02.96
= Possible to move in that direction for
5 sec.
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HIAB

BOSS MK 2.1

Basic Overload Safety System

El sistema HIAB BOSS MK 2.1 es el nuevo desarrollo del sistema HIAB BOSS
MK 2. Para las instalaciones estándar no habrá diferencia en el sistema de control
ni en los diseños de las cajas, etc. comparándolas con los sistemas HIAB BOSS
MK 2.

Se ha producido los siguientes cambios respecto a la versión HIAB BOSS MK 2:

- Se ha montado un fusible para evitar daños exteriores, como un

cortocircuito de cables, en sensores de corredera
o sensores de presión, etc.

Fusible

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BOSS MK 2.1 tillæg ES 30.04.98

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HIAB
- La capacidad del microprocesador ha sido incrementada para poder establecer
una limitación de carga en la zona instable del camión "OLP sector de
estabilidad". La capacidad de elevación en este
sector se podrá ajustar entre el 30%-100% de
la capacidad de trabajo.
Ajustar con un
destornillador en A

Zona de capacidad reducida

Zona de capacidad estándar

- Los sensores de corredera han sido rediseñados, son finales de carrera axiales
en las grúas articuladas y radiales en las grúas de brazo rigido.

Tipo axial Tipo radial

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BOSS MK 2.1 tillæg ES 30.04.98

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HIAB
- Las electroválvulas irán montadas sobre el propio distribuidor en el caso de
las grúas articuladas y del tipo externo para las grúas de brazo rigido.

Tipo construcción interna

Tipo externo

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BOSS MK 2.1 tillæg ES 30.04.98