Cattron North America 7700T15 Industrial Remote Control Transmitter User Manual Toggle Controller Manual Rev 006a

Laird Controls North America Inc. Industrial Remote Control Transmitter Toggle Controller Manual Rev 006a

user manual

 ©02/2010, CATTRON-THEIMEG™     - i -  TOGGLE CONTROLLER OPERATION & MAINTENANCE INSTRUCTIONS   CUSTOMER: MODEL NUMBER: SERIAL NUMBER: FREQUENCY ASSIGNMENT: ADDRESS ASSIGNMENT: MANUAL P/N:           68C-Toggle Rev. 006, 02/2010
 ©02/2010, CATTRON-THEIMEG™     - i -  FCC and IC Statements FCC and IC labeling can be found inside the user accessible lid of the battery compartment where it is protected from damage. FCC Warning Statements Changes or modifications not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment For Low Power License Exempt Units FCC Warning Statements Note: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant  to  part  15  of  the  FCC  Rules.  These  limits  are  designed  to  provide  reasonable  protection against  harmful  interference  when  the  equipment  is  operated  in  a  commercial  environment.  This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance  with  the  instruction  manual,  may  cause  harmful  interference  to  radio  communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.  This  device  complies  with  Part  15  of  the  FCC  rules.  Operation  is  subject  to  the  following  two conditions: (1) This device may not cause harmful interference, and (2) This device must accept any interference received, including interference that may cause undesired operation. IC Warning Statements This device complies with Industry Canada license-exempt RSS standard(s). Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device. Le présent appareil est conforme aux CNR d'Industrie Canada applicables aux appareils radio exempts de licence. L'exploitation est autorisée aux deux conditions suivantes : (1) l'appareil ne doit pas produire de brouillage, et (2) l'utilisateur de l'appareil doit accepter tout brouillage radioélectrique subi, même si le brouillage est susceptible d'en compromettre le fonctionnement This Class A digital apparatus complies with Canadian ICES-003. Cet appareil numérique de la classe A est conforme à la norme NMB-003 du Canada
 ©02/2010, CATTRON-THEIMEG™     Page ii IMPORTANT NOTICES Your new Toggle Controller has been pre-configured to operate on a specific frequency before leaving our factory which cannot be changed by yourselves.  We have assigned this frequency based upon our existing  records  of  control  equipment  previously  supplied  to  yourselves.    However,  we  strongly recommend you satisfy yourselves that the frequency of your toggle controller does not match that of any other radio remote control system located at, or around, your operating facility.       WARNING: CATTRON-THEIMEG™ MAKES  EVERY  EFFORT  TO  ENSURE  THE ADDRESS  ASSIGNED  TO  YOUR  NEW  CONTROL  SYSTEM  IS  NOT DUPLICATED  BASED  UPON  RECORDS  WHICH  INDICATE  THE ADDRESSES OF ALL PAST PORTABLE RADIO REMOTE CONTROL (PRRC) SYSTEMS AS SHIPPED FROM OUR FACILITY TO YOURS.   THEREFORE IT SHOULD BE FULLY UNDERSTOOD THAT WHEN A PRRC SYSTEM  HAS  LEFT  OUR  FACTORY,  CATTRON-THEIMEG™  HAS  NO CONTROL  OF  THE  ADDRESS  ASSIGNMENTS  OF  ANY  OTHER  PRRC SYSTEM(S) THAT MAY BE IN OPERATION IN CLOSE PROXIMITY WITHIN YOUR OPERATING AREA.   CONSEQUENTLY,  AND  PURSUANT  TO  THE  ABOVE  STATEMENT, CATTRON-THEIMEG™  SHALL  NOT  BE  HELD  LIABLE  FOR  PERSONAL INJURY, DEATH,  EQUIPMENT OR  PROPERTY DAMAGE ARISING FROM DUPLICATED ADDRESSES OF RADIO CONTROL SYSTEMS.  This  equipment  is  firmware  based,  including  encoder,  decoder,  transmitter,  and  receiver.  Any duplication of operating firmware without written consent of CATTRON-THEIMEG™ is prohibited.  All firmware, product listings, assembly files, and this manual are protected by U.S. Copyright Laws.   This manual has been prepared by Stuart C. Banks  MSTC (USA), MISTC (UK) CATTRON Group® International Technical Writer/illustrator.
 ©02/2010, CATTRON-THEIMEG™     - iii -  List of Technical Abbreviations The following abbreviations (acronyms) are frequently used in CATTRON-THEIMEG™ Radio Remote Control Technology and may be used in this manual:   AC  Alternating Current    LED  Light Emitting Diode ASO  Automatic Safety Override   MK  Metal Keypad BCH  Bose-Chaudhuri-Hocquenghem (data error detection routines)   ML  Mainline CMOS  Complimentary Metal Oxide Semiconductor    NEMA  National Electrical Manufacturer’s Association CS  Crane Specific    Ni-Cad  Nickel Cadmium DC  Direct Current    OPR  Operate DOC  Department of Communication    PRC  Portable Remote Control DP  Dual Pressure    PTO  Push-to-Operate  EDP  Electronic Data Processing    RF  Radio Frequency EEPROM  Electrically Erasable Programmable Read Only Memory   RFI  Radio Frequency Interference EMI  Electro-Magnetic Interference    RST  Reset Relay EOT  Electrical Overhead Tracked    SP  Single Pressure EPROM  Erasable Programmable Read Only Memory    SYNC  Synchronization FCC  Federal Communications Commission    TP  Test Point GND  Ground    TS  Transfer Switch I/O  Input/Output    VAC  Volts Alternating Current  IR   Infra-red    VDC  Volts Direct Current  LCD  Liquid Crystal Display    VFD  Variable Frequency Drive
 ©02/2010, CATTRON-THEIMEG™     Page iv Introduction How to use this Manual. This manual contains generic operation and maintenance procedures applicable to the entire series of CATTRON-THEIMEG™ Radio Remote Toggle Controllers.    Because no  two  Toggle Controllers  or  Portable Remote Control (PRC)  applications are exactly the same, a General Operating Procedure is included in Section 3.  This procedure is followed by Operator Instructions  for  the  three  most  popular  control  applications:  (1)  Cranes,  (2)  Locomotives,  and  (3) Railroad Ballast Cars.  By selecting the application (1), (2) or (3) closest to  your PRC system, you should be able to familiarize yourself with the basic operating procedures and control functions that apply to your system.   We  emphasize  that  safety  considerations  are  paramount  when  using  portable  remote  controllers.  Accordingly,  Section  2  should  be  read  in  its  entirety.    Also,  for  your  consideration  and  possible adoption, Recommended Safety Rules for Remote Controlled Cranes, and Recommended Safety Rules for Radio Remote Controlled Locomotives are provided as an addendum at the end of this manual.
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 ©02/2010, CATTRON-THEIMEG™     Page vi Safety Summary  WARNING  and  CAUTION  statements  have  been  strategically  placed  throughout  all  text  prior  to operating or maintenance procedures, practices or conditions considered essential to the protection of personnel (WARNING), or equipment and property (CAUTION).  A WARNING and CAUTION will apply each time the related step is repeated.  Before starting any task, the WARNINGS or CAUTIONS included in the text for the task shall be reviewed and understood.  All WARNINGS and CAUTIONS appearing in this manual are included below. WARNINGS.     WARNINGS: WITH  THE  EXCEPTION  OF  LOCOMOTIVES,  ALL  EQUIPMENT  MUST HAVE A MAINLINE (ML) CONTACTOR INSTALLED AND ALL TRACKED EQUIPMENT (i.e. CRANES) HAVE A BRAKE INSTALLED. THE  REMOTE  CONTROL  OPERATE  (OPR)  RELAY  MUST  BE CONNECTED  TO  THE  MAINLINE  SO  THAT  STOP  COMMANDS  OR FAULT CONDITIONS MONITORED BY AUTOMATIC SAFETY OVERRIDE (ASO)  CIRCUITRY  WILL  DE-ENERGIZE  THE  MAINLINE  CONTACTOR AND SET THE EQUIPMENT BRAKE.  FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN SERIOUS  INJURY  OR  DEATH  TO  PERSONNEL  AND  DAMAGE  TO EQUIPMENT.       WARNING: MORE  THAN  ONE  REMOTE  CONTROL  SYSTEM  MAY  BE  USED  AT, AROUND,  OR  NEARBY  YOUR  OPERATING  FACILITY.    THEREFORE, YOU MUST  INSURE  THE  ADDRESS  CODE  AND  FREQUENCY  OF YOUR TOGGLE CONTROLLER EXACTLY MATCHES THE ADDRESS CODE AND FREQUENCY OF THE DESIRED EQUIPMENT TO BE OPERATED. FAILURE  TO  COMPLY  WITH  THE  ABOVE WARNING MAY RESULT  IN THE  UNDESIRED  OPERATION  OF  OTHER  EQUIPMENT  WHICH,  IN TURN, COULD RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.     WARNING: NEVER DISABLE THE PUSH TO OPERATE (PTO) BAR SWITCH ON YOUR REMOTE CONTROLLER.  FAILURE TO COMPLY WITH THIS WARNING MAY  RESULT  IN  DAMAGE  TO  EQUIPMENT,  SERIOUS  INJURY,  OR DEATH.
 ©02/2010, CATTRON-THEIMEG™     - vii -  Safety Summary WARNINGS, continued.     WARNING: ON CAB AND REMOTE OPERATED CRANES OR CARRIERS AN AUDIBLE OR  VISUAL  WARNING  MEANS  SHALL  BE  PROVIDED.    IN  ADDITION, ALL  EQUIPMENT  SHALL  HAVE  AUDIO  OR  VISUAL  ALARM INDICATIONS MEETING GOVERNMENTAL REQUIREMENTS. FAILURE TO IMPLEMENT THIS WARNING MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.     WARNINGS: UNCODED  ADDRESS  PLUG(S)  SHALL  BE  PROGRAMMED  WITH  THE SAME  ADDRESS  CODE  AS  SET  IN  THE  TARGET  RECEIVER/DECODER.    IT  SHOULD  BE  FULLY  UNDERSTOOD  THAT  CATTRON-THEIMEG™ SHALL  NOT  BE  HELD  LIABLE  FOR  PERSONAL  INJURY,  DEATH, EQUIPMENT  OR  PROPERTY  DAMAGE  ARISING  FROM  DUPLICATED, INCORRECTLY PROGRAMMED OR INCORRECT CODE PLUG USAGE. IT  IS  YOUR  RESPONSIBILITY  TO  ESTABLISH  A  PROCEDURE  THAT INSURES  ONLY  THE  CODE  PLUG  CONFIGURED  FOR  A  PARTICULAR ADDRESS  IS  INSTALLED  IN  EQUIPMENT  DESIGNED  TO  OPERATE  ON THE  SAME  ADDRESS.    NEVER  PUT  MORE  THAN  ONE  CONTROLLER INTO  OPERATION  ON  THE  SAME  ADDRESS  AT  ANY  GIVEN  TIME.  CATTRON-THEIMEG™ STRONGLY  ADVISES  YOU TO IMPLEMENT  AND REGULARLY  UPDATE  A  REGISTER  OF  INDIVIDUAL  ADDRESSES  AND OPERATING  FREQUENCIES  ASSIGNED  TO  EACH  PORTABLE  RADIO REMOTE  CONTROL  (PRRC)  SYSTEM  LOCATED  AT  YOUR  OPERATING FACILITY.   IN ADDITION, ANY SPARE CODE PLUGS, OR CODE PLUGS INSTALLED  IN  EQUIPMENT  THAT  ARE  CONFIGURED  FOR  THE  SAME ADDRESS OF EQUIPMENT THAT IS IN SERVICE, MUST BE HELD UNDER LOCK AND KEY BY A DESIGNATED SUPERVISOR.   FAILURE  TO  COMPLY  WITH  THESE  WARNINGS  MAY  RESULT  IN OPERATION  OF  UNDESIRED  EQUIPMENT  WHICH  IN  TURN  COULD RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.
 ©02/2010, CATTRON-THEIMEG™     Page viii Safety Summary WARNINGS, continued.      WARNINGS: ALL  TRACKED  EQUIPMENT  (i.e.  locomotives)  MUST  HAVE  A  BRAKE INSTALLED. THE  REMOTE  CONTROL  OPERATE  (OPR)  RELAY  MUST  BE CONFIGURED  SO  THAT  STOP  COMMANDS  OR  FAULT  CONDITIONS MONITORED  BY  AUTOMATIC  SAFETY  OVERRIDE  (ASO)  CIRCUITRY WILL  SET  THE  THROTTLE  TO  IDLE,  DISCONNECT  THE  GENERATOR FIELD, AND SET THE INDEPENDENT BRAKE.  FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN SERIOUS  INJURY  OR  DEATH  TO  PERSONNEL  AND  DAMAGE  TO EQUIPMENT.       WARNING: AFTER CHANGING AN ADDRESS OR FREQUENCY SELECTOR SWITCH, YOU  MUST,  IN  THE  FIRST  INSTANCE,    INSURE  THE  TARGETED MACHINE  IS  UNDER  REMOTE  CONTROL  BEFORE  OPERATING  ANY MOTION  FUNCTION  SWITCH.    THIS  MAY  BE  ACCOMPLISHED  BY OPERATING  A  NON  MOTION  FUNCTION  SWITCH  ON  THE  REMOTE CONTROLLER SUCH AS A HORN OR LIGHT.  FAILURE  TO  COMPLY  WITH  THE  ABOVE  WARNING  MAY  RESULT  IN THE UNDESIRED OPERATION OF OTHER EQUIPMENT WHICH, IN TURN, COULD RESULT IN  SERIOUS  INJURY  OR  DEATH TO PERSONNEL  AND DAMAGE TO EQUIPMENT.       WARNING: ELECTRICAL  POWER  TO  THE  TARGET  CONTROLLED  EQUIPMENT MUST  BE  COMPLETELY  ISOLATED  TO  PREVENT  OPERATION  UNDER REMOTE CONTROL IN THE SWITCH DIAGNOSTIC MODE.  FAILURE  TO  COMPLY  WITH  THE  ABOVE  WARNING  MAY  RESULT  IN THE UNDESIRED OPERATION OF EQUIPMENT WHICH, IN TURN, COULD RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.
 ©02/2010, CATTRON-THEIMEG™     - ix -  Safety Summary WARNINGS, continued.     WARNING: DUE  TO  FCC  PART  15  AND  DOC  RSS-210  RADIO  TRANSMIT REGULATIONS,  THE  OPR  OUTPUT  TO  WHICH  YOUR  CONTROLLED EQUIPMENT’S MAINLINE CONTACTOR IS CONNECTED WILL REMAIN ENERGIZED FOR TEN MINUTES AFTER THE CONTROLLER POWER IS SET  TO  ‘OFF’,  OR  FOR  TEN  MINUTES  AFTER  THE  LAST  TIME  A FUNCTION SWITCH  IS ACTIVATED.  CONSEQUENTLY, SPECIAL  CARE MUST BE TAKEN IF THE CRANE OR TRACKED MACHINE IS EQUIPPED WITH  A  PARKING  BRAKE  THAT  IS  CONFIGURED  TO  ENGAGE  WHEN THE MAINLINE CONTACTOR DE-ENERGIZES.    TO PREVENT A POTENTIALLY HAZARDOUS SITUATION, YOU SHOULD IMMEDIATELY SET THE CONTROLLER’S POWER ON/OFF SWITCH(ES) TO ‘OFF’ AFTER COMPLETION OF OPERATIONS.  SUCH ACTION WILL INSURE  THE  PARKING  BRAKE  (IF  EQUIPPED  AND  CONFIGURED  AS ABOVE)  IS  SET,  PREVENTING  UNINTENTIONAL  MOVEMENT  OF  THE CRANE OR TRACKED MACHINE. FAILURE TO COMPLY WITH THIS WARNING MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.  CAUTIONS.   CAUTIONS: (1) CATTRON-THEIMEG™  Battery  Conditioners  are  designed  for  use  with CATTRON-THEIMEG™ Ni-Cad Battery Packs only.   (2) Battery Packs must be removed or disconnected from Battery Conditioners within 48-hours of achieving the fully charged state.   Failure to comply with these Cautions  may result in  equipment and/or battery damage and will void our warranty.   NOTES.   Important Safety Note: When  using  the  controller,  operators are  instructed  to  wear  a  factory  approved carrying harness with the controller attached at all times.  If a controller must be left  unattended,  the  STOP  switch  (when  installed  to  the  controller)  should  be depressed and the controller’s power ON/OFF switch set to ‘OFF’.  If the power ON/OFF  switch  is  a  key  switch,  the  key  should  also  be  removed  to  prevent unauthorized use of the controller.
 ©02/2010, CATTRON-THEIMEG™     Page x Safety Summary, continued  GENERAL. The  following  are  general  safety  precautions  that  are  not  related  to  any  specific  procedure  and therefore do not appear elsewhere in this manual.  These are general safety precautions and instructions that people must understand and apply during many phases of operation and maintenance to ensure personal safety and health and the protection of your company property.  KEEP  AWAY  FROM  LIVE  CIRCUITS.    Maintenance  personnel  must  observe  all  safety requirements at all times.  Do not replace components or make adjustments inside the equipment with the  electrical  supply  turned  on.    Under  certain  conditions,  danger  may  exist  even  when  the  power control is in the off position due to charges retained by capacitors.  To avoid injuries, always remove power, discharge and ground a circuit before touching it.  Adhere to all lock out/tag requirements.   DO NOT SERVICE OR ADJUST ALONE.  Whenever possible, do not attempt internal service or adjustment of equipment unless another person capable of rendering aid and resuscitation is present.   FINGER  RINGS/JEWELRY.    Finger  rings  have  caused  many  serious  injuries.    Remove  rings, watches and other metallic objects that may cause shock or burn hazards.     SOLDERING/DE-SOLDERING.    Avoid  breathing  fumes  generated  by  soldering/de-soldering. Perform all operations in a ventilated area.  Eye protection is required.   CLEANING SOLVENTS.  Some cleaners and solvents have adverse effects on skin, eyes, respiratory tract and internal organs.  These adverse effects range from discomfort to serious injury and death, depending on the material and degree of exposure.  Observe manufacturers’ warning labels and contact your immediate supervisor if in any doubt.   Remember…. the person now reading these instructions is primarily responsible for his or her own health and safety.
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 ©02/2010, CATTRON-THEIMEG™     - i -   Table of Contents Front Matter: FCC and IC Warnings…………………………………………….................…………...i Important Notices ...........................................................................................................  ii List of Technical Abbreviations ....................................................................................  iii How to use this Manual  ................................................................................................  iv Safety Summary warnings and cautions..................................................................... vi-x Section 1 – Product Data and Specifications: Introduction .................................................................................................................  1-1 Notable Performance and Safety features ...................................................................  1-2 Frequently asked questions .........................................................................................  1-3 Standard Specifications ...............................................................................................  1-5 Overview of CATTRON-THEIMEG™ Remote Control Systems ..............................  1-7 Section 2 – Safety Information: Safety Considerations  .................................................................................................  2-1 Safety and Security Features ...........................................................................  2-1 Typical Method of Operation incorporating ...................................................  2-2 Safety & Security Features Radio Control Operator’s Duties – General Equipment .............................................  2-4 Radio Control Operator’s Duties – EOT Crane ..........................................................  2-8 Radio Control Operator’s Duties – Locomotive .......................................................  2-12 Section 3 – Operating Instructions: Controls and Indicators ...............................................................................................  3-1 General Operating Procedure ......................................................................................  3-3 Crane Control Functions (typical)  ..............................................................................  3-6 Locomotive Control Functions (typical) .....................................................................  3-9 Ballast Railcar Control Functions (typical)  ..............................................................  3-13
 ©02/2010, CATTRON-THEIMEG™     Page ii Section 3 – Operating Instructions, continued: Switch Diagnostic Mode  ........................................................................................... 3-15 Battery Packs and Battery Pack Charging ................................................................. 3-16   Battery Pack Conditioner  .............................................................................. 3-16   Battery Pack Replacement ............................................................................. 3-16   Battery Pack Conditioning/Charging – Ni-Cad Battery packs only .............. 3-18 Pre-Programmed Frequency Selection ...................................................................... 3-20 Controller Operating Position for Mining Applications ............................................ 3-22 Section 4 – Maintenance Instructions: CATTRON-THEIMEG™ Maintenance Philosophy .................................................... 4-1 Preventive Maintenance  .............................................................................................. 4-2 Troubleshooting ........................................................................................................... 4-2   Troubleshooting Guide .................................................................................... 4-3 Corrective Maintenance ............................................................................................... 4-4 Functional Check ......................................................................................................... 4-4 Replacement Items  ...................................................................................................... 4-4   Battery Pack ..................................................................................................... 4-4   Address Code Plug  .......................................................................................... 4-5   Side Lever (optional item) ............................................................................... 4-9   External Antenna (optional item)  .....................................................................4-9 Section 5 – Replacement Items and Accessories: Replacement Items  ...................................................................................................... 5-1 Consumable items and Optional Accessories ....................................................  5-4 – 5-7 Index. Addendum. 1.  RECOMMENDED  SAFETY  RULES  FOR  PORTABLE  REMOTE CONTROLLED (PRC) CRANES. 2.  RECOMMENDED  SAFETY  RULES  FOR  PORTABLE  RADIO  REMOTE CONTROLLED (PRRC) LOCOMOTIVES.
 ©02/2010, CATTRON-THEIMEG™     Section 1, Page 1 Section 1 – Product Data & Specifications Introduction. The  CATTRON-THEIMEG™  Toggle  Controller  has  a  unique  shape  and  style  that  provide  the equipment operator with a controller that is durable, lightweight and convenient.  Designed specifically for heavy duty in harsh working environments, the toggle controller is ideally suitable for both indoor and  outdoor  remote  control  applications  within  the  steel,  glass,  automotive,  shipping,  mining, distribution, and railroad industries.  It can be used with all CATTRON-THEIMEG™ AT Series or MP Series  receiver/decoder  units  as  well  as  being  used  with  existing  CATTRON-THEIMEG™ PRRC systems as either a replacement or spare controller.   Our lightweight toggle controller was initially developed to enable remote control of locomotives and cranes  by  duplicating  the  operating  characteristics  of  their  cab  controls.    Subsequently,  a  toggle controller  with  additional  side  paddles  was  introduced  to  replace  the  bulkier,  ‘belly-box’  style  of controller  typically  associated  with  these  control  applications,  thus  reducing  weight  and  enhancing ease of use for crane and locomotive operators.  All CATTRON-THEIMEG™ Toggle Controllers are now offered with optional side paddles and each controller is individually customized at our factory for your specific control requirements. Your  toggle  controller  is  designed  to  duplicate  the  operating  characteristics  of  the  controls  most commonly found on the controlled machine, therefore the change from manual to radio remote control is easily learned by the operator.  The  CATTRON-THEIMEG™  toggle  controller  employs  advanced  micro-computer  electronics  and utilizes surface mount technology.  A highly advanced encoder circuit board is built using industrial grade  components  and  incorporates  a  powerful  microcomputer  that  uses  sophisticated  operating software.  The  main  housing  that  surrounds  and  protects  the  electronic  circuitry  is  made  of  epoxy  coated aluminum.  The ends of the housing are of fiberglass construction and coated with urethane to make shock  absorbing end  ‘bumpers’  and  switch  guards.    The  controller  incorporates  the  highest quality ‘mil-spec’ toggle switches whose reliability and construction have been field-tested and proven under extreme conditions.  These switches are manufactured with gold-plated contacts and employ a pinned shaft to prevent damage from direct end-on impacts. Total water and dust sealing makes these switches suitable for indoor and outdoor operation. A variety of synthesized and crystal-controlled RF transmitter configurations can be provided with this controller, allowing operation on licensed and non-licensed VHF and UHF radio channels.  In addition, all CATTRON-THEIMEG™  toggle controllers  meet  the  FCC's  requirements  regarding narrow band and 12.5 kHz bandwidths.
 Section 1, Page 2    ©02/2010, CATTRON-THEIMEG™ Notable Performance and Safety Features. POWER ON SELF TEST (POST) DIAGNOSTICS - When the operator first turns the power switch on,  a  sophisticated  self-test  routine  tests  the  microcomputer  and  all  critical  switch  inputs  to  detect unwanted commands in the system.   Any optional paddle lever style switches are tested for neutral at this time.  A small speaker beeps twice when the test has been completed satisfactorily. TRANSMIT/BATTERY CHARGE INDICATOR - The low battery detection circuit is a two stage design.  With a good battery, this indicator light flashes green for each burst of transmitted data.  If the battery  voltage  drops  below  the  normal  level,  this  LED  flashes  red  during  each  transmission.    A beeping sound every 10 seconds alerts the operator.  When this happens, the battery has approximately one hour of operating time remaining.  The controller stops transmitting before the voltage drops so low that erratic operation could occur.   BATTERY SAVER – If the controller has not been operated for 15 minutes, a battery management system detects this inactivity and puts the controller into a ‘deep sleep’ mode.  To reset the controller, the POWER ON/OFF SWITCH must be set to ‘OFF’, and then set to ‘ON’ again. BATTERY  PACK  OPTIONS  –  Alkaline  (disposable)  &  Ni-Cad  (rechargeable)  battery  packs  are available  from  CATTRON-THEIMEG™.      Whether  you  choose  disposable  or  rechargeable  battery packs, changing the battery pack is easy - simply unlatch and open the gasketed battery door, drop the battery pack in place and close and latch the battery door.  There are no wires or connectors to insert into the battery pack, which improves long-term reliability of this unit. RUGGED HOUSING - The housing that surrounds and protects the electronic circuitry is a thick-walled extruded aluminum, which has a hard anodized exterior.  The ends of the housing are rubber coated plates that make shock absorbing end 'bumpers’ which shield the toggle switches. DURABLE/OUTDOOR OPERATION – The toggle switches are extremely long lived units that are sealed, providing water and dust protection.  All modules and sub-components are gasketed, making your controller suitable for outdoor operation in rain and snow. TOGGLE  SWITCH  PLACEMENT  -  Each  layout  is  customized  according  to  user  needs.    The switch levers are placed far enough apart to accommodate operators who wear heavy gloves. SIDE-MOUNTED LEVER STYLES - One or two side-mounted lever pods can be installed as an option.  Standard units have a large easy-to-locate and comfortable 'FLAG' style paddle.  Shaped knobs are available as an additional option. SAFETY BAR - A safety bar is provided to function as an enable device to all motion switches.  It is a large full-length switch that is easily and naturally activated by a convenient and comfortable part of the operator's hand any time he or she activates a motion switch.  This push-to-operate (PTO) safety bar electronically disconnects all motion switches when it is released, thus stopping motion commands from these switches.    This feature is  programmable.  Certain applications  may have some switches removed from control of the PTO bar.  An example of this is the ballast door open/close command applicable to hopper railcars.
 ©02/2010, CATTRON-THEIMEG™     Section 1, Page 3 Notable Performance and Safety Features, continued. INTERNAL TILT SWITCH – If the controller is tilted in any axis beyond 60 degrees of upright for longer than the programmed time (typically 3 seconds), a programmable function is sent automatically.  This function can be assigned in the decoder to stop the equipment, sound an alarm, or both.  Reset time is also programmable. OPERATING  FREQUENCIES  -  A  variety  of  RF  transmitters  are  available  allowing  controller operation in 72-76 MHz, 402-420 MHz, and 450-470 MHz bands on licensed radio channels and 447-471 MHz on unlicensed channels.  Most models in the 450 MHz range are synthesized (16 frequency channels maximum). APPLICATIONS  -  The  toggle  controller  can  operate  any  digital  series  receiver/decoder  built  by CATTRON-THEIMEG™.    It  can  be  used  with  existing  CATTRON-THEIMEG™ systems  as  a replacement or as an extra transmitter/encoder. Frequently Asked Questions. Refer to Table 1-1 below for the most frequently asked questions about your toggle controller.   Table 1-1.  Toggle Controller, questions and answers QUESTION  ANSWER SAFETY   Protection against operator becoming disabled or falling down?  YES - fitted with a tilt switch and Push to Operate (PTO) safety bar switch as standard Protection against accidental switch operation?  YES - PTO safety bar switch and toggle switches are protected by case design.  Spring return to OFF  Simple operation by position and feel (without looking at controller)?  YES -  Toggle switches are custom arranged, usually vertically High quality custom labeling?  YES – Customized text, moderate size, durable, reverse side engraved, paint filled Number of functions sent to activate a motion?  TWO  (toggle switch and PTO) Protection against false commands or data as battery discharges?  YES - Low battery warning, then cut off before reaching unstable levels Protection against stray radio signals and other Remote Control systems?  YES - Unique digital address sent at the beginning of each data message. Protection against other digital data radio (e.g; pagers, cell, fax) or radiation from computer equipment? YES - Unique (non-standard) data baud rate, each motion command has data in at least two bytes, very complex data error detection (BCH)  Protection against broken switches or wiring sending motion commands?  YES - Detects stuck switch at initial power on. Switch wiring is tested for open or short circuits before every digital transmission  Withstand static discharge and high magnetic fields?   YES - Unit tested for EMI/RFI by independent lab.  Passes and can carry CE mark.  Has been used successfully in high magnetic fields.
 Section 1, Page 4    ©02/2010, CATTRON-THEIMEG™ Frequently Asked Questions, continued. Table 1-1.  Toggle Controller, questions and answers QUESTION  ANSWER RELIABILITY   Durable case material?  YES - Aluminum with epoxy coating.  Fiberglass ends coated in urethane Enclosure water/dust/oil proof?   YES - NEMA 12 (IP-65)  or optional NEMA 4 (IP-66) Long toggle switch operating life?  YES – To military specification (mil-spec). Greater than 100 thousand operations Reliable toggle switch  wiring?  YES - Mounted to circuit board using soldered flex circuits for each toggle  Simple and reliable electrical connection method to battery?   YES - Stainless steel contacts that mate with stainless pads on battery. Automatic wiping at each insertion into controller Ability to survive repeated drops on to concrete floor?   YES - Tested by UL labs to mil-specs.  Drops will not cause motion Maximum number of function speed steps per motor available?  1, 2, or 3 speed steps with toggle only.  One or two Side Paddles can be added for 5 steps each, or for stepless motion State of the art electronic construction techniques?  YES - Machine built PC board (1) using surface mount components primarily MAINTAINABILITY   High quality component grades used?  YES - Industrial and mil-spec Internal antenna?  YES - Di-pole, printed circuit design, located internally as part of housing side cover on unlicensed controllers.  Optional external antennas available. Operator diagnostics - battery condition indication?  YES - TWO stage battery condition indicator: flash GREEN – OK.  Flash RED – battery needs changing, audible beeps every 10 seconds anytime red indicator is flashing. Operator diagnostics - determining switch operation condition?  YES - Can be placed in switch beep mode by turning on power while unit is tilted. Beep when a motion control function  toggle switch is operated indicates switch functioning correctly. Data transmit indicator?  YES – GREEN LED flashes with each message being sent (will normally be synchronized with receiver LED's) Easy Disassembly and Assembly?   YES - by CATTRON-THEIMEG™ trained customer technicians only. Minimal wires and few connections PC diagnostics capability?  YES - by CATTRON-THEIMEG™ trained customer technicians only.   PC testing port, cable, and diagnostic software available. Helps real time troubleshooting  Test method for RF frequency, modulation and related tests?  YES - by CATTRON-THEIMEG™ trained customer technicians only. Unit can be placed in a special test mode by holding PTO bar down while turning on power (also prevent operator tampering)
 ©02/2010, CATTRON-THEIMEG™     Section 1, Page 5 Frequently Asked Questions, continued. Table 1-1.  Toggle Controller, questions and answers QUESTION  ANSWER OPERATIONAL FEATURES   FCC approval for narrow band licensed operation in new 12.5 kHz channels? YES - Approved for both non-licensed and licensed services with ongoing designs for changing USA and Canadian rules and regulations. Transmitters can be assigned 12.5kHz channels.  In addition, units have a wide number of approvals and frequency ranges for European, UK  and Australian operation Operational  range without Close Start or Range limited receiver /decoder (Maximum distance)? Low power (unlicensed) units typically 300 feet for operation indoors in an industrial environment. 500 feet outdoors under best conditions.  Licensed units typically 800 to 1000 feet indoors. Higher power is available for operation up to 1500 feet outdoors. Longer ranges by special design (e.g. external antenna's and repeaters) Special display features for operator?   YES - LED (day/night) optional - selects data to be sent e.g., door number to control.  LCD and individual LED's available for Talkback  Comfortable weight to operate?  YES - Weighs approximately 3 pounds with battery Carrying methods available to provide comfortable, (all day) operation? YES – Two carrying  methods are available: (1)  Shoulder strap sling positioning  the unit at waist level.  (2) Chest harness that places the unit in the center of the chest  Standard Specifications. Case Material:   Epoxy coated Aluminum with Urethane coated Fiberglass end caps.  Weight:    3.2 lbs. (1.4 Kgs), including Battery Pack.  Dimensions:    Height: 9.75" (25.0 cm) Depth: 4" (10.0 cm) Width: 3.75" (9.5 cm).  Environmental:  -4° F to +140° F (-20° C to +60° C), RH 0 to 95% Non-condensing.  Switch Types:  Spring Return to Center Toggle, Maintained Toggle, Momentary Pushbutton, Rotary Select.  Number of  Functions:    40 ‘ON/OFF’ (space permitting) or 2 Analog with 30 ‘ON/OFF’ max.  Lever Switch Choices:  2 maximum – side mounted.  Detented (5 steps each side of center) or Stepless (analog).
 Section 1, Page 6    ©02/2010, CATTRON-THEIMEG™ Standard Specifications, continued.  Side Mounted Lever Styles:    Large Flag Type, Special Shaped Lever Knobs Optional.  Push To Operate Safety Bar:    Standard.  Lever Guards:   Optional.  Labeling:    Custom, Reverse Engraved Polycarbonate and Multi-layered Mylar.  Keylock Switch:  Standard (Power ON/OFF).  Security:    An optional ‘keyless entry code’ is available.  Antenna:    Internal (external optional on licensed versions only).  Low Battery Indicator:    2 Color LED:  GREEN - Battery Normal, RED - Battery Low.  Short Circuit Protection:    Automatically Resettable Polyswitch (no fuses).  Conformal Coating:  Standard on PC Board.  Transmitter Frequency:    Synthesized and Crystal Control Models       72-76 MHz, 402-420 MHz, or 450-470 MHz - License Required.       447-471 MHz - No License Required.  Power Output:   450-470 MHz: 40 mW Nominal (250 mW optional).       402-420 MHz: 40 mW Nominal (250 mW optional).       72-76 MHz: 100 mW Nominal.       447-471 MHz: Maximum According to FCC Rules Part 15. Synthesized Channels:    16 Maximum (Factory Programmed).
 ©02/2010, CATTRON-THEIMEG™     Section 1, Page 7 Overview – CATTRON-THEIMEG™ Radio Remote Control Systems. Figure 1-1 below shows a simplified block diagram of a typical CATTRON-THEIMEG™ radio remote control system. Refer to this figure and the following paragraphs for a functional description of the remote control system. The  target  receiver/decoder  is  controlled  by  the  Toggle  Controller,  which  sends  signals  to  the receiver/decoder using a UHF radio link.  The signal is picked up by the antenna and passed on to the receiver.  Provided the frequency of the toggle controller exactly matches that of the target receiver and passes all data tests, the signal is passed on to the decoder. The decoder compares the address code of the signal to its own address code. If the signal’s address code does not match the decoder’s address code, it is ignored and a message is displayed on a system status display usually located in the receiver/decoder unit.  If the address code is correct, the decoder processes the message and energizes and de-energizes the appropriate control and auxiliary function relays located within the control system.  An Automatic Safety Override (ASO) function continually monitors the state of any directional relay output (i.e. Forward/Reverse). If a monitored relay electrically fails closed without a command from the  controller,  the  ASO  circuit  logic  de-energizes  the  master  output  relay  (OPR)  which  should  be connected to the mainline contactor of your controlled machine. During operation,  the  microprocessor  on  the  decoder  board  resets  multiple  watchdog timer  circuits whenever valid messages are received and decoded.  If the microprocessor fails to reset the watchdog timers,  the  timer  circuits  shut  down  and  de-activate  all  relay  outputs.  The  decoder  microprocessor requires continuously valid transmitted signals to be received and decoded or all relay output functions will be de-activated unless programmed otherwise. It should be noted that the mainline control relay (OPR) may be maintained for up to 10 minutes, depending on system configuration. Figure 1-1. Typical Radio Remote Control System  - simplified block diagram CONTROLLERADDRESS ADDRESS FREQFREQRxTxRECEIVERMACHINE WIRINGDECODER12 VDCPOWERSUPPLYWATCHDOGTIMERMAINS INPUT50-60 HZAUXILIARY FUNCTIONOUTPUT RELAYSDIRECTIONALOUTPUT RELAYSASO END OF SECTION
 Section 1, Page 8    ©02/2010, CATTRON-THEIMEG™         This page intentionally left blank
 ©02/2010, CATTRON-THEIMEG™     Section 2, Page 1 Section 2 – Safety Information Safety Considerations. CATTRON-THEIMEG™ believes that to safely operate any remotely controlled equipment, the overall system needs to be configured so that movement or operation of the equipment will take place only when the  device  is  commanded  to  move or operate.   For example, overhead cranes or locomotives must be equipped with a braking system that can only be released when an electrical signal is sent to the motor.  Removal of electrical power or loss of the radio transmitted signal results in application of the  brakes.    On  cranes,  this  is  provided  when  a  CATTRON-THEIMEG™  Electro-Hydraulic  brake package is installed – contact the factory for details.  On locomotives, an air valve opens, applying independent braking and the throttle returns to idle.  In keeping with this philosophy - NO COMMAND, NO MOVEMENT - CATTRON-THEIMEG™ has designed your radio remote control system with the following safety and security features which may, at your request, be modified to meet specific operating requirements. CATTRON-THEIMEG™ engineers are always available to work with you to provide optimum operating system safety.  Safety & Security Features. Unique  address  code:  Each  controller  and  receiver/decoder  pair  is  configured  with  a unique  address  code  so  that  the  equipment  will  respond  only  to  the  controller  whose address code matches that of the decoder. Intelligent digital message protocol: CATTRON-THEIMEG™ remote control systems utilize  a  unique  message  protocol  for  industrial  control  applications  rather  than  the customary Electronic Data Processing (EDP) type of message format. Power ON/OFF switch: The controller has a power ON/OFF Key or Toggle Switch that must be set  to  ‘ON’  in  order  to  send commands  to the receiver/decoder.  If the  power ON/OFF  Switch  is  set  to  ‘OFF’,  the  decoder  will  remove  all  commands  from  the controlled  machinery,  stopping  all  movement.    However,  the  mainline  control  relay (OPR) may be maintained for up to 10 minutes, depending on system configuration. Operate relay (OPR): The operate (OPR) output relay shall be wired to control a user-provided  electro-magnetic  power  contactor.  The  electro-magnetic  contactor  opens  and closes the main electrical supply circuit(s) to the controlled device. Automatic  Safety  Override:  The  Automatic  Safety  Override  (ASO)  function continually monitors all selected decoder directional relay outputs.  If a directional relay closes without command from the controller, the Operate (OPR) Relay immediately de-energizes.  This  prevents  any  movement  of  the  controlled  machine  without  command from the controller.
 Section 2, Page 2    ©02/2010, CATTRON-THEIMEG™ Safety & Security Features, continued. Data Error Checking: All communications from the controller to the receiver/decoder contain error-checking information (BCH data error detection routines).  The entire data command packet must pass error detection tests before being processed. Push-To-Operate (PTO) Bar: This easily activated switch bar must be released when power  is  turned  on,  then  pressed  and  held  to  enable  the  motion  switch  functions.  Releasing  the  PTO  during  normal  operation  causes  the  controller  to  send  neutral commands to the receiver or decoder.  In certain cases the PTO will be programmed NOT to enable or disable a particular function switch, i.e. railcar hopper doors and locomotive braking  functions.      Refer  to  the  schematic  drawing  for  your  custom  controller  serial number to understand its configuration. NOTE:  Holding the PTO bar down when power is turned on places the controller in a technical diagnostic mode.  Refer to Maintenance Instructions (Section 4) for details. Optional ‘Keyless Entry Code’: This available feature requires an operator to activate a series of switches correctly before the controller power is turned on. Typical method of operation (incorporating above safety features) using a radio controlled overhead crane as an example: The Operate (OPR) relay is energized for the first time when: The  controller’s  Power  ON/OFF  Switch  is  set  to  ‘ON’  and  the  target  receiver/decoder  has  power applied.  With these conditions satisfied, a matching address code is sent by way of RF signal from the controller to the decoder. The OPR relay is wired to the mainline (ML) contactor on the crane. Once the mainline is energized, a continuously repeated valid signal must be received for function outputs to engage. If this signal is interrupted for any reason, all function outputs will turn off unless programmed otherwise.  When operating within the USA, FCC rules state that RF transmitters in non-licensed controllers must switch off within five seconds after the operator releases a function button.  Consequently, the OPR output is programmed to stay on for ten minutes after the last valid message is received.  During this time all Automatic Safety Override (ASO) monitored outputs must stay off or the ASO sensing in the decoder will interrupt this hold up time, de-energizing OPR. Figure 2-1 opposite shows an Operate (OPR) contact wired directly to the mainline (ML) contactor. Setting the controller’s Power ON/OFF Switch to ‘ON’ will energize the mainline contactor. An  auxiliary  function  may  be  used  as  a  Reset  (RST)  output  that  will  only  be  effective  when  the Operate  (OPR)  relay  has  been  closed.    Momentary  closure  of  the  Reset  (RST)  relay  picks  up  the mainline (ML) contactor, which is maintained under control of the OPR.  Thus, power is supplied to the  controlled  device.    If  OPR  opens,  the  mainline  contactor  releases,  removing  power  from  the controlled device and stopping all motion.
 ©02/2010, CATTRON-THEIMEG™     Section 2, Page 3 Typical method of operation (continued).  Figure 2-1.  Operate (OPR) contact wiring  Figure 2-2 below shows the Operate (OPR) relay and optional Reset (RST) relay wired to control a mainline (ML) contactor. This configuration requires the operator to activate the reset function on the controller after he/she has turned the unit on.  Once reset, the ML contactor stays energized until OPR de-energizes.  In  addition  to  being  energized  by  the  presence  of  a  signal  from  the  controller,  OPR  is  under supervision  of  the  Automatic  Safety  Override  (ASO)  circuit.  The  ASO  circuit  disables  the  OPR (shutting down the controlled machinery) if a directional output relay is active when no corresponding command is being received from the controller.  In this event, no action is required by the operator to stop  the  equipment.  The  ASO  safety circuitry will  stop  motion  automatically  without  any  operator command when a directional output relay fault is detected. Figure 2-2.  Operate (OPR) contactor and Reset Relay (RST) wiring  OPR120VRSTRRCC5.0A5.0AL1 MLMLMLMANUALDISCONNECTL2L3 LL1LL2LL3 TOMOTORRECEIVER/DECODEREXISTING CONTROLS 120VL1 MLMLMANUALDISCONNECTL2L3 LL1LL2LL3 TOMOTORRECEIVER/DECODEREXISTING CONTROLS OPRRC5.0A
 Section 2, Page 4    ©02/2010, CATTRON-THEIMEG™ Radio Control Operator’s Duties – General Equipment.      WARNINGS: ALL  EQUIPMENT  MUST  HAVE  A  MAINLINE  (ML)  CONTACTOR INSTALLED  AND  ALL  TRACKED  EQUIPMENT  (I.E.  CRANES)  HAVE  A BRAKE INSTALLED. THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BE CONNECTED TO THE MAINLINE SO THAT STOP COMMANDS OR FAULT CONDITIONS MONITORED  BY  AUTOMATIC  SAFETY  OVERRIDE  (ASO)  CIRCUITRY WILL  DE-ENERGIZE  THE  MAINLINE  CONTACTOR  AND  SET  THE EQUIPMENT BRAKE.  FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN SERIOUS  INJURY  OR  DEATH  TO  PERSONNEL  AND  DAMAGE  TO EQUIPMENT.       WARNING: MORE  THAN  ONE  REMOTE  CONTROL  SYSTEM  MAY  BE  USED  AT, AROUND, OR NEARBY YOUR OPERATING FACILITY.  THEREFORE, YOU MUST  INSURE  THE  ADDRESS  CODE  AND  FREQUENCY  OF  YOUR TOGGLE CONTROLLER EXACTLY MATCHES THE ADDRESS CODE AND FREQUENCY OF THE DESIRED EQUIPMENT TO BE OPERATED. FAILURE  TO  COMPLY  WITH  THE  ABOVE  WARNING  MAY  RESULT  IN THE UNDESIRED OPERATION OF OTHER EQUIPMENT WHICH, IN TURN, COULD  RESULT IN  SERIOUS  INJURY  OR  DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.      WARNING: ON CAB AND REMOTE OPERATED CRANES OR CARRIERS AN AUDIBLE OR VISUAL WARNING MEANS SHALL BE PROVIDED.  IN ADDITION, ALL EQUIPMENT  SHALL  HAVE  AUDIO  OR  VISUAL  ALARM  INDICATIONS MEETING  GOVERNMENTAL  REQUIREMENTS.  FAILURE  TO IMPLEMENT  THIS  WARNING  MAY  RESULT  IN  SERIOUS  INJURY  OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.
 ©02/2010, CATTRON-THEIMEG™     Section 2, Page 5 Radio Control Operator’s Duties – General Equipment, continued.     WARNING: DUE  TO  FCC  PART  15  AND  DOC  RSS-210  RADIO  TRANSMIT REGULATIONS,  THE  OPR  OUTPUT  TO  WHICH  YOUR  CONTROLLED EQUIPMENT’S MAINLINE CONTACTOR IS CONNECTED WILL REMAIN ENERGIZED FOR TEN MINUTES AFTER THE CONTROLLER POWER IS SET  TO  ‘OFF’,  OR  FOR  TEN  MINUTES  AFTER  THE  LAST  TIME  A FUNCTION  SWITCH  IS  ACTIVATED.   CONSEQUENTLY,  SPECIAL  CARE MUST BE TAKEN IF THE CRANE OR TRACKED MACHINE IS EQUIPPED WITH  A  PARKING  BRAKE  THAT  IS  CONFIGURED  TO  ENGAGE  WHEN THE MAINLINE CONTACTOR DE-ENERGIZES.    TO PREVENT A POTENTIALLY HAZARDOUS SITUATION, YOU SHOULD IMMEDIATELY SET THE CONTROLLER’S POWER ON/OFF SWITCH(ES) TO ‘OFF’ AFTER COMPLETION OF OPERATIONS.  SUCH ACTION WILL INSURE  THE  PARKING  BRAKE  (IF  EQUIPPED  AND  CONFIGURED  AS ABOVE)  IS  SET,  PREVENTING  UNINTENTIONAL  MOVEMENT  OF  THE CRANE OR TRACKED MACHINE. FAILURE TO COMPLY WITH THIS WARNING MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.    WARNING: NEVER DISABLE THE PUSH TO OPERATE (PTO) BAR SWITCH ON YOUR REMOTE CONTROLLER.  FAILURE TO COMPLY WITH THIS WARNING MAY  RESULT  IN  DAMAGE  TO  EQUIPMENT,  SERIOUS  INJURY,  OR DEATH.    NOTE.   Important Safety Note: When  using  the  controller,  operators are  instructed  to  wear  a  factory  approved carrying harness with the controller attached at all times.  If a controller must be left  unattended,  the  STOP  switch  (when  installed  to  the  controller)  should  be depressed and the controller’s power ON/OFF switch set to ‘OFF’.  If the power ON/OFF  switch  is  a  key  switch,  the  key  should  also  be  removed  to  prevent unauthorized use of the controller.
 Section 2, Page 6    ©02/2010, CATTRON-THEIMEG™ Radio Control Operator’s Duties – General Equipment, continued. The  following  procedures  provide  general  guidelines  for  radio  control  operation  of  equipment  and should not be used as a substitute for your plant operating procedures. 1. Before operating equipment, carry out the following: a. Insure  the address  code  and  frequency of  your  toggle  controller  exactly  matches  the address code and frequency of the target equipment to be operated.  The address and frequency assigned to your controller is recorded (1) on the front page of this manual, and (2) on a serial tag located inside the battery door. The address and frequency of the target receiver/decoder is recorded (1) on the front page of the manual supplied with the portable remote control system, and (2) on a label located inside the receiver/decoder.  If  a  controller  having  the  wrong  address  code  and  frequency  is  selected,  the  target equipment will not operate.  However, other equipment located at,  around, or nearby your facility may become operational. Note:  If you are not familiar with the controls and indicators on your  controller,  please refer to ‘Controls and Indicators’ in Section 3 of this manual and the operational description provided with your controller. b. Set  the  controller’s  Power  ON/OFF  Switch  to  the  ‘ON’  position.  When  transmitting with  a  good  battery,  two  short  ‘beeps’  will  be  heard  immediately  after  the  Power ON/OFF Switch is set to ‘ON’ and a green TRANSMIT LED will ‘flash’ rhythmically.  When the battery starts to go low, the green LED changes to a red LOW BATTERY LED  which  ‘flashes’  continuously.    This  means  you  should  change  or  re-charge  the battery pack as soon as possible - refer to Battery Packs and Battery Pack Charging in Section 3 of this manual.  c. When  installed,  depress  the  ALARM/RESET  toggle  switch  on  the  controller  (this  is normally  an  optional  function  that  sounds  the  equipment  alarm  and  resets  the  main power contactor). d. Check each function independently to be sure that equipment is responding correctly. e. Where a limit switch is provided, you should check the limit switch at the beginning of each shift as defined by your plant operating procedures. f. Check Range Limiting if used – refer to Appendix ‘A’ of the manual supplied with your PRC system. g. Check STOP operation h. Check brake operation. 2. You must report all defective or missing safety equipment, mechanical or electrical defects to your supervisor without delay.  Do not continue operation until fully repaired. 3. If anyone is in the path of equipment travel, stop and sound the alarm before proceeding. Do not proceed until the path is clear.
 ©02/2010, CATTRON-THEIMEG™     Section 2, Page 7 Radio Control Operator’s Duties – General Equipment, continued. 4.  Persons operating this equipment shall not use a limit stop as a utility stopping device. 5  When leaving the equipment area for any reason, set the controller’s Power ON/OFF Switch to the ‘OFF’ position.  If this is a Key Switch, remove the key from the controller and keep it on your person. 6.  Do not allow any unauthorized person to operate the controller. 7.  Do not operate the controller at a distance where the equipment and all surrounding objects are not visible. 8.  Do not attempt to override any of the safety features built into the Radio Control System. 9. If,  for  any  reason,  you  or  anyone  has  to  board  the  radio  controlled  equipment,  set  the controller’s Power ON/OFF Switch to the ‘OFF’ position.  If this is a Key Switch, remove the key from the controller and keep it on your person.
 Section 2, Page 8    ©02/2010, CATTRON-THEIMEG™ Radio Control Operator’s Duties – Electrical Overhead Tracked (EOT) Crane.      WARNINGS: WITH  THE  EXCEPTION  OF  LOCOMOTIVES,  ALL  EQUIPMENT  MUST HAVE A MAINLINE (ML) CONTACTOR INSTALLED AND ALL TRACKED EQUIPMENT (I.E. CRANES) HAVE A BRAKE INSTALLED. THE REMOTE CONTROL OPERATE (OPR) RELAY MUST BE CONNECTED TO THE MAINLINE SO THAT STOP COMMANDS OR FAULT CONDITIONS MONITORED  BY  AUTOMATIC  SAFETY  OVERRIDE  (ASO)  CIRCUITRY WILL  DE-ENERGIZE  THE  MAINLINE  CONTACTOR  AND  SET  THE EQUIPMENT BRAKE.  FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN SERIOUS  INJURY  OR  DEATH  TO  PERSONNEL  AND  DAMAGE  TO EQUIPMENT.       WARNING: MORE  THAN  ONE  REMOTE  CONTROL  SYSTEM  MAY  BE  USED  AT, AROUND, OR NEARBY YOUR OPERATING FACILITY.  THEREFORE, YOU MUST  INSURE  THE  ADDRESS  CODE  AND  FREQUENCY  OF  YOUR TOGGLE CONTROLLER EXACTLY MATCHES THE ADDRESS CODE AND FREQUENCY OF THE DESIRED EQUIPMENT TO BE OPERATED. FAILURE  TO  COMPLY  WITH  THE  ABOVE  WARNING  MAY  RESULT  IN THE UNDESIRED OPERATION OF OTHER EQUIPMENT WHICH, IN TURN, COULD  RESULT IN  SERIOUS  INJURY  OR  DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.      WARNING: ON CAB AND REMOTE OPERATED CRANES OR CARRIERS AN AUDIBLE OR VISUAL WARNING MEANS SHALL BE PROVIDED.  IN ADDITION, ALL EQUIPMENT  SHALL  HAVE  AUDIO  OR  VISUAL  ALARM  INDICATIONS MEETING  GOVERNMENTAL  REQUIREMENTS.    FAILURE  TO IMPLEMENT  THIS  WARNING  MAY  RESULT  IN  SERIOUS  INJURY  OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.
 ©02/2010, CATTRON-THEIMEG™     Section 2, Page 9 Radio Control Operator’s Duties – EOT Crane, continued.       WARNING: DUE  TO  FCC  PART  15  AND  DOC  RSS-210  RADIO  TRANSMIT REGULATIONS,  THE  OPR  OUTPUT  TO  WHICH  YOUR  CONTROLLED EQUIPMENT’S MAINLINE CONTACTOR IS CONNECTED WILL REMAIN ENERGIZED FOR TEN MINUTES AFTER THE CONTROLLER POWER IS SET  TO  ‘OFF’,  OR  FOR  TEN  MINUTES  AFTER  THE  LAST  TIME  A FUNCTION SWITCH IS ACTIVATED.  CONSEQUENTLY, SPECIAL CARE MUST BE TAKEN IF THE CRANE OR TRACKED MACHINE IS EQUIPPED WITH  A  PARKING  BRAKE  THAT IS  CONFIGURED  TO  ENGAGE  WHEN THE MAINLINE CONTACTOR DE-ENERGIZES.    TO PREVENT A POTENTIALLY HAZARDOUS SITUATION, YOU SHOULD IMMEDIATELY SET THE CONTROLLER’S POWER ON/OFF SWITCH(ES) TO ‘OFF’ AFTER COMPLETION OF OPERATIONS.  SUCH ACTION WILL INSURE  THE  PARKING  BRAKE  (IF  EQUIPPED  AND  CONFIGURED  AS ABOVE)  IS  SET,  PREVENTING  UNINTENTIONAL  MOVEMENT  OF  THE CRANE OR TRACKED MACHINE. FAILURE TO COMPLY WITH THIS WARNING MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.     WARNING: NEVER DISABLE THE PUSH TO OPERATE (PTO) BAR SWITCH ON YOUR REMOTE CONTROLLER.  FAILURE TO COMPLY WITH THIS WARNING MAY  RESULT  IN  DAMAGE  TO  EQUIPMENT,  SERIOUS  INJURY,  OR DEATH.    NOTE.   Important Safety Note: When  using  the  controller,  operators are  instructed  to  wear  a  factory  approved carrying harness with the controller attached at all times.  If a controller must be left  unattended,  the  STOP  switch  (when  installed  to  the  controller)  should  be depressed and the controller’s power ON/OFF switch set to ‘OFF’.  If the power ON/OFF  switch  is  a  key  switch,  the  key  should  also  be  removed  to  prevent unauthorized use of the controller.
 Section 2, Page 10    ©02/2010, CATTRON-THEIMEG™ Radio Control Operator’s Duties – EOT Crane, continued.  The following procedures provide general guidelines for radio control operation of an EOT crane and should not be used as a substitute for your plant operating procedures.  Please note that a complete set of Recommended Safety Rules for Cranes is provided at the end of this manual.  1. Before lifting any loads, carry out the following: a.  Insure  the  address  code  and  frequency  of  your  toggle controller  exactly  matches  the address code and frequency of the target equipment to be operated.  The address and frequency assigned to your controller is recorded (1) on the front page of this manual, and (2) on a serial tag located inside the battery door.  The address and frequency of the target receiver/decoder is recorded (1) on the front page of the manual supplied with the portable remote control system, and (2) on a label located inside the receiver/decoder.  If  a  controller  having  the  wrong  address  code  and  frequency  is  selected,  the  target equipment will not operate.  However, other equipment located at,  around, or nearby your facility may become operational. Note:  If  you  are  not  familiar  with  the  controls  and  indicators  on  your  controller,  please refer to ‘Controls and Indicators’ in Section 3 of this  manual  and  the  operational  description  provided  with  your controller. b. Set the controller’s Power ON/OFF Switch to the ‘ON’ position.   When transmitting with  a  good  battery,  two  short  ‘beeps’  will  be  heard  immediately  after  the  Power ON/OFF Switch is set to ‘ON’ and a green TRANSMIT LED will ‘flash’ rhythmically.  When the battery starts to go low, the green LED changes to a red LOW BATTERY LED  which  ‘flashes’  continuously.    This  means  you  should  change  or  re-charge  the battery pack as soon as possible - refer to Battery Packs and Battery Pack Charging in Section 3 of this manual. c. When  installed,  depress  the  ALARM/RESET  toggle  switch  on  the  controller  (this  is normally  an  optional  function  that  sounds  the  equipment  alarm  and  resets  the  main power contactor). d.  Where a limit switch is provided, you should check the limit switch at the beginning of each shift as defined by your plant operating procedures. e.  Check each function independently to be sure that equipment is responding correctly. f. Check range limiting if used – refer to Appendix ‘A’ of the manual supplied with your PRC system. g. Check STOP operation. h. Check Brake operation. 2.  You must report all defective or missing safety equipment, mechanical or electrical defects to your supervisor without delay.  Do not continue operation until fully repaired. 3.  When raising or lowering a load, proceed slowly and make certain the load is under control.
 ©02/2010, CATTRON-THEIMEG™     Section 2, Page 11 Radio Control Operator’s Duties – EOT Crane, continued.    4.  When lifting maximum load, you should test the brakes by raising the load a few inches from the floor.  If the brakes will not hold, the load shall be immediately lowered and not moved until brakes are adjusted or repaired.   5.  Center the Trolley directly over the load before starting to hoist.   6.  Take slack out of chains or slings gradually and make sure hands and other objects are clear before making the lift.   7.  Keep all parts of the body away from the lifts.  Also, do not stand under a lift. 8. Do not make a lift or move the equipment if anyone is in a position to be injured. 9. Load should not be carried over workmen's heads. 10.  If anyone is in the path of travel, stop and sound the alarm before proceeding.  Do not proceed until the pathway is clear 11.  Do not drag slings, chains, etc. along the floor. 12.  Persons operating this equipment shall not use a limit stop as a utility stopping device. 13.  Bumping other cranes or run-away stops is prohibited. 14.  When  moving  the  equipment  to  the  loading  point,  be  sure  that  hook  block,  attachment,  or cables will not fall on the adjacent equipment. 15.  When leaving  the  crane  area  for  any  reason, be  sure  slings or  chains  are raised  and  set  the controller’s Power ON/OFF Switch to the ‘OFF’ position.  If this is a Key Switch, remove the key from the controller and keep it on your person. 16.  Do not allow any unauthorized person to operate the controller. 17.  Do not operate the controller at a distance where the crane and all surrounding objects are not visible. 18.  Do not attempt to override any of the safety features built into the Radio Control System. 19. If,  for  any  reason,  you  or  anyone  has  to  board  a  radio  controlled  crane,  set  the  controller’s Power ON/OFF Switch to the ‘OFF’ position.  If this is a Key Switch, remove the key from the controller and keep it on your person.
 Section 2, Page 12    ©02/2010, CATTRON-THEIMEG™ Radio Control Operator's Duties - Locomotive.     WARNINGS: ALL TRACKED EQUIPMENT (i.e. LOCOMOTIVES) MUST HAVE A BRAKE INSTALLED. THE  REMOTE  CONTROL  OPERATE  (OPR)  RELAY  MUST  BE CONFIGURED  SO  THAT  STOP  COMMANDS  OR  FAULT  CONDITIONS MONITORED  BY  AUTOMATIC  SAFETY  OVERRIDE  (ASO)  CIRCUITRY WILL SET  THE THROTTLE TO IDLE, DISCONNECT THE GENERATOR FIELD, AND SET THE INDEPENDENT BRAKE.  FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN SERIOUS  INJURY  OR  DEATH  TO  PERSONNEL  AND  DAMAGE  TO EQUIPMENT.        WARNING: MORE  THAN  ONE  REMOTE  CONTROL  SYSTEM  MAY  BE  USED  AT, AROUND, OR NEARBY YOUR OPERATING FACILITY.  THEREFORE, YOU MUST  INSURE  THE  ADDRESS  CODE  AND  FREQUENCY  OF  YOUR TOGGLE CONTROLLER EXACTLY MATCHES THE ADDRESS CODE AND FREQUENCY OF THE DESIRED EQUIPMENT TO BE OPERATED. FAILURE  TO  COMPLY  WITH  THE  ABOVE  WARNING  MAY  RESULT  IN THE UNDESIRED OPERATION OF OTHER EQUIPMENT WHICH, IN TURN, COULD  RESULT IN  SERIOUS  INJURY  OR  DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.       WARNING: ON  CAB  AND  REMOTE  OPERATED  LOCOMOTIVES  OR  CARRIERS  AN AUDIBLE  OR  VISUAL  WARNING  MEANS  SHALL  BE  PROVIDED.    IN ADDITION, ALL  EQUIPMENT SHALL HAVE AUDIO OR VISUAL ALARM INDICATIONS  MEETING  GOVERNMENTAL  REQUIREMENTS.   FAILURE TO IMPLEMENT THIS WARNING MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.    WARNING: NEVER DISABLE THE PUSH TO OPERATE (PTO) BAR SWITCH ON YOUR REMOTE CONTROLLER.  FAILURE TO COMPLY WITH THIS WARNING MAY  RESULT  IN  DAMAGE  TO  EQUIPMENT,  SERIOUS  INJURY,  OR DEATH.
 ©02/2010, CATTRON-THEIMEG™     Section 2, Page 13 Radio Control Operator's Duties – Locomotive, continued.   Important Safety Note: When  using  the  controller,  operators are  instructed  to  wear  a  factory  approved carrying harness with the controller attached at all times.  If a controller must be left  unattended,  the  STOP  switch  (when  installed  to  the  controller)  should  be depressed and the controller’s power ON/OFF switch set to ‘OFF’.  If the power ON/OFF  switch  is  a  key  switch,  the  key  should  also  be  removed  to  prevent unauthorized use of the controller.  The following procedures provide general guidelines for radio control operation of a locomotive and should not be used as a substitute for your plant operating procedures.  Please note that a complete set of Recommended Safety Rules for Locomotives is provided at the end of this manual.   1.  Perform  all  locomotive  pre-departure  tests  according  to  the  locomotive  manufacturer's operation manual.  Do not proceed unless the locomotive is operating satisfactorily according to the manufacturer's instructions. 2. Before departure, carry out the following: a.  Insure the  address  code  and  frequency  of  your  toggle controller  exactly  matches  the address code and frequency of the target equipment to be operated.  The address and frequency assigned to your controller is recorded (1) on the front page of this manual, and (2) on a serial tag located inside the battery door.  The address and frequency of the target receiver/decoder is recorded (1) on the front page of the manual supplied with the portable remote control system, and (2) on a label located inside the receiver/decoder.  If  a  controller  having  the  wrong  address  code  and  frequency  is  selected,  the  target equipment will not operate.  However, other equipment located at, around, or nearby your facility may become operational. Note:  If  you  are  not  familiar  with  the  controls  and  indicators  on  your  controller,  please refer to ‘Controls and Indicators’ in Section 3 of this  manual  and  the  operational  description  provided  with  your controller. b.  Set the controller’s Power ON/OFF Switch to the ‘ON’ position.   When transmitting with  a  good  battery,  two  short  ‘beeps’  will  be  heard  immediately  after  the  Power ON/OFF Switch is set to ‘ON’ and a green TRANSMIT LED will ‘flash’ rhythmically.  When the battery starts to go low, the green LED changes to a red LOW BATTERY LED  which  ‘flashes’  continuously.    This  means  you  should  change  or  re-charge  the battery pack as soon as possible - refer to Battery Packs and Battery Pack Charging in Section 3 of this manual. c.  Depress the HORN switch on the controller.  The horn should sound on the target locomotive.
 Section 2, Page 14    ©02/2010, CATTRON-THEIMEG™ Radio Control Operator's Duties – Locomotive, continued. d. Check  each  brake  function  independently  to  be  sure  the  locomotive  is  responding correctly  to  all  brake  applications,  including  emergency  stop  and  release  commands.  Observe gages  in  the cab  for  proper  readings  and  verify that  the  brake cylinders are moving properly.  e.  Test train brakes (if equipped). f.  Check all auxiliary equipment, such as bell, headlight, sanders, uncouple, etc.   3.  You must report all defective or missing safety equipment, mechanical or electrical defects to your supervisor without delay.  Do not continue operation until fully repaired.    4.  When ready to  move the locomotive for the first time, proceed slowly and make certain the load is under control.     5.  Take the slack out of the couplers gradually and make sure hands and other objects are clear before making command.   6.  Keep all  parts  of the body away from the rolling  equipment and never walk on the tracks ahead of the train.    7.  Do not move the locomotive if anyone is in a position to be injured.   8.  If anyone is in the path of travel, stop and sound the horn before proceeding.  Do not proceed until the track is clear.   9.  Heavy bumping of cars or stops is prohibited. 10.  When leaving the locomotive for any reason, be sure the locomotive throttle is set to ‘IDLE’ and the  brakes  are  fully applied.    Set  the  controller’s  Power  ON/OFF Switch to  the  ‘OFF’ position.    If  this  is  a  Key  Switch,  remove  the  key  from  the  controller  and  keep  it  on  your person. 11.  Do not allow any unauthorized person to operate the controller. 12.  Do not operate the controller at a  distance  where  the locomotive, railcars,  rail-track, and all surrounding objects are not visible. 13.  Do not attempt to override any of the safety features built into the Radio Control System. 14.  If, for any reason, you or anyone has to board a radio controlled locomotive or train, set the controller’s Power ON/OFF Switch to the ‘OFF’ position. If this is a Key Switch, remove the key from the controller and keep it on your person.    END OF SECTION
 ©02/2010, CATTRON-THEIMEG™     Section 3, Page 1 Section 3 – Operating Instructions  Controls and Indicators. Each toggle controller has been designed and custom built for a specific remote control application, therefore its operation will differ from model to model.   For this reason, it is not possible to describe an  individual  controller’s  switch  and  indicator  configuration  in  this  manual  –  there  are  too  many variations.    However,  all  toggle  controllers  incorporate  some  or  all  of  the  controls  and  indicators identified in Figure 3-1 below.  For your controller’s exact switch and indicator configuration, please refer to the schematic drawing provided with your toggle controller. Figure 3-1.  Toggle Controller – controls, indicators and features PTO BAR SWITCHON/OFFKEY SWITCHEXTERNAL ANTENNA‘LOW BATTERY’& ‘TRANSMIT’ LEDSTRAP/HARNESSANCHOR BRACKETSIDE MOUNTEDLEVER POD‘FLAG’ STYLELEVER PADDLETOGGLESWITCHPUSHBUTTONSWITCHROTARYSELECTORSWITCHDIGITALDISPLAY
 Section 3, Page 2    ©02/2010, CATTRON-THEIMEG™ Controls and Indicators, continued. POWER ON/OFF KEY SWITCH – This key switch prevents unauthorized personnel from operating the control system.   When the key switch is set to ‘ON’, internal battery power is applied to an RF transmitter  within  the  controller  and  the  operator  can  control  all  auxiliary  (non-motion)  functions without  pressing the  PUSH-TO-OPERATE  (PTO)  bar.    The  power  ON/OFF  key switch  controls  a mainline magnetic contactor on the machine.  This in turn controls the main power to the machine motors.  When the controller is not in use, the key may be withdrawn from its switch location and kept on the operator’s person.   Note that on some controllers, a front panel mounted, maintained 2-position toggle switch may be substituted for this side mounted key switch. PUSH-TO-OPERATE (PTO) BAR  - This bar is a large, full length, spring-return switch located on top  of  the  unit  that  is  generally  used  as  a  safety  device  that  electronically  disconnects  all  motion switches  when  it  is  released,  thus  stopping  motion  commands  from  these  switches.    The  switch  is easily and naturally activated by a convenient and comfortable part of the operator's hand and must be depressed and maintained before and when any motor or motion command is initiated.   It should be noted that operation of the PTO bar is not required for auxiliary functions, i.e. magnet, lights, etc.  For the  exact  configuration  of  the  PTO  Bar,  refer  to  the  custom  drawing  package  supplied  with  your controller.  SWITCHES –  Depending upon the control application, your controller may be configured with some or all of the following switch types: • 3-position, spring return-to-center toggle – mainly used for motion control • Maintained 2-position toggle – mainly used for function select (forward/reverse) • Momentary pushbutton or toggle – mainly used for non motion functions (horn, light) • Rotary selector – mainly used for address selection.    SIDE MOUNTED LEVER POD(S) – Side mounted lever pods can be added to one or both sides of the toggle controller.  These lever type switches provide functional control of proportional devices, as well  as  five  steps  either  side  of  center.    For  locomotive  applications,  when  the  throttle  and  brake controls each require their own lever pod, normal configuration is: (1) lever for the THROTTLE on the right hand side, (2) lever for the BRAKE on the left hand side, and (3) all other functions using toggle or pushbutton switches.   For crane applications, an auxiliary hoist with stepped or stepless control may require a single lever pod mounted to the right hand side of the controller.  All other functions (brake, alarm, three-speed bridge, trolley, and hoist) will be satisfied using toggle switches.  In addition to the ‘Flag’  style  lever  paddle  (illustrated),  different  style  levers  and  knobs  are  available  –  refer  to ‘Accessories’ in Section 5 of this manual for details. TRANSMIT & LOW BATTERY LED – This LED is part of the battery management system and  flashes  green  when  the  controller’s  Power  ON/OFF  Switch  is  set  to  ‘ON’  and  the  controller  is transmitting with a good battery installed.  The LED flashes red when the battery is low and sounds a beeper  to  alert  the  operator.  In  addition,  a  low  battery  cut-off  circuit  stops  the  controller  micro-processor  when  voltage  goes  below  safe  operating  range.    This  is  because  RF  transmitters  always operate at full power over the entire life of the battery. DIGITAL DISPLAY – This display is provided when multiple systems are under the control of one controller.  A typical example is a ballast train with up to 1,000 hopper cars, where any one of these railcars may be individually targeted, selected and unloaded using the toggle controller.  The digital display is used to select and display the targeted railcar using its identification number.
 ©02/2010, CATTRON-THEIMEG™     Section 3, Page 3 General Operating Procedure.  NOTES:  When using the controller, operators are instructed to wear a factory approved carrying harness with the controller attached at all times.     If a controller must be left unattended, the STOP Switch (when installed to the controller) should be depressed and the controller’s POWER ON/OFF switch set to ‘OFF’.  If the POWER ON/OFF switch is a key switch, the key should also be removed to prevent unauthorized use of the controller.   Carrying the controller using a Shoulder Strap or Chest Harness will greatly enhance operator comfort.  Refer to Figure 3-2 below for illustrative details and CATTRON-THEIMEG™ Part Numbers. 1. Referring to Figure 3-2 below, put on the shoulder strap or chest harness, attach the controller to the harness and adjust for comfortable operation. Figure 3-2. Toggle Controller - carrying options CHEST HARNESSPART NUMBER 42C-0056SHOULDER STRAPPART NUMBER 42C-0057
 Section 3, Page 4    ©02/2010, CATTRON-THEIMEG™ General Operating Procedure, continued.  NOTES:   Holding the PTO bar down when power is turned on places the controller in a technical diagnostic mode - refer to Maintenance Instructions (Section 4) for details.  The PTO bar must be up when starting the controller or the system will not operate.    On some controllers, the side mounted Power ON/OFF Key Switch may be replaced with a front panel mounted, 2-position maintained toggle switch. 2. Set  the  controller’s  Power  ON/OFF  Switch  to  ‘ON’.    Observe  that  the  TRANSMIT/LOW BATTERY LED momentarily flashes yellow and two quick ‘beeps’ are heard. If the LED is red, replace or recharge the battery pack – refer to Battery Packs and Battery Pack Charging at the end of this section. When transmitting with a good battery pack, the green TRANSMIT LED should ‘flash’ rhythmically. 3. When your controller is equipped with the optional ‘Keyless Entry Code’ feature, an assigned sequence of function switches must be operated within 10 seconds after the Power ON/OFF Switch is set to ‘ON’.  These switches will not operate any functions and the controller power comes on only after the correct sequence has been entered. 4. When  your controller is equipped with an ADDRESS SELECTOR  SWITCH, operating  this switch  will  change the system  address,  thus  allowing a single  controller  to  operate  multiple controlled  machines.    Extreme  caution  should  be  used  to  insure  that  you  do  not  select  the wrong machine.      WARNING: AFTER  CHANGING  AN  ADDRESS  SELECTOR  SWITCH,  YOU  MUST,  IN THE FIRST  INSTANCE,   INSURE THE  TARGETED  MACHINE  IS  UNDER REMOTE  CONTROL  BEFORE  OPERATING  ANY  MOTION  FUNCTION SWITCH.    THIS  MAY  BE  ACCOMPLISHED  BY  OPERATING  A  NON MOTION FUNCTION SWITCH ON THE REMOTE CONTROLLER SUCH AS A HORN OR LIGHT.  FAILURE  TO  COMPLY  WITH  THE  ABOVE WARNING MAY RESULT  IN THE  UNDESIRED  OPERATION  OF  OTHER  EQUIPMENT  WHICH,  IN TURN, COULD RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.
 ©02/2010, CATTRON-THEIMEG™     Section 3, Page 5 General Operating Procedure, continued.  5. Place a convenient and comfortable part of the operator's hand on the PUSH TO OPERATE BAR on top of the controller.  This switch must be depressed and maintained before and when any motor or motion command is initiated.   WARNING: NEVER DISABLE THE PUSH TO OPERATE (PTO) BAR SWITCH ON YOUR REMOTE CONTROLLER.  FAILURE TO COMPLY WITH THIS WARNING MAY  RESULT  IN  DAMAGE  TO  EQUIPMENT,  SERIOUS  INJURY,  OR DEATH.    6.  Operate the motion control toggle switches as required, remembering that the toggles must be pulled upward for all REVERSE and UP motions and pushed down for all FORWARD and DOWN  motions.    A  speed increase is  obtained  by selecting  different,  appropriately marked toggle  switches.    Compass  direction  labels  (N,  S,  E,  &  W)  may  be  engraved  next  to  the appropriate switches.   7.  While commanding a motion with a switch, release the PUSH TO OPERATE BAR without centering the toggle switch.   The motion must stop - if this does not happen, set the controller’s Power ON/OFF Switch to ‘OFF’ and notify your supervisor immediately.
 Section 3, Page 6    ©02/2010, CATTRON-THEIMEG™ TYPICAL CRANE CONTROL FUNCTIONS.   In addition to the controls and indicators described at the beginning of this section, some or all the control functions described and illustrated below may be applicable to your crane control application.  Unless  notified  to  the  contrary,  the  following Control  Functions  do  not require  the  PTO  Bar  to  be pressed to enable their operation.   Figure 3-3.  Crane Toggle Controller – typical configuration   1.  ALARM, RESET or ALARM/RESET SWITCH (if equipped) – When this momentary toggle or pushbutton switch is used as an ALARM, it operates a bell, horn, or other warning device on the  crane.    When  used  as  a  RESET,  this  switch  resets  the  mainline  contactor  when  it  has previously  been  switched  or  tripped  OFF  due  to  a  relay  failure  or  overload,  thus  allowing power  to  be  supplied  to  the  crane  motors.    When  used  as  an  ALARM/RESET,  this  switch operates the ALARM and RESET functions simultaneously.
 ©02/2010, CATTRON-THEIMEG™     Section 3, Page 7 TYPICAL CRANE CONTROL FUNCTIONS, continued. 2.  MAGNET, VACUUM, or GRAB - Extra precautions are built into the MAGNET, VACUUM and  GRAB  functions  to  prevent  accidental  release.    Two  momentary  switches  (buttons  or toggles) are normally used for these functions.  Accidental operation of the magnet, vacuum or grab is minimized by locating these buttons as far as possible from other controls and requires two fingers to release the load.   The Standard Operating Procedure (SOP) for  each of these functions is detailed below; however, this procedure may be changed, depending on the system application.    Please  note  that  any  deviation  from  the  SOP  will  be  advised  in  the  drawing package supplied with your PRC system.  Magnet  To Lift, press and hold ‘LIFT’ for one second. To Drop, press and hold ‘LIFT’, wait for one second, then press and hold  ‘DROP’. After load is dropped, release ‘LIFT’ first, then release ‘DROP’.    Vacuum  To Lift, press and hold ‘VACUUM’ for one second. To Drop, press and hold ‘VACUUM’, wait for one second, then press and hold ‘RELEASE’. After  load  is  dropped,  release  ‘VACUUM’  first,  then  release ‘RELEASE’.  Grab    To Close, press ‘CLOSE’. To open, press and hold ‘CLOSE’, then press ‘OPEN’. After grab is opened, release ‘CLOSE’ first, then release ‘OPEN’.   3.  BRAKE SWITCH - This momentary pushbutton switch is used for manual control of the crane bridge  brakes,  usually  a  parking  brake,  or  the  second  step  of  a  running  brake  (first  step normally comes on when motor is made neutral and released when direction is selected). Other brake functions are available such as PARKING BRAKE RELEASE, COAST, etc. 4.  HOOK/GRAB ROTATE SWITCH - This control function is normally a spring return-to-center (OFF  position)  toggle  switch.    It  allows  a  motorized  hook  or  grab  to  be  turned  in  either  a clockwise (CW) or counter-clockwise (CCW) direction.  5.  CRANE LIGHT ON/OFF SWITCH - This maintained toggle switch provides ON/OFF control of the crane lights.  Proper decoder circuitry insures that they remain latched ‘ON’ if required. 6. CRANE SELECT SWITCH - This rotary or toggle switch is used when the controller operates more than one crane. The switch is used to select the desired crane by changing the controller's digital address. If switched while the unit is on, the power is switched off automatically for 10 seconds, then starts up automatically on the new address. All motor levers and motion control switches on the controller must be neutral during this time.
 Section 3, Page 8    ©02/2010, CATTRON-THEIMEG™ TYPICAL CRANE CONTROL FUNCTIONS, continued.      WARNING: AFTER CHANGING AN ADDRESS OR FREQUENCY SELECTOR SWITCH, YOU  MUST,  IN  THE  FIRST  INSTANCE,    INSURE  THE  TARGETED MACHINE  IS  UNDER  REMOTE  CONTROL  BEFORE  OPERATING  ANY MOTION  FUNCTION  SWITCH.    THIS  MAY  BE  ACCOMPLISHED  BY OPERATING  A  NON  MOTION  FUNCTION  SWITCH  ON  THE  REMOTE CONTROLLER SUCH AS A HORN OR LIGHT.  FAILURE TO COMPLY WITH THE ABOVE WARNING MAY RESULT IN THE  UNDESIRED  OPERATION  OF  OTHER  EQUIPMENT  WHICH,  IN TURN, COULD RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.  7.    OPERATOR RELEASE ‘PITCH AND CATCH’ (Optional) – ‘Pitch and catch’ is the operation of  a  single  crane  by  two,  three,  or  four  operators  on  a  first-come,  first-served  basis.  This method provides lock out of the non-commanding operator(s) and allows only one operator at a time. An example of a two operator ‘pitch and catch’ operation follows: 7-1.  The crane is sitting idle and both controllers ‘A’ and ‘B’ are switched OFF. 7-2.  Operator ‘A’ turns his/her controller power to ‘ON’ and captures the crane.  One of two colored lights  on  the  crane,  energized  by  auxiliary  function  relays  in  the  receiver/decoder, indicates which operator has taken control of the crane.  It should be noted that Operator ‘A’ remains in control  even  if  Operator  ‘B’  switches  his  or  her  controller  power  to  ‘ON’  and  attempts  to control the crane – control access is denied to Operator ‘B’ at this time.  7-3. Operator ‘A’ may release the control of the crane to Operator ‘B’ in one of two ways: (1) The  first  way  is  by  pressing the  ‘RELEASE’  button  on  his/her  controller  (‘pitch’)  after Operator ‘B’ has turned his/her controller power to ‘ON’ and is ready to take control of the crane.   If Controller ‘B’ is transmitting the correct system identification address, Operator ‘B’  is  allowed  to take control (‘catch’).   Operator  ‘A’  is  now  denied control  access and should switch his/her controller power to ‘OFF’.  (2) The second way to transfer  control  from Operator ‘A’ to Operator ‘B’ is to simply turn Controller ‘A’ power to ‘OFF’ for a designated period of time (typically 45 seconds).  After this period of no transmission, if Controller ‘B’ power is set to ‘ON’ first, Operator ‘B’ will capture the crane. 8.  AUXILIARY HOIST UP/DOWN LEVER – this right hand side mounted lever pod allows the auxiliary hoist to be  moved ‘UP’ or ‘DOWN’.   If the lever is moved to  the center (neutral) position, hoist movement is disabled.   Note that the PTO Bar must be pressed to enable this motorized control function.
 ©02/2010, CATTRON-THEIMEG™     Section 3, Page 9 TYPICAL LOCOMOTIVE CONTROL FUNCTIONS.  In addition to the controls and indicators described at the beginning of this section, some or all the control  functions  described  and  illustrated  below  may  be  applicable  to  your  locomotive  control application.  Unless notified to the contrary, the following Control Functions do not require the PTO Bar to be pressed to enable their operation.   Figure 3-4.  Locomotive Toggle Controller – typical configurations  1. HORN - This momentary pushbutton or toggle switch sounds the horn when pressed. 2. HORN/RESET – This momentary pushbutton or toggle switch sounds the horn and provides the initial ‘RESET’ command to the radio receiver/decoder on  the locomotive.  This  switch must be activated after powering up the controller, otherwise the locomotive will not operate.  Observe that the horn will sound, thus identifying the locomotive is under radio control. 3.  DIRECTION  SWITCH  –  this  maintained  3-position  toggle  switch  controls  ‘FORWARD’ (hood)  and  ‘REVERSE’  (cab)  functions.  If  the  switch  is  moved  to  the  ‘NEUT’  (neutral  or center) position, direction is disabled.
 Section 3, Page 10    ©02/2010, CATTRON-THEIMEG™ TYPICAL LOCOMOTIVE CONTROL FUNCTIONS, continued. NOTE:  A change  in  the  Locomotive  direction  will  not occur  until  the  throttle is moved  to  idle  for  at  least  3-seconds.    Attempting  to  make  a  change  in direction while the throttle is advanced will cause the throttle to return to idle.    Some  systems  require  that  an  independent  brake  is  applied  for  3 seconds, or a specific brake cylinder pressure has been reached, before a change in direction can occur. 4.  ACCEL/HOLD/DECEL  SWITCH  - Controls  the  locomotive throttle.   This  spring return-to-center toggle switch spring returns to the ‘HOLD’ position when released.  Pulling the switch upwards to ‘ACCEL’ increments the throttle from idle to full, in 1-second steps.  Pushing the switch down to ‘DECEL’ causes the throttle to decrease, usually in 1-second steps.   Note that the PTO Bar must be pressed to enable this control function. If the PTO Bar is released, the throttle will normally be returned to ‘IDLE’. 5.  THROTTLE LEVER (Optional Side Mounted) Spring Return to  Idle - Controls  the throttle. Note  that  the  PTO  Bar  must be  pressed  to  enable  this  control  function.    If  the  PTO  Bar  is released, the throttle will normally be returned to ‘IDLE’. 6.  INDEPENDENT  BRAKE  LEVER  (Optional  Side  Mounted)    -  Controls  the  locomotive (independent)  brakes  using  five  maintained  positions  that  provide  the  following  braking functions: ‘REL’ -   Releases the brakes. ‘LAP'  –  Holds the independent brakes at the last applied pressure.     ‘SA’  -     Slow application of the independent brakes.     ‘QA’  -    Quick application of the independent brakes.   ‘EMG’ – Emergency application of the brakes, including the application of sand. Note that the  PTO Bar must  be pressed to  release the brakes.  In  most control  applications, when the PTO Bar is released, the independent brakes will be slowly applied. 7.  ‘LOCO’ BRAKE SWITCH  - Controls  the locomotive (independent)  braking functions.  This toggle switch has the following positions: ‘REL’ (Maintained) - Releases the independent brakes. ‘HOLD’  (Maintained)  –  In  this  position  the  independent  brakes  are  held  at  the  last applied brake pressure. ‘APPLY’ (Momentary) - Slow application of the independent brakes as long as switch is held.  Upon release, this switch spring-returns to the ‘HOLD’ position and maintains the last applied brake pressure. Note that the  PTO Bar must  be pressed to  release the brakes.  In  most control  applications, when the PTO Bar is released, the independent brakes will be slowly applied.
 ©02/2010, CATTRON-THEIMEG™     Section 3, Page 11 TYPICAL LOCOMOTIVE CONTROL FUNCTIONS, continued.   8.  ‘EMG  BRAKE’  SWITCH  –  When  set  to  the  ‘EMG  BRAKE’  position,  this  maintained  2-position switch applies the independent brakes, together with the application of sand.   9.  ‘TRAIN’ BRAKES -  This  3-position  switch  controls the  train  brakes  and  has the  following functions: APPLY (Momentary) – Applies the railcar brakes by reducing the air supply to the train air line. HOLD (Maintained) - Seals off the train air line so no further reduction or release will occur. RELEASE (Maintained) - Puts air into the train air line to release the railcar brakes. 10. SAND  –  This  momentary toggle  switch applies  sand to  the rails  when  held  in  the  ‘SAND’ position. 11. BELL - Sounds the locomotive bell when set to ‘ON’.  This function may be programmed to activate with throttle or direction. 12. HEADLIGHT  ON/OFF  –  When  installed,  this  maintained  toggle  switch enables  the HEADLIGHT ‘BRIGHT/DIM’ headlight function described below. 13. HEADLIGHT  ‘BRIGHT/DIM’  –  Provided  (1)  the  HEADLIGHT  ON/OFF  switch  is  set  to ‘ON’, or (2) the headlight switch in the locomotive cab is set to dim, this maintained switch selects the desired brightness of the headlight.  14. UNCOUPLE – Provided there is no tractive pull on the couplers, setting this spring return-to-center (OFF position) switch to ‘FRONT’ or ‘REAR’ will retract the respective coupling pin from the front or rear of the locomotive. 15. ALERTER - If equipped with the ‘ALERTER’ option, a switch must be moved by the operator at least once every 20 seconds (or the amount of time you have programmed) or the controller beeper will sound.  If no action is taken within the next 10 seconds, a function is sent to stop the locomotive.  Moving any switch, including the PTO Bar, will reset the Alerter timeout.
 Section 3, Page 12    ©02/2010, CATTRON-THEIMEG™ TYPICAL LOCOMOTIVE CONTROL FUNCTIONS, continued. 16.   OPERATOR RELEASE ‘PITCH  AND CATCH’  (Optional) –  Locomotive  ‘pitch and  catch’ allows two operators to swap control to and from each other, based upon which operator should be  commanding  movement.      Typically,  a  selector  switch  mounted  on  the  side  of  the locomotive  mounted  Receiver/decoder  enclosure  is  used  to  select  single  or  dual  operator control.   When  the  switch  is  selected  for  two  operators,  the  Receiver/decoder  will  not  allow  the locomotive  to  operate  unless  both  transmitters  are  detected.      If  at  any  time,  only  one transmitter is detected, the throttle will return to idle and the brakes will set.  While in two-operator mode, the primary controller operator will have control of all functions (i.e. throttle, direction, brakes, etc.) and be protected by the controller’s internal tilt switch. The secondary controller operator will maintain control of the ‘HORN’, ‘BELL’, and ‘STOP’ functions, together with other auxiliary functions as designated at the time of system design.  He or she will also be protected by the controller’s internal tilt switch.  For example, should either the primary or secondary operator fall, the Receiver/decoder will stop  the  locomotive  (typically,  setting  throttle  to  idle,  applying  full  independent  brakes, sounding the horn for 10 minutes and, when installed, activating a ‘MAN DOWN’ alarm).   It must be noted that the operator who commands a tilt or ‘STOP’ shutdown must also be the one to ‘RESET’ the shutdown condition. In a typical locomotive application, before a pitch can be made, the following conditions must be satisfied: • The Locomotive must be stopped. • Both controllers must be selecting ‘NEUTRAL’. • Both  controllers  must  have  the  same  selection  on  the  ‘INDEPENDENT’  and ‘AUTOMATIC’ brake override switch. • The  primary  controller  operator  must  depress  the  ‘OPERATOR  RELEASE’ pushbutton. • The  secondary  controller  operator  must  depress  the  ‘OPERATOR  ACCEPT’ pushbutton. As  long  as  the  above  conditions  are  met,  transfer  of  control  will  occur.      In  addition,  if TALKBACK™ is available on your control system, a ‘PRIMARY CONTROL’ indicator will illuminate on the controller in full control.
 ©02/2010, CATTRON-THEIMEG™     Section 3, Page 13 TYPICAL RAILCAR CONTROL FUNCTIONS – BALLAST CAR.  In addition to the controls and indicators described at the beginning of this section, some or all the control functions described and illustrated below may be applicable to your railcar.  In the example application  given  below,  up  to  two  remote  control  operators  are  able  to  control  the  distribution  of ballast  to  the  rail  track.    The  two  operators  can  safely  open  and  close  all  four  hopper  car  doors, directing ballast to the left, center, or right of each rail.  Both operators are normally positioned on opposite sides of the ballast car and should not have the same channel address selected on their toggle controllers.   In this particular application, Control Functions do not require the PTO Bar to be pressed to enable their operation.   Figure 3-5.  Ballast Car Toggle Controller – typical configuration   1.  ADDRESS CHANNEL SELECTOR – This 3-position rotary selector switch is used to select which side of the ballast car the two operators will be stationed.  For example: Operator No. 1 selects  controller  ‘CHANNEL  1’  and  stands  trackside  with  a  commanding  view  of  the  two hopper  doors  on  the  left  hand  side  of  the  targeted  ballast  car.    Conversely,  Operator  No.  2 selects controller ‘CHANNEL 2’ and stands trackside to view the two hopper doors on the right hand side of the same ballast car.   With this selector switch set to its center ‘OFF’ position, no address channel is selected and remote control operations will be disabled.
 Section 3, Page 14    ©02/2010, CATTRON-THEIMEG™ TYPICAL RAILCAR CONTROL FUNCTIONS, continued.  2.  CAR I.D. TOGGLE SWITCH – These 3-position, spring return-to-center switches are used to set the targeted ballast car identification (I.D.) number.   This I.D. number consists of the last three  digits  of  the  serial  number  located  on  the  outside  of  the  ballast  car.    Starting  with  the HUNDREDS switch,  pushing upwards  increments  the  first  (hundred’s) digit of  the CAR  I.D. DISPLAY.  Conversely, pushing the same switch down decrements the first (hundred’s) digit of the CAR I.D. DISPLAY. Operation of the TENS and UNITS toggle switches in the same manner will increment or decrement the second and third digits of the CAR I.D. DISPLAY respectively.  In  this  application,  the  first  time  one  of  these  toggle  switches  is  activated,  the  CAR  I.D. DISPLAY will illuminate and the digit count is not incremented or decremented.   3.  CAR I.D.  DISPLAY –  This  digital  display  shows  the  current  3-digit  ballast  car  I.D.  number selected on the controller.  To conserve battery power, the display automatically blanks out after 5 seconds if no new car I.D. selections are made.  In addition, if no new car I.D. selections have been made after one hour has lapsed, the display goes into a ‘deep sleep’ mode.  To reset the display, the controller’s Power ON/OFF Switch must be set to ‘OFF’, and then set to ‘ON’ again. 4.  SIDE  SELECTOR  –  This  3-position  rotary  selector  switch  is  used  to  select  the  SIDE  1, CENTER or SIDE 2 doors.  5.  DOOR OPEN/CLOSE TOGGLE SWITCHES – Four toggle switches are provided, one for each door.  The ballast car has four doors denoted A, B, C, and D, with three sides each that allow ballast to be released to SIDE 1, CENTER, or SIDE 2 of the rail as the train moves.  These 3-position, spring return-to-center switches are used to OPEN and CLOSE the selected door. Select the required DOOR A, B, C, or D, and operate the appropriate DOOR OPEN/CLOSE TOGGLE SWITCH.  Pushing the toggle switch upwards will OPEN the selected door. Pushing the toggle switch downwards will CLOSE the selected door.
 ©02/2010, CATTRON-THEIMEG™     Section 3, Page 15 Switch Diagnostic Mode. In this mode the operator can easily check that all function switches (motion and non-motion) are fully operational.       WARNING: ELECTRICAL  POWER  TO  THE  TARGET  CONTROLLED  EQUIPMENT MUST BE COMPLETELY ISOLATED TO PREVENT OPERATION UNDER REMOTE CONTROL IN THE SWITCH DIAGNOSTIC MODE.  FAILURE TO COMPLY WITH THE ABOVE WARNING MAY RESULT IN THE  UNDESIRED  OPERATION  OF  EQUIPMENT  WHICH,  IN  TURN, COULD RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.  This is accomplished by first turning off power to the controller using the Power ON/OFF Key and/or Toggle Switch. Then, place the controller in a tilted (horizontal) position  with  its battery door face down.  To enable the switch diagnostic mode, re-apply power using the Power ON/OFF Switch(es) while the controller is in the horizontal position.  This  mode  of  diagnostics  activates  the  beeper  when  (1)  each  non-motion  (auxiliary)  toggle  and pushbutton switch changes state, and (2) when any motion toggle, pushbutton, or side mounted paddle switch  changes  state,  provided the  PTO  Bar  is  pressed  and  held  down  each  time  the  function switch changes state.    For example,  push  any  one  of  the  auxiliary toggle  switches  UP  and  a  single  ‘beep’ will  be  heard.  Release the toggle switch and another single ‘beep’ will be heard as the switch spring returns to center.  Repeat  this  procedure  on  the  remaining  non-motion  toggle  and  pushbutton  switches  in  both  the UP/DOWN or  ON/OFF  positions.   If the switches  are functioning correctly, a ‘beep’ will be heard each time the switch changes state.  Repeat the above procedure on all motion function switches, remembering to enable these switches by pressing and holding the  PTO  Bar  down  at all  times while  operating these  motion switches.   If  an enabled motion function switch is functioning correctly, a ‘beep’ will be heard each time the switch changes state. To disable the switch diagnostic mode, simply turn the controller power to ‘OFF’, then re-apply power to the controller while it is in an upright position.
 Section 3, Page 16    ©02/2010, CATTRON-THEIMEG™ Battery Packs and Battery Pack Charging. The following battery pack and charging options are available for your controller and may be ordered from your nearest CATTRON-THEIMEG™ facility identified on the back page of this manual. Alkaline  Battery  Pack  providing  75  hours  of  continuous  operation.    This  battery  pack  is  not re-chargeable and should be discarded when exhausted. Nickel-Cadmium (Ni-Cad) Battery Pack providing approximately 23 hours of continuous operation.  This battery pack is re-chargeable using the CATTRON-THEIMEG™ 70C-0004 Battery Conditioner.  Table 3-1.  Battery Pack Options CATTRON-THEIMEG™ PART NUMBER TYPE  COLOR LIFE OPERATING HOURS RE-CHARGING TIME (using 70C-0004 Conditioner/charger) LIFETIME CYCLES C-8096  Ni-Cad Battery Pack Yellow  23*               3-Hours  200+ 60C-0023  Alkaline Battery Pack White  75*   Do Not Charge  1 * Battery life operating hours are based on continuous transmissions. Battery Conditioner - A CATTRON-THEIMEG™ Battery Conditioner/Charger (Part # 70C-0004) is available for use with CATTRON-THEIMEG™ C-8096 Ni-Cad Battery packs only.     Battery Pack Replacement, (Figure 3-6). When the TRANSMIT/LOW BATTERY LED starts flashing red, this alerts the operator that he or she has approximately one hour of continuous operation remaining, after which the battery pack must be replaced or re-charged.   To replace the battery pack, set the controller’s Power ON/OFF Switch(es) to the ‘OFF’ position.   Referring to  Figure 3-6  opposite,  unlatch  the battery  door  catch,  open  the  battery  door  and  lift  the battery pack out of the tray.   Install a fresh, fully charged battery pack in the unit, making sure the contacts on the underside of the battery pack locate with their corresponding pick-up contacts in the battery tray.
 ©02/2010, CATTRON-THEIMEG™     Section 3, Page 17 Battery Pack Replacement, continued. Close  the  battery  door  and  secure  by  latching  the  battery  door  catch.    Set  the  controller’s  Power ON/OFF  Switch(es)  to  ‘ON’.    Observe  that  the  TRANSMIT/LOW  BATTERY  LED  momentarily flashes yellow and two quick beeps are heard. When resuming  your  remote  control  operation,  observe the  TRANSMIT/LOW BATTERY  LED as you operate a non-motion function toggle switch such as a horn or light.  If this LED is now flashing green, your controller is fully operational. Figure 3-6.  Battery Pack Replacement. BATTERY PACKBATTERY PICKUPCONTACTSBATTERY DOORLATCHBATTERYDOORCATCHSERIALTAGHINGEDBATTERYDOOR
 Section 3, Page 18    ©02/2010, CATTRON-THEIMEG™ Ni-Cad Battery Pack Conditioning/Charging (Figure 3-7).   CAUTIONS: (1) CATTRON-THEIMEG™  Battery  Conditioners  are  designed  for  use  with CATTRON-THEIMEG™ Ni-Cad Battery Packs only.   (2) Battery Packs must be removed or disconnected from Battery Conditioners within 48-hours of achieving the fully charged state.   Failure to comply with these Cautions may result in equipment and/or battery damage and will void our warranty.   A  Ni-Cad  battery  pack  must  be  removed  from  the  controller’s  battery  compartment  for  external charging.  The Battery Conditioner includes a Mains VAC Adaptor that allows operation from mains supply  voltages  between  100  and  240VAC  @  50/60  kHz.      Referring  to  Figure  3-7  opposite,  this adaptor  is connected  as  shown.   Similarly,  when  installing the  Ni-Cad  Battery  Pack  to  the  Battery Conditioner, refer to Figure 3-7 for the appropriate locating instructions.  The Battery Conditioner automatically conditions the battery pack by first discharging it at 600mA for 2-hours  before  applying  a  rapid  charge  for  1-hour.    The  conditioner  incorporates  end  of  charge detection circuitry to accurately sense when the battery pack is fully charged.   When this condition has been detected, the conditioner switches to a ‘trickle’ mode that keeps the battery pack fully charged and ready to use for up to 48-hours.  To prevent damage to the battery pack, it should be removed from the conditioner within 48-hours of achieving a fully charged state. The  CATTRON-THEIMEG™  Battery  Conditioner  incorporates  an  LED  that  indicates  status  as follows: Amber Color – indicates the battery pack is being discharged. Red Color - indicates the battery pack is being charged at a rapid rate. Green Color - indicates the battery pack is fully charged and that a ‘trickle’ charge is being applied to maintain the fully charged state.  The battery pack is ready for use and should be removed from the conditioner within 48-hours.
 ©02/2010, CATTRON-THEIMEG™     Section 3, Page 19 Ni-Cad Battery Pack Conditioning/Charging , continued. Figure 3-7.  Ni -Cad Battery Pack Conditioning – interconnection details. 1.  REAR VIEW - CONNECTING THE VAC ADAPTOR2.  FRONT VIEW - INSTALLING THE BATTERY PACKOUTPUT JACKFROM MAINSVAC ADAPTORMAINS VAC ADAPTORVAC OUTLET18 VDC INPUT SOCKETBATTERY CONDITIONER(PART # 70C-0004)STATUSLEDNi-Cad BATTERY PACK(PART # C8096)
 Section 3, Page 20    ©02/2010, CATTRON-THEIMEG™ Pre-programmed Frequency Selection. If your Controller will be used to operate more than one crane, locomotive, or controlled machine, or be used as a spare controller for multiple remote control systems, up to sixteen selectable frequencies may  have  been  factory  pre-programmed  into  the  controller’s  EPROM.    To  see  if  this  selectable frequency option applies to your controller, refer to Figure 3-6 above and locate the serial tag on the inside  of  the  battery  door.    If  the  serial  tag  indicates  a  specific  frequency  in  the  FREQ  line  (i.e., 448.1000 MHz) the selectable pre-programmed frequency option does not apply to your controller.  If the serial tag indicates ‘SELECTABLE’ in the FREQ. line, refer to the frequency chart provided in your  custom  drawing  package.    This  frequency  chart  will  specify  the  pre-programmed  channel frequencies available with your controller.       WARNING: MORE  THAN  ONE  REMOTE  CONTROL  SYSTEM  MAY  BE  USED  AT, AROUND,  OR  NEARBY  YOUR  OPERATING  FACILITY.    THEREFORE, YOU MUST INSURE THE FREQUENCY OF YOUR TOGGLE CONTROLLER EXACTLY MATCHES THE FREQUENCY OF THE DESIRED EQUIPMENT TO BE OPERATED. FAILURE  TO  COMPLY  WITH  THE  ABOVE  WARNING  MAY  RESULT  IN THE  UNDESIRED  OPERATION  OF  OTHER  EQUIPMENT  WHICH,  IN TURN, COULD RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.  To select a pre-programmed frequency, proceed as follows: 1. Record the operating frequency of the intended equipment to be controlled – this may be found on the front cover of the manual provided with the target receiver/decoder, or on a serial tag located inside the target receiver/decoder enclosure. 2. Referring to the Frequency Chart supplied with your controller drawing package, locate the controller frequency that matches the equipment operating frequency recorded in the previous step, noting its corresponding Channel Address Number which may be from ‘0’ thru ‘7’ or ‘A’ thru ‘F’. 3. Set the controller’s Power ON/OFF Switch(es) to ‘OFF’. Referring to Figure 3-6 above, unlatch the battery door catch, open the battery door and remove the battery pack.   4. Referring to Figure 3-8 overleaf, set the four Frequency Channel Selector Switches to select the Channel Address Number previously noted in step 2., above.   5. Replace the battery pack in the unit, making sure the contacts on the underside of the battery pack locate with their corresponding pick-up contacts in the battery tray.  Close the battery door and secure by latching the battery door catch.  6. Set  the  controller’s  Power  ON/OFF  Switch(es)  to  ‘ON’.  Observe  that  the TRANSMIT/LOW BATTERY LED momentarily flashes yellow and two quick beeps are heard.  7. Operate a non-motion function such as a horn or light on the target equipment using the  appropriate  switch  and  observe  the  TRANSMIT/LOW  BATTERY  LED  and  the selected horn or light.  If the LED flashes green and the horn or light activates, your controller is fully operational.
 ©02/2010, CATTRON-THEIMEG™     Section 3, Page 21 Pre-programmed Frequency Selection, continued. Figure 3-8.  Pre-programmed Frequency Selection
 Section 3, Page 22    ©02/2010, CATTRON-THEIMEG™ Controller Operating Position for Mining Applications. Remote control operation in underground mining locations may be carried out in areas where space for the operator is severely restricted.  Frequently, the operator is required to sit, kneel, crouch, and stand when performing remote control operations.  To insure safe remote controlled operation at all times, the preferred Toggle Controller operating position is illustrated in  Figure 3-9 below.  Note that the Toggle Controller should always be  positioned with the control switches  facing upwards and the ‘PUSH TO OPERATE’ Bar facing forwards.   Figure 3-9.  Operating position- mining applications  'PUSH TO OPERATE'BAR  END OF SECTION
 ©02/2010, CATTRON-THEIMEG™     Section 4, Page 1 Section 4 – Maintenance Instructions CATTRON-THEIMEG™ Maintenance Philosophy. Our maintenance philosophy is that inoperative Toggle Controllers are returned as complete units to our  workshops  for  repair.    This  is  because  (a)  each  controller  is  customized  for  a  specific  control application which  severely restricts component/part  interchangeability, (b)  the  internal circuit  board and microprocessor is extremely sensitive to electrostatic discharge, and (c) internal components are highly  miniaturized  and  assembled  to  within  very  close  tolerances.    However,  CATTRON-THEIMEG™  will  permit  certain  preventive  and  corrective  maintenance  to  be  performed  without voiding our warranty, as follows:   Preventive Maintenance is a periodic check of the system to keep it functioning at peak performance. Preventive  maintenance  can  also  help  prevent  breakdowns  and  equipment  outages  by  identifying potential problems before they become real problems.  Corrective  Maintenance  refers  to  fixing  a  problem  once  it  has  occurred.  The  goal  of  corrective maintenance  is  to  get  the  system  back  on  line  as  quickly  as  possible  with  a  minimum  impact  on operations. Preventive maintenance. Preventive maintenance for CATTRON-THEIMEG™ Toggle Controllers is minimal because they are extremely durable and reliable units.  Preventive maintenance procedures are detailed in the following sub paragraphs: Daily Visual Inspection. Before use, visually inspect the controller for cleanliness, physical damage, and security of external parts  (screws,  switches,  rubber  grips,  etc.).  CATTRON-THEIMEG™  emphasizes  that  regular  visual inspections  not  only  mean  quickly  locating  a  source  of  potential  problems,  but  also  may  prevent serious problems from developing later. Special RF Test (CATTRON-THEIMEG™ trained technicians only). The  special  RF  test  mode  is  a  diagnostic  mode  that  is  incorporated  in  your  Toggle  Controller.  Controller outputs can be monitored on a spectrum analyzer/communication service monitor set to the same  frequency  as  the  controller.      We  emphasize  this  procedure  is  only  for  use  by  customer technicians  that  have  been  trained  by  ourselves  where  further  details  are  presented  during  the CATTRON-THEIMEG™ training course.   For information purposes, the actual RF test procedure is summarized on the next page:
 Section 4, Page 2    ©02/2010, CATTRON-THEIMEG™ Special RF Test, continued. With  PTO  Bar  switch  depressed,  setting  the  ON/OFF  KEYSWITCH  to  ‘ON’  will  transmit  a continuous beep and the green LED will illuminate continuously.  Continually cycling (pressing and releasing) the PTO bar switch three times will initiate the RF diagnostic sequence (the beep will stop).  Further PTO bar switch cycling will make the controller transmit the following: CYCLE    CONTROLLER TRANSMISSION 4    Maximum Low Frequency (a frequency 2.4 kHz lower than carrier) 5    Q- Sync (center of carrier) 6    Maximum High Frequency (a frequency 2.4 kHz higher than carrier) 7    2 kHz modulating sine wave (tone) 8    1-2-2-1 pattern square wave Annual Netting Check. Netting means that the receiver and transmitter of the radio control system are aligned on the same frequency.  It is very important that the receiver is exactly tuned to the frequency required. This check should be done once a year by a qualified radio technician utilizing calibrated test equipment. Troubleshooting. A  basic  Troubleshooting  Guide  is  provided  on  page  3  of  this  section.    For  safety  reasons,  when troubleshooting the Toggle controller, the power supply to the target equipment motors and all motion functions must be completely isolated to prevent operation under remote control.  However, the other major components of the remote control system (power supply and receiver/decoder) should be fully operational.  The remote control operator should also be located within 500 feet (160+ meters) of the target receiver/decoder.
 ©02/2010, CATTRON-THEIMEG™     Section 4, Page 3 Troubleshooting Guide.  WARNINGELECTRICAL POWER TO THE TARGET CONTROLLEDEQUIPMENT MUST BE COMPLETELY ISOLATED TO PREVENT OPERATION UNDER REMOTE CONTROLIN THE SWITCH DIAGNOSTIC MODE.FAILURE TO COMPLY WITH THIS WARNING MAY RESULTIN THE UNDESIRED OPERATION OF EQUIPMENTWHICH, IN TURN, COULD RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT.
 Section 4, Page 4    ©02/2010, CATTRON-THEIMEG™ Corrective maintenance. Corrective maintenance for the Toggle Controller is restricted to replacing the Battery Pack, Address Code  Plug  and,  when  installed,  Side  Lever(s)  and  External  Antenna.  Refer  to  the  Replacement Procedures below when removing and replacing items.  Having replaced an item, and before placing the Toggle Controller into operational service, carry out a Functional Check as follows:  Functional Check. 1.  Set  the  controller’s  Power  ON/OFF  Switch  to  ‘ON’.    Observe  that  the TRANSMIT/LOW BATTERY LED momentarily flashes yellow and two quick ‘beeps’ are heard.  2.  Operate a non-motion function such as a horn or light on the target equipment using the  appropriate  toggle  switch  and  observe  the  TRANSMIT/LOW  BATTERY  LED which should flash green. 3.  Set the controller’s Power ON/OFF Switch to ‘OFF’.   4.  Operate the controller in Switch Diagnostic Mode (refer to Section 3 for procedure), insuring all toggle, pushbutton, and side paddle function switches are fully operational.  Replacement Items. Replacement  items  and  accessories  for  your  controller  may  be  ordered  direct  from  CATTRON-THEIMEG™.    To  order  replacement  items,  refer  to  Section  5  of  this  manual  for  details  and  part numbers.   Replacement Procedures. Battery Pack Replacement. To replace the battery pack, proceed as follows: 1. Set the controller’s Power ON/OFF Switch to ‘OFF’.  2. Referring to Figure 4-1 opposite, unlatch the battery door catch, open the battery door and lift the battery pack out of the tray. 3. Install a fresh or fully charged battery pack in the unit, making sure the contacts on the underside of  the  battery pack locate with  their corresponding pick-up contacts  in the battery tray. 4. Close the battery door and secure by latching the battery door catch.   5. Carry out a Functional Check on the controller – refer to page 4 of this Section for details.
 ©02/2010, CATTRON-THEIMEG™     Section 4, Page 5 Battery Pack Replacement, continued. Figure 4-1.  Battery Pack Replacement. BATTERY PACKBATTERY PICKUPCONTACTSBATTERY DOORLATCHBATTERYDOORCATCHSERIAL TAGHINGEDBATTERYDOOR Address Code Plug Replacement. Each CATTRON-THEIMEG™ Toggle Controller is equipped with a code plug.  This code plug sets the address of the controller, which should always match the address of the target receiver/decoder.  When a command is received by the receiver/decoder, the address of the controller sending the signal is checked against the address of the receiver/decoder.  If the addresses do not match, the signal is ignored and an error message is displayed on the receiver/decoder.  For safety reasons, it is important that  no  two  controllers  at  a  location  use  the  same  address  settings.  This  could  cause  operation  of undesired equipment resulting in damage to equipment and/or personal injury. While the factory address setting will be adequate for most users, there may be conditions where it is necessary to change the address code.  Such conditions include the use of a spare controller, or when your  controller  will  be  used  to  operate  more  than  one  crane,  locomotive,  or  controlled  machine.  Before making any change in the address code setting, you will be required to identify the address code of the target receiver/decoder. The code assigned  to  the receiver/decoder at  the  factory  is  found on a  serial  tag  located  inside the target receiver/decoder. For information on setting the address code for your receiver/decoder, refer to the documentation provided with the receiver/decoder.
 Section 4, Page 6    ©02/2010, CATTRON-THEIMEG™ Address Code Plug Replacement, continued.    WARNINGS: UNCODED  ADDRESS  PLUG(S)  SHALL  BE  PROGRAMMED  WITH  THE SAME  ADDRESS  CODE  AS  SET  IN  THE  TARGET  RECEIVER/DECODER.    IT  SHOULD  BE  FULLY  UNDERSTOOD  THAT  CATTRON-THEIMEG™ SHALL  NOT  BE  HELD  LIABLE  FOR  PERSONAL  INJURY,  DEATH, EQUIPMENT  OR  PROPERTY  DAMAGE  ARISING  FROM  DUPLICATED, INCORRECTLY PROGRAMMED OR INCORRECT CODE PLUG USAGE. IT  IS  YOUR  RESPONSIBILITY  TO  ESTABLISH  A  PROCEDURE  THAT INSURES  ONLY  THE  CODE  PLUG  CONFIGURED  FOR  A  PARTICULAR ADDRESS  IS  INSTALLED  IN  EQUIPMENT  DESIGNED  TO  OPERATE  ON THE  SAME  ADDRESS.    NEVER  PUT  MORE  THAN  ONE  CONTROLLER INTO  OPERATION  ON  THE  SAME  ADDRESS  AT  ANY  GIVEN  TIME.  CATTRON-THEIMEG™ STRONGLY  ADVISES YOU TO  IMPLEMENT  AND REGULARLY  UPDATE  A  REGISTER  OF  INDIVIDUAL  ADDRESSES  AND OPERATING  FREQUENCIES  ASSIGNED  TO  EACH  PORTABLE  RADIO REMOTE  CONTROL  (PRRC)  SYSTEM  LOCATED  AT  YOUR  OPERATING FACILITY.   IN ADDITION, ANY SPARE CODE PLUGS, OR CODE PLUGS INSTALLED  IN  EQUIPMENT  THAT  ARE  CONFIGURED  FOR  THE  SAME ADDRESS OF EQUIPMENT THAT IS IN SERVICE, MUST BE HELD UNDER LOCK AND KEY BY A DESIGNATED SUPERVISOR.   FAILURE  TO  COMPLY  WITH  THESE  WARNINGS  MAY  RESULT  IN OPERATION  OF  UNDESIRED  EQUIPMENT  WHICH  IN  TURN  COULD RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO EQUIPMENT. CATTRON-THEIMEG™ sets the address code of all toggle controllers before they leave the factory.  If  the  code  must  be  changed,  a  new  code  plug  with  the  new  address  code  must  be  obtained  from CATTRON-THEIMEG™.    In  some  circumstances  CATTRON-THEIMEG™  may  provide  blank,  or unset, code plugs.  An unset code plug must have a code set prior to installing in the decoder.  This is described  in  the  procedure  below.    Installing  an  unset  code  plug  in  the  controller  will  prevent  the controller from operating. To replace the code plug for your Toggle Controller, proceed as follows: 1. Set the controller’s Power ON/OFF Switch(es) to ‘OFF’.  2. Record the address code of the intended equipment to be controlled – this may be found on the front cover of the manual provided with the target receiver/decoder, or on a serial tag located inside the target receiver/decoder enclosure.
 ©02/2010, CATTRON-THEIMEG™     Section 4, Page 7 Address Code Plug Replacement, continued. 3.  Referring to Figure 4-1 above, unlatch the battery door catch, open the battery door and lift the battery pack out of the tray. 4.  Referring  to  Figure  4-2  below,  using  a  pair  of  small  flat  nosed  pliers,  remove  the existing ‘set’ code plug by pulling it straight up and away from its battery compartment location.  We recommend you: (1) tag the removed code plug with the serial number of the controller, and (2) deposit the code plug in a safe place under lock and key. Figure 4-2.  Code Plug Location.  5.  If the new code plug is blank (unset), set the new address code previously recorded in Step 2.  To set the code, pins 2 through 8 must be cut in a specific pattern.  Figure 4-3 below shows all possible address codes for the code plug.   For example, to set the code plug to Address Code 14, pins 4, and 6 must be cut.  DO NOT cut Pins 1, 9 and 10. ‘A’Top ofControllerBATTERYCOMPARTMENT‘SET’ CODEPLUG
 Section 4, Page 8    ©02/2010, CATTRON-THEIMEG™ Address Code Plug Replacement, continued. Figure 4-3.  Code plug settings.
 ©02/2010, CATTRON-THEIMEG™     Section 4, Page 9 Address Code Plug Replacement, continued. 6. Write  the  newly  set  address  code  on  the  side  of  the  code  plug  using  a  permanent marker.  7. Carefully install the new code plug, making sure the dot (Pin 1) faces the top of the controller – see Figure 4-2, above. 8. Referring  to  Figure  4-1  above,  replace  the  battery  pack  in  the  unit,  making sure  the contacts on the underside of the battery pack locate with  their corresponding pick-up contacts in the battery tray.  Close the battery door and secure by latching the battery door catch.  9. Carry out a Functional Check on the controller – refer to page 4 of this Section for details. Side Lever Replacement, (Figure 4-4). 1. To replace a side lever, remove Screw (1) using a 6/32" hexagonal key and withdraw Lever (2) from Shaft (3). 2. Install a new Lever (2) to the Shaft (3) and secure using Screw (1). Figure 4-4.  Lever Replacement.  External Antenna Replacement, (Figure 4-5).   1. Remove the External Antenna (1) by unscrewing in a counter-clockwise direction from its threaded TNC Connector (2) located on top of the controller. 2. The  new  Antenna  (1)  is  simply  installed  by  screwing  it  clockwise  into  the  TNC Connector (2).  1.  SCREW2.  LEVER3.  SHAFT123
 Section 4, Page 10    ©02/2010, CATTRON-THEIMEG™ External Antenna Replacement, continued. Figure 4-5.  External Antenna Replacement.           END OF SECTION  1.  EXTERNAL ANTENNA2.  THREADED TNC CONNECTORTOP OF CONTROLLER21
 ©02/2010, CATTRON-THEIMEG™     Section 5, Page 1 Section 5 – Replacement Items and Accessories Notable differences between controllers will include the quantity, type, and placement of toggle and pushbutton  switches.    For  an  individual  controller’s  exact  switch  and  indicator  configuration, including quantities  and part numbers,  you should  refer to  the schematic  drawing originally supplied with the toggle controller. NOTE: Replacement items referred to in Figure 5-1 overleaf should only be installed by approved customer technicians who have attended the CATTRON-THEIMEG™ Technician Training Course.     Referring to the illustration overleaf (Figure 5-1): • Toggle Switch Assemblies are supplied in a variety of configurations - cross refer to Table 5-1 below.  • Two types of Pushbutton Switch Assemblies are available - cross refer to Table 5-2 below.  • Items 1 through 26 are common to most toggle controllers  - cross refer to Table 5-3. Table 5-1.  Toggle Switch Assemblies COMPONENT DESCRIPTION  SWITCH BODY* IDENTIFIER CATTRON-THEIMEG™  PART NUMBER ON-OFF-ON   12TW1-1  40C-0112 ON-OFF-ON LKG.   12TW1-1A  40C-0356 ON-OFF   12TW1-3  40C-0005 ON-OFF LKG.   12TW1-3D  40C-0337 ON-OFF-(ON)   12TW1-5  40C-0113 ON-OFF-(LIFT ON)   12TW1-5N  40C-0315 (ON) OFF (ON)   12TW1-7  40C-0111 (LIFT ON) OFF (LIFT ON)   12TW1-7E  40C-0347 OFF (ON)   12TW1-8  40C-0170 OFF (LIFT ON)   12TW1-8F  40C-0303 * The identifier number is engraved on the switch body Table 5-2.   Pushbutton  Switch Assemblies COMPONENT DESCRIPTION  CATTRON-THEIMEG™  PART NUMBER RED PUSHBUTTON  40C-0308 GRAY PUSHBUTTON  40C-0308GRY
 Section 5, Page 2    ©02/2010, CATTRON-THEIMEG™ Figure 5-1.   Exploded ViewPUSHBUTTONSWITCH ASSEMBLY(see Table 5-2)10101516111214131317182024262526132245667891921222310TOGGLE SWITCHASSEMBLY(see Table 5-1)PUSHBUTTONSWITCHASSEMBLY(see Table 5-2)
 ©02/2010, CATTRON-THEIMEG™     Section 5, Page 3 Table 5-3.  Common items FIGURE 1, ITEM NUMBER COMPONENT DESCRIPTION  QUANTITY PER ASSEMBLY CATTRON-THEIMEG™  PART NUMBER 1  Screw, Truss Head, Phillips, 4-40 x 3/16  6  03C-0134 2  Nut, Hex, Encl Top 15-32  As required  02C-0011 3  Washer, Sealing, 15/32-32, Switch Panel  As required  04C-0047 4  Face Plate*  1  Refer to Controller S/N 5  Gasket, Sponge, 0.125" thick  2  32C-0066 6  Screw, Truss Head, Phillips, 8-32 x 1/4"  4  03C-0098 7A  Bracket, Delrin, 3.0" x 0.5"**  2  07C-0117 7B  Bracket, Aluminum, Face Mount, TO1  2  07C-0169 8  Switch Board, Toggle  1  01C-0183 9  Flexible Circuit, for Toggle Switch  As required  84C-0098 10  Screw, Truss Head, Phillips, 8-32 x 5/8"  14  03C-0094 11  Bracket Ring for carrying harness  2  07-83585B01 12  Screw, Truss Head, Phillips, 6-32 x 3/8"  4  03C-0095 13  ‘ON’/‘OFF’ Keyswitch Assembly  1  40C-0369 14  Key, complete with Hexagonal Knob  1  55C-0369K 15  LH Endcap Assembly  1  01C-0172L-03 16  Nut, Hex, 6-32, Self Locking, Nylon Insert  4  02C-0045 17  Encoder w/Transmitter***  1  E840T90 Series 18  Battery Door  1  15C-0073-01  -  …Gasket, Battery Door  1  32C-0031 -  …Tray, Battery  1  01C-0282 -  …Gasket, Battery Tray  1  32C-0050 19  Upper Housing  1  15C-0071-01 20  Lower Housing  1  15C-0072-02 21  LED, 2-color  1  48C-0227 22  PTO Bar, complete with Label  1  01C-0178-01 23  RH Endcap Assembly  1  01C-0172R-03 24  Catch, Miniature, Battery Cover  1  42C-0036 25  Strike Hook, Battery Door  1  42C-0037 26  Screw, Flat Head, Phillips, 2-56 x 1/8"  4  03C-0085    *   Custom manufactured at CATTRON-THEIMEG™ -  send controller S/N to obtain replacement.  **   For use with Revision 23 and older Switch Boards. ***  See schematic drawing originally supplied with controller for correct part number.
 Section 5, Page 4    ©02/2010, CATTRON-THEIMEG™ Consumable Items and Optional Accessories. Consumable  Items  and  Optional  Accessories  are  listed  in  Table  5-4  below  and  illustrated  on  the following pages.    When  ordering  replacement  items  from  CATTRON-THEIMEG™,  contact  our  sales  department  for pricing and  provide  the  Controller  model/serial  number  located  on  the  serial  tag  inside  the  battery compartment door. Table 5-4.  Consumable Items and Optional Accessories Item Number  CATTRON-THEIMEG™ Part Number Order Quantity  Item Description 1  60C-0023  1  Battery pack, Alkaline, 12.5V, non-rechargeable 2  C-8096  1  Battery pack, Ni-Cad, re-chargeable, 12.5V, 850 mAH 3  70C-0004  1  Battery Conditioner, 100-240 VAC input  4  42C-0057  1  Carrying strap, Padded, Shoulder style 5  42C-0056  1  Carrying strap, Chest Pack style 6  06C-0232  1  Code Plug, Unprogrammed 7  06C-0232P  1  Code Plug, Programmed 8  36C-0066  1  Custom Lever, Right Hand, Blank, threaded 9  36C-0067  1  Custom Lever, Left Hand, Blank, threaded 10  36C-0073-O   1    Knob, Oval, for Items 8 and 9 above 11  36C-0073-S  1    Knob, Square, for Items 8 and 9 above 12  36C-0073-C  1    Knob, Cylindrical, for Items 8 and 9 above 13  36C-0073-H  1    Knob, Hexagonal, for Items 8 and 9 above
 ©02/2010, CATTRON-THEIMEG™     Section 5, Page 5 Consumable Items and Optional Accessories, continued.    Item 1 – Part Number 60C-0023         Item 2 – Part Number C-8096   Item 3 – Part Number 70C-0004  MULTI-VOLTAGE ADAPTERBATTERY PACK CONDITIONERPART NUMBER 70C-0004 NON RE-CHARGEABLEALKALINE BATTERY PACK         (white color)RE-CHARGEABLENI-CAD BATTERY PACK       (yellow color)
 Section 5, Page 6    ©02/2010, CATTRON-THEIMEG™ Consumable Items and Optional Accessories, continued.   Item 4 – Part Number 42C-0057         Item 5 – Part Number 42C-0056  Item 6 – Part Number 06C-0232         Item 7 – Part Number 06C-0232P    CHESTHARNESSCARRYINGSTRAPSHOULDERCARRYINGSTRAP
 ©02/2010, CATTRON-THEIMEG™     Section 5, Page 7 Consumable Items and Optional Accessories, continued.  Item 8 – Part Number 36C-0066      Item 9 – Part Number 36C-0067   Item 10 – Part Number 36C-0073-O      Item 11 – Part Number 36C-0073-S   Item 12 – Part Number 36C-0073-C      Item 13– Part Number 36C-0073-H    END OF SECTION   CUSTOM RIGHTHAND LEVERCUSTOM LEFTHAND LEVER OVALKNOBSQUAREKNOBCYLINDRICALKNOB HEXAGONALKNOB
 Section 5, Page 8    ©02/2010, CATTRON-THEIMEG™      This page intentionally left blank
 03/2007, CATTRON-THEIMEG™   Index i Index A Accessories  ..................................... 5-4 Address code ................................... 2-1 Applications .................................... 1-3 Automatic safety override ............... 2-1 B Battery Conditioner ............... 3-16, 5-2   Battery door  ................................. 3-17 Battery pack conditioning ............ 3-18 Battery pack options  ..............1-2, 3-16 Battery pack replacement....... 3-17, 4-4 Battery Saver ................................... 1-2 C Carrying options ....................... 3-3, 5-3 Code plug replacement .................... 4-5 Controls and indicators  ................... 3-1 Corrective maintenance  .................. 4-4 Crane Control Functions.................. 3-6 Custom side levers & knobs  ........... 5-4 D Data error checking ........................  2-2 Digital display option .....................  3-2    F Frequency options .........................   1-3 Frequency selection ....................    3-18 Frequency verification  ...............    3-18 Frequently asked questions .............. 1-3 Functional check  ...........................   4-4 G General operating procedure .........   3-3 I Intelligent digital message protocol   2-1 L Lever replacement ......................... . 4-9 List of Abbreviations .......................... ii Locomotive Control Functions  .... ...3-9 M Maintenance instructions  ..............   4-1 Maintenance philosophy  ...............   4-1 N Netting Check ...............................   4-2 O ON/OFF power switch .................... 3-2 Operate (OPR) relay ..................... .. 2-1 Operating frequency ..................... .. 1-3 Operating instructions .................. .. 3-1 Optional accessories ..................... .. 5-4  Overview, remote control systems .. 1-7
 Index ii    ©03/2007, CATTRON-THEIMEG™ Index P Power On Self Test (POST)  ..........  1-2 Power ON/OFF switch  ..................  3-2  Pre-programmed Frequency  ........   3-18       selection Preventive maintenance .................  4-2 Push To Operate bar switch...... 2-2, 3-2 R Radio control operator’s duties:   General Equipment  ................  2-4   EOT Crane  ...........................    2-8   Locomotive  ..........................   2-12 Railcar Control Functions ............   3-13 Replacement items ................... 4-4, 5-1 Replacements:   Battery pack  ...........................  4-4   Address code plug....................  4-5   Side lever (optional)................  4-9   External Antenna (optional) ...  4-9    S Safety considerations ...................    2-1 Safety & security features ............    2-1 Side mounted levers................   1-2, 3-2 Standard specifications ................    1-5 Switches .......................................    3-2 Switch diagnostic mode................   3-15 T Technical Abbreviations .................    ii Toggle switch placement  ...............  1-2 Transmit/Low Battery indicator  ....  3-2 Troubleshooting guide..................    4-3 Typical method of operation ........    2-2
 02/2010, CATTRON-THEIMEG™   Cranesafety – page 1 RECOMMENDED SAFETY RULES FOR PORTABLE REMOTE CONTROLLED (PRC) CRANES For  the  purpose  of  these  rules,  Portable  Remote  Control  or  PRC  refers  to  Radio  Frequency  (RF) Controls. The information contained herein is based on data gathered from various users of portable remote control crane systems.  We emphasize that the recommendations contained herein are not intended to supersede the rules or regulations of our customers, or the rules and regulations of any applicable local, state, or federal government organizations.  It  must be fully understood that  the recommendations  contained  herein  are  provided  solely  for  your  consideration  and possible adoption. TABLE OF CONTENTS SECTION  TITLE                PAGE      1    Preface                     1      2    Operator Safety Basics                 2      2-1    Area Inspection                 2      2-2    Crane Inspection (mechanical & structural)           2      2-3    Operational Safety Check               3      3    Persons Authorized to Operate Remote Controlled cranes         3      4    Training Check List for Operation of Remote Controlled cranes       3      5    Operating Area for Remote Controlled Cranes           4      6    The Hand-held Portable Remote Controller             4      7    Operating the Remote Controlled Crane             5      8    Boarding the Remote Controlled Crane             6      9    On Board the Remote Controlled Crane             6    10    Remote Controlled Crane under Repair             7    11    The Condition of the Remote Controlled Crane           8 1.  PREFACE. 1-1.  Electric Overhead Traveling (EOT) Cranes typically operate in three motions.  They are large, bulky pieces  of equipment  that  handle heavy loads efficiently at comparatively high speeds.  Frequently, they are operated in restricted areas where workmen are engaged in various tasks on  the  floor  below.    Under these  conditions  crane  operators  using  Portable  Remote  Control (PRC) must take great care, and workmen must be constantly on the alert if accidents are to be avoided. 1-2.  The following guidelines have been carefully assembled and are promoted to indicate just how important  your  careful  and thoughtful  actions  are  in helping to  protect  you  and  your  fellow workers from harm, and also to prevent equipment damage. 1-3.  These  guidelines cover cranes when  they are  operational  in  Portable Remote Control (PRC) mode.    If  a  crane  is  operated  from  cab  or  pendant  control,  the  PRC  system’s  controller(s) should be completely isolated by removing the battery and held under lock and key. 1-4.  A routine pre-shift inspection of the crane takes a lot less time than repairing a crane suffering from a major problem.  In addition, such pre-shift inspections are to be considered as ‘safety basics’ which are an important part of a crane operator’s duties.
 Cranesafety – page 2    02/2010, CATTRON-THEIMEG™  2. OPERATOR SAFETY BASICS.  Before starting your shift as the crane operator, you should make  sure  the  crane  has  a  current  inspection  certificate  and  that  qualified  personnel  have carried out the following inspections and checks.  If any item below does not pass inspection, you should notify your supervisor immediately.  In many cases, the problem will need to be fixed before you are allowed to operate the crane.  In addition, did you realize that the person now reading these instructions is primarily responsible for his or her own health and safety? 2-1   Area Inspection.  • Take a good look around the work area for any obstructions. • Check that the rails are intact and not bent or damaged.  • Make sure there are no oil or brake fluid leaks on the area below where the crane travels. • Make sure rail stops are present, physically secure, and free of damage at the end of all crane rails.  • Check that walkways are sturdy and have handrails.  Ladders are not to be loose and all rungs are to be in place. 2-2.  Crane Inspection (mechanical & structural). • Make sure all moving machinery has protective guards installed over moving parts. • Make sure all bridge and trolley rail stops are welded or bolted in position with no evidence of damage from bridge or trolley impact.  • Check  for  proper  fluid  levels  and  make  sure  all  grease  fittings  are  lubricated  to manufacturer recommendations.  • Check for broken welds and cracks in the bridge structure.  • Check for wheel damage, broken welds on the frame, and drum damage.  • Check the wheels for flange wear, cracks, holes, or visible signs of bearing damage. • Make sure wire rope drums show proper wire rope lay; for example, each wire rope must lay in its own groove.  This does not mean in the non-grooved area in the center of the drum.  • Make  sure  wire  rope  size  is  correct  for  the  sheaves.    Look  for  either  oversized  or undersized rope that will not lay in the sheaves correctly.  Make sure the sheaves show no evidence of rope corrugation and have the proper wall thickness.  • Look for any type of bluing on the brake drums which indicates excessive heat.  Make sure there are no protruding rivets from the brake shoes.  Examine the shoes for glazing.  • Look for carbon dust around the inspection covers of electric motors.  Smell for any type of burning  smells.    Check  for  any  type  of  burning  on  electrical  covers.    Make  sure  all protective covers are installed. • Check  the  festoon  system  for  proper  connections  and  inspect  all  hooks  connecting  the festoon to the holding wire. • Load  bearing  parts  such  as  blocks  and  hooks  shall  have  no  signs  of  damage  and  be  in perfect working order.
 02/2010, CATTRON-THEIMEG™   Cranesafety – page 3 2.  OPERATOR SAFETY BASICS, continued.   2-3.  Operational Safety Check.  As a crane operator, you should satisfy yourself of the following.  If  any  item  below  does  not  meet  the  checklist  criteria,  you  shall  immediately  notify  your supervisor.  In many cases, the problem will need to be fixed before you are allowed to operate the crane.  Remember that the person now reading these instructions is primarily responsible for his or her own health and safety! • Horns, buzzers and all other warning devices shall be in working order. • All controls shall be in good working order. • STOP Buttons (when equipped) shall be in working order.  • The load brakes  shall  hold  the  load safely  at  all times.    The  only way  to  ensure  this is through a load test and inspection. • The ‘raise’ and ‘lower’ limit switches shall work correctly to help prevent two-blocking and accidental floor contact.  3.  PERSONS AUTHORIZED TO OPERATE REMOTE CONTROLLED CRANES. • Only  properly  trained  employees  who  have  been  designated  by  management  shall  be permitted to operate the crane. • Both the operator and management shall insure the correct controller to operate the crane is selected  and  that  any  spare  equipment  capable  of  controlling  the  crane  is  completely isolated and held under lock and key. • The crane shall not be operated by personnel who cannot read and understand the signs, notices and operating instructions. • The crane shall not be operated by personnel with seriously defective eyesight or hearing, personnel under the influence of drugs or alcohol that will impair judgment, or personnel who may be suffering from a disease which may cause physical failure.   4.  TRAINING  CHECKLIST  FOR  OPERATORS  OF  REMOTE  CONTROLLED CRANES.  As a minimum, Portable Remote Control Operators shall: • have knowledge of hazards inherent to crane operation. • have knowledge of safety guidelines for portable remote controlled cranes. • have the ability to judge distance to stationary objects. • have knowledge of the portable remote control system controller’s operation. • have performed limit switch test procedure before operating the crane. • have performed hoist, trolley and bridge brake test procedure before operating the crane. • have instructions as to plugging of crane motions when and where authorized. • observe signal lights on crane. • avoid striking any obstructions. • check for proper clearance of lifts or hooks before moving bridge or trolley. • properly store the portable remote controller when not in use. • know how to properly transfer the portable remote controller to another person. • report unsafe or unusual operating conditions. • use caution in approaching bridge or trolley end-stops. • know the crane’s capacity. • keep body clear of lifts, avoiding ‘pinch’ points. • Inspect cables and hooks.
 Cranesafety – page 4    02/2010, CATTRON-THEIMEG™ 5. THE OPERATING AREA FOR THE REMOTE CONTROLLED CRANE. • Unobstructed aisles between equipment, stock, etc. shall be maintained for the PRC crane operator's movement.  These aisles should be a minimum of 3 feet wide (1m) or per local regulations. • PRC crane operators shall always position themselves in a safe location with the best view of the crane they are controlling and never operate the crane blindly.  They shall always keep  the  crane  and  load  in  sight,  staying  as  close  as  practical  to  the  crane  load  while maintaining  a  safe  harms-way  distance.    Operators  shall  never  position  themselves  or others underneath the load or in a ‘pinch’ point. 6.  THE HAND-HELD PORTABLE REMOTE CONTROLLER. • Typically,  the  portable  remote  controller  incorporates  a  Push-To-Operate  (PTO)  bar  or START button, and its motion switches are spring return to OFF.  The PTO bar acts as a guard  for  these  switches  to  prevent  movement  of  the  crane  if  one  of  the  switches  is accidentally  bumped.    These  switches  and  the  PTO  bar  must  never  be  mechanically blocked in any ‘ON’ position. • Using  the  power  ON/OFF  switch(es),  the  portable  remote  controller  shall  be  switched ‘OFF’ when not in use.  When the controller is equipped with a STOP button, it shall be set to  the  ‘STOP’  position  before  switching  off  power  to  the  controller.    In  addition,  if equipped with a key, the key should be removed after use and kept in a secure location.  • A prescribed, controlled, storage space shall be provided for portable remote controllers.  All controllers shall have their batteries removed and be placed there when not in use.  This precaution  is  intended  to  prevent  unauthorized  personnel  from  operating  the  remote controlled crane. • When an operator is putting on or taking off the controller by means of its belt loop strap, carrying harness, or shoulder strap, the controller shall be switched OFF beforehand, using the appropriate ON/OFF switch(es).  When the controller is equipped with a STOP button, it shall be set to the ‘STOP’ position before switching off power to the controller. • The portable remote controller shall always be switched ‘OFF’ when not in use and, when practical, stored under lock and key.
 02/2010, CATTRON-THEIMEG™   Cranesafety – page 5 7.  OPERATING THE REMOTE CONTROLLED CRANE. • All  crane limit  switches  shall  be  checked at  the  beginning  of  each  turn  or  when  a  new operator takes control of the crane.  While checking the limit switches, the hoist shall be centered over an area free of personnel and equipment so that if the limit switches fail, and the  hook  and  block  assembly  falls,  no  one  will  be  injured  and  no  equipment  will  be damaged. • The limit switches shall never be used as a regular stopping devices.  They are intended to be protective devices only. • The bridge and trolley brakes shall be tested at the beginning of each turn or when a new operator takes control of the crane.  They should be tested with the bridge and trolley at low speed. • When lifting maximum or near maximum loads, the operator shall test the hoist brakes by raising the load a few inches from the floor.  If hoist brakes do not hold, the load shall be immediately lowered to the floor and a report made to the supervisor. • Do not make lifts in excess of the rated capacity of the crane.  • When making lifts, the bridge and trolley shall be centered directly over the load to prevent load swinging when the load is raised. • Side  pulls  shall  be  made  only  with  the  permission  of,  and  under  direct  supervision  of management.  When such a lift is being made, operators shall not position themselves in the line or path of travel of the load, but shall operate the crane from a position to the side opposite to the path of travel. • When  raising  or  lowering  a  load,  proceed  slowly  and  make  certain  the  load  is  under control.  Tag lines shall be used for handling lengths or bulky loads.  Take the slack out of the chains or slings gradually.  Make sure all personnel are clear before making a lift. • PRC  crane  operators  shall  keep  all  parts  of  their  bodies  away from  the  load  and  never position themselves under the load. • Do not make a lift or move the crane if anyone is in a position to be injured. • If a PRC crane operator is being helped, he or she shall not move the crane until he or she receives an ‘all clear’ signal from the helper(s). • Loads shall not be carried over workers' heads. • If anyone is in the path of travel, the portable remote control crane operator shall stop and clear the area before proceeding. • Bumping into runway stops or into other cranes on the same runway is prohibited. • When  moving  the  crane,  the  PRC  crane  operator  shall  make  sure  the  hook  block, attachment and/or cables will not fall on nearby equipment. • The PRC  crane operator shall not drag slings, chains,  etc.  along the floor.   These could snag on something on the floor, causing the cables to break and  strike the operator or a fellow worker. • If  gloves are  not  required for safety  reasons,  they shall not  be  used  when  operating the portable remote controller. • All loose material or parts shall be removed from the load before starting the lift.  Such material can fall and injure people below. • The PRC  crane operator  shall  hoist  lifts high enough to  clear  all apparatus  and workers below the crane.
 Cranesafety – page 6    02/2010, CATTRON-THEIMEG™ 7.  OPERATING THE REMOTE CONTROLLED CRANE, continued. • Plugging shall not be used as a regular means of stopping the crane and should be used for emergency stops only.  If approved, plugging should only be performed as dictated by plant operating procedures.   • If PRC crane operators are asked to do something they believe unsafe, they shall call their supervisors for advice. • PRC crane operators shall never permit anyone to ride on the load or hook except when authorized by their supervisor. • When  another  crane  on  the  same runway  is  stationary with  or  without  a  load,  the  PRC crane  operator  shall  maintain  a  safe  distance  between  the  crane  being  operated  and  the stationary  crane.    In  a  power  outage,  the  PRC  crane  operator  shall  set  the  ON/OFF switch(es)  on  the  controller  to  ‘OFF’,  keeping  them  in  the  OFF  position  until  power  is restored.   • If the PRC crane fails to respond correctly, the operator shall stop operation immediately by  setting  the  ON/OFF  switch(es)  on  the  controller  to  ‘OFF’.  When  the  controller  is equipped with a STOP button, this shall be set to the ‘STOP’ position before switching off power to the controller.  The fault condition shall be reported immediately to a supervisor. • Outside cranes subject to movement by winds, storms, etc. shall be securely anchored when left unattended.  If the crane is equipped with a bridge parking brake, it shall also be set. 8.  BOARDING THE REMOTE CONTROLLED CRANE (MAINTENANCE CREW). • The PRC crane shall not be boarded without permission of the supervisor in charge of crane operations in the area. • Using the power ON/OFF switch(es), the person boarding the PRC crane shall switch the portable remote controller to ‘OFF’ and take it with him or her on to the crane.  When the controller is equipped with a STOP button, this shall be set to the ‘STOP’ position before switching off power to the controller. • If the boarding party consists of more than one person, one person shall be designated as the leader of the boarding party. • The leader shall board the crane first, open and lock out the main switch (securing it with a padlock), and then signal the other members of the party that it is safe for them to board the crane. 9.  ON BOARD THE REMOTE CONTROLLED CRANE (MAINTENANCE CREW). • Head room is at a minimum in some crane cabs and on some crane walkways.  Caution shall be exercised by all people on board such cranes.  Hard hats shall be worn at all times. • If the repair crew consists of more than one person, one person shall be designated as the crew leader. • Warning signs shall be placed on the floor beneath the crane or suspended from the crane indicating the crane is being serviced. • If  any work to  be  done  on  the  crane  is  carried  out in  locations unprotected  by standard handrails,  safety  belts  shall  be  worn  by  all  crew  members  working  in  such  unprotected locations.
 02/2010, CATTRON-THEIMEG™   Cranesafety – page 7 9.  ON BOARD THE REMOTE CONTROLLED CRANE, continued. • All tools and equipment shall be moved onto the crane by the use of hand lines.  All tools and equipment shall be securely attached to hand lines. • If it is necessary to have the control circuits on the crane energized, the repair crew leader shall open all power circuits to the motions before closing the main switch. • If,  during the  course  of  repairs,  it  becomes  necessary to  move  the  crane,  it  shall  be  the responsibility  of  the  crew  leader  to  insure  that  all  personnel  located  on,  and  within  the operational area of the crane are in a safe position out of harms-way.  In addition the crew leader shall insure all tools and materials are stowed or tightly restrained before the crane is moved. • When the repair work is completed, the crew leader shall see that all crew members are off of the crane before he or she closes the main switch. • If more that one person is on board the PRC crane, one person shall be made responsible for seeing that all workers are off the crane before the portable remote controller is returned to operational use. 10.  REMOTE CONTROLLED CRANE UNDER REPAIR. • All persons operating other cranes on the same or adjacent runways shall be notified before anyone boards the subject crane.  Such notification should include limitations of adjacent crane movement while others are on board. • PRC  cranes which  have  been pre-positioned  for  repairs and  cannot be  moved should be protected against being bumped by other cranes on the runway.  Suitable bumpers adequate for the job should be installed on the exposed sides of the crane under  repair and  as far away from the crane as possible, with a minimum distance of 20 ft. (approximately. 6.1 m).  The location of these bumpers shall be indicated by red lights so that they are clearly visible to other persons operating cranes traveling on the same runway.  When it is impossible to use  bumpers  for  protection,  red  lights  shall  be  placed  in  clear  view  of  other  persons operating cranes on the same runway to indicate the restricted travel zone.  It is desirable that such red lights be located a minimum of 20 ft. (approx. 6.1 m) from the crane under repair.   • All  operators  of  cranes  on  the  same  runway  must  be  informed  of  the  repair  work, thoroughly instructed as to what their conduct should be for the duration of said repairs, and informed when repairs are completed.  • When there is a runway adjacent to the runway on which the crane is being repaired, and if any hazard exists involving repairmen, red lights shall be placed in clear view of persons traveling on the adjacent runway to indicate the restricted travel zone.  It is desirable that such red lights be located a minimum of 20 ft. (approx. 6.1 m) from the crane under repair.  When it is necessary to operate cranes on adjacent runways, such cranes shall come to a full stop before entering the restricted area.  Cranes traveling on adjacent runways may only proceed through the restricted area when permission has been received from a signalman posted for this purpose. • Access of persons to and from the crane being repaired shall be under the control of the repair crew leader.
 Cranesafety – page 8    02/2010, CATTRON-THEIMEG™ 10.  REMOTE CONTROLLED CRANE UNDER REPAIR, continued. • The floor area below the point where crane repairs are being made shall be roped off and posted with danger signs. • Handling of all small tools and materials, etc. from ground level to workers above shall be accomplished through the use of hand lines.  Tools, materials, etc. shall not be tossed from the crane to the ground level and vice versa. • If crane repairs make it necessary for crew members to work on areas of the crane other than those protected by standard handrails, such crew members shall wear approved safety belts. • If it is necessary to move the crane to check the performance of operation, the crew leader shall designate who remains on the crane.  The crew leader shall insure that all personnel located  on,  and  within  the  operational  area  of  the  crane  are  physically  located  in  a  safe position out of harms-way.  In addition the crew leader shall insure all tools and materials are stowed or tightly restrained before the main switch is closed and the crane is put into operation. • Upon completion of repairs, it is the crew leader's duty to personally insure that each person has left the crane and is clear before he or she removes the lock above the main switch and the crane is put back in operation. 11.  THE CONDITION OF THE REMOTE CONTROLLED CRANE.  It is recommended that a written report be sent to your supervisor whenever you detect any condition that makes the crane unsafe.   Many plants  supply printed  forms  for this purpose.   The  PRC crane  operator shall fill out these forms and turn them in at the end of each shift.  Certain faults which the PRC crane operator may detect will be so critical that the crane must be shut down at once and not operated until the fault is corrected.  Typical check list items may include some or all of the following: • Condition of hoisting cable, drum, and hook blocks (broken strands, clipped sheave wheels, etc.). • Condition of brakes (hoist, trolley and bridge). • Oil or brake fluid leaks on the runway area. • Alignment of bridge (screeching or squealing wheels indicate that bridge is out of line). • Condition of bridge structure (broken welds, cracks and distortion). • Broken, cracked or chipped rails on bridge or runway. • Condition  and  security  of  trolley  and  bridge  rail  end-stops  (missing  or  damaged  from impact). • Condition of all limit switches. • Conditions of controls (electrical or mechanical defects that may lead to faulty operation). • Condition of electric motors (carbon dust around inspection covers indicate worn brushes).  • Condition  of  gears  (grinding  or  squealing  may  mean  a  lack  of  lubrication  or  foreign materials in gear teeth). • Frequent overload relay tripping of power circuits. • Mechanical parts loosened by vibration (loose rivets, covers, etc.). • Wheel condition (flange wear, cracks, holes, or visible signs of bearing damage).
 02/2010, CATTRON-THEIMEG™   Cranesafety – page 9 11.  THE CONDITION OF THE REMOTE CONTROLLED CRANE, continued. • Bumpy riding (worn wheels). • Worn collector shoes or bars. • Burned out, broken, or inoperable warning or signal lights. • Unintended  stopping  or  starting  of  any  crane  motion,  warning  device,  light  or  auxiliary function. • Condition of walkways and ladders (missing or loose handrails, ladder rungs, etc.)  Portable Remote-controlled Crane operators shall not attempt to make any repairs by themselves. The fault condition(s) shall be reported to a supervisor to enable repairs to be carried out by suitably qualified personnel.  END   Internet Address for All CATTRON-THEIMEG™ Companies: www.cattron-theimeg.com
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 02/2010, CATTRON-THEIMEG™   Locosafety – page 1 RECOMMENDED SAFETY RULES FOR PORTABLE RADIO REMOTE CONTROLLED (PRRC) LOCOMOTIVES The  information  contained  herein  is  based  on  data  gathered  from  various  users  of  portable  radio remote control  locomotive  systems.  We emphasize that the recommendations contained herein are  not  intended  to  supersede  the  rules  or  regulations  of  our  customers,  or  the  rules  and regulations of any applicable local, state, or federal government organizations.  It must be fully understood  that  the recommendations  contained  herein  are  provided  solely  for  your consideration and possible adoption.  TABLE OF CONTENTS SECTION  TITLE                    PAGE      1    Preface                        1      2    Operator Safety Basics                    2      2-1    Area Inspection                    2      2-2    Locomotive & Railcar Inspection (mechanical & structural)         2      2-3    Operational Safety Check                  2      3    Persons Authorized to Operate Remote Controlled Locomotives          2      4    Training Checklist for Operation of Remote Controlled Locomotives      3      5    Operating Area for Remote Controlled Locomotives             3 6 Pre-departure Checks under Manual Control               3 7 The Portable Radio Remote Controller                4 8 Transferring the Locomotive to Radio Remote Control            5 9 Pre-departure Checks under Radio Remote Control              5 10    Operating the Remote Controlled Locomotive              6 11    Boarding the Remote Controlled Locomotive              7 12    On Board the Remote Controlled Locomotive              8 13    Remote Controlled Locomotive under Repair              8 14    The Condition of the Remote Controlled Locomotive          10 1. PREFACE. 1-1.  Locomotives operate in two motions.  They are large, bulky pieces of equipment that handle heavy loads  efficiently  at  comparatively high speeds.   Quite  frequently they are operated  in restricted areas where workmen are engaged in various tasks or there is pedestrian or vehicular traffic.    Under  these  conditions  locomotive  operators  using  Portable  Radio  Remote  Control must  take  great  care,  and  workmen  must  be  constantly  on  the  alert  if  accidents  are  to  be avoided. 1-2.  The following guidelines have been carefully assembled and are promoted to indicate just how important  your  careful  and thoughtful  actions  are  in helping to  protect  you  and  your  fellow workers from harm, and also to prevent equipment damage. 1-3. These  guidelines  cover  Locomotives  when  they  are  operational  in  Portable  Radio  Remote Control  (PRRC)  mode.  If  a  locomotive  is  operated  from  cab  control,  the  PRRC  system’s controller(s) should be completely isolated by removing the battery and stored under lock and key. 1-4. A  routine  pre-shift  inspection  of  the  locomotive  takes  a  lot  less  time  than  repairing  a locomotive suffering from a major problem.  In addition, such pre-shift inspections are to be considered as ‘safety basics’ which are an important part of a locomotive operator’s duties.
 Locosafety – page 2    02/2010, CATTRON-THEIMEG™ 2.  OPERATOR SAFETY BASICS.  Before starting your shift as the locomotive operator, you should  make  sure  the  locomotive  has  a  current  inspection  certificate  and  that  qualified personnel have carried out the following inspections and checks.  If any item below does not pass inspection, you should notify your supervisor immediately.  In many cases, the problem will need to be fixed before you are allowed to operate the locomotive.  In addition, did you realize that the person now reading these instructions is primarily responsible for his or her own health and safety? 2-1   Area Inspection.  • Take a good look around the work area for any obstructions. • Check that the rails are intact and not bent or damaged.  • Make sure there are no fresh oil or fluid leaks on the track bed below where the locomotive is standing. • When installed, insure rail stops are physically secure and free of damage at the end of the rail track.  2-2.  Locomotive and Rail Car Inspection (mechanical & structural). • Check  for  proper  fluid  levels  and  make  sure  all  grease  fittings  are  lubricated  to manufacturer recommendations.  • Check the locomotive and rail car wheels for flange wear, cracks, holes, or visible signs of bearing damage. • Check all locomotive and rail car hoses and couplings for wear and physical damage.  2-3.  Operational  Safety  Check.    As  a  locomotive  operator,  you  should  satisfy  yourself  of  the following.  If any item below does not meet the checklist criteria, you shall immediately notify your supervisor.  In many cases, the problem will need to be fixed before you are allowed to operate the locomotive.  Remember that the person now reading these instructions is primarily responsible for his or her own health and safety! • Horn, headlight, bell, and all other warning devices shall be in working order. • All locomotive manual (cab) controls shall be in good working order. • STOP Buttons (when equipped) shall be in working order.  • The  locomotive  and  railcar  braking  systems (including the  application  of  sand  when equipped)  are  fully  operational.      The  only  way  to  ensure  this  is  by  testing  under ‘MANUAL’ (cab) control. 3.  PERSONS AUTHORIZED TO OPERATE REMOTE CONTROL LOCOMOTIVES. • Only properly trained  employees who have been designated by management shall  be permitted to operate the locomotive(s). • The locomotive shall not be operated by personnel who cannot read and understand the signs, notices and operating instructions. • The locomotive shall not be operated by a person with seriously defective eyesight or hearing, personnel under the influence of drugs or alcohol that will impair judgment, or personnel who may be suffering from a disease which may cause physical failure.
 02/2010, CATTRON-THEIMEG™   Locosafety – page 3 4.    TRAINING  CHECKLIST  FOR  OPERATORS  OF  REMOTE  CONTROLLED LOCOMOTIVES.   As a minimum, Locomotive Operators shall: • have knowledge of hazards inherent to locomotive operation  • have knowledge of safety rules for remote controlled locomotives  • have the ability to judge distance to stationary objects  • have  knowledge  of  the  PRRC  system  controller’s  operation  –  see  customized operational description provided with the controller  • inspect all aspects of the locomotive in manual  operation before commencing remote control operation • have  performed  pre-departure  brake  test  procedures  in  manual  operation  before commencing remote control operation   • know how to transfer the locomotive from ‘MANUAL’ to ‘REMOTE’ Control • be familiar with the procedure for testing all operational features • observe all signal lights and other railroad signaling devices   • avoid striking any obstructions  • check for proper clearance before entering buildings, etc.  • properly store the portable radio remote controller when not in use  • know how to properly transfer the portable radio remote controller to another person • report unsafe or unusual operating conditions • use caution in approaching all crossings • keep body clear of the rail track and avoid ‘pinch’ points  5.  THE OPERATING AREA FOR THE REMOTE CONTROLLED LOCOMOTIVE. • PRRC operators shall always position themselves in a safe location with the best view of the train they are controlling and never operate the locomotive blindly.  • Operators  shall  always  keep  the  train  and  locomotive  in  sight,  staying  as  close  as practical to the locomotive while maintaining a safe harms-way distance. • Operators  shall  follow  their  Employer’s  Safety  Rules,  Procedures,  and  Directives  in regard to riding on, walking in front of, and boarding/de-boarding at the leading edge of the train in respect to its direction of travel.     • Operators shall never position themselves or others in a ‘pinch’ point between rail cars, other locomotives, or track side structures. • Operators shall never position themselves between the rails of tracks. 6.  PRE-DEPARTURE CHECKS UNDER MANUAL CONTROL. • When  installed,  insure  the  STOP  buttons  located  on  the  sides  of  the  locomotive  are pulled ‘OUT’ immediately before boarding the locomotive. • When installed to the locomotive, insure: (1) Remote Control Disconnect Switch is set to  ‘OFF’,  (2)  MANUAL/REMOTE  Transfer  Switch  is  set  to  ‘MANUAL’,  and  (3) MANUAL/REMOTE Air Valves are in the ‘MANUAL’ (down) position. • Perform all locomotive pre-departure tests according to the locomotive manufacturer's operation  manual.  Do  not  proceed  unless  the  locomotive  is  operating  satisfactorily according to the manufacturer's instructions.
 Locosafety – page 4    02/2010, CATTRON-THEIMEG™ 6.  PRE-DEPARTURE CHECKS UNDER MANUAL CONTROL, continued. • All non-motion control functions (Horn, headlight, bell, sanders, uncouple, etc.) shall be checked  at  the  beginning  of  each  turn  or  when  a  new  operator  takes  control  of  the locomotive. • All  braking  functions  shall  be  checked  independently  to  insure  the  locomotive  is responding correctly to all brake applications and release commands.  Observe gages in the cab for proper readings and verify the brake mechanisms/cylinders operate properly. • Test train brakes (if equipped). 7.  THE PORTABLE RADIO REMOTE CONTROLLER. • Typically, the portable radio remote controller incorporates a Push-To-Operate (PTO) bar and its THROTTLE switch will spring return to IDLE.  The PTO bar acts as a guard for  the  throttle  switch  to  prevent  movement  of  the  locomotive  if  the  switch  is accidentally  bumped.    The  THROTTLE  switch  and  the  PTO  bar  must  never  be mechanically blocked in any ‘ON’ position. • When the portable radio remote controller incorporates a ‘Vigilance’ system in place of the Push-To-Operate (PTO) bar, the designated VIGILANCE pushbutton, bar switch, or toggle  switch  may  need  to  be  momentarily  depressed  to  initiate  a  motion  control function.  The designated VIGILANCE pushbutton, bar switch, or toggle switch must never be mechanically blocked in the ‘ON’ position. • Direction and brake levers normally have no spring return and will stay where they are  placed.    Although  the  PTO  Bar  is  not  normally  required  for  brake  apply commands,  it  must  be  depressed  to  release  the  independent  brakes  and,  when equipped, the train brakes. • Using the power ON/OFF switch(es), the portable radio remote controller shall be switched ‘OFF’ when not in use.  When the controller is equipped with a STOP button, it shall be set to  the  ‘STOP’  position  before  switching  off  power  to  the  controller.    In  addition,  if equipped with a key, the key should be removed after use and kept in a secure location.  • To  prevent  unauthorized  personnel  from  operating  the  remote  controlled  locomotive,  a prescribed,  controlled,  storage  space  shall  be  provided  for  portable  radio  remote controllers.  All controllers shall have their batteries removed and be stored there when not in use. • When an operator is putting on or taking off the controller by means of its belt loop strap, carrying harness, or shoulder strap, the controller shall be switched OFF beforehand, using the appropriate ON/OFF switch(es).  When the controller is equipped with a STOP button, it shall be set to the ‘STOP’ position before switching off power to the controller. • The portable radio remote controller shall always be switched ‘OFF’ when not in use and, when practical, stored under lock and key.
 02/2010, CATTRON-THEIMEG™   Locosafety – page 5 8.  TRANSFERRING THE LOCOMOTIVE TO RADIO REMOTE CONTROL. • Both  the  operator  and  management  shall  insure  the  correct  controller  to  operate  the locomotive is identified and selected. • Both  the  operator and  management shall  insure that  any spare  equipment  capable  of locomotive control is completely isolated and stored under lock and key. • Immediately  before  transferring  the  locomotive  from  ‘MANUAL’  to  ‘REMOTE’ control, insure the locomotive cab controls are set as follows:  Throttle to ‘IDLE’  Reverser to ‘NEUTRAL’ with handle removed  Independent Brake Lever to ‘RUN’ position and handle removed  Automatic Brake Lever to ‘LAP’ position and handle removed  Double Heading Cock to trailing position (MU - operation)  MANUAL/REMOTE Air Valves to ‘REMOTE’ (up) position  Remote Control Disconnect Switch to ‘ON’ position  MANUAL/REMOTE Transfer Switch to ‘REMOTE’ position 9.  PRE-DEPARTURE CHECKS UNDER RADIO REMOTE CONTROL.  Following is a typical pre-departure checkout procedure based upon a typical configuration.  Refer to the information supplied with the equipment for the specific checkout procedure.     • With the remote controller set to ‘OFF’, check brake cylinder for air pressure.  The red external  locomotive  lights  (if  equipped)  should  illuminate,  indicating  independent brakes are applied. • Set remote controller to ‘ON’.  When applicable, check the PRRC system display(s) for any  fault/alarm  conditions  and  correct  the  same  before  operating  the  appropriate ALARM/SYSTEM RESET switch.   • With  Push  to  Operate  (PTO)  Bar  depressed,  move  the  independent  brake  lever  on remote  controller  to  release  (REL).    Independent  brakes  should  release  and  the  red external locomotive lights should extinguish. • Move independent brake lever on remote controller to an ‘apply’ position (SA = Slow Apply,  QA  =  Quick  Apply).  Independent  brakes  should  apply  with  corresponding external red lights illuminated. • Move  independent  brake  lever  on  remote  controller to  ‘EMG’ (emergency)  position. When  equipped,  train  brakes  should  apply  along  with  independent  brakes.    When equipped, sand should also be applied. • Move direction lever on remote controller to ‘FORWARD’.  Forward direction should be  selected,  as  indicated  by  the  clear  external  locomotive  lights  (if  equipped) illuminating. • Move direction lever on remote controller to ‘REVERSE’.  Reverse direction should be selected as indicated by the amber external locomotive lights (if equipped) illuminating and the clear lights extinguishing.
 Locosafety – page 6    02/2010, CATTRON-THEIMEG™ 9.  PRE-DEPARTURE CHECKS UNDER RADIO REMOTE CONTROL, continued. • Move  direction  lever  on  remote  controller  to  center  ‘NEUTRAL’  position. ‘NEUTRAL’  should  be  selected  as  indicated  by  both  amber  and  clear  lights extinguished. • With  independent  brakes  released  (PTO  must  be  depressed  and  maintained)  and  a direction selected, advance THROTTLE lever on remote controller to first ‘step’.  The green  external  locomotive  lights  (if  equipped)  should  illuminate  and  the  locomotive should move. • Release  Push  to  Operate  (PTO)  Bar  on  remote  controller.    Throttle  should  return  to ‘idle’  and  independent  brakes  should  apply,  stopping  the  locomotive  (red  external locomotive lights illuminated and green lights extinguished). • With  independent  brakes  released  (PTO  must  be  depressed  and  maintained)  and  a direction selected, advance THROTTLE lever on remote controller to first ‘step’.  The green external locomotive lights should illuminate and the locomotive should move. • Tilt  remote  controller  60°  or  more.    Throttle  should return to  ‘idle’  and  independent brakes  should  apply,  stopping  the  locomotive  (red  external  locomotive  lights illuminated and green lights extinguished). Return the remote controller to the upright position and independent brakes should release (red external lights extinguished). • With  independent  brakes  released  (PTO  must  be  depressed  and  maintained)  and  a direction selected, advance THROTTLE lever on remote controller to first ‘step’.  The green external locomotive lights should illuminate and the locomotive should move. • Set remote controller to ‘OFF’. Throttle should return to ‘idle’ and independent brakes should apply, stopping the locomotive (red external locomotive lights illuminated and green lights extinguished).  • De-board the locomotive and assume an operating position on the ground next to the locomotive.  Set remote  controller to ‘ON’.   With independent brakes released (PTO must be depressed and maintained) and a direction selected, advance THROTTLE lever on  remote  controller  to  first  ‘step’.    The  green  external  locomotive  lights  should illuminate and the locomotive should move. Immediately after the locomotive starts to move, push  in  a STOP  switch  (if  equipped)  on  side  of  locomotive.   The  locomotive should  stop  and  independent  brakes  should  apply.      Repeat  this  step  with  all  STOP switches.    STOP  switches  should  be  checked  daily.  If  the  above  checks  have  been successfully completed, the locomotive is now ready for remote control operation. 10.  OPERATING THE REMOTE CONTROLLED LOCOMOTIVE. • When ready to move the locomotive for the first time, proceed slowly and make certain the load is under control.   • Take the slack out of the couplers gradually and make sure hands and other objects are clear before making command. • Keep all parts of the body away from the rolling stock.   • Do not walk on the tracks between the rails.  • Do not move the locomotive or train if anyone is in a position to be injured. • If anyone is in the path of travel, stop and sound the horn before proceeding.
 02/2010, CATTRON-THEIMEG™   Locosafety – page 7 10.  OPERATING THE REMOTE CONTROLLED LOCOMOTIVE, continued. • If gloves are not required for safety reasons, they shall not be used when operating the portable remote controller. • PRRC operators shall not use a STOP switch, VIGILANCE switch or Push-to-Operate bar as a utility stopping device. • If PRRC locomotive operators are asked to do something they believe unsafe, they shall contact their supervisor for advice. • PRRC  locomotive  operators shall  never  permit  anyone to  ride  in  the locomotive  cab except when authorized by their supervisor. • Heavy bumping of cars or rail stops is prohibited. • When  leaving  the  locomotive  for  any  reason,  set  the  locomotive  throttle  to  ‘IDLE’, apply the brakes, and set the ON/OFF switch(es) on the controller to ‘OFF’.  When the controller  is  equipped  with  a  STOP  button,  this  shall  be  set  to  the  ‘STOP’  position before switching off power to the controller. • If the locomotive fails to respond correctly under remote control, the operator shall stop operation immediately by  setting  the  ON/OFF  switch(es) on  the  controller to  ‘OFF’. When the controller is equipped with a STOP button, this shall be set to the ‘STOP’ position  before  switching  off  power  to  the  controller.    The  fault  condition  shall  be reported immediately to a supervisor. • Do not allow any unauthorized person to operate or assist with the operation while in Radio Remote Control. • Do not operate the Remote Controller from a distance where the locomotive, railcars, rail-track, and all surrounding objects are not visible. • Under no circumstances should an operator override any of the safety features built into the  PRRC system or the locomotive. 11.  BOARDING  THE  REMOTE  CONTROLLED  LOCOMOTIVE  (MAINTENANCE CREW). • The  PRRC  locomotive  shall  not  be  boarded  without  permission  of  the  supervisor  in charge of railroad operations in the area. • Using the power ON/OFF switch(es), the person boarding the PRRC locomotive shall switch the portable radio remote controller to ‘OFF’ and take it with him or her on to the locomotive.  When the controller is equipped with a STOP button, this shall be set to the ‘STOP’ position before switching off power to the controller. • If the boarding party consists of more than one person, one person shall be designated as the leader of the boarding party. • The  leader  shall  board  the  locomotive  first,  secure  the  throttle  and  brakes,  and  then signal the other members of the party that it is safe for them to board.
 Locosafety – page 8    02/2010, CATTRON-THEIMEG™ 12.  ON  BOARD  THE  REMOTE  CONTROLLED  LOCOMOTIVE  (MAINTENANCE CREW). • Headroom is at a minimum in some locomotive cabs and on some engine walkways.  Caution shall be exercised by all people on board such locomotives.  Hard hats shall be worn at all times. • If  the  maintenance  crew  consists  of  more  than  one  person,  one  person  shall  be designated as the crew leader. • The leader shall  mark all  locomotives that have  been pre-positioned  for  maintenance with  a blue flag.    The  locomotive shall  not  be  coupled to, or  moved  in  any manner, while the blue flag is in position. The leader is solely responsible for removing the blue flag before moving the locomotive, or when maintenance has been completed. • Warning signs shall be placed on the front, rear, and both sides of the locomotive to indicate that maintenance is being carried out. • If it is  necessary to have the control  circuits on  the  locomotive energized, the leader shall insure that traction power is disabled (i.e. generator field switch set to the ‘OFF’ position). • If, during the course of maintenance, it becomes necessary to move the locomotive, it shall be the responsibility of the crew leader to insure that all personnel located on, and inside  the  locomotive are in a  safe  position  out of  harms-way.    In addition  the  crew leader shall insure all tools and materials are stowed or tightly restrained, all doors are secured, and the blue flag is removed before moving the locomotive. • When the maintenance work is completed, the leader shall see that all personnel are off the locomotive before he or she re-enables traction power.  • If  more  that  one  person  is  on  board  the  locomotive,  one  person  shall  be  made responsible for seeing that all personnel are off the locomotive before the portable radio remote controller is returned to operational use. 13.  REMOTE CONTROLLED LOCOMOTIVE UNDER REPAIR. • All persons operating other locomotives on the same or adjacent tracks shall be notified before  anyone  boards  the  subject  locomotive.    Such  notification  should  include limitations of adjacent locomotive movement while others are on board. • If it is  necessary to have the control  circuits on  the  locomotive energized, the leader shall insure that traction power is disabled (i.e. generator field switch set to the ‘OFF’ position). • The  leader  shall  mark  all  locomotives  that  have  been  pre-positioned  for  repairs,  and cannot be moved during repairs, with a blue flag.  The locomotive shall not be coupled to,  or moved in  any manner, while the blue flag is in  position.   The  leader is solely responsible for removing the blue flag when repairs have been completed. • Locomotives  that  have  been  pre-positioned  for  repairs,  and  cannot  be  moved  during repairs,  shall  be  protected  against  being  bumped  by  other  locomotives  on  the  track.  Suitable  derailers  adequate  for  the  job  should  be  installed  on  both  ends  of  the locomotive  under  repair  and  as  far  away  from  the  locomotive  as  possible  with  a minimum distance of 100 feet.  The location of these derailers shall be indicated by red lights  placed  so  that  they  are  clearly  visible  to  other  persons  operating  locomotives traveling on the same or adjacent tracks.
 02/2010, CATTRON-THEIMEG™   Locosafety – page 9 13.  REMOTE CONTROLLED LOCOMOTIVE UNDER REPAIR, continued. • When it is impossible to use derailers for protection, red lights shall be placed in clear view of other persons operating locomotives on the same or adjacent tracks to indicate the restricted travel zone.  It is desirable that such red lights be located a minimum of 100 feet (approx. 30.5 m) from the locomotive under repair. • All operators of locomotives on the same or adjacent tracks must be informed of the repair work, thoroughly instructed as to what their conduct should be for the duration of said repairs, and informed when repairs are completed. • When  there  is  a  track  adjacent  to  that  of  the  locomotive  being  repaired,  and  if  any hazard exists involving repairmen, red lights shall be placed in clear view of persons traveling on the adjacent tracks to indicate the restricted travel zone.  It is desirable that such red lights be located a minimum of 100 ft. (approx. 30.5 m) from the locomotive under repair.     • When  it  is  necessary  to  continue  operation  of  locomotives  on  adjacent  tracks,  such locomotives shall come to a full stop before entering the restricted area.  Locomotives on adjacent tracks may only proceed through the restricted area when permission has been received from a signalman posted for this purpose. • Access  of  persons  to  and  from  the  locomotive  being  repaired  should  be  under  the control of the repair crew leader. • Warning signs shall be placed on the front, rear, and both sides of the locomotive to indicate that repairs are being carried out. • Handling of all small tools and materials, etc. from ground level to workers above shall be accomplished safely.  Tools, materials, etc. shall not be tossed from the locomotive to the ground level and vice versa. • If it  is  necessary to move the locomotive to check the performance of  operation, the crew  leader  shall  designate  who  remains  on  the  locomotive.    The  crew  leader  shall insure that all personnel located on, and inside the locomotive are physically located in a safe position out of harms-way.  In addition the crew leader shall insure all tools and materials  are  stowed  or  tightly  restrained  and  that  all  doors  are  secured  before  the locomotive is moved. • When the maintenance work is completed, the leader shall see that all personnel are off the locomotive before he or she re-enables traction power.
 Locosafety – page 10    02/2010, CATTRON-THEIMEG™ 14.  THE  CONDITION  OF  THE  REMOTE  CONTROLLED  LOCOMOTIVE.      It  is recommended  that  a  written  report  be  sent  to  your  supervisor  whenever  you  detect  any condition  that  makes  the  locomotive  unsafe.    Many  plants  supply  printed  forms  for  this purpose.  The radio control locomotive operator should fill out these forms and turn them in at the end of each shift.  Certain faults which the radio control locomotive operator may detect will be so critical that the locomotive must be shut down at once and not operated until the fault is corrected.  Typical check list items may include some or all of the following: • Condition of engine, brakes, and auxiliary functions (i.e., headlight, horn). • Fresh oil or fluid leaks on the track bed below where the locomotive is standing. • Broken, cracked or chipped rails. • Condition  of  controls  (electrical  or  mechanical  defects  that  may  lead  to  faulty operation). • Frequent overload relay tripping of power circuits. • Mechanical parts loosened by vibration (loose rivets, covers, etc.). • Wheel condition (flange wear, cracks, holes, or visible signs of bearing damage). • Insufficient main reservoir air pressure or a bad compressor. • Condition of hoses and couplings. • Burned out, broken, or inoperable warning or signal lights. • Unintended  stopping  or  starting  of  any  locomotive  motion,  warning  device,  light  or auxiliary function.  Portable  Remote-controlled  Locomotive  operators  shall  not  attempt  to  make  any  repairs  by themselves.  The fault condition(s) shall be reported to a supervisor to enable repairs to be carried out by suitably qualified personnel.     END  Internet Address for All CATTRON-THEIMEG™ Companies: www.cattron-theimeg.com
    United States Cattron-Theimeg Inc. 58 West Shenango Street Sharpsville, PA 16150-1198 Phone: 1-724-962-3571 Fax:  1-724-962-4310 e-mail: mail@cattron-theimeg.com  Canada Cattron-Theimeg Canada Ltd. 150 Armstrong Avenue, Units 5 & 6 Georgetown, Ontario L7G 5G8 Phone: 1-905-873-9440 Fax:  1-905-873-9449 e-mail: salescdn@cattron-theimeg.com  United Kingdom Cattron-Theimeg (UK) Ltd. Riverdene Industrial Estate, Molesey Road, Hersham Walton-on-Thames, Surrey KT12 4RY Phone:  44-1932-247511 Fax:  44-1932-220937 e-mail: sales@cattronuk.com  South Africa Cattron-Theimeg Africa (PTY.) Ltd. 24 O'Rielly Merry Road, Rynfield, Benoni P.O. Box 15444, Farrarmere, Benoni Gauteng 1518, South Africa Phone: 27-11-425-1123 Fax:  27-11-849-5717 e-mail: cattron@iafrica.com  South America (Brazil) Cattron-Theimeg Américas Ltda. Rua Antonio Rodrigues de Carvalho, 435 13033-220 - Campinas – SP Phone: 55-19-3243-7803 Fax:  55-19-3243-9258 e-mail: cattronamericas@cattron-theimeg.com   Europe (Germany) Cattron-Theimeg Europe GmbH & Co. Krefelder Straße 423-425 41066 Mönchengladbach Phone: 49-2161-63630 Fax:  49-2161-6363100 e-mail: theimeg@theimeg.de    Internet Address for All CATTRON® Group International Companies: www.cattron-theimeg.com

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