Telemotive telePendant Assembly instructions

TCTX12P-0 Rev. D 8/2/2004
P
PR RO OG GR RA AM MM MI IN NG G A AN ND D U US SE ER RS S M MA AN NU UA AL L
TELEMOTIVE
telePendantTM
TRANSMITTERS
R
RA AD DI IO O
C
CO ON NT TR RO OL L
E
EQ QU UI IP PM ME EN NT T
N49 W13650 Campbell Drive
Menomonee Falls, WI 53051
Phone: [phone] Fax: [phone]
Website: www.telemotive.com
telePendant programming is
found on page 20.

Table of Contents
2
1- Service Information .................................................................................................3
2- Radio Controlled Crane Safety................................................................................4
3- General System Information..................................................................................11
4- Operation................................................................................................................12
5- Programming..........................................................................................................18
6- Spare Parts .............................................................................................................30

Section 1 - Service Information
1-1. Service Information.
For questions regarding service or technical
information or ordering replacement parts, ask
for Telemotive Customer Care. Telemotive’s
normal business hours are Monday through
Friday 8:00 AM to 5:00 PM Central Standard
Time. After hours emergency technical service is
available.
For new product orders or quotations, ask for
Telemotive Sales.
Magnetek Material Handling Group
N49 W13650 Campbell Drive
Menomonee Falls, WI 53051
Telephone: [phone]
Website: www.telemotive.com
e-mail: [email protected]
Fax Numbers
Main: 800-298-3503
Sales: 262-783-3510
Service: 262-783-3508
Telemotive Industrial Control trademarks:
Boommate, GateMate, 10K, inteleSmart,
Telemotive, telePilot, telePendant, Laser
Guard, Teledrive, Teltec, TeleMotion are either
trademarks or registered trademarks of
Telemotive Industrial Controls.
Third-party trademarks: All other trademarks,
trade names or company names referenced
herein are used for identification only and are the
property of their respective owners.
CAUTION
•DO NOT ATTEMPT TO OPEN OR SER-
VICE THE TELEPENDANT UNIT.
•ONLY TRAINED QUALIFIED INDIVIDU-
ALS SHOULD DO SERVICING.
•STRICT ANTI-STATIC HANDLING
PROCEDURES MUST BE FOLLOWED.
•FAILURE TO FOLLOW THIS CAUTION
COULD RESULT IN SERIOUS DAMAGE TO
EQUIPMENT AND/OR VOID THE
WARRANTY.
.

Section 2 – Radio Controlled Safety
4
2-1. Warnings, Cautions and Notes.
Through out this document WARNING, CAUTION
and NOTE statements have been deliberately placed
to highlight items critical to the protection of
personnel and equipment.
WARNING – A warning highlights an essential
operating or maintenance procedure, practice, etc.
which if not strictly observed, could result in injury
or death of personnel, or long term physical hazards.
Warnings are highlighted as shown below:
WARNING
CAUTION – A caution highlights an essential
operating or maintenance procedure, practice, etc.
which if not strictly observed, could result in damage
to, or destruction of equipment, or loss of functional
effectiveness. Cautions are highlighted as shown
below:
CAUTION
NOTE – A note highlights an essential operating or
maintenance procedure, condition or statement. Notes
are shown as below:
NOTE
WARNINGS, CAUTIONS AND NOTES SHOULD
NEVER BE DISREGARDED.
The safety rules in this section are not intended to
replace any rules or regulations of any applicable
local, state, or federal governing organizations. The
following information is intended to be used in
conjunction with other rules or regulations already in
existence. It is important to read all of the safety
information contained in this section before installing
or operating the Radio Control System.
2-2. Critical Installation Considerations.
WARNING
ALL EQUIPMENT MUST HAVE A MAINLINE
CONTACTOR INSTALLED AND ALL TRACKED
CRANES AND SIMILAR EQUIPMENT MUST
HAVE A BRAKE INSTALLED. FAILURE TO
FOLLOW THIS WARNING COULD RESULT IN
SERIOUS INJURY OR DEATH AND DAMAGE
TO EQUIPMENT.
WARNING
ON ALL REMOTE CONTROLLED CRANES AN
AUDIBLE AND/OR VISUAL WARNING MEANS
MUST BE PROVIDED. THESE AUDIBLE
AND/OR VISUAL WARNING DEVICES MUST
MEET ALL GOVERNMENTAL REQUIRE-
MENTS. FAILURE TO FOLLOW THIS WARN-
ING COULD RESULT IN SERIOUS INJURY OR
DEATH AND DAMAGE TO EQUIPMENT.
WARNING
REMOVE ALL ELECTRICAL POWER FROM
THE CRANE OR MACHINERY BEFORE AT-
TEMPTING ANY INSTALLATION PROCE-
DURES. DE-ENERGIZE AND TAG OUT ALL
SOURCES OF ELECTRICAL POWER BEFORE
TOUCH TESTING ANY EQUIPMENT. FAILURE
TO FOLLOW THIS WARNING COULD RESULT
IN SERIOUS INJURY OR DEATH AND DAM-
AGE TO EQUIPMENT.

Section 2 – Radio Controlled Safety (Continued)
5
WARNING
THE DIRECT OUTPUTS OF THIS PRODUCT
ARE NOT DESIGNED TO INTERFACE DI-
RECTLY TO TWO STATE SAFETY CRITICAL
MAINTAINED FUNCTIONS, I.E., MAGNETS,
VACUUM LIFTS, PUMPS, EMERGENCY
EQUIPMENT, ETC. A MECHANICALLY LOCK-
ING INTERMEDIATE RELAY SYSTEM WITH
SEPARATE POWER CONSIDERATIONS MUST
BE PROVIDED. FAILURE TO FOLLOW THIS
WARNING COULD RESULT IN SERIOUS IN-
JURY OR DEATH AND DAMAGE TO EQUIP-
MENT.
2-3. General.
Radio controlled overhead cranes and other material
handling equipment operate in several directions.
They are large, bulky pieces of equipment that handle
heavy loads efficiently at high speeds. Quite
frequently, the equipment is operated in areas where
people are working on the floor below. The crane
operator must exercise extreme caution at all times.
Workers must constantly be alert to avoid accidents.
The following rules have been included to indicate
how your careful and thoughtful actions may prevent
injuries, damage to equipment, or even save a life. If
radio controlled material-handling equipment is
operated from the cab, special care must be taken to
secure the transmitter. Refer to section titled Section
2-9. Boarding The Crane for specific safety rules.
2-4. Persons Authorized To Operate Radio
Controlled Cranes.
Only properly trained persons designated by
management should be permitted to operate radio-
controlled cranes.
Radio controlled cranes should not be operated by
any person who cannot read or understand signs,
notices and operating instructions that pertain to the
crane.
Radio controlled cranes should not be operated by
any person with insufficient eyesight or hearing or by
any person who may be suffering from a disorder or
illness or is taking any medication that may cause
loss of crane control.
2-5. Training Checklist for Crane Operators.
Anyone being trained to operate a radio-controlled
crane should possess as a minimum the following
knowledge and skills before operating the crane:
The operator should have knowledge of hazards
peculiar to crane operation.
The operator should have knowledge of the safety
rules for radio-controlled cranes.
The operator should have the ability to judge distance
or moving objects.
The operator should have knowledge of the radio
transmitter.
The operator should know the limit switch test
procedure.
The operator should know, where authorized,
instructions for plugging motions.
The operator should have knowledge of the use of
crane warning lights and alarms.
The operator should have knowledge of observing
crane signal lights.
The operator should be trained to avoid striking any
obstructions.
The operator should have knowledge of the proper
clearance of lifts or hooks before moving bridge or
trolley.
The operator should have knowledge of the proper
storage space for radio control box when not in use.
The operator should be trained in transferring radio
control box to another person.
The operator should be trained how and when to
report unsafe or unusual operating conditions.
The operator should be trained how to exhibit caution
in approaching bridge or trolley bumpers.
The operator should know equipment capacity.
The operator should be trained in making lifts below
floor level.
The operator should be trained in making side pulls.
The operator should know how to keep himself and
other people clear of lifts and to avoid "pinch" points.

Section 2 – Radio Controlled Safety (Continued)
6
The operator should know cable and hook inspection
procedures.
The operator should know procedures for testing
hoist, trolley, and bridge brakes.
2-6. Operating Area.
Aisles between equipment, stock, etc., should be free
of obstructions so the crane operator can move freely.
These aisles should be a minimum of three feet (one
meter) wide, or meet local regulations.
Crane operators should always position themselves
for the best view of the crane they are controlling.
The crane should never be operated blindly. The
operator should stay as close to the crane load as
possible. Operators should never position themselves
in a "pinch" point.
2-7. Transmitter Unit.
Transmitter switches should never be mechanically
blocked ON or OFF for any crane motion. When not
in use turn the transmitter OFF. A secure storage
space should be provided for the transmitter unit and
the transmitter unit should always be placed there
when not in use. This precaution will prevent
unauthorized people from operating the crane.
Spare transmitters should be stored in a secure
storage space and only removed from the storage
space after the current transmitter in use has been
turned OFF, taken out of the service area and
secured.
Before putting the transmitter in service the
transmitter unit should be inspected for any damage
or excessive wear. Units with, but not limited to, any
of the following: broken housings, broken or sticking
switches and levers or broken handles, missing
battery doors, damaged or missing switch boots or
damaged or missing switch knobs should be repaired
before putting into service.
2-8. Operating the Crane.
2-8.1. Pre-operation Test.
At the start of each work shift, or when a new op-
erator takes control of the crane, operators shall do as
a minimum the following steps before making lifts
with any crane or hoist:
Test the upper-limit switch. Slowly raise the
unloaded hook block until the limit switch trips.
When checking limit switches the hoist should be
centered over an area free of personnel and
equipment.
Visually inspect the hook, load lines, trolley, and
bridge as much as possible from the operator's
station; in most instances, this will be the floor of the
building.
The bridge and trolley brakes should be tested. On
transmitter units equipped with two or more speeds,
use the "lowest" speed when testing braking devices.
When lifting maximum loads, the crane operator
should test the hoist brakes by raising the load a few
inches from the floor. If the brakes do not hold, the
load should immediately be lowered to the floor.
If provided, test the lower-limit switch.
Test all warning devices.
Test all direction and speed controls for both bridge
and trolley travel.
Test all bridge and trolley limit switches, where
provided, if operation will bring the equipment in
close proximity to the limit switches.
Test the transmitter emergency stop.
Test the hoist brake to verify there is no drift without
a load.
If any crane or hoist fails any of the above tests notify
the supervisor and lock out and tag for repair.
2-8.2. General Rules for Operation.
Consult the crane manufacturer, local and
governmental regulations for complete rules of
operation. In general the following rules apply to
remotely controlled cranes:
The limit switches should never be used as a regular
stopping device. They are intended to be protective
devices.
Do not make lifts in excess of the equipment rated
capacity.
The bridge and trolley should be centered directly
over the load when the load is raised to prevent
swinging when making lifts.
A crane designed for this purpose and only with
supervisor permission should make side pulls. When
a lift is being made, the crane operator should not be

Section 2 – Radio Controlled Safety (Continued)
7
positioned in the line of travel. The crane or hoist
should be operated from a position either to the side
or opposite from the direction of travel.
When raising or lowering a load, proceed slowly and
make certain the load is under control. Tag lines
should be used for handling unusual lengths or bulky
loads. Remove slack from chains or slings gradually.
Make certain all personnel are clear before making a
lift.
The crane operator should keep all body parts away
from the lift and should never be positioned under the
lift.
Do not make a lift or move a load if anyone is in a
location where they could be struck by the crane or
the load.
If the crane operator is being helped, the crane should
not be moved until the helper signals they are clear of
the crane and its load.
When a load is hanging from the crane hook and the
crane is being moved, the crane operator should
sound all warning devices frequently.
Loads should not be carried over workers heads. If a
worker is in the path of crane travel, the crane
operator should stop the crane and clear the area
before proceeding.
Runway stops or other cranes should never be
bumped into.
When moving the crane, the crane operator should be
sure that the hook block and attachments or cables
would not catch on nearby equipment. Slings, chains,
or cables should never be dragged along the floor.
Unless required for operator safety, gloves should not
be worn when operating the transmitter unit.
All loose materials or parts should be removed from
the load before starting the lift.
The crane operator should always hoist lifts high
enough to clear all equipment and workers.
The crane operator should never permit anyone to
ride on the load or hook except when authorized by
the supervisor.
When another crane on the same runway is stationary
with a load hanging, the crane operator should
maintain a safe distance between the stationary crane
and the one under their control.
Never leave suspended loads unattended. In an
emergency, if the crane is inoperative and a load
suspended, notify the supervisor immediately,
barricade and post signs on the floor beneath crane
and load.
If power to the crane is removed, the crane operator
should turn the transmitter unit OFF and keep it OFF
until power is restored.
If the crane fails to respond properly, the crane
operator should stop operation, turn the transmitter
unit OFF and immediately report the condition to
their supervisor.
Outdoor cranes, which are subject to movement by
wind, should be securely anchored when left
unattended. If the crane is equipped with bridge
brakes, the parking brake should be set immediately.
2-9. Boarding the Crane.
The crane should not be boarded without permission
of the supervisor.
The crane operator should turn off the transmitter and
take it with them when boarding the crane.
If more than one person is boarding the crane, one
person should be made responsible for ensuring all
personnel are off the crane before the system is
returned to operation.
2-10. Crane Maintenance and Repair.
Qualified personnel must maintain a regularly, i.e.,
such as monthly, scheduled crane inspection. During
this crane inspection the functionality and safety of
the crane remote control must also be tested. The
inspection shall include, but be not limited to items
listed in Section 2-12. Condition of the Radio
Controlled Crane. Consult crane manufacturer, local
and governmental regulations for recommended
inspection intervals and proper inspection
procedures. Problems noted during this inspection
must be repaired before using the crane or the remote
control.
Minor repairs include routine maintenance and
repairs such as greasing, cleaning and control
troubleshooting. All other repairs should be con-
sidered major. If the repair crew consists of more
than one person, one person should be designated as
the repair crew leader with the following
responsibilities. If the repair crew consists of only
one person, that person has the following
responsibilities:

Section 2 – Radio Controlled Safety (Continued)
8
For minor repairs warning signs should be placed on
the floor beneath the crane or suspended from the
crane. For major repairs, the floor area below the
crane should be roped off.
When major repairs are to take place, all persons
operating other cranes on the same or adjacent
runways, if any, must be notified prior to starting
repairs. Notification should include the nature of the
repair, safeguards provided, and movement
limitations while repairs are in progress.
When practical, radio controlled cranes which cannot
be moved during repairs must be protected against
being bumped by other cranes on the runway.
Bumpers should be installed on the exposed side or
sides of the crane under repair. They should be
placed as far away as possible. The location of these
bumpers should be indicated by red lights placed so
that they are clearly visible to other crane operators
traveling on the same runway. When it is not possible
to use bumpers, red lights must be placed so they are
clearly visible to other crane operators traveling on
the same runway to indicate the restricted travel zone.
All crane operators on the same runway must be
informed of the repair effort and thoroughly
instructed to what their operations are limited to and
informed they will be notified when repairs are
completed.
If any hazard involving the repairmen exists when
there is a runway adjacent to the crane under repair,
the adjacent runway should be blocked off as
described above. When it is necessary to continue
crane operation on the adjacent runways warning
lights must be installed and be visible to operators of
cranes on those runways. All cranes should come to a
complete stop prior to entering the restricted area and
should proceed through this area only after receiving
permission from a signal person designated for this
purpose. Access of persons to and from the crane
being repaired should be under control of the repair
crew leader.
When boarding the crane, the transmitter should be
turned OFF and the transmitter should remain with
the repair crew leader. The leader should board the
crane first, open and lock out the main switch, and
then signal the other members of the crew it is safe to
board the crane.
If work on the crane is to be done in areas not
protected by standard handrails, the repair crew
should wear approved safety belts.
All tools and equipment should be moved onto the
crane by the use of hand lines. The tools and
equipment should be adequately secured to the hand
lines.
If it is necessary to have the crane control circuits
energized, all power circuits for crane movement
must be opened prior to energizing the control
circuits.
All personnel and tools should be moved to a safe
spot before moving the crane during repairs.
Headroom is at a minimum in some crane cabs and
on some crane walkways. Caution should be
exercised when boarding or working on cranes. Hard
hats should be worn whenever possible.
When repairs are finished, all personnel, tools and
repair equipment should be removed before
energizing the crane circuits.
2-11. Using the Crane as a Work Platform.
When the crane is to be used as a stationary work
platform, follow all rules provided in Section 2-10.
Crane Maintenance and Repair. When it is necessary
for the crane to be moved from time to time, the
crane operator should board the crane with the
transmitter unit. The crane operator should ensure all
personnel working on the crane are in a secure
position before moving the crane to the next
workstation. It should also be the crane operator’s
responsibility to ensure the main switch is open and
locked down before work is resumed.
WARNING
THE CRANE OPERATOR SHOULD NOT AT-
TEMPT TO REPAIR ANY OF THE ITEMS
STATED BELOW. THE CRANE CONDITION
SHOULD BE REPORTED TO THE SUPERVISOR.
FAILURE TO FOLLOW THIS WARNING COULD
RESULT IN SERIOUS INJURY OR DEATH AND
DAMAGE TO EQUIPMENT.
2-12. Condition of the Radio Controlled Crane.
If the crane fails to respond properly, the crane
operator(s) should notify their supervisor. When
serious conditions are noticed (conditions that make
the crane unsafe to operate), the crane should be shut

Section 2 – Radio Controlled Safety (Continued)
9
down immediately and the supervisor notified. The
following is a list of some of the items that should be
included in the report. (See the crane manufacturer
for specifics and possible additional items):
Condition of hoisting cable and hook block (broken
strands, clipped sheave wheels, etc.).
Condition of brakes (hoist, trolley, and bridge). (No
bluing, rivets on shoes showing, glazing, etc.).
Condition of trolley and rail stops.
Condition of bridge structure.
Condition of festoon system.
Broken welds in any part of the crane structure.
Proper fluid levels and lubrication.
Condition of bridge and trolley stops.
Carbon dust or signs burning on the covers of motors.
Indication of fluid, oil or grease leaks.
Condition of rail sweeps.
Walkways required handrails and ladders are in
place, sturdy and not loose.
Protective guards are in place for all moving parts.
Alignment of bridge (screeching or squealing wheels
indicate bridge is out of line).
Broken, cracked, or chipped rails on trolley or
runway.
Condition of limit switches.
Condition of electrical and mechanical control
(electrical or mechanical defects which cause faulty
operation such as un-commanded stopping or starting
of any crane motions, warning devices, lights, or
auxiliary functions).
Condition of gears (grinding or squealing may
indicate foreign materials in gear teeth or a lack of
lubrication.
All controls especially E-STOPs are in place and in
working order.
Frequent relay tripping of power circuits.
Mechanical parts loosened by vibration (loose rivets,
covers, bolts, etc.).
Uneven riding (worn or damaged wheels).
Condition of collector shoes or bars.
Condition of warning or signal lights and horns.
(Burned out or broken).
2-13. Batteries
WARNING
KNOW AND FOLLOW PROPER BATTERY
HANDLING, CHARGING AND DISPOSAL PRO-
CEDURES. IMPROPER BATTERY PROCE-
DURES CAN CAUSE BATTERIES TO EXPLODE
OR DO OTHER SERIOUS DAMAGE. FAILURE
TO FOLLOW THIS WARNING COULD RESULT
IN SERIOUS INJURY OR DEATH AND DAM-
AGE TO EQUIPMENT.
2-13.1. Battery Handling.
Use only batteries approved by Telemotive for the
specific product.
Do not dispose of a battery pack in fire; it may
explode.
Do not attempt to open the battery pack.
Do not short circuit battery.
Do not attempt to use a battery that is leaking,
swollen or corroded.
For intrinsically safe environments only use specified
Telemotive intrinsically safe batteries.
Keep the battery pack environment cool during
charging operation and storage, (i.e., not in direct
sunlight or close to a heating source).
Do not submerse battery in water.
If battery leaks avoid contact with electrolyte.

Section 2 – Radio Controlled Safety (Continued)
10
2-13.2. Battery Charging.
For those transmitters equipped with battery chargers,
please familiarize all users with the instructions of
the charger before attempting to use.
Use only Telemotive approved chargers for the
appropriate battery pack.
Do not attempt to charge non-rechargeable battery
packs.
Avoid charging the battery pack for more than 24
hours.
Do not charge batteries in a hazardous environment.
Do not short charger.
Do not attempt to charge a damaged battery.
Charger units are not intended for outdoor use. Use
only indoors.
Always unplug the charger when not in use.
Do not store, place or use the charger where it could
come into contact with water or moisture.
To reduce the risk of electric shock, unplug your
charger from the wall outlet before cleaning.
2-13.3. Battery Disposal.
Before disposing of batteries consult local and
governmental regulatory requirements for proper
disposal procedures.