GREER Company MICROGUARD 424 Operation/Troubleshooting Operation/Troubleshooting Manual Download Page 1

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Greer Company

Crane Systems

1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626
MICROGUARD



424 OPERATION/TROUBLESHOOTING MANUAL

PN W424103 REV A 02/13/01

MICROGUARD



424

RATED CAPACITY INDICATOR SYSTEM

OPERATION/TROUBLESHOOTING

MANUAL

TELESCOPIC BOOM CRANES

HORIZONTAL DISPLAY

Summary of Contents for MICROGUARD 424

Page 1: ... MICROGUARD 424 424 424 424 RATED CAPACITY INDICATOR SYSTEM RATED CAPACITY INDICATOR SYSTEM RATED CAPACITY INDICATOR SYSTEM RATED CAPACITY INDICATOR SYSTEM OPERATION TROUBLESHOOTING OPERATION TROUBLESHOOTING OPERATION TROUBLESHOOTING OPERATION TROUBLESHOOTING MANUAL MANUAL MANUAL MANUAL TELESCOPIC BOOM CRANES TELESCOPIC BOOM CRANES TELESCOPIC BOOM CRANES TELESCOPIC BOOM CRANES HORIZONTAL DISPLAY H...

Page 2: ...e of electronic parts created to aid in crane operation and in the protection of crane operators and associated personnel This manual has been developed to assist in helping Service Personnel to understand locate and identify problems that may arise during the operation of the MicroGuard 424 Rated Capacity Indicator System Persons using this Manual must be familiar with the MicroGuard 424 System a...

Page 3: ...ING MANUAL TABLE OF CONTENTS TABLE OF CONTENTS TABLE OF CONTENTS TABLE OF CONTENTS SECTION 1 OPERATION SECTION 1 OPERATION SECTION 1 OPERATION SECTION 1 OPERATION MICROGUARD 424 SYSTEM DESCRIPTION 4 DISPLAY WINDOWS 5 6 PUSH BUTTONS ICONS LAMPS ALARMS 7 10 MICROGUARD 424 SYSTEM OPERATION 11 CONFIGURATION SELECTION 12 15 EXAMPLES OF CRANE SET UP 16 20 MAIN BOOM 16 MAIN BOOM PLUS 35 OFFSETTABLE FLY 1...

Page 4: ...tored in the computer memory If an overload is approached the MicroGuard 424 System warns the operator by means of audible and visual alarms and can be configured to cause function kick out The MicroGuard 424 indicator provides the operator with a continuous display of Rated Capacity Actual Load Percentage of Rated Capacity Radius of the Load Angle of the Main Boom Working Area Crane Configuration...

Page 5: ...graph in the upper display that gives a visual indication of how much of the crane capacity is being used and the rate at which an overload is being approached This bar graph in conjunction with the 100 capacity marker gives a visual indication of when the overload point is reached 3 PERCENTAGE OF RATED CAPACITY is a part of the bar graph display A digital readout within the bar graph display expr...

Page 6: ...d the message ROPE LIMIT will appear in the information area 3 The WINCH IN USE display indicates the selected winch F indicates front R indicates rear 4 The ANGLE LENGTH display gives a continuous indication of the angle of the main boom relative to horizontal When the angle length push button is pressed and held the display will give a momentary readout of the length of the Main Boom from the bo...

Page 7: ...ction kick out this will occur simultaneously for an Overload Wire Rope Limit or an Anti Two Block condition but function kick out will not occur when exceeding an operator set alarm 5 The BAR GRAPH ICON is a part of the analog bar graph in the upper display This display bar graph gives a visual indication of how much of the crane s capacity is being used and the rate at which an overload is being...

Page 8: ...ARM BUTTONS AND CONTRAST S AND CONTRAST S AND CONTRAST S AND CONTRAST 9 VIEW is a push button used during the setting of operator alarms It is used to start the routine and to view the current alarm settings 10 SET is a push button used during the setting of operator alarms to set a new alarm setting 11 CLEAR is a push button used during the setting of operator alarms to clear the current alarm se...

Page 9: ...push button used to select the Front or Rear winch When switching between winches the parts of line previously selected for the other winch is recorded and displayed whenever the alternate winch is selected 4 The ANGLE LENGTH icon indicates the area of the display that gives a read out of angle or length This icon is also a push button used to select the alternate display of Length Length is displ...

Page 10: ...IGHT PUSH BUTTONS AND ICONS LOWER RIGHT PUSH BUTTONS AND ICONS 1 and 3 UP DOWN ARROWS are push buttons used as arrows for scrolling 2 DEDUCT INDICATOR is an icon that contains two amber lamps which indicate stowed and erected deducts When a deduct is selected the appropriate lamp will illuminate to warn the operator that a deduct has been applied 4 and 6 RIGHT and LEFT ARROW are push buttons used ...

Page 11: ...of either an Overload an Anti Two Block alarm A T B or an Operator Settable alarm The audible alarm may be canceled by pressing and releasing the CANCEL ALARM button The audible alarm remains canceled until the condition which caused the alarm has been removed For example if the audible alarm was canceled because of an overload condition it will remain canceled until the overload condition is remo...

Page 12: ...USH BUTTON TO SELECT THE LIFTING POINT ALL OF THE INFORMATION REQUIRED BY THE SYSTEM IS ENTERED DURING CRANE SET UP THE PARTS OF LINE IN USE FOR EACH WINCH MUST ALSO BE SET FOR THE SYSTEM TO OPERATE CORRECTLY FOR SPECIFIC EXAMPLES OF CRANE SET UP REFER TO PAGES 16 20 PARTS PARTS PARTS PARTS OF OF OF OF LINE LINE LINE LINE Press and hold the PARTS OF LINE push button to scroll through the available...

Page 13: ...s illuminated in the deduct information panel which is below the Stowed push button To view the current selection when indicated by the illuminated lamp press the Stowed push button After confirming or changing the selection press the SELECT push button to complete the selection and return to the normal working screen ALTERNATE DISPLAYS ALTERNATE DISPLAYS ALTERNATE DISPLAYS ALTERNATE DISPLAYS The ...

Page 14: ...TTED AUX HEAD NOT FITTED SELECT SCROLL TO ATTACHMENT NO ATTACHMENT 35 OFSET FLY 2 35 OFSET FLY 15 35 OFSET FLY 30 35 TELE FLY 2 35 TELE FLY 15 35 TELE FLY 30 OR Ø Ø Ø Ø 48 TELE FLY 2 48 TELE FLY 15 48 TELE FLY 30 61 TELE FLY 2 61 TELE FLY 15 61 TELE FLY 30 45 TUBE JIB 5 45 TUBE JIB 17 5 45 TUBE JIB 30 45 TUBE JIB 45 60 TUBE JIB 5 60 TUBE JIB 17 5 60 TUBE JIB 30 60 TUBE JIB 45 75 TUBE JIB 5 75 TUBE...

Page 15: ... OFSET FLY 15 35 OFSET FLY 30 35 TELE FLY 2 35 TELE FLY 15 35 TELE FLY 30 OR Ø Ø Ø Ø 48 TELE FLY 2 48 TELE FLY 15 48 TELE FLY 30 61 TELE FLY 2 61 TELE FLY 15 61 TELE FLY 30 45 TUBE JIB 5 45 TUBE JIB 17 5 45 TUBE JIB 30 45 TUBE JIB 45 60 TUBE JIB 5 60 TUBE JIB 17 5 60 TUBE JIB 30 60 TUBE JIB 45 75 TUBE JIB 5 75 TUBE JIB 17 5 75 TUBE JIB 30 75 TUBE JIB 45 SELECT FOLLOWING THE SELECTION OF CRANE SET ...

Page 16: ...ELECT FULLY EXTENDED OUTRIGGERS SELECT COUNTERWEIGHT ATTACHED SELECT MAIN BOOM SELECT AUX HEAD FITTED SELECT NO ATTACHMENT SELECT LIFTING POINT FOR FRONT WINCH MAIN BOOM SELECT LIFTING POINT FOR REAR WINCH AUXILIARY HEAD PRESS WINCH SELECT ITEM 2 TO SELECT FRONT WINCH F PRESS PARTS OF LINE ITEM 3 TO SELECT 6 PARTS OF LINE PRESS WINCH SELECT ITEM 2 TO SELECT REAR WINCH R PRESS PARTS OF LINE ITEM 3 ...

Page 17: ... START THE SELECTION BY PRESSING THE CRANE SET UP BUTTON ITEM 1 SELECT FULLY EXTENDED OUTRIGGERS SELECT COUNTERWEIGHT REMOVED SELECT MAIN BOOM MANUAL SELECT AUX HEAD FITTED SELECT 35 OFSET FLY 15 OFFSET SELECT LIFTING POINT FOR FRONT WINCH MAIN BOOM MANUAL SELECT LIFTING POINT FOR REAR WINCH 35 OFSET FLY 15 OFFSET PRESS WINCH SELECT ITEM 2 TO SELECT FRONT WINCH F PRESS PARTS OF LINE ITEM 3 TO SELE...

Page 18: ...ION BY PRESSING THE CRANE SET UP BUTTON ITEM 1 SELECT FULLY EXTENDED OUTRIGGERS SELECT COUNTERWEIGHT ATTACHED SELECT MAIN BOOM SELECT AUX HEAD NOT FITTED SELECT 48 TELE FLY 30 OFFSET SELECT LIFTING POINT FOR FRONT WINCH MAIN BOOM SELECT LIFTING POINT FOR REAR WINCH 48 TELE FLY 30 OFFSET PRESS WINCH SELECT ITEM 2 TO SELECT FRONT WINCH F PRESS PARTS OF LINE ITEM 3 TO SELECT 4 PARTS OF LINE PRESS WIN...

Page 19: ...ON ITEM 1 SELECT PICK AND CARRY CENTERED REAR SELECT COUNTERWEIGHT REMOVED SELECT MAIN BOOM SELECT AUX HEAD FITTED SELECT NO ATTACHMENT SELECT LIFTING POINT FOR FRONT WINCH MAIN BOOM SELECT LIFTING POINT FOR REAR WINCH AUXILIARY HEAD PRESS WINCH SELECT ITEM 2 TO SELECT FRONT WINCH F PRESS PARTS OF LINE ITEM 3 TO SELECT 4 PARTS OF LINE PRESS WINCH SELECT ITEM 2 TO SELECT REAR WINCH R PRESS PARTS OF...

Page 20: ...e mode is selected START THE SELECTION BY PRESSING THE CRANE SET UP BUTTON ITEM 1 SELECT RIGGING TRAVEL MODE THE LOWER RIGHT DISPLAY WILL READ Rigging Travel Mode THE LEFT DISPLAY WILL READ To Resume press CRANE SETUP CAUTION THE RIGGING TRAVEL MODE INHIBITS ALL MOTION CUT AND AUDIBLE ALARMS FOR ALL ALARM CONDITIONS IT IS TO BE USED ONLY FOR THE RIGGING OR TRAVEL OF THE MACHINE DURING WHICH TIME A...

Page 21: ...h and maximum height alarms These alarms can be programmed for each job site and set rapidly for the prevailing site conditions thereby aiding the operator in the safe operation of the crane Most alarms will occur automatically as a result of limitations imposed by the capacity chart The operator has control over additional alarms which are set to define the working range of the machine for partic...

Page 22: ...reen by use of the UP DOWN arrows When the cursor is pointing to an alarm the numerical value displayed will be the current position of the crane except when that alarm has previously been SET In this case the SET value will be indicated and will alternate with the word SET Alarms which are set but to which the cursor is not pointing indicate the previously set value Other alarms which are NOT SET...

Page 23: ...ow 30 The message MIN ANGLE will appear in the INFORMATION area on the left display EXAMPLE EXAMPLE EXAMPLE EXAMPLE B B B B To have an alarm whenever the boom is above 60 angle use the following procedure 1 Press VIEW to access the alarm screen The cursor will be at MIN ANGLE Press the DOWN ARROW to move the cursor to MAX ANGLE 2 Move the boom to 60 angle 3 Press SET to enter the alarm The display...

Page 24: ...ernate with the word SET Press SELECT to return to the working screen The red lamp and the audible alarm will operate whenever the boom tip height exceeds 75 feet The message MAX HEIGHT will appear in the INFORMATION area on the left display CANCELING ALARMS CANCELING ALARMS CANCELING ALARMS CANCELING ALARMS CLEAR is used to cancel a previously SET alarm Alarms can only be CLEARED when the cursor ...

Page 25: ... tripping the switch on EITHER the Main OR the Jib switch causes the A T B alarm to operate 4 Set the Selector Switch to Jib 5 Check that raising the weight on the Jib switch only and tripping the switch causes the A T B alarm to operate FUNCTION KICK FUNCTION KICK FUNCTION KICK FUNCTION KICK OUT OUT OUT OUT If the crane is equipped with Function Kick Out check the operation of the system as follo...

Page 26: ...ight agrees with the test load The displayed load includes the hook block and any lifting attachments such as slings pins and shackles If the capacity chart is rated for specific areas e g side front or rear the system should be checked by swinging the boom into the permitted areas and checking that the Rated Capacity reading agrees with the crane Capacity Chart ROUTINE MAINTENANCE ROUTINE MAINTEN...

Page 27: ...UBLESHOOTING FAULT DIAGNOSTIC PROCEDURES 29 GROUP A FAULT CODES 30 31 POWER SUPPLY VOLTAGES 32 INPUT POWER 32 INTERNAL POWER SUPPLIES 32 ACCESSING THE COMPUTER AND TERMINATION BOARDS 33 CHECKING ANALOG DRIVE VOLTAGE 33 PRESSURE CHANNEL FAULT GUIDE 34 36 FUNCTIONAL TESTS 34 TRANSDUCER RESISTANCE MEASUREMENT 35 PISTON PRESSURE TRANSDUCER 35 ROD PRESSURE TRANSDUCER 35 36 ANALOG DRIVE VOLTAGE 36 BOOM ...

Page 28: ...tal Display Hydraulic Cranes 28 of 52 W424103 REV A 02 13 01 PARTS REPLACEMENT 43 45 PRESSURE TRANSDUCERS 43 EXTENSION REEL 43 BOOM ANGLE SENSOR HTC8660 ONLY 43 BOOM ANGLE SENSOR 44 EXECUTIVE ROM CHIP 44 PERSONALITY ROM CHIP 44 DUTY ROM CHIP 44 COMPUTER BOARD 44 COMPUTER BOX 45 CHIP REMOVAL AND INSTALLATION 45 GLOSSARY 46 48 COMPUTER BOARD LAYOUT 49 TERMINATION BOARD LAYOUT 50 EXTENSION REEL LAYOU...

Page 29: ...n the system they can be diagnosed using the display Details of the fault locations are obtained by pressing and holding the test button Holding the test button will cause the system to go through a self test during which faults will be detected Following completion of the self test If the test button continues to be pressed the fault screen will appear The fault screen will remain visible for as ...

Page 30: ...ach sensor is allocated a FAULT CODE and this is the number that appears under the group heading in the fault code display 001 Sensor 0 Piston Pressure 002 Sensor 1 Rod Pressure 004 Sensor 2 Extension Sensor 008 Sensor 3 Boom Angle 016 Sensor 4 S structure Angle 032 Sensor 5 Swing Pot r A 064 Sensor 6 Swing Pot r B When there are no faults detected in the system 000 will appear under all group hea...

Page 31: ... Boom angle sensor Fault 10 Fault 10 Fault 10 Fault 10 AAAB CC DD 010 0 00 00 Boom angle sensor Rod pressure transducer Fault 11 Fault 11 Fault 11 Fault 11 AAAB CC DD 009 0 00 00 Boom angle sensor Piston pressure transducer Rod pressure transducer Fault 32 Fault 32 Fault 32 Fault 32 AAAB CC DD 032 0 00 00 Swing potentiometer A Fault 64 Fault 64 Fault 64 Fault 64 AAAB CC DD 064 0 00 00 Swing potent...

Page 32: ... input voltage is measured across the B and B terminals on the Terminal Connection Board and corresponds to the battery voltage of the crane At voltages below 10 5 and above 38 volts the system will power down until correct voltage is restored If the INPUT POWER is not within these limits check the battery and or alternator before servicing the computer INTERNAL POWER SUPPLIES INTERNAL POWER SUPPL...

Page 33: ...n cables must remain connected to the Main Computer Board for voltage checks CHECKING ANALOG DRIVE VOLTAGE CHECKING ANALOG DRIVE VOLTAGE CHECKING ANALOG DRIVE VOLTAGE CHECKING ANALOG DRIVE VOLTAGE To check the Analog Sensor Drive Voltage use the following procedure 1 Access the Termination Board 2 With the system power on and a digital volt meter set to read DC voltage place the negative lead on a...

Page 34: ...ft Arrow 5 and then use the Up 3 or Down 4 arrow keys to select TX1 pressure transducer rod side With no pressure in the cylinder the upper display should read 0 20 bits 7 If the transducers were disconnected in step 5 tighten the fittings With the boom fully retracted boom up to a 60 angle 8 Access the Zero of TX 0 as described in step 5 The upper display should read 200 100 bits 9 Access the Zer...

Page 35: ...n pins C an D of connector MS3474W14 5PZ The resistance should be 350Ω 10Ω 3 With the DVM set to the Ohms range measure the resistance between pins B an E of connector MS3474W14 5PZ The resistance should be 350Ω 10Ω 4 With the DVM set to the Ohms range measure the resistance between pins B C D E and the case of the transducer Measure the resistance between B C D E and the case of the connector The...

Page 36: ...e voltage is out of range disconnect all of the analog sensors by disconnecting the sensor connectors from the computer in order to determine if any sensor or its cabling is causing the drive voltage to be incorrect 5 If the drive voltage is correct with all of the sensors disconnected connect each sensor in turn to determine which sensor is causing the drive voltage to incorrect 6 If any sensor i...

Page 37: ...he left side of the main boom section and remove the cover 9 Under the cover on the right side of the extension reel you will see a terminal strip This terminal strip has six wires connected to the bottom screws 10 With a digital voltmeter set to read DC Voltage place the negative lead on the terminal with the blue wire attached to it Drive and the positive lead on the terminal with the red wire a...

Page 38: ...igital voltmeter set to read DC Voltage place the negative lead on the terminal with the blue wire attached to it Drive and the positive lead on the terminal with the red wire attached to it Drive 11 The voltage should be 5 25 0 1 volts If this voltage is out of range and the Analog Drive Voltage checked in step 2 was OK then it is possible that the reeling drum cable is open or grounded between t...

Page 39: ...on 3 has a black wire attached to it 3 Connect the black lead of the DVM to connection 3 black wire and the red lead of the DVM to connection 1 red wire The voltage should be 4 125 0 1 volts If this voltage is out of range the Termination Board will need to be replaced 4 With the black lead on any 0 Volt terminal check the voltage at AIN 5 terminal and AIN 6 terminal The voltage should be 4 50 0 1...

Page 40: ...AM SCRATCHPAD RAM SCRATCHPAD RAM The Scratchpad Ram fault code indicates the failure of IC6 on the Main Computer Board This item is not user serviceable and requires the replacement of the Main Computer DUTY ROM DUTY ROM DUTY ROM DUTY ROM This fault is associated with the failure of the Duty Chip IC3 on the Main Computer Board It can be replaced without the need for re calibration It contains the ...

Page 41: ...w a Two Block warning there is a ground in the wiring or connections between the extension reel and the Switch at the boom head Check all wires and connections between these two components and repair or replace as required SYSTEM SHOWS TWO SYSTEM SHOWS TWO SYSTEM SHOWS TWO SYSTEM SHOWS TWO BLO BLO BLO BLOCK WHEN CRANE CK WHEN CRANE CK WHEN CRANE CK WHEN CRANE IS NOT TWO IS NOT TWO IS NOT TWO IS NO...

Page 42: ...itch will go to the open position thereby removing the ground from ATBIN and causing ATB Alarm and Function Disconnect The ATB alarm and Function Disconnects are controlled separately by the ATB board in the computer The ATB board located in the computer box Operates the function disconnects by controlling the coil of RL2 ATB relay at D OUT 1 Operates the audible alarm and on screen message by con...

Page 43: ...w reel to the boom secure with the mounting bolts and connect the Extension Reel Cable Connector 6 Remove the shipping cable clamp from the new cable and allow it to slowly rewind onto the Extension Reel until there is no pre tension Continue to re wind the reel in the same direction until the distance between the boom head and the connector is approximately 12 ft At this point there will be no pr...

Page 44: ...EPLACEMENT PERSONALITY ROM CHIP REPLACEMENT The Personality ROM Chip must be the proper chip for the particular crane serial number This chip contains calibration data that is unique to each machine 1 Access the Main Computer Board Refer to page 33 of this manual 2 With the power off remove IC7 the Personality ROM Chip from its socket Refer to General Chip Removal and Installation page 45 in this ...

Page 45: ...TER BOX REPLACEMENT COMPUTER BOX REPLACEMENT COMPUTER BOX REPLACEMENT TERMINAL BOARD AND BOX ONLY USE THE COMPUTER BOARD FROM THE ORIGINAL BOX 1 Remove the Main Computer Board 2 Disconnect all cable connectors from the Computer Box 3 Remove the four screws securing the Computer Box 4 Remove the Computer Box 5 Install the new computer and secure with the four mounting screws 6 Reconnect all cable c...

Page 46: ...sewhere e g in a service department BOOM DEFLECTION The change of radius due to the bending of a boom under load BOOM MOMENT The turning moment around the boom pivot caused by the moment of the unladen boom BORE The piston side of a boom hoist cylinder CALIBRATION The adjustment of the graduation of sensors CAPACITY CHART A table showing the rating of a crane CENTER OF GRAVITY The point at which t...

Page 47: ...a from a memory prior to a new calibration INTEGRATED CIRCUITS A tiny complex of electronic components and connections on a small slice of material such as silicon MEASURE HEIGHT The vertical distance below the boom pivot at which radius measurements are to be made when calibrating MICROPROCESSOR A computer processor contained on an integrated chip MILLIVOLT One thousandth of a volt MOMENT The pro...

Page 48: ... between two limits SPAN The calibration of an analog sensor between zero and maximum span STOWED ATTACHMENT An attachment usually stowed on the main boom when not in use SUPERSTRUCTURE The structural part of a crane above the carrier usually rotating SWING The rotation of a crane upper around its center line SWL SWL Percentage of safe working load The proportion of the crane capacity which is bei...

Page 49: ...ard 424 Operation Troubleshooting Manual Horizontal Display Hydraulic Cranes 49 of 52 W424103 REV A 02 13 01 COMPUTER BOARD LAYOUT COMPUTER BOARD LAYOUT COMPUTER BOARD LAYOUT COMPUTER BOARD LAYOUT I C3 DUTY I C2 EXEC I C8 RAM I C7 PERS LAYOUT OF M AI N COM PUTER BOARD I C2 EXECUTI VE ROM I C3 DUTY ROM I C7 PERSONALI TY CHI P I C8 RAM CHI P NOT REM OVABLE ...

Page 50: ...N BOARD TERMINATION BOARD TERMINATION BOARD TERMINATION BOARD B B FS2 FS1 DR 0V 0V DR TX1 TX1 DR TX0 TX0 DR DR 0V AIN0 AIN1 DR DR AIN2 AIN3 AIN4 DR 0V DR DR 0V AIN5 AIN6 VP VP VP VP 0V 0V 0V 0V DIN1 DIN2 DIN3 DIN4 DIN5 DIN6 DIN7 DIN8 DIN9 DIN10 DIN11 DIN12 DIN13 DIN14 DIN15 ATBIN ATBOUT 0V RES DB DA 5VB 5VA 0V DOUT7 DOUT6 DOUT5 DOUT4 DOUT3 DOUT2 DOUT1 DOUT0 RL1 RL2 O LOAD ATB ATB BOARD RL1 RL2 NC ...

Page 51: ...8 EAST GLENWOOD PLACE SANTA ANA CA 92705 Tel 714 259 9702 Fax 714 259 7626 MicroGuard 424 Operation Troubleshooting Manual Horizontal Display Hydraulic Cranes 51 of 52 W424103 REV A 02 13 01 Angl e Sensor A220210 Dat a Pot r P010110 Ter m i nal St r i p EXTENSION REEL LAYOUT ...

Page 52: ...el 714 259 9702 Fax 714 259 7626 MicroGuard 424 Operation Troubleshooting Manual Horizontal Display Hydraulic Cranes 52 of 52 W424103 REV A 02 13 01 1918 East Glenwood Place Santa Ana CA 92705 Telephone 714 259 9702 Fax 714 259 7626 1918 East Glenwood Place Santa Ana CA 92705 Telephone 714 259 9702 Fax 714 259 7626 ...

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