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Greer – MG514
Retrofit

Installation, Calibration, and Service Manual

Summary of Contents for Greer MG514

Page 1: ...Greer MG514 Retrofit Installation Calibration and Service Manual...

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Page 3: ...his document contains proprietary information which is protected by copyright and all rights are reserved No part of this document may be photocopied reproduced or translated to another language witho...

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Page 5: ...liminary Checks and Measurements 15 2 4 1 Boom Pivot Dimensions 15 2 4 2 Winch Dimensions 16 2 4 3 Boom Cylinder Dimensions 17 2 4 4 Span Dimensions 17 2 4 5 Auxiliary Head Dimensions 18 2 4 6 Stowed...

Page 6: ...t Codes 52 3 3 2 Group B Fault Codes 53 3 3 3 Group C Fault Codes 54 3 3 4 Group D Fault Codes 55 3 3 5 No Fault Code Problems 56 3 3 5 1 Anti Two Block Alarm ATB 56 3 3 5 2 Displayed Load or Radius E...

Page 7: ...7 7 Checking the Angle Sensor Voltage 71 3 7 8 Reeling Drum Replaceable Parts 71 3 7 8 1 Reeling Drum Cable 72 3 7 8 2 Slip Ring Assembly 74 3 7 8 3 Sensor Baseplate Assembly 75 3 7 8 4 Signal Cable A...

Page 8: ...ectangular shaped reeling drum be replaced with our current production reeling drum A240690 The rectangular shaped reeling drum has been classed obsolete There is no longer field support for this prod...

Page 9: ...or upgrading Link Belt cranes and operates with Link Belt style menus 1 2 3 A240690 Reeling Drum If you replace the existing reeling drum with A240690 you must also replace the guides for the Anti Two...

Page 10: ...outside of our computer module to assist in the wiring connections It is the responsibility of the installer to identify the proper wire identifications and routings on the crane for connecting to th...

Page 11: ...12 4 Display Power BLD 41 Power 12V Power for Display JP 12 5 BLD 42 Display Ground Wire Connection Connection Work Instructions JP9 1 BLD 26 Digital Input 12V JP9 2 BLD 27 Digital Input 12V JP9 3 BL...

Page 12: ...Chart Front BLD 28 DIN 2 Over Front Chart Between Tires BLD 29 DIN 3 Between Tires Chart Power BLD 30 VP Switched Power BLD 26 BLD 27 BLD 30 BLD 29 BLD 26 BLD 27 BLD 30 DIN 0 DIN 1 VP NO NC C BLD 28 B...

Page 13: ...ning 3 bolts and ensure the computer is firmly attached 9 Lower the boom completely Remove the existing pressure sensors 10 Install the new pressure hoses and retain the velocity fuses NOTE Install th...

Page 14: ...o ensure the pressure hoses and electrical cables are routed properly ATTENTION It is easy to misroute the pressure hoses and electrical cables If misrouted when the boom is raised the 1st time the ho...

Page 15: ...distance of 35 6 would be entered into the system as 35 5 feet Whole inches can be easily converted by dividing by 12 6 12 5 Fractions of an inch are converted by dividing the numerator by the denomin...

Page 16: ...ht The cursor will appear as flashing brackets on either side of the number Button A is used to enter the number Button C is used to exit the number entry subroutine As each number is selected press B...

Page 17: ...decimal then press button A 3 Repeat steps 1 and 2 to enter the numbers 9 and 8 4 After the numbers are entered press button B or D until the minus sign is selected and then press button A 5 If the v...

Page 18: ...the center of the boom pivot and the center of the boom hoist cylinder upper pivot Dimension J The vertical distance between the center of the boom pivot and the center of the boom hoist cylinder uppe...

Page 19: ...e It is important to indicate a positive or negative value Dimension L0 and L1 The distance between the centerline of the boom pivot perpendicular to the horizontal boom plane and the center of the bo...

Page 20: ...XIMUM STABILITY ENSURE ALL BOOM EXTENSIONS AND LOADS ARE LIFTED WITHIN THE APPROPRIATE LOAD CHARTS AND LIMITS FAILURE TO COMPLY WITH THESE LIMITS MAY RESULT IN SERIOUS INJURY OR DEATH Dimension S This...

Page 21: ...D THE MEASUREMENT 2 4 6 Stowed Jib Dimensions Dimension G This is the distance between the center of the boom pivot and the center of gravity of the stowed jib USE THE SPACE PROVIDED IN APPENDIX A TO...

Page 22: ...clockwise until a click is heard indicating that the power spring clutch is engaged 3 Turn the reeling drum counterclockwise five 5 complete turns and physically restrain it from moving 4 Remove enoug...

Page 23: ...information and error codes 01 Crane Data Used to reset the crane personality data 02 Dimensions Used to enter the crane geometry dimensions previously recorded 03 Zero Sensor Used to set the zero po...

Page 24: ...owing information is displayed a System error codes b Computer serial number should match the number on the label on the enclosure 3 Press the Exit button to leave the routine or press the More button...

Page 25: ...s crane specific information and dimensions It will also copy any known data from the flash applications file to the working memory for use by the system NOTE No calibration may be modified unless Per...

Page 26: ...on 5 Use the buttons adjacent to the numerical values at the bottom of the window to scroll left or right and highlight each number 6 Use the Swing Offset button to enter the number When complete the...

Page 27: ...s in the right of the information window 3 Press the 03 Zero Sensor button to enter the routine 4 Press the Zero Extension XXX button 5 The extension sensor will now show Zero No 2 0 6 Press the Next...

Page 28: ...3 Ensure the crane setup is adequate then raise the boom and fully extend the boom sections 4 Press the Next button to access the No 2 XX XX Press the No 2 XX XX button to calibrate the span for No 2...

Page 29: ...cation the display will access the number entry screen for Angle Span 3 Take the angle span number from the digital level and enter into the system After entry the boom angle screen should be in agree...

Page 30: ...utton until 05 Swing Potentiometer appears in the information window at the right 2 Press the 05 Swing Potentiometer button to enter the routine 3 Stow the boom in road travel mode Press the Zero butt...

Page 31: ...J G and H dimensions have been calculated and entered into the system 2 Press the 06 Pressure button to enter the routine 3 Enter the piston diameter If not press the Exit button 4 Enter the rod diame...

Page 32: ...hook weights in thousandths of pounds Example Enter 1 400 pounds as 1 4 14 Pick up the calibration load and allow it to settle Press the Yes button to continue Pressing the No button will exit the ro...

Page 33: ...y appear briefly while calibration is completed unless there is an error as shown here If there are no errors the top level menu will appear next 18 If the proper result is not achieved and the dimens...

Page 34: ...IMITS FAILURE TO COMPLY WITH MANUFACTURER S LIMITS MAY RESULT IN SERIOUS INJURY OR DEATH IMPORTANT ANY ATTACHMENTS ON THE SIDE OR TIP OF THE BOOM DURING THESE TESTS CAN CAUSE INACCURACY IN THE MAIN BO...

Page 35: ...s Moment button Enter Tare load 1 1 is 1100lbs and press Exit Buttons 1 2 will be used to select the number and button 3 will be used to enter the number 3 1 2 SkyAz l Equipment Solutions www skyazul...

Page 36: ...it button to begin the Radius Moment If you see this message Boom to an angle below 20 degrees or above 70 degrees and Press Angle is a High or Angle is a Low SkyAz l Equipment Solutions www skyazul c...

Page 37: ...to 0 degrees or as the Load Chart will allow Fully retract the BOOM and Press Bas 0 Measure radius from center of pivot pin to load rope and enter as low radius and Press Exit SkyAz l Equipment Solut...

Page 38: ...or as the Load Chart will allow Remain fully retracted and Press Bas 0 D Measure radius from center of pivot pin to load rope and enter as high radius and Press Exit SkyAz l Equipment Solutions www sk...

Page 39: ...S Calibrate Radius Moment 1 extension complete Extend the boom to the next extension and repeat the above USE THE SPACE PROVIDED IN APPENDIX A TO RECORD THE MEASUREMENTS SkyAz l Equipment Solutions ww...

Page 40: ...IMUM STABILITY ALSO MAKE SURE ALL BOOM EXTENSIONS AND LOADS ARE LIFTED WITHIN THE APPROPRIATE LOAD CHARTS AND LIMITS FAILURE TO COMPLY WITH MANUFACTURER S LIMITS MAY RESULT IN SERIOUS INJURY OR DEATH...

Page 41: ...adjacent to the numerical values at the bottom of the window to scroll left or right and highlight each number Press the Enter On Load Radius button to enter the number 7 When complete the menu will...

Page 42: ...ss 3 Use a digital level on the top of the boom head section to enter the angle readings into the calibration 4 Press the 09 Head Angle button to enter the head angle readings from the boom extensions...

Page 43: ...ment press the Edit View button The menu items will scroll up one at a time and give you the opportunity to enter new information or edit existing information 4 If adjustments are needed to the geomet...

Page 44: ...utton until 11 Enable Winches appears in the information window at the right 2 Press the 11 Enable Winches button to enter the routine NOTE There must be at least one winch enabled on the crane The sy...

Page 45: ...inputs 1 Press the Next or Prev button until 12 Digital Inputs appears in the information window at the right 2 Press the 12 Digital Inputs button to enter the routine 3 When viewing is complete pres...

Page 46: ...ssure without the need to set the Rod Diameter first 1 Press the Next or Prev button until 13 Pressure Monitor appears in the information window at the right 2 Press the View Cylinder Pressures button...

Page 47: ...er of the boom pivot G1 The horizontal distance between the center of the rear winch and the center of the boom pivot H0 The vertical distance between the center of the front winch and the center of t...

Page 48: ...stance between the center of the boom pivot and the center of the sheave with the boom fully retracted Boom span T S AUXILIARY HEAD DIMENSIONS Auxiliary Head Weight Auxiliary Head Offset Angle Auxilia...

Page 49: ...46 LOAD VERIFICATIONS Test Displayed Length Displayed Angle Displayed Radius Measured Radius Radius Error Displayed Load Actual Load Load Error SkyAz l Equipment Solutions www skyazul com 301 371 6126...

Page 50: ...875 11 16 6875 13 64 203125 45 64 703125 7 32 21875 23 32 71875 15 64 234375 47 64 734375 1 4 25 3 4 75 17 64 265625 49 64 765625 9 32 28125 25 32 78125 19 64 296875 51 64 796875 5 16 3125 13 16 8125...

Page 51: ...roblem noting any unusual system responses that may help us to quickly and effectively solve your problem 3 1 Overview Preparation This Troubleshooting Manual for the MicroGuard RCI 514 Rated Capacity...

Page 52: ...conds following power on or pressing the TEST button the display will show the following indications All display segments of the bar graph display B will be black ON All display segments of the load a...

Page 53: ...e display console indications No FAULT diagnoses of other system problems can be carried out without the proper function of the display console and its communication with the computer unit To solve pr...

Page 54: ...e RED OVERLOAD LAMP will illuminate The AUDIBLE ALARM will sound WARNING SYSTEM FAULT will be displayed at the bottom of the text window Fault codes may be displayed on the display console To view the...

Page 55: ...to take in the right column FAULT CODE SWING SENSOR BOOM ANGLE SENSOR EXTENSION SENSOR Tdx 1 ROD PRESSURE Tdx 0 PISTON PRESSURE ACTION 000 No Fault Found NONE 001 X Replace Computer 002 X 003 X X 004...

Page 56: ...8 3 3 8 6 3 8 7 3 10 029 X X X X Replace Computer 030 X X X X 031 X X X X X 3 3 2 Group B Fault Codes Group B fault codes represent faults detected for internal analog functions and power feeds to the...

Page 57: ...1 X Contact Technical Support 002 X 003 X X 005 X 006 X 007 X X 009 X 010 X 011 X X 013 X 014 X 015 X X 016 X Re select crane setup configuration If not resolved Contact Technical Support 017 X X Cont...

Page 58: ...02 X Boom length is out of range for selected chart Check crane setup boom length and extension 003 X X Check other sensor faults first Re select CRANE CONFIGURATION 004 X Swing to correct working are...

Page 59: ...xtension reel off cable for damage Ensure the Two Block switches are correctly connected Check the slip ring and wiring inside the extension reel Check the signal cable from the reeling drum to the co...

Page 60: ...must be between 0 2 and 0 2 with the boom fully retracted If the extension value is incorrect refer to CHAPTER 2 CALIBRATION Fully telescope the boom and ensure the displayed boom length value matche...

Page 61: ...reading within 0 2 If the displayed angle is incorrect refer to SECTION 3 10 4 SPAN CALIBRATION Check Pressure Sensors The pressure sensing system is calibrated at the factory Pressure sensors are no...

Page 62: ...crane wiring harness via 60 way bulkhead connector There are no wiring connections or screw terminals within the unit The two hydraulic pressure sensors required to sense pressure within the boom hoi...

Page 63: ...ight of the boom any attachments and the load The pressure sensor on the rod side monitors the pressure necessary to control the down motion of the boom The computer unit uses this information along w...

Page 64: ...the electrical connectors 4 Remove the protective caps from the hydraulic ports 5 Connect the base side pressure GREEN P on the enclosure hose to the piston pressure port 6 Connect the rod side press...

Page 65: ...the rear of the display console For bracket mounted applications it is clearly visible on the rear of the housing On flush mounted versions it is hidden behind the panel within the dash assembly This...

Page 66: ...n for future use 3 Remove the defective display console from the bracket in the cab INSTALLATION 1 Put the OPERATOR S DISPLAY CONSOLE on the bracket located in the cab by positioning it between the br...

Page 67: ...operator may check the LED operation at any time by pressing the test button on the operator s display console With the System powered there should always be at least one GREEN LED lit The REMOTE BAR...

Page 68: ...inside against pressure washing or heavy rainfall If this occurs replace the remote bar graph 3 6 6 Remote Bar Graph Replacement Removal of Remote Bar Graph 1 Turn off the power 2 Remove the display c...

Page 69: ...o measure the main boom angle and an electrical slip ring which transfers the Anti Two Block signal from the reeling drum cable to the system computer Complete the setup and maintenance of these devic...

Page 70: ...the boom fully out and then fully in 2 Check that the reeling drum cable forms a flat single layer across the surface of the extension reel with each successive turn of cable laying next to the last N...

Page 71: ...l Check the reeling drum wiring within the reel and at connector j305 3 7 3 Checking the Boom Extension Sensor Voltage 1 Fully retract the boom 2 Remove the reeling drum cover 3 With a digital voltmet...

Page 72: ...n gear wheel connected to the extension sensor by pulling the sensor arm in the direction shown 4 Rotate the gear clockwise until the sensors clutch starts to drag At the next click stop rotating the...

Page 73: ...ush the pendulum downwards and ensure it moves freely Some resistance of movement may be encountered as the pendulum is moved however this is due to the magnets that provide the damping 4 Release the...

Page 74: ...1 1 and the GREEN wire TB1 2 With the boom horizontal the voltage should be between 0 3 and 0 5 volts If the voltage is incorrect follow the ANGLE SENSOR SETUP PROCEDURE 3 Measure the voltage at TB1 1...

Page 75: ...act and lower the boom Disconnect the REELING DRUM CABLE from the Anti Two Block switch or connector 2 Grip the cable firmly and release it from the tie off post 3 Continue to grip the cable firmly wh...

Page 76: ...Rotate the reeling drum Ensure the path of the new cable is unimpeded then tighten the strain relief 8 Wind the reeling drum cable onto the reeling drum in a single layer 9 Set pre tension 5 turns co...

Page 77: ...th Phillips screws that hold the lower half of the slip ring on the shaft and remove the slip ring 5 Disconnect the two wires connecting the lower half of the slip ring assembly at TB1 5 and TB1 6 on...

Page 78: ...the extension and angle sensors and connects the sensors the Anti Two Block switch signal to the slip ring and the signal cable to the system computer Electrical or mechanical failure of either the an...

Page 79: ...th the reeling drum spline Route the wires to the terminal block and hook up the wires as indicated below SIGNAL BOOM POSITION ACTION VOLTAGE VOLTMETER CONNECTION MIN MAX RED BLACK SENSOR DRIVE 4 7V 5...

Page 80: ...the main shaft in the center of the Reeling Drum This cable has a strain relief encircled with an O ring which creates a tight fit to prevent water intrusion NOTE If it is difficult to remove the cab...

Page 81: ...the wires lay flay and toward the terminal connectors Ensure there is enough space to clear the wires when the arm of the Slip Ring rotates 11 Replace the cover on the Reeling Drum 12 Install the Ree...

Page 82: ...s lifted by the hook block the switch contact is opened and the computer will sense a low signal input 0 volts from the ATB signal return Since the computer checks the protected feed voltage internall...

Page 83: ...ted to the ATB switches at the boom head jib 1 Remove the reeling drum cover 2 Disconnect the slip ring arm from the plug by pulling it away from the center of the reeling drum 3 Close the ATB switch...

Page 84: ...r swing alarms working area alarms If the swing sensor fails the computer will be unable to select a valid capacity chart For fault diagnosis access the swing sensor by removing the collector cover co...

Page 85: ...wing sensor or cabling connections If voltages are incorrect proceed to SECTION 3 10 3 CHECKING THE SWING SENSOR RESISTANCE 3 9 3 Checking the Swing Sensor Resistance 1 Disconnect the connector behind...

Page 86: ...r is present calibration is not required 1 Press the Next or Prev button until 05 Swing Potentiometer appears in the information window at the right 2 Press the 05 Swing Potentiometer button to enter...

Page 87: ...e this command to remove the swing pot from the system This is usually only used as a troubleshooting tool and is not part of the calibration routine 7 Press the Exit button to return to the main menu...

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Page 90: ...2 SkyAz l Equipment Solutions www skyazul com 301 371 6126 SkyAz l Inc 16 Walnut Street Middletown MD 21769 Phone 301 371 6126 Fax 301 371 0029 info skyazul com www skyazul com...

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SkyAzúl Greer MG514, Installation, Calibration, And Service Manual

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