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MicroGuard 510

Retrofit for Terex

Installation, Calibration and

Troubleshooting Manual

Pos

Neg

Existing Crane

Wiring

Ba

tt

er

y

FK

O

Sol

en

oi

d

White

Black

Red

Green

Existing Reeling

Drum

Red

White

Black
Green

- BLD 2

- BLD 1

- BLD 8
- BLD 7

White

Red

Green
Black

- BLD 37

- BLD 34

- BLD 36
- BLD 35

B

2

A

1

Existing Swing Pot

A450769

Computer

A450251

RCI 510 Display

White

Green

Red

Black

1
2
3
...
»

Содержание MicroGuard MG510

Страница 1: ...al Pos Neg Existing Crane Wiring Battery FKO Solenoid White Black Red Green Existing Reeling Drum Red White Black Green BLD 2 BLD 1 BLD 8 BLD 7 White Red Green Black BLD 37 BLD 34 BLD 36 BLD 35 B 2 A...

Страница 2: ...ns 16 2 3 3 Boom Cylinder Dimensions 17 2 3 4 Span Dimensions 17 2 3 5 Auxiliary Head Dimensions 18 2 3 6 Stowed Jib Dimensions 18 2 4 Installation Checks 19 2 4 1 Attaching the Anti Two Block ATB Cab...

Страница 3: ...ion Sensor Drive Voltage 60 3 7 3 Checking the Boom Extension Sensor Voltage 60 3 7 4 Physical Zero 61 3 7 5 Checking the Angle Sensor Pendulum 62 3 7 6 Checking the Angle Sensor Drive Voltage 63 3 7...

Страница 4: ...computer and display Greer Company recommends the exisiting rectangular shaped reeling drum be replaced with our current production reeling drum A240690 The rectangular shaped reeling drum is obsolet...

Страница 5: ...rading Terex cranes and operates with Terex style menus Pos Neg Existing Crane Wiring Battery FKO Solenoid White Black Red Green Existing Reeling Drum Red White Black Green BLD 2 BLD 1 BLD 8 BLD 7 Whi...

Страница 6: ...nstaller must replace the guides for the Anti Two Block cabling The guides support the level wind system fo the reeling drum The part number for the new guide kit is K056005 and includes the new guide...

Страница 7: ...ller to properly identify the correct wires and routings on the crane for connections to the MG510 computer Please reference the wiring diagram below NOTE The Green wire may have been replaced by a ju...

Страница 8: ...Display Power BLD 41 Power 12V Power for Display JP 12 5 BLD 42 Ground Display Ground Wire Connection Connection Work Instruction A450663 A450763 JP9 1 BLD 26 Digital Input 12V JP9 2 BLD 27 Digital In...

Страница 9: ...3 Work Instructions Rear BLD 20 DIN 0 Digital 0V Side BLD 27 DIN 1 Over Side Chart Front BLD 28 DIN 2 Over Front Chart Between Tires BLD 29 DIN 3 Between Tires Chart Power BLD 30 VP Switched Power Ove...

Страница 10: ...ing one of the existing bolt holes Use the new computer as a template to drill three new mounting holes 8 Screw in the remaining bolts Ensure the computer is securely attached 9 Lower the boom complet...

Страница 11: ...4 Install the display 15 Install the display cable 16 Install the power and FKO cables to the new computer 17 Slowly elevate the boom to its maximum angle to ensure the pressure hoses and electrical c...

Страница 12: ...measuring tape Fiber type graduated in tenths of a foot NOTE The computer calculates measurements in feet and tenths of a foot Using the correct tape measure is critical for entering the measurements...

Страница 13: ...The cursor will appear as flashing brackets on either side of the number Use the A button to enter the number Use the C button to exit the number entry subroutine As each number is selected press But...

Страница 14: ...on 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 value is correct press bu...

Страница 15: ...D THE MEASUREMENTS Dimension L The horizontal distance between the center of the boom pivot and the center of the boom hoist cylinder upper pivot Dimension J The vertical distance between the center o...

Страница 16: ...in the illustration dimension J will be negative 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...

Страница 17: ...MUM 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 USE THE SPACE PROV...

Страница 18: ...DIX A TO RECORD THE MEASUREMENT 2 3 6 Stowed Jib Dimensions USE THE SPACE PROVIDED IN APPENDIX A TO RECORD THE MEASUREMENTS Dimension G This is the distance between the center of the boom pivot and th...

Страница 19: ...m Ensure the reeling drum spring is properly pre tensioned by following the procedure below 1 Fully retract the boom assembly and remove the reeling drum cover 2 Slowly rotate the Reeling Drum clockwi...

Страница 20: ...n calibration mode To access calibration mode 1 Hold down the TEST and SET buttons simultaneously The audible alarm will sound and you will be prompted to enter the security code You will have five 5...

Страница 21: ...oom Deflection Used to calibrate deflection for the main boom and attachments 09 Compensation Sets rod side pressure compensation when booming down 10 Erected Attachments Used to calibrate the radii m...

Страница 22: ...m has become corrupt the display will read Personality not in use In this case proceed with the Crane data reset routine and reset the data 5 To reset the data press 01 Crane Data button and the syste...

Страница 23: ...eet and tenths of a foot 4 Pressing the upper right key adjacent to the item needing a dimension will immediately open the number entry screen 5 Use the B and D buttons adjacent to the numerical value...

Страница 24: ...ess the Menu Up or Menu Down button until 03 Extension Sensor appears in the information window at the right 2 Press the 03 Extension Sensor button to enter the routine 3 With the cover removed from t...

Страница 25: ...extend the boom and then enter the value for the span Extended Boom Retracted Boom Span 3 Use the buttons adjacent to the numerical values at the bottom of the window to scroll left or right and high...

Страница 26: ...he inclinometer reads 60 or slightly higher Enter the value for the angle from the inclinometer 6 Use the B and C buttons adjacent to the numerical values at the bottom of the window to scroll left or...

Страница 27: ...en rotating to the right or in a clockwise direction If no swing potentiometer is present calibration is not required 1 Press the Next or Prev button until 05 Swing Potentiometer appears in the inform...

Страница 28: ...the boom hoist cylinder A calibrated load is needed to calculate the diameter of the boom hoist cylinder Use a load approximately 80 of the single part load rating If a smaller weight is all that is a...

Страница 29: ...to proceed with the calibration of the load press Yes 6 The system will then prompt for the measured load radius measurement Carefully measure from the center of the load to the centerline of rotatio...

Страница 30: ...unds 0 1 to the actual weight will guarantee a slightly positive load reading in all operating configurations 4 Up to seven Radius Moment points may be stored and must include a Boom fully retracted b...

Страница 31: ...r the tare load is entered press Exit to enter the load into the calibration procedure 11 After telescoping to the proper length and press OK The system will prompt for high or low boom angle When the...

Страница 32: ...ars in the information window at the right 2 Press the 08 Boom Deflection button to enter the routine and display the current F Factor in the center of the screen The system will offer the opportunity...

Страница 33: ...compensation extend the boom approximately halfway out using a load of say 2000 pounds and lowering the boom at a slow rate If the displayed load diminishes or disappears during this operation press E...

Страница 34: ...ght on the main boom while calibrating the jib however if this is unavoidable you must enter this hook weight If the main hook weight has been removed enter 0 00 3 Press the Exit button to access the...

Страница 35: ...ore the measurement and allow for the last measurement which is low angle 10 Lower the boom to the lowest angle allowing the system to display a maximum capacity Press the Calibrate button and enter t...

Страница 36: ...t screen press the Exit button to return to the main menu Menu 12 Stowed Attachments This screen allows the entry of Stowed attachments jibs dimensions weights and center of gravity 1 Pressing the 12...

Страница 37: ...able attachments and their status 3 Press the button adjacent to the attachment you wish to enable or disable will prompt a YES Calibrate screen When the approval is given the attachment will become e...

Страница 38: ...cess to reading and editing the Radius Moment Data and Fly Data If no selection is made the display will return to the main menu Menu 17 Language This menu allows the language to be displayed while in...

Страница 39: ...of the front winch and the center 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...

Страница 40: ...nded S The distance 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...

Страница 41: ...41 W450769A 01 14 Load Verification Test Displayed Length Displayed Angle Displayed Radius Measured Radius Radius Error Displayed Load Actual Load Load Error...

Страница 42: ...5625 11 64 171875 43 64 67185 3 16 1875 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 29687...

Страница 43: ...tor who is knowledgeable in safety guidelines crane capacity information and the crane manufacturer s specifications Use of calibration routines without consulting the Greer Company invalidates the wa...

Страница 44: ...xperience in the procedure for operation and setup of this System When appropriate the procedures in this manual are based on crane operation and function A basic tool kit consisting of wrenches and s...

Страница 45: ...determining computer and display communication problems After the system is powered up or after pressing the TEST button T the display will show the following indications All display segments of the b...

Страница 46: ...lly Each time the system is turned on it completes a Self Test lasting approximately six seconds that automatically detects most faults in the system During normal operation a self test can be initiat...

Страница 47: ...ult Found NONE 001 X Replace Computer 002 X 003 X X 004 X Follow SECTION 3 8 3 005 X X Replace Computer 006 X X 007 X X X 008 X Follow SECTIONS 3 8 5 3 8 7 009 X X Replace Computer 010 X X 011 X X X 0...

Страница 48: ...ckout and anti two block switches The following chart details all of the available codes in the left column and the actions to take in the right column FAULT CODE FKO POWER FEED ATB POWER FEED ACTION...

Страница 49: ...AM ACTION 000 No Fault Found NONE 001 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 Co...

Страница 50: ...sensor faults first Re select CRANE SETUP 002 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 SETU...

Страница 51: ...B feed and the ATB switch es Check the Reeling Drum cable for damage Ensure the Two Block switches are correctly connected Check the slip ring and wiring inside the Reeling Drum Check the signal cable...

Страница 52: ...of the boom If the length value is incorrect refer to SECTION 3 10 4 SPAN CALIBRATION 3 4 2 2 Check Main Boom Radius 1 Ensure the correct crane configuration is in use and fully retract the boom NOTE...

Страница 53: ...em will necessitate changing the entire computer unit 1 Lower the boom until the boom hoist cylinder is fully retracted and on its stop 2 Loosen the hydraulic connections to the pressure sensors to en...

Страница 54: ...contained inside are calibrated during production These sensors are unable to be replaced in the field 3 5 1 Computer Unit Layout 3 5 2 Internal Status Indicators The computer unit contains a row of...

Страница 55: ...t 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 with...

Страница 56: ...check the accuracy of the boom angle and the radius measurements and tape at four or five points 2 Ensure the hydraulic connections are secure and not leaking at the computer unit 3 Secure the comput...

Страница 57: ...al Flush Mounted Consoles the horn is outside the housing If there is a problem with the horn ensure the Horn Drive Wire is connected correctly to the black terminal on the rear of the display console...

Страница 58: ...sfers the Anti Two Block signal from the reel off cable to the system computer Complete the setup and maintenance of these devices using the following procedures Incorrect maintenance will result in s...

Страница 59: ...extension errors as the boom retracts 1 Telescope 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 Reeling Drum with each s...

Страница 60: ...circuit within the Reeling Drum 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...

Страница 61: ...Disengage the main gear wheel connected to the extension sensor by pulling the sensor arm in the direction shown FIGURE 3 8 4 SENSOR BASEPLATE ASSEMBLY 4 Rotate the gear clockwise until the sensors cl...

Страница 62: ...Refer to Figure 3 8 5 below 3 Push the pendulum downwards and ensure it isn t sticking Some resistance of movement may be encountered as the pendulum is moved however this is due to the magnets that p...

Страница 63: ...between the blue wire TB1 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 refer to Chapter 2 Menu 04 Angle Sensor 3 Mea...

Страница 64: ...Removing the Reeling Drum Off Cable 1 Fully retract 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...

Страница 65: ...y from the strain relief to the slip ring 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...

Страница 66: ...FUNCTION OVERVIEW Figure 3 7 10 Slip Ring Assembly 3 7 10 1 Removing the Slip Ring Assembly 1 Remove the Reeling Drum cover 2 Hold the reeling drum cable on the arm of the slip ring and cut the tie wr...

Страница 67: ...6 on the sensor baseplate assembly Ensure the black signal cable wire is also correctly connected 4 Screw the bottom half of the slip ring to the shaft with the two Phillips screws Ensure the wires ex...

Страница 68: ...al parts of the Reeling Drum and the signal cable connecting the reel to the system computer Electrical diagnoses of the boom sensors may be made at this terminal block Figure 3 7 11 SENSOR BASEPLATE...

Страница 69: ...ne Route the wires to the terminal block and hook up the wires as indicated below 5 Tuck the unconnected remaining yellow and orange wires down into the shaft 6 Screw the slip ring assembly to the bas...

Страница 70: ...he back of the Reeling Drum exposed insert the end of the signal cable with the O ring into the mounting plate and down the shaft in the center of the reel 3 Seat the strain relief with attached O rin...

Страница 71: ...l return Since the computer checks the protected feed voltage internally the system is capable of detecting a short circuit of the feed or the ATB signal return when the switch is closed to the crane...

Страница 72: ...ectly connected 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...

Страница 73: ...ing area alarms If the swing sensor fails the computer will be unable to select a valid capacity chart If this occurs use the Cancel Alarm Button to lower the load to the ground For fault diagnosis ac...

Страница 74: ...e shown in Steps 2 and 3 indicate a problem with the swing sensor or cabling connections If voltages are incorrect proceed to SECTION 3 10 3 CHECKING THE SWING SENSOR RESISTANCE 3 9 3 Checking the Swi...

Страница 75: ...t or Prev button until 05 Swing Potentiometer appears in the information window at the right 3 Press the 05 Swing Potentiometer button to enter the routine 4 Press the Zero button 5 The swing is now z...

Страница 76: ...0 Fax 918 298 8301 www team twg com Greer Company is a part of TWG As a leader in product innovation Greer Company is committed to the ongoing improvement of its equipment We reserve the right to make...

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