Summary of Contents for GREER Company MICROGUARD 434
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® MICROGUARD RATED CAPACITY LIMITER SYSTEM TROUBLESHOOTING MANUAL ® MicroGuard 434 System — Troubleshooting Manual PN W434800 Rev D 09/19/06...
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The Greer Company The Greer Company is dedicated to the design and manufacture of electronic parts created to aid in crane operation and in the protection of crane operators and associated personnel. The following manual has been developed to assist in helping Service Personnel to understand, locate, and identify problems that may ®...
TABLE OF CONTENTS ® MicroGuard Rated Capacity Limiter System ROUBLESHOOTING ANUAL Introduction SERVICE DEDICATION ..............INSIDE FRONT COVER WHERE TO GO FOR HELP ..................... SYSTEM DIAGRAM................INSIDE BACK COVER Section I PREPARATION ........................ Section ll PROBLEM FINDER TABLES ................... Section III SYSTEM INSTALLATIONS ....................
Link-Belt Construction Equipment Company Product Support: Lexington, KY Telephone:(606) 263-0241 FAX: (606) 263-5260 Greer Company Service: Santa Ana, CA Telephone:(714) 259-9702 FAX: (714) 259-7626 Information provided to support personnel must be accurate and complete. Please follow the Troubleshooting Table guidelines.
This Troubleshooting Manual for the MicroGuard 434 Rated Capacity Limiter System, manufactured by the Greer Company and installed on Link-Belt Construction Equipment Company (LBCE) cranes, provides information and methods for isolating problems that may arise during operation of the System. Some of these problems can be corrected in the field. Other problems may require replacement of parts or a return of a part to the factory for servicing.
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SECTION II PROBLEM FINDER TABLES These Problem Finder Tables are designed to aid in determining the location and type of problem experienced. It is important to review these Tables carefully before contacting us. SYSTEM SELF-TEST ......................... 8 COMPUTER/DISPLAY COMMUNICATION ..............9-12 DISPLAY OF FAULT CODES ..................
SYSTEM SELF-TEST The Computer and Operator’s Display Console do a Self-Test when the power is turned on or during operation when the ”TEST” button is pressed. The Self-Test verifies that the Computer, Display Console, cables, and all remote sensors are working properly. TEST SEQUENCE FOR DISPLAY CONSOLE: 1.
COMPUTER/DISPLAY COMMUNICATION Communication problems are difficult to isolate because of the interaction between the Display Console and the Computer. Failure of either unit causes malfunction of the Display Console. Such problems need resolution before using the Problem Finding Tables. Six wires, identified below and shown in the following diagram, connect the Computer to the Display Console.
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COMPUTER/DISPLAY COMMUNICATION CONTINUED NORMAL OCCURRENCES WHEN SYSTEM IS TURNED ON WHEN “TEST” BUTTON IS PUSHED. OPERATOR’S DISPLAY COMPUTER REMOTE BAR GRAPH CONSOLE READS: After Self-Test, the relays All lights turn on during Self-Test ”This is a SELF-TEST.” turn on and allow crane and then return to normal.
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COMPUTER/DISPLAY COMMUNICATION CONTINUED DA AND DB ARE OPEN TO THE DISPLAY OPERATOR’S COMPUTER REMOTE BAR GRAPH DISPLAY CONSOLE Graphics Display Reset repeats every 5 seconds. All lights on. READS: “Serial comms. Failure” Lamps are on. Relays click with every reset. Audio alarm on.
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COMPUTER/DISPLAY COMMUNICATION CONTINUED +VP (RED WIRE) IS OPEN DISPLAY COMPUTER REMOTE BAR GRAPH Entire Operator’s Display Console Relays turn on and allow crane Normal. does not respond. motions. Relay clicks when TEST button is pushed. ® MicroGuard 434 System — Troubleshooting Manual PN W434800 Rev D 09/19/06...
DISPLAY OF FAULT CODES When the System detects a problem, it is identified in the System as a Fault and given a Fault Code Number. At the same time a warning is activated. Fault Codes are displayed by holding down the TEST button.
CRANE MOTIONS ARE DISABLED Problem: Unable to boom down, extend boom, or hoist up. Reason: The crane Motion Cut Solenoids aren’t powered. ® Theory: The MicroGuard 434 System protection circuit has 2 relays, in series, between the Battery ®...
ANTI-TWO-BLOCK CIRCUIT The ANTI-TWO BLOCK switch is normally closed connecting ATBIN input to 0 volts. The ANTI-TWO BLOCK WEIGHT holds the switch in this position. The switch is opened when the weight is lifted. The ATBIN input has a 1 megohm pull up resistor that goes Hi when the switch opens.
SWING POT SENSOR FAULT CODE AAA 096 The Swing Pot Sensor is a 2.5k pot with two wiper arms separated at 90°. The System Diagram on the inside back cover of this Manual shows the Swing Pot. The Swing Pot can be checked with an Ohm meter. Disconnect cable 6 and measure from pin “C” to “D”...
BOOM EXTENSION SENSOR FAULT CODE AAA 004 The Boom Extension Sensor sends a voltage to the computer. The voltage is sent through cable 3 to AIN2 on the Termination Board. The voltage on AIN2 is about .2v when the boom is retracted and increases about .125v per drum revolution.
BOOM ANGLE SENSOR FAULT CODE AAA 008 The Boom Angle Sensor sends a voltage to the computer. The voltage is sent through cable 3 to AIN 3 on the Termination Board. The voltage on AIN3 is about .437v when the Boom is at 0° and 4.375v at 90°.
PRESSURE TRANSDUCERS FAULT CODE AAA 001 OR 002 The Rod/Piston Pressure Transducers turn hydraulic pressure into voltages that can be used by the computer. Each transducer has its own cable. They plug into connectors 1 and 2. Connector 1 goes to Terminal Block 2, pins 1, 2, 3, + 4 and connector 2 uses pins 6, 7, 8, + 9 on the Termination Board.
PRESSURE TRANSDUCERS CONTINUED CONNECTOR 2 IS THE TX1 CHANNEL ON THE INTERFACE BOARD PROBLEM ACTION RESULTS INDICATOR OUT OF Press and hold the TEST Fault Code AAA SERVICE Alarm. button. Power from the computer to Measures the +5.25v Terminal block 2 the transducer is missing.
REMOTE BAR GRAPH The Remote Bar Graph is connected to the computer with 4 wires. Serial Communication Line Serial Communication Line Power Ground Power Return PROBLEM ACTION RESULT No lights. Unplug cable 5. Measure Pin A = + 5 volts. (Not getting power.) the 5 volt on connector 5 of Pin C = 0 volts...
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Section III ..................SYSTEM INSTALLATIONS SELECTING THE RIGHT SYSTEM INSTALLATION ILLUSTRATION....... SYSTEM LAYOUTS WITH CORRESPONDING SERIAL NUMBER PREFIX 1. SYSTEM INSTALLATION E1..................25 2. SYSTEM INSTALLATION D3, E9, F1, F2, & F3............26 ® MicroGuard 434 System — Troubleshooting Manual PN W434800 Rev D 09/19/06...
SELECTING THE RIGHT SYSTEM INSTALLATION ILLUSTRATION The information in this section is meant to familiarize the user with the major components and ® System setup for most models of the MicroGuard 434 System. To locate the correct illustration for your needs, match the first two digits of the serial number of your crane to the serial number prefix in column 1 of the following table.
SYSTEM LAYOUTS WITH CORRESPONDING SERIAL NUMBER PREFIX SYSTEM INSTALLATION Mounted on attachment Head Reel-Off Cable to Boom Head Anti-Two Block Anti-Two Block Switch Switch (Attachment) (Main Boom) Extension Drum & Angle Sensor Mounted at Boom Head BOOM ATTACHMENT OPERATOR CAB Cable 8 Display Console...
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SYSTEM LAYOUTS WITH CORRESPONDING SERIAL NUMBER PREFIX CONTINUED SYSTEM INSTALLATION Mounted on attachment Head Reel-Off Cable to Boom Head Anti-Two Block Anti-Two Block Switch Switch Extension Drum & Angle Sensor Mounted at Boom Head BOOM ATTACHMENT OPERATOR CAB Cable 8 Display Console Power / Motion Disconnect...
Section IV SYSTEM COMPONENTS AND ASSOCIATED FUNCTIONS .........31 THE COMPUTER UNIT .......................32 COMPUTER UNIT COMPONENTS..................32 ACCESSING THE COMPUTER BOARD AND THE TERMINATION BOARD......34 CHECKING THE COMPUTER UNIT ..................34 CONNECTORS ........................34 UNIT COVER........................34 COMPUTER BOARD ASSEMBLY ..................34 COMPUTER BOX WIRING/TERMINATION BOARD ASSEMBLY ........34 WIRE LENGTH......................34 INSULATION REMOVAL .....................35...
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EXTENSION REEL ........................46 CHECKING/TESTING EXTENSION REEL FUNCTIONS............47 CHECKING THE VOLTAGE OF THE BOOM EXTENSION SENSOR ........48 CHECKING THE VOLTAGE OF THE BOOM ANGLE SENSOR..........50 ANTI-TWO BLOCK FUNCTION ....................52 EXTENSION REEL PARTS REMOVAL AND INSTALLATION..........52 ANGLE SENSOR REMOVAL ..................
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Section IV SYSTEM COMPONENTS AND ASSOCIATED FUNCTIONS ® This section provides detailed information on the MicroGuard 434 System components and associated functions. System components include the Computer Unit, Operator’s Display Console, Remote Bar Graph, Extension Reel, and Pressure Sensor. Functions include the Anti-Two Block Function, the Power, Motion Disconnect, and Boom Mode Functions, and the Swing Sensor.
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FIGURE 4.0 THE COMPUTER UNIT THE COMPUTER UNIT ® The Computer Unit, shown in Figure 4.0, is the center of the MicroGuard 434 System. The Computer Unit provides all the necessary functions to read the sensors, create System computations, control the disconnect functions, and communicate with the Display Console.
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ACCESSING THE COMPUTER BOARD AND THE TERMINATION BOARD 1. Refer to Figure 4.1. To access the Computer Board, remove the four screws (B) that secure the cover (A) to the Computer Box. Carefully remove the lid from the Computer Box. Set the lid and the four screws aside.
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the Computer box is closed. Wires that are too short could break internally, when under tension. Insulation Removal: Remove Insulation around wires before clamping them in the terminal block. With too little exposed wire, the Terminal Block could attach to the insulation rather than the conductor.
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2. Turn on the power. 3. Connect the negative lead to the GND Test Point. 4. Place the positive lead in each of the following test points: • +5V Test Point [+4.90V ~ +5.10V] • +15V Test Point [+14.90V ~ +15.10V] •...
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REMOVING AND INSTALLING THE COMPUTER ASSEMBLIES The Computer Board Assembly and the Termination Board and Box Assembly may be replaced, if necessary. Step-by-step instructions for this procedure are outlined below. COMPUTER BOARD REMOVAL 1. Turn off the power. Remove the cover of the Computer Unit to access the Computer Board.
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6. Ensure that the ‘CALIBRATION ENABLED/DISABLED’ switch is set at the ‘DISABLED’ position. Refer to Figures 4.5 and 4.6. 7. Install the Computer Box cover. TERMINATION BOARD AND BOX REMOVAL 1. Remove the Computer Board. See Computer Board Removal, page 37.
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Calibration Switch FIGURE 4.6 THE MAIN COMPUTER BOARD The Duty ROM Chip, identified as IC3 on the Computer Board, contains a copy of the Load Chart which MUST MATCH the Load Chart in the crane. Installation of the Duty ROM Chip does NOT necessitate recalibration of the System.
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OPERATOR DISPLAY CONSOLE The Operator’s Display Console (Figure 4.7) allows the user to see the crane values (Angle, Radius, Load, etc.) and crane configuration selection. The Display also provides calibration functions used for testing and Fault diagnosis. DISPLAY CONSOLE MODELS There are two Operator’s Display Consoles: The in-dash horizontal and in-dash vertical mounts.
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CHECKING THE OPERATOR’S DISPLAY CONSOLE The Operator’s Display Console is normally very reliable. However, when operated for extended periods, under extreme conditions, the Console can become damaged. The damage is not always apparent. To help identify subtle faults that are sometimes difficult to find, or that may be attributed, mistakenly, to other kinds of problems, please review the following comments.
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HORN On bracket-mounted Display Consoles, the Horn is inside at the rear of the housing. On flush- mounted Consoles, the Horn is outside the housing. If there is a problem with the horn, ensure that the Horn Drive Wire is connected correctly to the black terminal on the rear of the Display Console housing.
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2. Connect the electrical cable to the electrical connector on the rear of the Operator’s Display Console. Refer to Figure 4.8. REMOTE BAR GRAPH The Remote Bar Graph, shown below, monitors the percentage of rated capacity in use. The Remote Bar Graph is normally mounted near the operator for easy viewing.
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LAMPS The ‘lamps’ are Light Emitting Diodes (LED’s). They are more reliable than standard incandescent bulbs and consume far less power. LED operation can be checked at any time by the operator using the ‘Lamp Test’ feature. Always replace the entire Bar Graph Unit, if it is found to be faulty. With the System powered, there should always be at least one (GREEN) LED lighted –...
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REMOTE BAR GRAPH REMOVAL AND INSTALLATION REMOVAL OF A REMOTE BAR GRAPH 1. Turn off the power. 2. Disconnect the Remote Bar Graph cable from the Computer Box. 3. Remove the Remote Bar Graph from its bracket by loosening and removing the knob at each end of the Remote Bar Graph.
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THE EXTENSION REEL The primary operation of the Extension Reel is to measure the extension of the telescoping sections of the boom. The Extension Reel includes an Anti-Two Block function that provides an electrical path for transmission of a signal to the Computer Unit. The Computer transmits this signal to the Operator’s Display Console warning the operator of an impending Two Block problem.
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CHECKING/TESTING THE EXTENSION REEL FUNCTIONS To check or test the following: • Boom Extension Sensor – See Checking the Voltage of the Boom Extension Sensor, page 48. • Boom Angle Sensor – See Checking the Voltage of the Boom Angle Sensor, page 50.
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CHECKING THE VOLTAGE OF THE BOOM EXTENSION SENSOR To check or test an Extension Sensor, check the voltage. Follow the steps outlined below: Fully retract the boom. Access the Termination Board (see Figure 4.12). Measure the Analog Sensor Drive Voltage.
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® MicroGuard 434 System — Troubleshooting Manual PN W434800 Rev D 09/19/06...
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CHECKING THE VOLTAGE OF THE BOOM ANGLE SENSOR Follow the steps below to check the voltage of the boom. Using an inclinometer for verification, place the main boom at a zero degree angle. Access the Termination Board (see Figure 4.12). Measure the Analog Drive Voltage. Refer to page 36, Figure 4.4.
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Drive Voltage AIN0 Ain2 voltage varies with Boom length AIN1 AIN3, Voltage varies with Boom angle. 0.4V at 0 deg. 3.02V at 60 deg. AIN2 AIN3 TX0+ AIN4 TX0- AIN5 TX1+ AIN6 TX1- FIGURE 4.12 TERMINATION BOARD AIN2 - LENGTH - WHITE WIRE BLUE - GREEN...
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may be faulty. ANTI-TWO BLOCK FUNCTION The Anti-Two Block Function is a safety function that signals an impending collision between the hook block or ball and head sheaves. When the distance between these points is within an acceptable range, there is a zero voltage reading.
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ANGLE SENSOR INSTALLATION Install the new Angle Sensor and secure it loosely with the two mounting nuts and washers. See Figure 4.11. 2. Secure the Angle Sensor cable to the triangle plate with the three cable clamps. 3.
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6. Reconnect the cable to the Two Block switch. 7. Manually turn the large gear connected to the potentiometer fully counter-clockwise. 8. Observe the display that shows boom length. Turn the large gear at least 3 clicks clockwise until the length on the Display shows the retracted boom length.
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CONNECTOR 1 BLUE BLUE CABLE 1 PISTON YELLOW YELLOW TX0+ GREEN GREEN TX0- CONNECTOR 2 BLUE BLUE CABLE 2 YELLOW YELLOW TX1+ GREEN GREEN TX1- FIGURE 4.16 PRESSURE SENSOR CONNECTION TO THE COMPUTER The maximum continuous working pressure for these devices is 250 Bar (3625 psi). There are no user-serviceable parts within the Pressure Sensor.
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BOTTOM RIGHT ARROW. Then quickly press the BOTTOM LEFT ARROW followed by the TOP RIGHT ARROW. (Complete this sequence in 5 seconds; if not, the SECURITY CODE will have to be entered again.) 6. The GRAPHICS DISPLAY will read: “RUN.” Press the ARROW next to MENU UP or MENU DOWN in the GRAPHICS DISPLAY and scroll to Command 03 ZERO SENSOR.
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SENSOR RESISTANCE MEASUREMENT The Pressure Sensor is a balanced bridge composed of strain gauges bonded to a flexible diaphragm. The following resistance tests can be performed to establish the condition of the Pressure Sensor. PISTON PRESSURE SENSOR 1.
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ROD PRESSURE SENSOR 1. Turn off the power. Disconnect the rod pressure sensor cable from connector 2 on the Computer Unit. 2. With the Digital Multimeter (DMM) set to the Ohms range, measure the resistance between pins “C”...
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PRESSURE SENSOR REMOVAL AND INSTALLATION PRESSURE SENSOR REMOVAL 1. We recommend that a new sensor being installed closely matches the sensitivity of the old sensor. The sensitivity value is recorded on the serial number plate (Figure 4.19). 2.
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The ATB board, shown on the Termination Board (Figure 4.20), operates: • the function disconnects by controlling the coil of RL2, ATB relay, at DOUT 1. • the audible alarm and on-screen message by controlling the logic level at DIN13.
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2 BLOCK SWITCH AT 2 BLOCK SWITCH AT MAIN JIB HEAD BOOM HEAD 2 BLOCK SWITCH FIGURE 4.22 ANTI-TWO BLOCK FUNCTION ® MicroGuard 434 System — Troubleshooting Manual PN W434800 Rev D 09/19/06...
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POWER, MOTION DISCONNECT, & BOOM MODE FUNCTIONS ® The Power and Function Disconnect wiring provides the MicroGuard System with battery power from the machine breaker and machine motion disconnect functions controlled by the computer unit. Some computer versions also provide a Boom Mode output which controls telescoping modes A & B of the machine.
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COMPUTER UNIT TERMINATION BOARD ORANGE DOUT4 SPARE/-CL +5VA YELLOW SPARE/+CL CONNECTOR #8 SPARE/C METRI-PAK CONNECTOR MS3475W14-5PW SPARE CONTACT BLUE BLUE BOOM MODE SPARE/NO BLUE BOOM MODE WHITE WHITE FKO FEED (BATT +) WHITE RL1/C RL1 CONTACT BLACK OVERLOAD GREEN...
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SWING SENSOR SWING POTENTIOMETER AIN5 AND AIN6 It is necessary to determine the position of the upper structure of the crane in relation to the base of the crane, known as the carrier. The swing potentiometer provides this signal. CHECKING THE SWING POTENTIOMETER 1.
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Drive Voltage AIN0 AIN5 & AIN6, Voltage varies AIN1 with rotation of the upper structure. 4.2V maximum, 0.36V minimum when the upper structure is rotating. AIN2 AIN3 TX0+ AIN4 TX0- AIN5 TX1+ AIN6 TX1- FIGURE 4.25 SWING POT CONNECTIONS Voltage measured between 2 and 4 = 5.25 Volts.
SECTION V FAULT CODES FAULT REPORTING AND FAULT CODES ................67 FAULT DIAGNOSTIC PROCEDURES ................67 FINDING AND UNDERSTANDING FAULT CODES...............68 ® MicroGuard 434 System — Troubleshooting Manual PN W434800 Rev D 09/19/06...
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Group AAA Analog Sensors FAULT REPORTING AND FAULT CODES System Fault Codes provide one of the most important NO FAULTS ways to quickly locate and assess problems in the TX.0 PISTON PRESSURE SENSOR ® MicroGuard System. Please review this section carefully. FAULT DIAGNOSTIC PROCEDURES TX.1 ROD PRESSURE SENSOR...
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FINDING AND UNDERSTANDING FAULT CODE(S) A Display Console window, shown below, shows how the various Fault Codes will be exhibited. The following tables have been created to simplify the identification of Faults detected by the Computer. Some Faults involve a combination of Code Numbers, indicating that there may be more than one problem or that a single problem is affecting other operations.
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FAULT No FAULT No DESCRIPTION DESCRIPTION No Faults No Faults Digital Input and Program ROM Duty ROM Analog Input and Output Faults 01 & 02 Faults 1 & 2 Scratchpad RAM Display Unit Faults 02 & 03 Faults 1 &...
SYSTEM DIAGRAMS ® MicroGuard 434 System — Troubleshooting Manual PN W434800 Rev D 09/19/06...
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SELECTION BOX MENU UP MENU DOWN EXIT MENU UP TO SCROLL TO BAR GRAPH DESIRED COMMAND MENU DOWN GRAPHICS DISPLAY WINDOW shown in SELECTION SELECTION TEST BUTTON CRANE SETUP BUTTON EXIT APPROVE & CONTINUE/CALIBRATE FIGURE 27: OPERATOR’S DISPLAY CONSOLE Refer to Section IV, page 40.
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® MicroGuard 434 System — Troubleshooting Manual PN W434800 Rev D 09/19/06...
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1918 East Glenwood Place Santa Ana, CA 92705 Telephone: (714) 259-9702 Fax: (714) 259-7626 ® MicroGuard 434 System — Troubleshooting Manual PN W434800 Rev D 09/19/06...
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