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SkyAzúl Greer MG514 Installation, Calibration, And Service Manual

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Greer – MG514
Retrofit
Installation, Calibration, and Service Manual

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  • Page 1 Greer – MG514 Retrofit Installation, Calibration, and Service Manual...
  • Page 3 Greer – MG514 Retrofit Installation, Calibration, and Service Manual NOTICE SkyAzúl makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and/or its fitness for a particular purpose. SkyAzúl will not be liable for errors contained in this manual or for incidental or consequential damages in connection with the furnishing, performance, or use of this manual.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Introduction ..........................5 System Information ........................5 Upgrade Parts ......................... 6 1.2.1 A450862 Computer Assembly ..................6 1.2.2 A450300 RCI 514 Display Module ..................6 1.2.3 A240690 Reeling Drum ....................6 Computer Wiring ........................7 Units with Swing Switches ....................... 9 Removal and Installation .......................
  • Page 6 2.6.7 Menu 06 - Pressure ......................28 2.6.8 Menu 07 - Radius/Moment....................31 2.6.9 Menu 08 - Boom Deflection .................... 37 2.6.10 Menu 09 - Head Angle ....................39 2.6.11 Menu 10 - Erected Attachments ..................40 2.6.12 Menu 11 - Enable Winches ..................... 41 2.6.13 Menu 12 - Digital Inputs ....................
  • Page 7 3.6.2 LEDs ..........................64 3.6.3 Brightness Control ......................64 3.6.4 Cable and Connector ...................... 65 3.6.5 Moisture.......................... 65 3.6.6 Remote Bar Graph Replacement ..................65 Reeling Drum Overview ......................66 3.7.1 Checking the Reeling Drum Cable Layering ..............67 3.7.2 Checking the Extension Sensor Drive Voltage ..............

  • Page 8: Introduction

    1.0 Introduction The MicroGuard MG514 replaces the previous Link Belt MG404, 414, and 434 systems currently in use. This chapter will cover information necessary for installing the MicroGuard 514 system. Please read the Operator’s Manual before operating the system. The system installer must be knowledgeable in safety guidelines, crane capacity information, and the crane manufacturer’s specifications.

  • Page 9: Upgrade Parts

    1.2 Upgrade Parts 1.2.1 A450862 Computer Assembly The computer assembly includes a wiring harness adapted to integrate with the existing Link Belt crane wiring harness. Refer to the installation drawing below. 1.2.2 A450300 RCI 514 Display Module This display module is designed specifically for upgrading Link Belt cranes and operates with Link Belt- style menus.

  • Page 10: Computer Wiring

    1.3 Computer Wiring The RCI 514 system wiring is based on the original wiring done by the factory. Greer Company cannot assume responsibility for color codes used on wiring done at the time of origin. We have identified the wiring inside and outside of our computer module to assist in the wiring connections.
  • Page 11 S450612 A450862 Work Instruction Connection Connection JP3-1Battery 0V BLD 1 Battery -VE Connect to Frame Ground Connect to Crane Power 12V - 36V (Fused at System Power JP3-2 BLD 2 Battery +VE 10 Amp power source) JP 5-1 Function Kick BLD 7 FKO Feed Incoming Crane Power for Function Kickout Out (FKO) Feed...

  • Page 12: Units With Swing Switches

    1.4 Units with Swing Switches Some older units in the field may use swing switches instead of swing potentiometers, use the appropriate work area schematic. Connection Description Work Instruction A450763 Rear BLD 26 DIN 0 Over Rear Side BLD 27 DIN 1 Over Side Chart Front...

  • Page 13: Removal And Installation

    1.5 Removal and Installation 1. Place the crane in rigging mode and raise the boom. This will allow access to the hose fittings and wiring harness connections. NOTE: Leave the Power and FKO cable connected to allow movement of the boom during the removal and installation process.
  • Page 14 15. Install the power and FKO cables to the new computer. 16. Slowly elevate the boom to its Maximum Angle to 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 hoses/cables can be damaged or destroyed.

  • Page 15: Calibration

    2.0 Calibration 2.1 Required Tools • 1/4” nut driver or T15 Torx driver • Digital or bubble level calibrated and accurate to 0.1° at level • Digital volt/Ohm Meter capable of measurements to three decimal places • 100 foot measuring tape: fiber type graduated in tenths of feet NOTE: The computer calculates measurements in feet and tenths of a foot, so using the correct tape measure is essential for entering the measurements.

  • Page 16: The Microguard 514 Display

    2.3 The MicroGuard 514 Display 2.3.1 Command Entry The A, B, C, and D buttons are used most for the procedures described in this document and their function will vary depending on the routine being performed. Commands for each routine will show in the information window as text adjacent to the buttons.
  • Page 17 NOTE: If a number is entered incorrectly, select the backspace “<” and press button A. 2. Select the 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.

  • Page 18: Preliminary Checks And Measurements

    2.4 Preliminary Checks and Measurements Record the following measurements and enter them into the system. Validate any data supplied by the crane manufacturer before calibration begins. Enter all dimensions into the computer in feet and tenths of a foot. 2.4.1 Boom Pivot Dimensions The boom must be in a horizontal position (0°) when taking the following measurements.

  • Page 19: Winch Dimensions

    2.4.2 Winch Dimensions Dimension “G0” and “G1” – The horizontal distance between the center of the front and rear winch, and the center of the boom pivot. Dimension “H0” and “H1” – The vertical distance between the center of the front and rear winch and the center of the boom pivot.

  • Page 20: Boom Cylinder Dimensions

    2.4.3 Boom Cylinder Dimensions Dimension “M” – This is the distance measured around the outside of the cylinder rod, divided by 12. Then divide this number by 3.14. Record this number for entry into the system. USE THE SPACE PROVIDED IN APPENDIX A TO RECORD THE MEASUREMENT. 2.4.4 Span Dimensions WARNING!

  • Page 21: Auxiliary Head Dimensions

    2.4.5 Auxiliary Head Dimensions USE THE SPACE PROVIDED IN APPENDIX A TO RECORD 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 RECORD THE MEASUREMENTS.

  • Page 22: Installation Checks

    2.5 Installation Checks See programming publication W450700 for programming instructions. Check swing switches, if fitted. Use the digital monitor screen (located under Menu 12 – Digital Inputs) to ensure the switches operate properly. TEST 2.5.1 Attaching the Anti-Two-Block (ATB) Cable and Extension Sensor Zero Ensure the extension sensor clutch is properly set for “0”, and the spring is properly pre- tensioned by following this procedure:...

  • Page 23: Entering Calibration Data

    2.6 Entering Calibration Data WARNING! WHEN THE SYSTEM IS IN CALIBRATION MODE, AUTOMATIC OVERLOAD CONTROLS ARE DISABLED. THE CRANE OPERATOR IS RESPONSIBLE FOR PROPER LOADING OF THE CRANE WHILE PERFORMING CALIBRATION. To enter the calibration data, it is necessary to put the system in calibration mode. Once in calibration mode, there is only five (5) seconds to enter the security code sequence.

  • Page 24: Menu 00 - Error Codes

    2.6.1 Menu 00 – Error Codes This menu displays error code and system information 1. Press the Next or Prev button until “00 Error Codes” appears at the right of the information window. TEST 2. Press the 00 Error Codes button to enter the routine. The following information is displayed: a.

  • Page 25: Menu 01 - Crane Data

    2.6.2 Menu 01 – Crane Data This menu displays the personality data. 1. Press the Next or Prev button until “01 Crane Data” appears at the right of information window. 2. Press the 01 Crane Data button to enter the routine. 3.

  • Page 26: Menu 02 - Dimensions

    2.6.3 Menu 02 - Dimensions Use this menu to enter the previously recorded physical dimensions of the crane. TEST 1. Press the Next or Prev button until “02 Dimensions” appears in the right of the information window. 2. Press the 02 Dimensions button to enter the routine. 3.

  • Page 27: Menu 03 - Zero Sensors

    2.6.4 Menu 03 - Zero Sensors This menu allows the user to enter the zero point of the extension sensor. 1. Ensure the boom is completely retracted and at 0°. Verify with a digital level. 2. Press the Next or Prev button until “03 Zero Sensors” appears in the right of the information window.

  • Page 28: Menu 04 - Span Sensor

    2.6.5 Menu 04 - Span Sensor This menu allows the user to enter the values for the Span Sensor and Angle Span. 1. Press the 04 Span Sensors button to enter the routines for spanning the Angle and Extension Sensors. WARNING! ENSURE THE AREA AROUND THE CRANE IS SAFE PRIOR TO EXTENDING THE BOOM.

  • Page 29: Angle Span

    2.6.5.1 Angle Span 1. Press the Next button on the left hand side of the screen to span the angle sensor. 2. With the boom still elevated to 60+ degrees, Press the Span No. 3 = button and after verification, the display will access the number entry screen for Angle Span. TEST 3.

  • Page 30: Menu 05 - Swing Potentiometer (If Equipped)

    2.6.6 Menu 05 - Swing Potentiometer (If Equipped) This menu is used to enter the zero point and the swing direction of the swing potentiometer (if equipped). The swing potentiometer is located in the collector ring assembly under the hydraulic swivel. The job of the potentiometer is to track the movement of the upper half of the crane all the way around the swing circle.

  • Page 31: Menu 06 - Pressure

    2.6.7 Menu 06 - Pressure This menu is used to determine the pressure of 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.
  • Page 32 8. Press Exit to return to the top menu. 9. When finished with the Pressure Threshold, press the Exit button to access the Rod Side Offset. TEST 10. Press the Exit button to return to the top menu. 11. Press the 06 Pressure button. 12.
  • Page 33 17. Pick up the calibration load and allow it to settle. Press the Yes button to continue. Press the No button to exit the routine. NOTE: The following screen will only appear briefly while calibration is completed, unless there is an error as shown here.

  • Page 34: Menu 07 - Radius/Moment

    2.6.8 Menu 07 - Radius/Moment This menu is used to calibrate the radius and moment of the boom. 1. Press the Next or Prev buttons until “07 Radius/Moment” appears in the information window at the right. ENSURE THE CRANE IS SET UP IN ACCORDANCE WITH THE MANUFACTURER’S OPERATION MANUAL FOR MAXIMUM STABILITY.
  • Page 35 Press 07 Radius / 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) SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126...
  • Page 36 Press the exit 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? SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126...
  • Page 37 Radius Moment #1 extension Boom 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 SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126...
  • Page 38 Boom to 70 degrees 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 SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126...
  • Page 39 Press Bas.0 (DU) Press YES! 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. SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126...

  • Page 40: Menu 08 - Boom Deflection

    2.6.9 Menu 08 - Boom Deflection This menu is used to enter the deflection of the main boom under the weight of a calibrated load. MAKE SURE THE CRANE IS SET UP ACCORDING TO THE MANUFACTURER’S OPERATION MANUAL TO ENSURE MAXIMUM STABILITY. ALSO MAKE SURE ALL BOOM EXTENSIONS AND LOADS ARE LIFTED WITHIN THE APPROPRIATE LOAD CHARTS AND LIMITS.
  • Page 41 1. Press the Next or Prev button until “08 Boom Deflection” appears in the information window at the right. 2. Press the 08 Boom Deflection button to enter the routine. TEST 3. Fully extend the boom at an angle greater than 60°. 4.

  • Page 42: Menu 09 - Head Angle

    2.6.10 Menu 09 - Head Angle This menu is used to enter data on boom head angles. 1. Measure the boom head angle on a new jib installation to ensure the jib radius displays correctly. Take this measurement in increments similar as used on the boom moments. 2.

  • Page 43: Menu 10 - Erected Attachments

    2.6.11 Menu 10 - Erected Attachments This menu is used to: • Hide and Unhide attachments • Enter and Adjust geometric data and moment data for the jib. 1. Press the 10 Erected Attachments button to allow the “Unhiding” of attachments. You will be able to enter or edit geometric data for the attachments.

  • Page 44: Menu 11 - Enable Winches

    2.6.12 Menu 11 - Enable Winches This menu is used to enable or disable available winches in the system. 1. Press the Next or Prev button until “11 Enable Winches” appears in the information window at the right. 2. Press the 11 Enable Winches button to enter the routine. TEST NOTE: There must be at least one winch enabled on the crane.

  • Page 45: Menu 12 - Digital Inputs

    2.6.13 Menu 12 - Digital Inputs This menu allows the user to view the status of the digital 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. TEST 3.

  • Page 46: Menu 13 - Pressure Monitor

    2.6.14 Menu 13 - Pressure Monitor This menu is used to view the pressure data from “Menu 06 Pressure” 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.

  • Page 47: Appendix A - Measurement Records

    2.6.15 APPENDIX A – Measurement Records Use the space provided below to enter the necessary dimensions. Record the measurements in feet and tenths of a foot. Callout Dimensions Measurement BOOM PIVOT DIMENSIONS The horizontal distance between the center of the boom pivot and the center of the boom hoist cylinder upper pivot.
  • Page 48 BOOM HOIST CYLINDER DIMENSIONS The distance measured around the outside of the cylinder rod, divided by 12. Number of cylinders SPAN DIMENSIONS The dimension between the center of the boom pivot and the center of the sheave with the boom fully extended.
  • Page 49 LOAD VERIFICATIONS Test Displayed Displayed Displayed Displayed Actual Measured Radius Load Radius Error Error Length Angle Radius Load Load SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126...
  • Page 50 Fraction-to-Decimal Conversion Chart Fraction Decimal Fraction Decimal 1/64 .015625 33/64 .515625 1/32 .03125 17/32 .53125 3/64 .046875 35/64 .546875 1/16 .0625 9/16 .5625 5/64 .078125 37/64 .578125 3/32 .09375 19/32 .59375 7/64 .109375 39/64 .609375 .125 .625 9/64 .140625 41/64 .640625 5/32 .15625...

  • Page 51: Troubleshooting

    3.0 Troubleshooting 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 Service Personnel in understanding, locating, and identifying problems during the operation of the MicroGuard®...

  • Page 52: System Self-Test

    3.2 System Self-Test The system will perform a “SELF-TEST” when the power is turned on or when the TEST button is pressed during operation. This will verify the computer, display console, cables, and all remote sensors are working properly. During the “SELF-TEST,” all display functions are activated, allowing the operator to ensure all indicators are functional.

  • Page 53: Display Console Problems

    3.2.1 Display Console Problems DISPLAY CONSOLE PROBLEMS are difficult to isolate because of the interaction between the display console and the computer unit. Failure of either unit, or interconnection of the two units, will cause a malfunction of the 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.

  • Page 54: Fault Reporting And Fault Codes

    3.3 Fault Reporting and Fault Codes The system performs a self-testing process lasting approximately six seconds that automatically detects most faults in the system. During normal operation, a self-test can be initiated at any time by pressing the TEST button on the display console. Many fault conditions are detected without a system self-test.

  • Page 55: Group "A" Fault Codes

    3.3.1 Group “A” Fault Codes Group “A” fault codes represent faults detected for analog sensors. NOTE: Check and repair “B” and “C” group faults before proceeding with group “A” fault finding sensors. The following chart details all the available codes in the left column and the actions to take in the right column.

  • Page 56: Group "B" Fault Codes

    Group “A” Fault Codes - Continued BOOM Tdx 1 Tdx 0 FAULT SWING EXTENSION ACTION ANGLE CODE SENSOR SENSOR PISTON SENSOR PRESSURE PRESSURE Follow SECTION 3.10 Replace Computer Follow SECTIONS 3.8.2, 3.8.3, 3.10 Replace Computer Follow SECTIONS 3.8.6, 3.8.7, 3.10 Replace Computer Follow SECTIONS 3.8.2, 3.8.3,...

  • Page 57: Group "C" Fault Codes

    3.3.3 Group “C” Fault Codes Group “C” fault codes represent faults detected for internal computer memories. The following chart details all the available codes in the left column and the actions to take in the right column. FAULT SERIAL DUTY PROGRAM ACTION CODE...

  • Page 58: Group "D" Fault Codes

    3.3.4 Group “D” Fault Codes Group “D” fault codes represent faults detected for capacity chart selection. The following chart details all the available codes in the left column and the actions to take in the right column. WRONG WRONG FAULT CHART NOT SWING BOOM...

  • Page 59: No Fault Code" Problems

    3.3.5 “No Fault Code” Problems This section addresses problems not reported by the computer fault code system. 3.3.5.1 Anti-Two-Block Alarm (ATB) This section gives direction to fault diagnosis of ATB alarm problems. For detailed information, schematic, and voltages, refer to SECTION 3.9 - ANTI TWO-BLOCK FUNCTION OVERVIEW. PROBLEM: •...

  • Page 60: Displayed Load Or Radius Errors

    3.3.5.2 Displayed Load or Radius Errors This section gives direction to fault diagnosis of load and radius errors. Load or radius errors can cause early or late tripping of overload alarms. Accuracy of load, radius, length, and angle is determined by the correct installation and maintenance of the system sensors.
  • Page 61 Check Boom Angle 1. Fully retract the boom. NOTE: The required accuracy of measured angles is within 0.2°. When taking boom angle measurements use a good quality inclinometer. Many inclinometers are only accurate at 0° (level). Ensure a reliable position on the top of the boom is used to measure the angle and that the inclinometer will provide an accurate reading at 0°...

  • Page 62: Computer Unit Overview

    3.4 Computer Unit Overview The COMPUTER UNIT is the center of the System. It reads the sensors, controls computations and disconnect functions, and communicates with the display console/internal bar graph. The computer unit connects to the crane wiring harness via 60-way bulkhead connector. There are no wiring connections or screw terminals within the unit.

  • Page 63: Internal Status Indicators

    3.4.2 Internal Status Indicators The computer unit contains a row of LED indicators for checking computer operation. During normal operation, all LEDs will be illuminated with the COMM indicator blinking. If not, please contact Technical Support for assistance. Use the following chart and Figure 3.4.1 for LED location. LED Indicator Function Communication Indicator TST0...

  • Page 64: Replacing The Computer Unit Computer Removal

    5. Check the NETT pressure values of both sensors. This should be between -35 and +35PSI. If not, replace the computer unit. 3.4.4 Replacing the Computer Unit Computer Removal 1. Lower the boom until the boom hoist cylinder is completely retracted and on its stop or the boom is firmly in the boom rest.

  • Page 65: Display Console Overview

    3.5 Display Console Overview The OPERATOR’S DISPLAY CONSOLE 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. When operated for extended periods, under extreme conditions, the console can become damaged. The damage is not always apparent.

  • Page 66: Replacing The Display Console

    3.5.5 Replacing the Display Console REMOVAL 1. Disconnect the electrical cable from the rear of the OPERATOR’S DISPLAY CONSOLE. 2. Remove the knob on each side of the console and retain for future use. 3. Remove the defective display console from the bracket in the cab. INSTALLATION 1.

  • Page 67: Remote Bar Graph Overview

    3.6 Remote Bar Graph Overview The REMOTE BAR GRAPH, shown below, displays the percentage of rated capacity of the crane. The remote bar graph is mounted at the top of the cab front window, in the operator’s line of sight. There are multiple brightness levels available on the device.

  • Page 68: Cable And Connector

    3.6.4 Cable and Connector The REMOTE BAR GRAPH uses a single cable to communicate with and receive power from the computer unit. The cable is not removable and is a fixed length. Do not discard the excess cable when the unit is installed. Extending this cable is not recommended. There is a single connector on the far end of the cable.

  • Page 69: Reeling Drum Overview

    3.7 Reeling Drum Overview The primary operation of the REELING DRUM is to measure the extension of the telescoping sections of the main boom. The reeling drum includes an angle sensor to 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.

  • Page 70: Checking The Reeling Drum Cable Layering

    3.7.1 Checking the Reeling Drum Cable Layering The reeling drum is designed to provide accurate measurement of boom extension. To provide accurate measurement, the REELING DRUM CABLE must form a single flat layer across the surface of the reeling drum as the boom is telescoped in and out. Any stacking of the cable will cause extension errors as the boom retracts.

  • Page 71: Checking The Extension Sensor Drive Voltage

    3.7.2 Checking the Extension Sensor Drive Voltage 1. Remove the reeling drum cover. 2. Use a digital voltmeter to measure the voltage between the RED (TB1-4) and BLUE (TB1-1) wires at the terminal block mounted on the sensor baseplate assembly. 3.

  • Page 72: Physical Zero

    3.7.4 Physical Zero Ensure the extension sensor potentiometer is correctly set to its minimum “zero” setting when the boom is fully retracted. This ensures the sensor will correctly measure over the full telescoping range of the boom. 1. Fully retract the boom. 2.

  • Page 73: Checking The Angle Sensor Pendulum

    3.7.5 Checking the Angle Sensor Pendulum The ANGLE SENSOR uses a copper pendulum, mounted behind the sensor assembly. In order to stop the pendulum from swinging uncontrollably during movements of the boom, two magnets provide damping. If problems with the angle sensor are suspected, ensure the pendulum and potentiometer are operating without restriction.

  • Page 74: Checking The Angle Sensor Drive Voltage

    3.7.6 Checking the Angle Sensor Drive Voltage 1. Remove the reeling drum cover. 2. Use a digital voltmeter to measure the voltage between the RED (TB1-4) and BLUE (TB1-1) wires at the terminal block mounted on the sensor baseplate assembly. 3.

  • Page 75: Reeling Drum Cable

    3.7.8.1 Reeling Drum Cable The REELING DRUM CABLE carries the Anti-Two-Block signal from the switches at the main boom head, aux head and erected jib/fly. The cable is made from stainless steel wire and a durable outer sheath. Damage to the cable will often result in bad Anti-Two-Block signals or bad measurement of boom extension.
  • Page 76 Installing the Reeling Drum Cable 1. Loosen the strain relief on the cheekplate and feed the REELING DRUM CABLE through the wall of the cheekplate. Leave enough slack to work easily with the cable. 2. If not already stripped, remove 1” of the outer jacket of the cable with an X-ACTO knife. 3.

  • Page 77: Slip-Ring Assembly

    3.7.8.2 Slip-Ring Assembly The main purpose of the SLIP-RING ASSEMBLY is to provide an electrical path for the feed and switch signal return, between the Two-Block switch and the system computer. If replacement becomes necessary, replace the upper and lower halves of the slip-ring assembly at the same time. Failure of the slip-ring assembly will most likely result in a continuous Anti-Two-Block alarm.

  • Page 78: Sensor Baseplate Assembly

    4. Screw the bottom half of the slip-ring to the shaft with the two Phillips screws. Ensure the wires exiting through the center of the shaft are not trapped. 5. Connect the extension reeling drum cable to TB2 on the arm of the slip-ring. The braided shield connects to the slip-ring TB2 black wire and the center of the cable connects to the slip-ring TB2 brown wire.
  • Page 79 Removing the Sensor Baseplate Assembly 1. Remove the aluminum cover on the extension reel. 2. Remove the screws holding the slip-ring to the mounting ring of the SENSOR ASSEMBLY. 3. Disconnect the brown and black wires. 4. Disconnect the signal cable wires to terminal block TB1. 5.

  • Page 80: Signal Cable Assembly

    3.7.8.4 Signal Cable Assembly The SIGNAL CABLE ASSEMBLY connects the reeling drum sensors, the Anti-Two-Block switch and the system computer. Removing the Reeling Drum from the Boom 1. Completely lower and retract the boom. 2. Disconnect the Reeling Drum Cable and the Anti-Two-Block switch. 3.
  • Page 81 10. Screw the Slip-Ring Assembly to the sensor baseplate assembly. NOTE: Ensure 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.

  • Page 82: Anti Two-Block Function Overview

    3.8 Anti Two-Block Function Overview This section describes fault diagnoses of the Anti-Two-Block detection circuit. The computer supplies a protected positive feed to the Anti-Two-Block switches at the boom/jib head via the reeling drum signal cable, slip-ring, and reeling drum cable. With the Anti-Two-Block weight hanging freely on the switch(es), the switch contact is closed and the signal return to the computer is high (6.25 volts).

  • Page 83: Checking The Reeling Drum Cable

    3.8.1 Checking the Reeling Drum Cable The outer braid of the cable carries the Anti-Two-Block feed to the switches. If the cable sheath is damaged, this may cause a short circuit to the boom/chassis and indicate a fault code above “B 8”(See SECTION 3.3.2 GROUP “B”...

  • Page 84: Swing Sensor Overview

    3.9 Swing Sensor Overview The SWING SENSOR measures the angle of the upper structure of the crane relative to its carrier. This angle is used to select capacity charts and operator 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 collector at the cranes swing center.

  • Page 85: Checking The Swing Sensor Drive Voltage

    3.9.1 Checking the Swing Sensor Drive Voltage 1. Remove the collector ring cover to expose the swing sensor. 2. With the system power turned on, measure the voltage between Terminal 1 of the swing sensor and crane ground. The voltage should be between 4.4 and 4.8 volts. 3.
  • Page 86 The swing potentiometer is located in the collector ring assembly under the hydraulic swivel. The job of the potentiometer is to track the movement of the upper half of the crane all the way around the swing circle. This function can only be zeroed in the stowed, or house lock positions, and the numbers should count up, when rotating to the right or in a clockwise direction.
  • Page 87 6. Press the Next button to view the Remove Swing pot command. Use 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. TEST 7.
  • Page 90 SkyAzúl, Inc. 16 Walnut Street Middletown, MD 21769 Phone 301-371-6126 Fax 301-371-0029 www.skyazul.com info@skyazul.com SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126...

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