TABLE OF CONTENTS Section 1: Operation ..........................6 1. Introduction ............................6 2. Technical Support ..........................6 3. Outline of Operation ..........................6 System Components ......................... 7 3.1.1 Element II Display Unit ....................7 3.1.2 MG5 Computer Unit ....................7 3.1.3 Pressure Transducers ....................
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6.10 Next ............................23 6.11 Outrigger ..........................24 6.11.1 Outrigger Position Sensing (If Equipped) ..............24 6.12 Man Basket ..........................25 6.13 Tires ............................25 6.13.1 Rigging Travel (Tires Sub-Menu) ................26 7. The Home Screen ..........................27 Adjusting the Brightness of the Display ................... 28 LMI Window ..........................
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Group “C” Fault Codes ......................46 14.4 Group “D” Fault Codes ......................46 14.5 15. Problems Not Reported by Fault Code System ................47 15.1 Anti-Two-Block Alarm (ATB) ....................47 15.2 Displayed Load or Radius Errors ..................... 47 15.2.1 Check Boom Extension ..................... 47 15.2.2 Check Main Boom Radius ..................
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18.8.1 Enabling and Disabling the Outrigger Position Sensors ..........69 18.9 Calibrating the Frame-Level Sensor (If Equipped) ..............70 18.10 After the Calibration Routine ....................72 19. Reeling Drum Overview ........................73 19.1 Checking the Reeling Drum Cable Layering ................74 19.2 Sensor Baseplate Assembly ....................
Section 1: Operation 1. Introduction The Greer LMI System with MG5 Computer & Element II Display is an aid to crane operation. It is hereinafter referred to as the "system". Do not use this system without a properly trained operator. The operator must be knowledgeable in safety guidelines, crane capacity information, and the crane manufacturer’s specifications.
3.1 System Components • Element II Display Unit • MG5 Computer Unit with Integrated Pressure Transducers • Reeling Drum Assembly, with Extension and Angle Sensors • Swing Sensor • Anti-Two-Block Switches • Cables • Audible Alarm • Operation Manual & Calibration/Troubleshooting Manual 3.1.1 Element II Display Unit The display unit provides the operator with:...
3.1.7 Swing Sensor The swing sensor measures the angle of the boom relative to the chassis. 3.1.8 Anti-Two-Block (ATB) The ATB switch monitors the approach of the hook block or overhaul ball to the boom head. The switch is held in the normal position until the hook block or overhaul ball raises a weight that is mounted around the hoist rope.
4. System Self-Test Immediately following system power up, or upon entering calibration mode, the system executes a self- test. The following sections describe the self-test in each case. 4.1 System Power Up Self-Test Immediately following system power up, the system performs a self-test which verifies that the computer, display console, cables, and sensors are working properly.
4.2 Calibration Mode Self-Test Immediately following entering calibration mode, the system performs a self-test lasting approximately 10 seconds. During this time the numerical display segments and bar graph segments are all turned on, the audible alarm will sound and alarm indicator lights are illuminated. NOTE: Display message is crane dependent.
5. System Setup 5.1 Frame-Level Screen (If Equipped) If the machine is equipped with a Frame-Level sensor, press the Menu button to access the Menu screen. NOTE: This option will not appear on machines without a Frame-Level sensor installed. Use the Frame-Level screen to ensure the machine is properly leveled. Machine angle from level Dot Indicator 0°-0.9°...
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If the Frame-Level sensor (or its connection) malfunctions, the home screen grid will display in red. The grid on the Frame-Level screen will also display in red. To exit the screen, press the Home button in the lower right corner. W450780 Rev.
5.2 Accessing the Configuration Screen NOTE: Press the Configuration button to access the Configuration screen. The system will remember all previously set data, including after the system is powered off and powered on. After the configuration has been set, the operator must choose the winch in use. Changing the winch will automatically change the lifting point and the parts of line to the previously set data for the selected winch.
6. The Configuration Screens The CONFIGURATION screens represent the current setup of the system with green indicators. Each area contains a group of one or more green indicators and a button to change the setup selection. W450780 Rev. 1 10/27/2020...
6.1 Pick Point The Pick Point button contains three green indicators. A single green indicator will illuminate to show the point of lift. Press the Pick Point button to scroll through the available options. W450780 Rev. 1 10/27/2020...
6.4 Jib Press the Jib button to access the different options. The Jib group contains 6 green indicators. They indicate the length and offset of the jib in use. W450780 Rev. 1 10/27/2020...
6.5 Boom Mode The Boom Mode group contains one green indicator for machines with pinned extensions or active boom tip options. Choose the boom mode in use. W450780 Rev. 1 10/27/2020...
6.7 Counter Weight The Counter Weight group contains one green indicator. It is only active on machines equipped with counterweight options. W450780 Rev. 1 10/27/2020...
6.8 Winch The Winch group contains two green indicators, which indicate the front or rear winch. The Winch button toggles between the two options. NOTE: If the crane is equipped with two winches, always select the winch to be used for the lift prior to the point of lift and parts of line.
6.11 Outrigger The Outrigger button contains three green indicators. They indicate full, intermediate, or retracted outriggers. Ensure the selection matches the current crane setup. Each button press will cycle through the available options. 6.11.1 Outrigger Position Sensing (If Equipped) The operator will be warned if the selected outrigger position does not match the detected outrigger position.
6.12 Man Basket The Man Basket button enables the optional Personnel Platform, if equipped. 6.13 Tires Press the Tires button to access the tire selection screen. The Tires group contains one green indicator. Choose the correct setting to be used. For machines with more than one tire option, it is important the operator selects the tire configuration for the tire chart used.
6.13.1 Rigging Travel (Tires Sub-Menu) After selecting Tires, select RIGGING/TRAVEL mode when the machine is in the rigging process or is a rough terrain crane traveling between jobs. When in RIGGING/TRAVEL mode all other functions are disabled. W450780 Rev. 1 10/27/2020...
7. The Home Screen The Home Screen shows the LMI window, Crane Configuration window, and the Information window. The LMI window is the upper left portion of the screen and displays information such as Actual Load, Angle, Load Radius, etc. The Crane Configuration window provides a pictorial representation of the current crane setup.
7.1 Adjusting the Brightness of the Display 1. Press the Menu button to access the Menu screen. 2. Press the Brightness button. 3. Then adjust the display to match the current conditions. 4. Press Exit when finished. The display will return to the Menu screen. W450780 Rev.
7.2 LMI Window 1. BAR GRAPH – This displays the ACTUAL LOAD relative to the RATED CAPACITY. 2. PRE-ALARM INDICATOR – This yellow indicator illuminates at 90% of the RATED CAPACITY to provide a visual indication of approaching overload. 3. OVERLOAD INDICATOR – This red indicator illuminates at 100% of the RATED CAPACITY to provide a visual indication of maximum load.
7.3 Crane Configuration Window The Crane Configuration window on the Home screen provides a graphical representation of the current Crane Configuration. The green indicators show the specifics of the crane setup. In this example, the crane is: • Using the main boom as the pick point •...
8. Cancel Alarm Button The Cancel Alarm button is used to silence the audible alarm. Pressing the button once will cancel an audible alarm caused by an: • Overload • ATB Alarm • Operator Programmable Alarm • Outrigger Horizontal Position Mismatch The audible alarm will remain cancelled until the condition which caused the alarm has been resolved.
9. Operator Programmable Alarms 9.1 Accessing the Operator Alarms Press the Operator Alarm button from the Home screen to access the operator alarms. The information screen will show the current status of the operator alarms. There are four buttons to the left and right of the Information window. Each button relates to the indicated alarm.
9.2 Setting the Minimum Boom Angle Alarm 1. Move the boom to the desired minimum angle, in this example, 26.9°. 2. Press the Operator Alarm button to access the Operator Alarm screen. 3. Press the MIN ANGLE button. In this example, the screen will read MIN ANGLE 26.9. 4.
9.4 Setting the Maximum Boom Length Alarm 1. Move the boom to the desired maximum length, in this example, 86.7 ft. 2. Press the Operator Alarm button to access the Operator Alarm screen. 3. Press the MAX LENGTH button. In this example the display will read MAX LENGTH 86.7. 4.
9.5 Setting the Maximum Tip Height Alarm 1. Move the boom tip to the desired maximum height, in this example, 89.9 ft. 2. Press the Operator Alarm button to access the Operator Alarm screen. 3. Press the MAX HEIGHT button. In this example the display will read MAX HEIGHT 89.9. 4.
9.6 Swing Alarms Overview These alarms permit the operator to define a Working Arc and an Exclusion Zone by two set points. The following diagram illustrates the Working Arc and Exclusion Zone. A left swing alarm is activated when swinging to the left. A right swing alarm is activated when swinging to the right.
9.7 Accessing the Swing and Work Area Alarms Access the swing and work area alarms from the main working screen by pressing the Operator Alarm button twice. The information window will show the current status of the swing and work area alarms. There are four buttons, one for each alarm.
9.9 Work Area Alarms Overview This alarm permits the operator to define an Operating Zone by only two set points. The use of this method results in an enhanced working area and defines the Exclusion Zone area more simply. The following diagram illustrates the Operating Zone and the Exclusion Zone.
9.10 Setting the Work Area Alarm 1. Press the Operator Alarm button twice to access the Work Area Alarm screen. 2. Move the boom, attachment, load, rigging, etc. to the desired LEFT SET POINT. 3. Press the LEFT POINT button. The display will read LEFT POINT SET. NOTE: The Left and Right Points must be set for the system to operate correctly.
Section 2: Calibration & Troubleshooting 10. Introduction The Greer LMI System with MG5 Computer & Element II Display is an aid to crane operation. It is hereinafter referred to as the "system". Do not use this system without a properly trained operator. The operator must be knowledgeable in safety guidelines, crane capacity information, and the crane manufacturer’s specifications.
12. System Self-Test Immediately following system power up, or upon entering calibration mode, the system executes a self- test. The following sections describe the self-test in each case. 12.1 System Power Up Self-Test Immediately following system power up, the system performs a self-test which verifies that the computer, display console, cables, and sensors are working properly.
12.2 Calibration Mode Self-Test Immediately following entering calibration mode, the system performs a self-test lasting approximately 10 seconds. During this time the numerical display segments and bar graph segments are all turned on, the audible alarm will sound and alarm indicator lights are illuminated. NOTE: Display message is crane dependent.
13. Element II Display Console Problems Display console problems can be difficult to isolate due to the interaction between the display and the computer unit. Failure of either unit or the cabling connecting the units can cause a malfunction. To solve problems using the display indications, observe the display at power up and through the self- test.
14. Fault Reporting and Fault Codes System fault codes provide a way to locate and assess problems within the system. The system performs a brief self-test each time it is powered on. Many fault conditions are detected without a system self-test. Faults detected during the self-test are indicated on the display console: •...
14.2 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 to group “A” faults. The following chart lists the possible fault codes in the left column and the actions to take in the right column.
14.4 Group “C” Fault Codes Group “C” fault codes represent faults detected for internal computer memories. The following chart lists the possible fault codes in the left column and the actions to take in the right column. If the displayed fault code is not listed here, see section Fault Codes for Multiple Faults. Group C Fault Codes Fault Code Description...
15. Problems Not Reported by Fault Code System This section addresses problems that are not reported by the computer fault code system. 15.1 Anti-Two-Block Alarm (ATB) The purpose of this section is to help diagnose ATB alarm problems. For detailed information, schematic, and voltages, refer to Anti-Two-Block Function Overview.
3. Check the zero of the extension sensor with the boom fully retracted. Enter the Calibration Mode and use the “SPAN” command. Select sensor No. 2 to view the extension value in feet. The value of extension must be between -0.2 and +0.2, with the boom fully retracted. If the extension value is incorrect, refer to Calibrating the Extension Sensor Zero.
15.2.4 Check Pressure Transducers WARNING! BOTH PRESSURE TRANSDUCERS ARE PRE-CALIBRATED FROM THE FACTORY. THE PRESSURE TRANSDUCERS CAN NOT BE REPLACED. REMOVAL OR REPLACEMENT OF THE PRESSURE TRANSDUCERS FROM THE COMPUTER VOIDS THE WARRANTY AND WILL ADVERSELY AFFECT THE PRESSURE CALIBRATION. There are two pressure transducers installed as part of the system.
16. MG5 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. Two hydraulic pressure transducers are contained in the computer unit. These sensors measure the rod-side pressure and piston-side pressure in the boom hoist cylinder.
16.2 Function Kickout Fuse (FUS1) NOTE: Prior to replacing the fuse, ensure any electrical shorts have been removed. The computer unit contains a standard 10 amp replaceable fuse. The fuse protects the function kickout circuit and relay contacts. Replace the fuse if the system error codes indicate that the function kickout power feed is missing.
17. Element II Display Console Overview The Element II Display console allows the user to see the crane values and crane configuration selection. The display also provides calibration functions used for testing and fault diagnosis. 17.1 Checking the Display Console When operated under extreme conditions the console can become damaged.
17.2 Unresponsive Buttons Not all button options are available for use at all times. It is important to verify that the non-responsive button is: • Programmed to respond during the operation of the system. In Calibration Mode, only the circled buttons will work, with a few exceptions. The Configuration button will allow you to access the Configuration page, but the user will not be allowed to make any changes.
17.3 Connectors The AMP connector on the display interface cable from the computer plugs into Connector 1 (Black) on the back of the display. Connector 2 (Gray) Connector 1 (Black) W450780 Rev. 1 10/27/2020...
17.4 Horn Ensure the horn is connected to the wiring harness via the two-pin Deutsch connector. 17.5 Ingress Protection Rating The display console conforms to IP67 in protection against dust and water, when correctly installed. 17.6 Replacing the Display Console 17.6.1 Removal 1.
18. Calibration Mode The Greer LMI System is an aid to crane operation. Only use this system with an operator trained in safety guidelines, crane capacity information, and the crane manufacturer’s specifications. When the computer is new, it has no zero or span calibrations. It is necessary to enter zero and span settings for accurate length and angle calculations.
18.1 Entering the Calibration Mode Follow the steps below to ensure proper calibration of the system. Ensure the actual crane setup is reflected on the display. See the Operation Manual for proper crane configuration after the calibration. 1. To enter Calibration Mode, the display must be on the Home screen. 2.
18.2 Calibration Menus Once the security code has been entered, the display will show the following menu. The main menu items used to calibrate the system are: • 02 Zero Sensors • 03 Span Sensors • 04 Swing Potentiometer The boom extension and the boom angle must be calibrated by being properly set to zero and spanned.
18.3 Inactive Buttons During Calibration Mode Please note the following buttons are inactive when in the Calibration Mode. The functionality of the buttons will return when the display is no longer in the Calibration Mode. W450780 Rev. 1 10/27/2020...
18.4 Calibrating the Extension Sensor Zero 1. Fully retract and lower the boom to 0.0°. Verify using a digital level. 2. Remove the cover from the reeling drum to expose the baseplate sensor assembly. 3. Rotate the extension sensor gear clockwise until the clutch drags/clicks, then rotate ½ turn counterclockwise.
18.5 Calibrating the Angle Sensor Zero The angle sensor is preset to zero on the potentiometer before leaving the factory. If the potentiometer is disturbed, the zero setting can be affected. If this happens, the angle sensor will be inaccurate. If the factory setting has been disturbed, reestablish it by loosening the attaching screws, and rotating the pot until the desired voltage reading is attained.
18.6 Calibrating Span of Extension and Angle WARNING! THE AREA OVERHEAD ABOVE THE CRANE MUST BE CLEAR OF OBSTRUCTIONS PRIOR TO CALIBRATING SPAN OF EXTENSION AND ANGLE! In order for the system to properly calculate the boom length and the boom angle, the “Span Number” must be entered into the system.
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7. Use this screen to enter the span (Extended Length – Retracted Length = Span). 8. The lower left and lower right buttons are used to select the number. The number inside the brackets is the current selection. In the image below, the number 4 is between the brackets. UPPER LEFT UPPER RIGHT LOWER LEFT...
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13. Press the Yes! Calibrate! button. 14. You will be prompted with the same screen from step 7. Use this screen to enter the span of angle measurement from the digital level. 15. This calibration routine is now complete. Press the Exit button to return to the calibration menu. W450780 Rev.
18.7 Calibrating the Swing Potentiometer After completing the extension and angle span, return to the main calibration screen. 1. Press the Menu Up button until 04 Swing Potentiometer is reached. This menu allows the operator to set the 0.0° point on the swing circle and set which rotation direction is defined as positive.
18.7.1 Calibrating Swing Direction For consistency, the swing should count upwards (0, 1, 2, 3, etc.) when rotating clockwise. The direction of the swing can be changed. 1. With the zero calibrated, if the swing direction is wrong, press the Menu Up button twice. 2.
18.8 Calibrating the Outrigger Position Sensors If an error code is displayed for a particular outrigger sensor, contact Greer/TWG Service for assistance. For cranes with digital switch outrigger position sensors, contact Greer/TWG Service for assistance. No calibration is needed. When directed by Greer/TWG Service to replace the string potentiometer outrigger position sensors, calibration is needed.
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c. Repeat these steps and install the remaining sensors. d. The message will change from Configure to Reset when calibration is finished. 5. With all sensors installed, ensure the outriggers are in the fully retracted position. Press the Fully Retracted Position button to set the retracted position in the computer. 6.
7. Move the outriggers to fully extended position and press the corresponding button to set the fully extended outrigger position. 8. The outrigger position sensors are now calibrated. 18.8.1 Enabling and Disabling the Outrigger Position Sensors In the Outrigger Sensing menu, the user can Enable or Disable the Outrigger Position Sensors. Press the indicated button to toggle between the two options.
18.9 Calibrating the Frame-Level Sensor (If Equipped) This is the procedure for calibrating the Frame-Level sensor on a new machine, or after replacing a faulty Frame-Level sensor. Ensure the sensor is mounted to a flat surface, this can affect the calibration.
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4. Enter the security code to calibrate the Frame-Level sensor. Press the buttons in the order shown. 5. This allows access to the Configure Sensor and Zero Sensor buttons. W450780 Rev. 1 10/27/2020...
6. Press the Configure Sensor button to activate the sensor. NOTE: To ensure proper operation, this must be done the first time the device is connected and powered on. This must also be performed with a replacement sensor, in the event of a failure. 7.
19. 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 also includes an angle sensor to measure the main boom angle along with an electrical slip-ring which transfers the two-block signal from the reeling drum cable to the system computer.
19.1 Checking the Reeling Drum Cable Layering The extension reel 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 extension reel as the boom is telescoped in and out. Any stacking of the cable will cause extension errors as the boom retracts.
19.2 Sensor Baseplate Assembly The sensor baseplate assembly supports and connects the extension and angle sensors. It also supports the anti-two-block switch signal and signal cable to the computer. Electrical or mechanical failure of either the angle sensor or the extension sensor potentiometers cannot be repaired in the field.
19.3 Reeling Drum Voltage Checks If problems occur with the two-block alarm operation, angle, or extension sensor, refer to the following chart. Follow the Boom Position/Action column before performing any voltage checks. Measure all voltages with a digital voltmeter set to DC volts range. BOOM VOLTAGE VOLTMETER CONNECTION...
19.4 Anti-Two-Block Function Overview The computer supplies a protected positive feed to the Anti-Two-Block switches at the boom/jib head via the reel-to-computer cable, slip-ring, and reeling drum cable. With the Anti-Two-Block weight hanging freely on the switch, the switch contact is closed and the signal return to the computer is high. When the weight is lifted by the hook block, the switch contact is opened, and the computer will sense a low signal input from the ATB signal return.
20. Swing Potentiometer Overview (If Equipped) The swing potentiometer 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 potentiometer fails, the computer will be unable to select a valid capacity chart. For fault diagnosis, access the swing potentiometer by removing the collector cover at the crane’s swing center.
20.1 Checking the Swing Potentiometer Drive Voltage 1. Remove the collector ring cover to expose the swing potentiometer. 2. With the system power turned on, measure the voltage between Terminal 1 of the swing potentiometer and crane ground. The voltage should be between 4.4 and 4.8 volts. 3.
21. Frame-Level Sensor Overview (If Equipped) The Frame-Level sensor measures the angle of the chassis relative to 0.0°. It is important to have the machine level before performing a lift. If the Frame-Level sensor fails, the indicator on the screen will turn red and no measurement will be available.
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