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GREER Company MICROGUARD 414 Troubleshooting Manual

Rated capacity limiter system
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MICROGUARD
414
RATED CAPACITY LIMITER
SYSTEM
TROUBLESHOOTING
MANUAL
®
MicroGuard
414 System — Troubleshooting Manual
PN W414800 Rev B 11/06/03
1

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  • Page 1 ® MICROGUARD RATED CAPACITY LIMITER SYSTEM TROUBLESHOOTING MANUAL ® MicroGuard 414 System — Troubleshooting Manual PN W414800 Rev B 11/06/03...
  • Page 2 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 ®...

  • Page 3: Table Of Contents

    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 .....................

  • Page 4: Where To Go For Help

    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. Have your crane Model Number and Serial Number ready.

  • Page 5: Preparation

    The Troubleshooting Manual for the MicroGuard 414 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.
  • Page 6 ® MicroGuard 414 System — Troubleshooting Manual PN W414800 Rev B 11/06/03...

  • Page 7: Problem Finder Tables

    SECTION II PROBLEM FINDER TABLES The Problem Finder Tables are designed to aid in determining the location and type of problem that you are experiencing. It is important that you review these Tables carefully before contacting us. SYSTEM SELF-TEST ......................... 8 COMPUTER/DISPLAY COMMUNICATION ..............9-12 OPERATOR’S DISPLAY CONSOLE................

  • Page 8: System Self-Test

    SECTION II SYSTEM SELF-TEST The Computer and 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. The Test Sequence for the Display Console: 1.

  • Page 9: Computer/Display Communication

    SECTION II 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. Seven wires, identified below and shown in the following diagram, connect the Computer to the Display Console.
  • Page 10 SECTION II COMPUTER/DISPLAY COMMUNICATION CONTINUED NORMAL OCCURRENCES WHEN SYSTEM IS TURNED ON OR WHEN “TEST” BUTTON IS PUSHED DISPLAY COMPUTER BAR GRAPH ”SYSTEM SELF-TEST.” After Self-Test, the relays All lights turn on during Self-Test turn on and allow crane and then return to normal. “IN PROGRESS.”...
  • Page 11 SECTION II COMPUTER/DISPLAY COMMUNICATION CONTINUED DA AND DB IS OPEN TO THE DISPLAY DISPLAY COMPUTER BAR GRAPH Liquid Crystal Display Reset repeats every 5 seconds. All lights on. shows 2 rows of black boxes. Lamps are on. Relays click with every reset. Audio alarm on.
  • Page 12 SECTION II COMPUTER/DISPLAY COMMUNICATION CONTINUED YELLOW WIRE (+5V) IS OPEN DISPLAY COMPUTER BAR GRAPH No Liquid Crystal Display Relays turn on and allow crane Normal. segments. motions. No lamps. No audio alarm. No Liquid Crystal Display back light. “Test” button resets the computer. Relay clicks when the “TEST”...

  • Page 13: Operator's Display Console

    SECTION II OPERATOR’S DISPLAY CONSOLE The Display Console interacts with the Computer. Before continuing with this section, please review the COMPUTER/DISPLAY COMMUNICATION section on the preceding pages. The computer must be working to check the Display Console. Check the computer power supply voltages.

  • Page 14: Fault Codes

    SECTION II 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. See SECTION V for a complete description of FAULTS. If a warning sounds or is exhibited on the Operator’s Display Console, and a FAULT does not register, check the OPERATOR’S SETTABLE ALARMS by pressing the VIEW button.

  • Page 15: Crane Motions Are Disabled

    SECTION II 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 414 System protection circuit has 2 relays, in series, between the ® Cranes Battery and Motion Cut Solenoids.

  • Page 16: Anti-Two-Block Condition

    SECTION II 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.

  • Page 17: Swing Pot Sensor

    SECTION II 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”...

  • Page 18: Swing Switches

    SECTION II SWING SWITCHES The swing switches and their connections are shown below. If a problem occurs, check the switches, cables, and connections to the computer. TRUCK CRANE CONFIGURATION CRANE PREFIX 64 Swing Switch Cable 6 Connector 6 MG 414 Termination Board Side + Front DIN2 Battery...

  • Page 19: Boom Extension Sensor

    SECTION II 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.

  • Page 20: Boom Angle Sensor

    SECTION II 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°.

  • Page 21: Pressure Transducers

    SECTION II 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.
  • Page 22 SECTION II 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.

  • Page 23: Remote Bar Graph

    SECTION II 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...
  • Page 24 ® MicroGuard 414 System — Troubleshooting Manual PN W414800 Rev B 11/06/03...

  • Page 25: System Installations

    Section III ..............SELECTING THE RIGHT SCHEMATIC ..SYSTEM LAYOUTS WITH CORRESPONDING SERIAL NUMBER PREFIX 27-32 3.1 D3 SYSTEM INSTALLATION ..................27 3.2 D7 SYSTEM INSTALLATION ..................28 F2 SYSTEM INSTALLATION 3.3 65 SYSTEM INSTALLATION ..................29 69 SYSTEM INSTALLATION 71 SYSTEM INSTALLATION 58 SYSTEM INSTALLATION 59 SYSTEM INSTALLATION 65 SYSTEM INSTALLATION...
  • Page 26 SECTION III 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 414 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.
  • Page 27 SECTION III 3.1 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 Connection Batt + Connector 8...
  • Page 28 SECTION III 3.2 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 Connection Batt + Connector 8...
  • Page 29 SECTION III 3.3 SYSTEM INSTALLATION Mounted on Attachment Head Reel-Off Cable to Boom Head Anti-Two Block Anti-Two Block Switch Switch (Attachment) (Main Boom) Mounted at Boom Head Extension Drum & Angle Sensor BOOM ATTACHMENT OPERATOR CAB Cable 8 Power / Motion Disconnect Connection Connector 8 Cable 7...
  • Page 30 SECTION III 3.4 SYSTEM INSTALLATION Reel-Off Cable to Inner-Mid Section ATTACHMENT Extension Drum Mounted at Boom Head (Inner-Mid Section) BOOM Mounted on attachment Head Anti-Two Block Anti-Two Block Switch Switch Reel-Off Cable to Boom Head Extension Drum & Angle Sensor OPERATOR CAB Cable 8 Display Console...
  • Page 31 SECTION III 3.5 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 Power / Motion Disconnect Connection Connector 8...
  • Page 32 SECTION III 3.6 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 Power / Motion Disconnect Connection Connector 8...

  • Page 33: System Components And Associated Functions

    Section IV SYSTEM COMPONENTS AND ASSOCIATED FUNCTIONS ......... THE COMPUTER UNIT .......................39 COMPUTER UNIT COMPONENTS..................39 ACCESSING THE COMPUTER BOARD AND THE TERMINATION BOARD ......41 CHECKING THE COMPUTER UNIT ..................41 CONNECTORS........................41 UNIT COVER ........................41 COMPUTER BOARD ASSEMBLY ..................41 COMPUTER BOX WIRING/TERMINATION BOARD ASSEMBLY ........41 WIRE LENGTH......................41 INSULATION REMOVAL....................42 FUSES ..........................42...
  • Page 34 DUTY ROM CHIP ........................46 COMPUTER CHIP REMOVAL AND INSTALLATION.............46 COMPUTER CHIP REMOVAL..................46 COMPUTER CHIP INSTALLATION..................46 OPERATOR’S DISPLAY CONSOLE ..................47 DISPLAY CONSOLE MODELS....................47 CHECKING THE OPERATOR’S DISPLAY CONSOLE ............48 READING THE (LIQUID CRYSTAL) DISPLAYS ..............48 BUTTONS THAT DON’T RESPOND ................48 CONNECTORS .........................48 HORN ..........................49 MOISTURE........................49 OPERATOR’S DISPLAY CONSOLE REMOVAL AND INSTALLATION ........49...
  • Page 35 REMOVAL OF A BAR GRAPH UNIT ..................52 INSTALLATION OF A BAR GRAPH UNIT ................52 EXTENSION REEL ........................53 EXTENSION REEL MODELS....................54 EXTENSION REEL MODELS (ALL EXCEPT SERIAL NO. PREFIX D6)......54 EXTENSION REEL MODEL SERIAL NO. PREFIX D6 ............. 54 CHECKING/TESTING EXTENSION REEL FUNCTIONS (ALL MODELS) ......
  • Page 36 SWING SENSOR ...........................73 SWING POTENTIOMETER ......................73 AIN 5 AND AIN 6.........................73 CHECKING THE SWING POTENTIOMETER................73 SWING SWITCHES ........................75 MODELS 64 AND 53 ONLY .......................75 ® MicroGuard 414 System — Troubleshooting Manual PN W414800 Rev B 11/06/03...
  • Page 37 Section IV SYSTEM COMPONENTS AND ASSOCIATED FUNCTIONS ® This section provides detailed information on the MicroGuard 414 System components and associated functions. System components include the Computer Unit, Operator Display Console, Bar Graph Unit, Extension Reel, and Pressure Sensor. Functions include the Anti-Two-Block Function, the Power, Motion Disconnect, and Boom Mode Functions, the Swing Sensor, and the Swing Switches.
  • Page 38 ® MicroGuard 414 System — Troubleshooting Manual PN W414800 Rev B 11/06/03...
  • Page 39 SECTION IV FIGURE 4.0 THE COMPUTER UNIT THE COMPUTER UNIT ® The Computer Unit, shown in Figure 4.0, is the center of the MicroGuard 414 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.
  • Page 40 SECTION IV FIGURE 4.1 COMPUTER UNIT COMPONENTS SPARE RELAY (BOOM MODE) DIN1 DOUT0 AIN0 DIN2 DOUT1 OVERLOAD AIN1 DIN3 DOUT2 DIN4 DOUT3 DIN5 DOUT4 DIN6 DOUT5 AIN2 DIN7 DOUT6 AIN3 DIN8 DOUT7 TX0+ AIN4 DIN9 TX0- DIN10 +5VA DIN11 +5VB DIN12 AIN5 DIN13...
  • Page 41 SECTION IV 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. Set the lid and the four screws aside. Note: The lid is not hinged.
  • Page 42 SECTION IV trapped or pinched when the Termination Board Assembly is replaced or when 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.
  • Page 43 SECTION IV 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 [+14.70V ~ +15.30V] •...
  • Page 44 SECTION IV 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.
  • Page 45 SECTION IV 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 44.
  • Page 46 SECTION IV 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.
  • Page 47 SECTION IV OPERATOR DISPLAY CONSOLE The Operator 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 three Operator Display Consoles: The in-dash horizontal and in-dash vertical mount and the horizontal bracket mount.
  • Page 48 SECTION IV CHECKING THE OPERATOR DISPLAY CONSOLE The Operator 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.
  • Page 49 SECTION IV Drive Wire is a single black lead that should be attached to the black terminal on the rear of the Display Console housing. 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.
  • Page 50 SECTION IV INSTALLATION OF HORIZONTAL BRACKET MOUNT CONSOLES 1. Install the new Operator Display Console on the bracket in the cab by positioning it between the bracket legs and inserting and tightening the knob on each side of the Operator Display Console.
  • Page 51 SECTION IV 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 Unit, if it is found to be faulty. With the system powered, there should always be at least one (GREEN) LED lighted –...
  • Page 52 SECTION IV BAR GRAPH UNIT REMOVAL AND INSTALLATION REMOVAL OF A BAR GRAPH UNIT 1. Turn off the power. 2. Disconnect the Bar Graph Unit cable from the Computer Box. 3. Remove the Unit from its bracket by loosening and removing the knob at each end of the Bar Graph Unit.
  • Page 53 SECTION IV 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 Display Console warning the operator of an impending Two-Block problem.
  • Page 54 SECTION IV EXTENSION REEL MODELS EXTENSION REEL MODELS (ALL EXCEPT SERIAL NUMBER PREFIX D6) The Extension Reel includes the Anti-Two-Block Function that warns of a developing Two- Block condition and houses the Boom Angle Sensor, which provides the angle of the load relative to the horizontal position of the boom.
  • Page 55 SECTION IV TB5 TB6 Computer Unit & AIN1 OVERLOAD Termination Board Connections RESISTOR DOUT4 470 OHM AIN2 BOARD ATBIN BLACK BLUE VIOLET VIOLET WHITE BLUE ORANGE MS3474W14-15SX MS3475W14-15PX MS3474W14-15S ORANGE MS3475W14-15P CONNECTOR #3 BOOM MODE SIGNAL WHITE BLACK BROWN POT'R #1 POT'R #1 BOOM EXTN TO ETCS BLACK BOOM EXTN...
  • Page 56 SECTION IV 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 4.15). Measure the Analog Sensor Drive Voltage.
  • Page 57 SECTION IV ® MicroGuard 414 System — Troubleshooting Manual PN W414800 Rev B 11/06/03...
  • Page 58 SECTION IV 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 4.15). Measure the Analog Drive Voltage. Refer to page 43, Figure 4.4.
  • Page 59 SECTION IV 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 4.15 TERMINATION BOARD AIN2 - LENGTH - WHITE WIRE BLUE - GREEN ANGLE SIGNAL...
  • Page 60 SECTION IV ANTI TWO-BLOCK FUNCTION The Anti-Two Block function is a safety function that signals an impending collision between the two blocks positioned above the hook of the crane. When the distance between these blocks is within an acceptable range there is a zero voltage reading. As distance changes to a dangerous zone, a voltage registers and releases a warning and/or a danger alert.
  • Page 61 SECTION IV ANGLE SENSOR INSTALLATION (EXCEPT SERIAL NUMBER PREFIX D6) Install the new Angle Sensor and secure it loosely with the two mounting nuts and washers. See Figure 4.13. 2. Secure the Angle Sensor cable to the triangle plate with the three cable clamps. 3.
  • Page 62 SECTION IV 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. 9.
  • Page 63 SECTION IV 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 4.19 PRESSURE SENSOR CONNECTION TO THE COMPUTER MicroGuard TEST 100% MA X CRANE STOWED WORKING...
  • Page 64 SECTION IV The maximum continuous working pressure for these devices is 250 Bar (3625 psi). There are no user-serviceable parts within the Pressure Sensor. A defective unit should be replaced. Refer to Pressure Sensor Removal and Replacement, page 67. PRESSURE CHANNEL FAULT GUIDE FUNCTIONAL TESTS PRESSURE CHANNEL FAULT GUIDE FUNCTIONAL TEST A fault in a pressure sensor can cause an apparent fault in the other channel.
  • Page 65 SECTION IV Access the Zero of TX.0 described in step 8. The upper display should read 200 ± bits. 13. Access the Zero of TX.1, described in step 9. The upper display should read 5 25 bits. ± 14. Boom down. As the boom is moving down, the displayed bits of TX.1 should increase. 15.
  • Page 66 SECTION IV 4. With the DMM set to the Ohms range, attempt to measure the resistance in turn between pins B, C, D, E, and the case of the sensor. The DMM should indicate that an open-circuit exists in each case. ROD PRESSURE SENSOR 1.
  • Page 67 SECTION IV 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 4.23). 2. Remove the connector from the faulty sensor in the computer box. 3.
  • Page 68 SECTION IV The ATB board, shown on the Termination Board (Figure 4.24), 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. The logic levels are as follows: NO ALARM ATB ALARM...
  • Page 69 SECTION IV FIGURE 4.26 ANTI-TWO BLOCK FUNCTION ® MicroGuard 414 System — Troubleshooting Manual PN W414800 Rev B 11/06/03...
  • Page 70 SECTION IV 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.
  • Page 71 SECTION IV COMPUTER UNIT TERMINATION BOARD CONNECTOR #8 MS3475W14-5PW METRI-PAK CONNECTOR WHITE WHITE WHITE FKO FEED (BATT +) GREEN GREEN RL1/C RL1 CONTACT OVERLOAD BLACK BLUE BLUE ORANGE FKO OUTPUT RL1/NO POWER - BATT + RL2/C RL2 CONTACT A-2-B CABLE #8 BLACK BLACK BLACK...
  • Page 72 SECTION IV COMPUTER UNIT TERMINATION BOARD CONNECTOR #8 MS3475W14-5PW METRI-PAK CONNECTOR WHITE WHITE GREEN GREEN FKO FEED (BATT +) RL1/C WHITE RL1 CONTACT BLACK OVERLOAD BLUE ORANGE FKO OUTPUT BLUE RL1/NO POWER - BATT + RL2/C RL2 CONTACT A-2-B CABLE #8 BLACK BLACK BLACK...
  • Page 73 SECTION IV 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.
  • Page 74 SECTION IV 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 4.31 SWING POT CONNECTIONS Voltage measured between 2 and 4 = 5.25 Volts.
  • Page 75 SECTION IV SWING SWITCHES SERIAL NUMBER PREFIXES 64 AND 53 ONLY Cranes with Serial Number Prefixes 64 and 53 do not have fitted Swing Potentiometers. The working area is determined by Swing Switches which are part of the collector column. These switches send signals to one or more of the Digital Inputs in the Computer Unit.

  • Page 76: Fault Codes

    SECTION V FAULT CODES FAULT DIAGNOSTIC PROCEDURES..................77 FINDING AND UNDERSTANDING YOUR FAULT CODES ...........78 ® MicroGuard 414 System — Troubleshooting Manual PN W414800 Rev B 11/06/03...
  • Page 77 SECTION V 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 your TX.0 PISTON PRESSURE SENSOR ® MicroGuard System. Please review this section carefully. FAULT DIAGNOSTIC PROCEDURES TX.1 ROD PRESSURE SENSOR...
  • Page 78 SECTION V FINDING AND UNDERSTANDING YOUR 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.
  • Page 79 SECTION V AAA Fault Codes AAA Fault Codes continued FAULT No. DESCRIPTION FAULT No DESCRIPTION Fault 002 & 016 Faults 004 & 32 Fault 001, 002, & 016 Faults 001, 004, & Fault 004 & 016 Faults 002, 004, & Fault 001, 004, &...
  • Page 80 SECTION V AAA Fault Codes continued AAA Fault Codes continued FAULT No DESCRIPTION FAULT No DESCRIPTION Faults 008, & 64 Faults 001, 004, 016, & 32 Faults 001, 008, & 64 Faults 002, 004, 016, & 32 Faults 002, 008, & Faults 001, 002, 004, 016, &...
  • Page 81 SECTION V AAA Fault Codes continued AAA Fault Codes continued FAULT No DESCRIPTION FAULT No DESCRIPTION Faults 002, 004, 008, Faults 001, 002, 008, 032, & 064 016, & 064 Faults 001, 002, 004, Faults 004, 008, 016, 008, 032, & 064 &...
  • Page 82 SECTION V 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 & 4 Faults 02 &...
  • Page 83 ® MicroGuard 414 System — Troubleshooting Manual PN W414800 Rev B 11/06/03...
  • Page 84 1918 East Glenwood Place Santa Ana, CA 92705 Telephone: (714) 259-9702 Fax: (714) 259-7626 ® MicroGuard 414 System — Troubleshooting Manual PN W414800 Rev B 11/06/03...

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