Terex RCI 500 Service Manual
Contents
1. 20 Extension Reel nennen nennen nnne n nnne nnns senis 20 Boom Angle Sensor Replacement eds Lien kd uri 20 21 Chip Replacement Executive ROM Chip Replacement 99 99 21 Personality ROM Chip Replacement 21 Duty ROM Chip 2 21 Processor Board 21 22 Terminal Board and Box eene 22 Chip Removal and Installation nennen 22 Processor Board Layout 23 Termination Board Layout RP tati ee datei 24 Extension Reel Layout ae 25 Crop 26 31 SkyAz l Equipment Solutions www skyazul com 301 371 6126 2 of 30 SYSTEM DESCRIPTION The Terex RCI 500 System is intended to aid the crane operator in the efficient operation of the crane by continuously monitoring the load and by warning of an approach to an overload or two block condition The Terex RCI 500 System monitors functions by means of high accuracy sensors that continuously compare the load suspended below the boom head with data from the crane capacity chart stored in the memory of the computer If an overload is2. y az EQUIPMENT SOLUTIONS TEREX RCI 500 SERVICE MANUAL SkyAz l 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 SkyAz l 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 This document contains proprietary information which is protected by copyright and all rights are reserved No part of this document may be photocopied reproduced or translated to another language without the prior written consent of SkyAz l SkyAz l reserves proprietary rights to all drawings photos and the data contained therein The drawings photos and data are confidential and cannot be used or reproduced without the written consent of SkyAz l The drawings and or photos are subject to technical modification without prior notice All information in this document is subject to change without notice SkyAz l Inc ag 200 W Main Street Suite 2A Middletown MD 21769 EQUIPMENT SOLUTIONS Fax 301 371 0029 info skyazul com SkyAzul Equipment Solutions www skyazul com 301 371 6126 MICROGUARD TEREX RCI 500 TROUBLESHOOTING MANUAL Cer SkyAzul Equipment Solutions www skyazul com 301 371 6126 1 of 30 TABLE CONTENTS TEREX RCI 500 TROUBLESHOOTING
3. AlddNS YIMOd NIV 9 2701 ANVANOD Y33Y49 0 JO GZ 9219 L L0 nzeAys mmm suonnios jueuudinb3 Inzv s duis 0110104 OLcOZCV eulula Jod JOSU9S 1n0AV 133 NOISN3LX3 GLOSSARY TERMS ABORT ALARM AMPLIFIER AMPLIFIER GAIN ANALOG ANGLE SENSOR ANNULAR ANNULAR GAIN BACKUP BOOM DEFLECTION BOOM MOMENT BORE CALIBRATION CAPACITY CHART CENTER OF GRAVITY CONFIGURATION DATA DEDUCT DEFLECTION TO STOP DATA ENTRY INTO THE SYSTEM BEFORE THE ENTRY PROCESS IS FINALIZED A VISUAL OR AUDIBLE WARNING SIGNAL INCREASES MAGNITUDE EXAMPLE A PRESSURE TRANSDUCER IN THE MILLIVOLT RANGE IS INCREASED OR AMPLIFIED UP TO TEN VOLTS THE FACTOR USED TO EXPRESS THE LEVEL OF AMPLIFICATION A MECHANISM IN WHICH DATA IS REPRESENTED BY CONTINUOUSLY VARIABLE PHYSICAL QUANTITIES A DEVICE THAT MEASURES THE ANGLE OF THE BOOM RELATIVE TO THE HORIZON RELATING FORMING RING E G THE PRESSURE AROUND THE ROD OF A BOOM HOIST CYLINDER THE FACTOR USED TO MODIFY THE PRESSURE SIGNAL FROM THE ROD SIDE OF THE BOOM HOIST CYLINDER BASED ON THE DIFFERENCE IN AREAS OF THE ROD AND THE BORE IN THIS CASE A COPY DATA SAVED IN A SEPARATE COMPUTER CHIP A CHANGE IN RADIUS DUE TO THE BENDING OF THE BOOM CAUSED BY THE WEI
4. 28 of 30 SCALE SENSITIVITY SENSOR SHEAVE SLEW OFFSET SPAN SPAN STOWED ATTACHMENT SUPERSTRUCTURE SWING SWL SWL TRANSDUCER TX O TX 1 UNLADEN WEIGHT SkyAz l Equipment Solutions THE USE OF A FACTOR TO SET THE SCALING OF ANALOG SENSORS SOMETHING GRADUATED WHEN USED IN MEASUREMENT THE CAPACITY OF ASENSOR TO RESPOND TO PHYSICAL STIMULI A DEVICE THAT RESPONDS TO A PHYSICAL STIMULUS AND TRANSMITS A RESULTING IMPULSE A GROOVED WHEEL OR PULLEY THE HORIZONTAL DISTANCE FROM THE BOOM PIVOT TO THE CENTER OF ROTATION AN EXTENT OR SPREAD BETWEEN TWO LIMITS THE CALIBRATION OF AN ANALOG SENSOR BETWEEN ZERO AND MAXIMUM SPAN AN ATTACHMENT USUALLY STORED IN AN INACTIVE POSITION ON THE MAIN BOOM THE STRUCTURAL PART OF A CRANE ABOVE THE CARRIER USUALLY ROTATING THE ROTATION OF A CRANE UPPER AROUND ITS CENTER LINE PERCENTAGE OF SAFE WORKING LOAD THE PROPORTION OF THE CRANE CAPACITY THAT IS BEING UTILIZED AT ANY ONE TIME EXPRESSED AS A PERCENTAGE OF RATED CAPACITY A DEVICE THAT IS ACTUATED BY ENERGY FROM ONE SYSTEM AND CONVERTS THIS TO ANOTHER FORM FOR USE BY A DIFFERENT SYSTEM AS A LOUDSPEAKER THAT IS ACTUATED BY ELECTRICAL SIGNALS AND SUPPLIES ACOUSTIC POWER THE PISTON SIDE PRESSURE TRANSDUCER THE ROD SIDE PRESSURE TRANSDUCER A BOOM THAT HAS NO ADDITIONAL STOWED OR ERECTED ATTACHMENTS AND IS NOT SUPPORTING A LOAD UNIT OF ELECTRICAL POTENTIAL DIFFERENCE AND EL
5. YELLOW YELLDW SIGNAL GREEN SIGNAL RED DRIVE 3502 10 SkyAz l Equipment Solutions www skyazul com 301 371 6126 PRESSURE CHANNEL FAULT GUIDE ANALOG DRIVE VOLTAGE Analog sensor voltages are measured at the analog input group terminals The drive voltage for all analog sensors is measured between any DR and DR in the analog input group and is 5 25 volts DC 0 1 To measure this voltage use a digital voltmeter set to the DC voltage range 1 Connect the black negative lead of the DVM to any DR terminal in the analog input group 2 Connect the red positive lead of the DVM to any DR terminal in the analog input group 3 Measure the drive voltage volts DC 0 1 4 Ifthe voltage is out of range disconnect all of the analog sensors by disconnecting the sensor connectors from the computer to determine if any sensor or its cabling is causing the drive voltage to be incorrect 5 Ifthe drive voltage is correct with all of the sensors disconnected connect each sensor in turn to determine which sensor is causing the drive voltage to be incorrect 6 Ifany sensor is causing the drive voltage to be incorrect carry out the troubleshooting procedure for that sensor If the drive voltage is incorrect with all sensors disconnected it may be necessary to replace the computer Before replacing the computer carry out the Power Supply Tests detailed
6. Ifthe Analog Drive Voltage is not within this range disconnect all of the external sensor cables including pressure transducers cables 1 through 5 6 Recheck the Analog Drive Voltage If the Faults in any cable or sensor can cause voltage is still out of range the Processor Board will need to be replaced If the voltage is within range reconnect each cable one at a time checking the Analog Drive Voltage after each cable is connected the analog drive voltage to be faulty 7 Ifthe Analog Drive Voltage goes out of range after reconnecting any one of the sensors it is probable that the wiring to the sensor is grounded or the sensor itself is faulty Check all wires and the sensor itself and repair or replace as required SkyAz l Equipment Solutions www skyazul com 301 371 6126 9 of 30 PRESSURE CHANNEL FAULT GUIDE FUNCTIONAL TESTS PRESSURE TRANSDUCERS A fault in a pressure transducer is such that a fault on one channel can cause an apparent fault in the other channel It is necessary to test both channels and both transducers together in order to determine which transducer is at fault 1 ccess the calibration routine by simultaneously pressing and holding KEY 1 and the TEST button RED button on right side of display The display will request entry of the calibration Security Code 2 Enter the Security Code using the Calibration Arrow Keys 1 4 as shown above These keys MUST
7. Remove the four screws from the extension reel located on the left side of the main boom 6 Connect a jumper wire between the black wire and the brown wire on the terminal strip The Anti Two Block warning should no longer be displayed e Ifitremains the brown wire is open between the Termination Board and the Extension Reel If the warning is no longer displayed the problem is somewhere between the extension reel and the boom head switch Check all wires and connections between these components and repair or replace as required EXTENSDN REEL TERM NAL STRIP BROWN A2B SGNAL SkyAz l Equipment Solutions www skyazul com 301 371 6126 TWO BLOCK LOGIC LEVELS The signal from the Anti Two Block ATB switches at the boom and fly tips is a switched ground The ground signal is powered in the computer at the 0 volt terminal of the digital input group When there is no ATB alarm the switches at the boom head are closed allowing the ground to be returned to the computer at the terminal When there is a two block condition the appropriate ATB switch will go to the open position thereby removing the ground from ATBIN and causing ATB Alarm and Function Disconnect The ATB alarm and Function Disconnects are controlled separately by the ATB board in the computer The ATB board located in the computer box e Operates the function disconnects by controlling the coil of RL2 ATB rel
8. 30 DE D 5 VOLTAGE ANO ol Votage vares w ih rotaton of u upper DR S A2maxium OV S 0 36 m mm um 4 DR o When the upper is 5 rotatng S 9 S S E E teo T Voltage m easured betw een 2 and 4 5 25 vols Volage m easured betw een 1 and 3 4 125 vots 301 371 6126 NO DUTY FOUND The System requires the same information that the operator needs in order to read a load chart If for any reason this information is not available the fault No Duty Found will appear This fault could occur if either the Boom Angle Sensor or the Extension Sensor inputs are faulty The System uses these inputs to determine the duty selection The System also uses information from the swing potentiometer to permit duty selection Upon correction of the Sensor fault the System will again be able to find a duty OTHER SYSTEM FAULTS EXECUTIVE ROM The Executive ROM fault code indicates failure 2 on the main Processor Board This chip can be replaced without the need for re calibration The chip is labeled M454400X PERSONALITY ROM The Personality ROM fault code will be prese
9. 9 of this manual With a digital voltmeter set to read DC voltage place the negative lead on 0 Volt terminal of the Analog Input Group Place the positive lead of the meter on the AIN2 terminal of the Analog Input Group The voltage should be greater than 0 25 volts Extend the boom as far as is safe to do so The boom need not be horizontal for this test The voltage should be less than 5 volts Usually around 2 5 volts depending on the boom length During extension the voltage should increase linearly during retraction the voltage should decrease linearly If the voltage is out of the range listed above remove the four screws that secure the cover on the extension reel which is located on the left side of the main boom section remove the cover Under the cover on the right side of the extension reel is a terminal strip This terminal strip has six wires connected to the bottom screws With a digital voltmeter set to read DC Voltage place the negative lead on the terminal with the attached white wire Drive and the positive lead on the terminal with the attached red wire Drive The voltage should be 5 25 0 1 volts If this voltage is out of range and if the Analog Drive Voltage measured in the computer was OK it is possible that the cable is open or grounded between the computer and the www skyazul com 13 of 30 extension reel Check all connections and plugs that may be between th
10. AAA B DD 001 0 00 00 010 0 00 00 Piston pressure transducer Boom angle sensor Fault 2 Rod pressure transducer AAA B DD Fault 11 002 0 00 00 AAA B DD Rod pressure transducer 011 0 00 00 Fault 3 Boom angle sensor AAA B CC DD Piston pressure transducer 003 0 00 00 Rod pressure transducer Piston pressure transducer Fault 32 Rod pressure transducer AAA B DD Fault 4 032 0 00 00 AAA B CC DD Swing potentiometer A 004 0 00 00 Fault 64 Extension Sensor AAA B CC DD Fault 5 064 0 00 00 AAA B cc DD Swing potentiometer B 005 0 00 00 Fault 96 Piston pressure transducer AAA B CC DD Extension sensor 096 0 00 00 Fault 6 Swing potentiometer A AAA B Swing potentiometer 006 0 en 90 This sequence continues up to the maximum fault code of 127 which is the sum of all GROUP A fault Extension sensor Rod pressure transducer codes Fault 7 Fault 127 AAA B cc DD AAA B cc DD 007 0 00 00 127 0 00 00 Piston pressure transducer All analog sensors bis re s This fault condition is seldom caused by the Extension sensor Fault 8 simultaneous failure of all sensors It is usually the AAA B CC DD result of the failure of the analog drive voltage which 008 0 00 00 supplies the voltage for all sensors This power supply Boom angle sensor fault may be due to the failure of the power supply or may be due to damage to the cable that connects the sensor to the computer When this fault occurs carry o
11. MANUAL System APP ee 3 Fault Diagnostic Procedures 4 Fault CodeS PEE 5 6 Voltage Checks Power Supply 141 lt 222 nennt nnne nhan n 7 The Processor Board and the Termination 8 9 Checking the Analog Drive Voltage coomomomeroimmssiacr nn 9 Pressure Channel Fault Guide Functional Tests Pressure Transducers eene nnne 10 11 Analog Drive Vollage sea a u aaa 12 Boom Extension Sensor AIN2 13 14 Boom Angle Sensor AIN3 a ea 15 Swing Potentiometer AIN5 and AING 22 42 16 No Duty Found sans ii 17 Other Systemi e e 17 Executive 17 Personality ROM 17 Scratchpad RAM nie an 17 Duty ROM essen ana 17 Current Duty Bad 17 Configuration Not Calibrated 17 Digital ana Analog IO ansehen hend 17 Display TTE 17 Anti TWO BIOGK lee 18 19 Pressure Transducer
12. SR Taie t vd ZA 6 ON VAG 1 2 0 a Ie ON 1000 TE ON 91000 ES 2 5 1100 e ie 2 y 1000 Er N 1100 9 IOO s ON 1100 i O 0100 2 HOLIMS 9NIMS CASA avo C 118 2 y 19 S G av 0 SIS NO A0 SIG 0 0 oS XI 919 vINIG NO S ONIV 0 S GNIV au S dM SiS ydi S dM SIG N S dA 0X S 6N ele UNIV Ox NI NIV SIG ONIG S SIG 0 2 9 NIC G INIV CNIC ONIV o NIC NOILVNIW M3 L tE ANSS Ae 5 y 890 0SNValI CL TIVO 1S3 20 61 X JAGI 4 91 20 6 8318 3ANOO 209190 204 Gt 9 9VLIOA ANVYO HOLVA NIH
13. approached the system warns the operator by means of audible and visual alarms The system can also be configured to cause function kick out The MicroGuard RCI 500 indicator provides the operator with a continuous display of e Rated Capacity e Actual Load e Percentage of Rated Capacity e Radius of the Load e Angle of the Main Boom e Working Area e Crane Configuration e Length of the Main Boom On screen messages provide the operator with visual indications of the various alarms that may occur during normal operation of the RCI 500 System These values appear on the left display The right display gives information about the currently selected crane configuration SkyAz l Equipment Solutions www skyazul com 301 371 6126 FAULT DIAGNOSTIC PROCEDURES Faults in the RCI 500 System are detected at start up with an automatic self test that lasts about 2 3 seconds This self test is activated each time the system is switched on During normal operation a self test can be initiated at any time by pressing and holding the red TEST button on the right of the display Fault conditions in external sensors are detected without the need for a system self test Faults detected in the system during a self test are identified on the display as follows e The word FAULT will appear in the information area The RED LAMP will illuminate e The AUDIBLE ALARM will sound Faults occurring in the system can b
14. be pressed in the following sequence Key 1 Key 3 Key 2 Key 4 Note Ifthe wrong sequence is used or if the entry is not completed within 5 seconds the calibration entry will be aborted and must be re entered After accessing the calibration routine the system alarm will sound indicating that the system is in the calibration routine 3 Use the Up 2 or Down 3 arrow keys to scroll to command 03 Zero Sensor Press key 1 10 11 Use the Up 2 or Down 3 arrow keys to select TX 0 pressure transducer 0 piston side Press key 1 With the boom in the rest or the boom hoist cylinder fully retracted relieve all pressure from both transducers With no pressure the upper display should indicate 0 20 bits Next use the Up 2 or Down 3 arrow keys to select TX1 pressure transducer rod side With no pressure in the cylinder the upper display should read 0 20 bits Ifthe transducers were disconnected in step 5 tighten the fittings With the boom fully retracted boom up to a 60 angle Access the Zero of TX 0 as described in step 4 the upper display should read 200 100 bits Access the Zero of TX 1 as described in step 6 the upper display should read 5 25 bits Boom down As the boom is moving down the displayed bits of TX 1 should increase Place the retracted boom at a 60 angle Access the Zero of TX 0 as described step 4 and extend the boom As the boom is extended the displ
15. number will correspond to one or more fault diagnostic numbers The meaning of these numbers can be determined by looking at the appropriate code in the fault interpretation table Fault codes in Group A relate to analog sensors Each sensor is allocated a number This number is also the number of the channel to which it is connected in the system e SensorO Piston Pressure e Sensor1 Rod Pressure e Sensor2 Extension Sensor e Sensor3 Boom Angle e Sensor4 Not Used e Sensor5 Swing Potentiometer e Sensor6 Swing Potentiometer B COLES SL Each sensor is allocated a FAULT CODE This code number appears under the group heading the fault code display 001 Sensor 0 002 Sensor 1 004 Sensor 2 Piston Pressure Rod Pressure Extension Sensor 008 Sensor 3 Boom Angle 032 Sensor 5 Swing Pot r A 064 Sensor 6 Swing Pot r B When no faults are detected in the system 000 will appear under all group headings When there are faults in only one sensor one of the above codes will be listed When there are faults in more than one sensor the codes indicated will be the sum of the fault codes SkyAz l Equipment Solutions www skyazul com 301 371 6126 EXAMPLES FAULT CODES Fault 9 Fault 0 DD AAA B DD 009 0 00 00 000 0 00 00 Piston pressure transducer No faults detected Boom angle sensor Fault 1 Fault 10 AAA B DD
16. AD ONLY MEMORY ROM CAPABLE OF RECOVERING SIZE OR SHAPE AFTER EXPANSION AN ATTACHMENT ON THE MAIN BOOM IN WORKING NOT STOWED POSITION A DEVICE THAT MEASURES THE EXTENSION OF THE TELESCOPING SECTIONS OF A BOOM AN ATTACHMENT CONNECTED BY ONE EDGE TO A CRANE BOOM E G A LATTICE FLY OR JIB ENERGY REQUIRED IN THIS CASE TO SUPPORT THE WEIGHT OF AN OBJECT MATHEMATICS ADDRESSED TO THE MEASUREMENT AND RELATIONSHIP OF POINTS LINES ANGLES SURFACES AND SOLIDS MARKED WITH DEGREES OF MEASUREMENT THE VERTICAL DISTANCE FROM THE GROUND TO THE TIP OF THE BOOM OR ATTACHMENT AN ABBREVIATION OF HEIGHT THE HEIGHT OF THE BOOM PIVOT ABOVE GROUND LEVEL PARALLEL TO THE HORIZON USING THE PRESSURE OF OIL FOR OPERATION THE ACTION OF INCREASING A NUMBER OR VALUE PREPARES PERSONALITY A COMPUTER MEMORY CHIP FOR NEW CALIBRATIONS ERASES ALL EXISTING DATA DURING THIS PROCESS www skyazul com 301 371 6126 27 of 30 INTEGRATED CIRCUITS MEASURE HEIGHT MEASURE HEIGHT MICROPROCESSOR MILLIVOLT MOMENT OUT OF DUTY OUTRIGGER PERSONALITY PRESSURE RADIUS RATED CAPACITY RATED CAPACITY RATING RESTORE ROM ROPE LIMIT SAVE SkyAz l Equipment Solutions COMPLEX OF ELECTRONIC COMPONENTS AND CONNECTIONS COLLECTED ON A SMALL SLICE OF MATERIAL SUCH AS SILICON TO DETERMINE THE VERTICAL DISTANCE FROM BELOW THE BOOM PIVOT TO THE GROUND RADIUS MEASUREMENTS ARE MADE FROM THESE POI
17. ECTROMOTIVE FORCE THE AMOUNT THAT A BODY WEIGHS OR THE POUNDAGE TO BE CARRIED BY A HORSE IN A HANDICAP RACE www skyazul com 301 371 6126 29 of 30 WRITE PROTECTED AN AREA OF MEMORY IN A COMPUTER THAT CANNOT BE ACCESSED BY AMICROPROCESSOR FOR DATA ENTRY OR CHANGE ZERO THE ZERO POINT ON A GRADUATED SCALE SkyAz l Equipment Solutions www skyazul com 301 371 6126 30 of 30 SkyAz l Inc 200 W Main Street Suite 2A En Middletown MD 21769 Phone 301 371 6126 EQUIPMENT SOLUTIONS Fax 301 371 0029 www skyazul com info skyazul com
18. EPLACEMENT The Duty ROM Chip must be specific to the load chart used in the crane This chip contains a copy of the load chart and must match the load chart in the crane 1 Access the Processor Board Refer to page 8 of this manual 2 With the power off remove IC3 the Duty ROM Chip from its socket Refer to General Chip Removal and Installation in this manual 3 Install the new Duty ROM Chip in the socket Ensure that the notch in the chip is lined up with the notch in the socket and all pins are properly inserted NOTE Replacement of the Executive or Duty ROM Chip does NOT necessitate the re calibration of the system NOTE Replacement of the Personality ROM Chip does NOT necessitate re calibration of the system if the new Personality ROM Chip is an exact duplicate of the original If a copy of the Personality Chip is not available the System will need to be completely re calibrated PROCESSOR BOARD REPLACEMENT 1 With the power off access the Processor Board Refer to pages 8 and 23 of this manual 2 Locate the two ribbon cables connecting the Processor Board to the Termination Board 3 The ribbon cables are held in place by two locking tabs on each cable end These locking tabs must be pushed away from the cable to disconnect the cable As the locking tabs are pushed the connector will come loose from the Processor Board 4 Loosen the two screws holding the computer backing plate to the box
19. GHT OF LOAD THE TURNING MOMENT AROUND THE BOOM PIVOT CAUSED BY THE MOMENT OF THE UNLADEN BOOM THE PISTON SIDE OF A BOOM HOIST CYLINDER THE ADJUSTMENT OF THE GRADUATION OF SENSORS A TABLE SUPPLIED BY THE CRANE MANUFACTURER SHOWING THE SPECIFICATIONS AND RATINGS FOR EACH INDIVIDUAL CRANE THE POINT AT WHICH THE ENTIRE WEIGHT OF A BODY MAY BE CONSIDERED AS CONCENTRATED SO THAT IF SUPPORTED AT THIS POINT THE BODY WOULD REMAIN IN EQUILIBRIUM IN ANY POSITION THE POSITION OF THE CRANE SUPPORTING APPENDAGES AND ALL LIFTING ELEMENTS FACTUAL INFORMATION USED AS A BASIS FOR CALCULATION A REDUCTION IN RATED CAPACITY FOR AN UNUSED STOWED OR ERECTED ATTACHMENT THE BENDING OF A BOOM OR THE STRETCHING OF PENDANT LINES WITHIN THE ELASTIC LIMITS OF THE BOOM OR PENDANTS SkyAz l Equipment Solutions www skyazul com 301 371 6126 26 of 30 DIGITAL DIGITAL INPUTS DIRECTION DUTY EEPROM ELASTIC ERECTED ATTACHMENT EXTENSION SENSOR FLY JIB FORCE GEOMETRY GRADUATED HEIGHT HITE HORIZONTAL HYDRAULIC CRANES INCREMENT INITIALIZES SkyAz l Equipment Solutions OPERATING WITH NUMBERS SHOWN AS DIGITS COMPUTER INPUTS USUALLY CONTROLLED BY EXTERNAL ON OFF SWITCHES THE COURSE ON WHICH THE UPPER SECTION SUPERSTRUCTURE OF A CRANE ROTATES THE WORKING CONFIGURATION OF A CRANE THAT CAN USUALLY BE FOUND IN A SINGLE COLUMN OF A CAPACITY CHART ELECTRICALLY ERASABLE AND PROGRAMMABLE RE
20. MINATION BOARD B GND VP 5V RES 15V 15V SkyAz l Equipment Solutions www skyazul com 301 371 6126 8 of 30 3 To check voltages on the Termination Board remove the two screws located at the 8 left and right of the main computer backing DRVE ANO plate and swing the assembly up Take care an d 1 not to damage the ribbon cables These DE ribbon cables must remain connected to the ov Processor Board for voltage checks DR AN2 CHECKING ANALOG DRIVE VOLTAGE 2 DR AN3 To check the Analog Sensor Drive Voltage use 9 Ulrxo amaS S vp S LIvxo 1918 vp the following procedure Ov ov S9 VP 1 Access the Termination Board DR DR S VP e 2 With the system power on and a digital volt di iR els TX1 eres to read DC voltage piace ine BI DR negative lead DR Drive terminal du SEES T 1 of the Analog Input Group The anabg drive voltage can m easured betw een any DR tem mal and DR tem nal Es 5 25 volts 4 The voltage should be 5 25 0 1volts DC 0 1 vols 3 Place the positive lead of the meter on any DR Drive terminal 2 5
21. NTS WHEN CALIBRATING TO DETERMINE THE VERTICAL DISTANCE FROM BELOW THE BOOM PIVOT TO THE GROUND RADIUS MEASUREMENTS ARE MADE FROM THESE POINTS WHEN CALIBRATING A COMPUTER PROCESSOR CONTAINED ON AN INTEGRATED CHIP ONE THOUSANDTH OF A VOLT THE PRODUCT OF FORCE AND DISTANCE IN RELATION TO A PARTICULAR AXIS OR POINT A POINT THAT IS EITHER LONGER THAN THE LONGEST PERMITTED RADIUS OR LOWER THAN THE LOWEST PERMITTED ANGLE ON A CAPACITY CHART A MECHANICAL DEVICE THAT PROJECTS FROM THE MAIN STRUCTURE OF THE CRANE TO PROVIDE ADDITIONAL STABILITY OR SUPPORT COMPUTER CHIP STORING ACTIVE CALIBRATION DATA HYDRAULIC PRESSURE IN THE BOOM HOIST CYLINDER THE HORIZONTAL DISTANCE FROM THE CENTERLINE OF ROTATION TO THE CENTER OF THE HOOK THE LIFTING CAPACITY OF A CRANE AS PROVIDED BY THE MANUFACTURER INA CAPACITY CHART THE LOAD THAT A CRANE CAN SAFELY HANDLE BASED ON FACTORS SUCH AS STRENGTH STABILITY AND RATING A FACTOR DETERMINED BY LEGISLATION THAT LIMITS THE ACTION OF A CRANE IN A LIFTING OPERATION USUALLY EXPRESSED AS A PERCENTAGE OF STRENGTH OR STABILITY TO MOVE CALIBRATION DATA FROM A BACK UP CHIP TO THE PERSONALITY A ACTIVE CHIP READ ONLY MEMORY DATA CAN BE READ BUT NOT CHANGED AFTER PROGRAMMING THE MAXIMUM PERMITTED SINGLE LINE PULL DETERMINED BY THE CONSTRUCTION AND DIAMETER OF A WIRE ROPE TO MOVE DATA FROM THE WORKING PERSONALITY TO A WRITE PROTECTED AREA OF MEMORY www skyazul com 301 371 6126
22. SkyAz l Equipment Solutions www skyazul com 301 371 6126 5 Remove the Processor Board Assembly There are three computer chips on the Processor Board that must be the correct type These three chips are IC2 Executive ROM IC3 Duty ROM IC7 Personality ROM The Executive ROM must be specific to the System The Duty ROM contains a copy of the load chart and must correspond to the Load Chart Number of the particular serial number of the crane The Personality ROM contains data that is unique to the particular serial number of the crane 6 Install the e Executive ROM Chip e Duty ROM Chip e Personality ROM Chip 7T Place the Computer Assembly into the computer box and tighten the two mounting screws be careful to allow access to the ribbon cables 8 Reconnect the two ribbon cables Fully engage the connector and locking tabs 9 Replace the Computer Box cover and secure with the four screws COMPUTER BOX REPLACEMENT TERMINAL BOARD AND BOX ONLY USE THE PROCESSOR BOARD FROM THE ORIGINAL BOX 1 Remove the Processor Board 2 Label each cable Refer to page 24 Then label each wire with its terminal location Remove cable from gland entry Repeat with each cable 3 Remove the four screws securing the Computer Box SkyAz l Equipment Solutions www skyazul com 4 Remove the Computer Box 5 Install the new computer and secure with the four mounting screws 6 Reconnect all cables in rev
23. angle with an inclinometer While viewing the display adjust the sensor until the display reads 60 Tighten the mounting bolts 5 Place the boom a horizontal position With an inclinometer verify that the boom angle is at zero degrees 6 Verify that the displayed boom angle reads zero 0 0 5 EXECUTIVE ROM CHIP REPLACEMENT The Executive ROM Chip contains the main program data that the computer uses to function and must be specific to the System 1 Access the Processor Board Refer to pages 8 and 23 of this manual 2 With the power off remove IC2 the Executive ROM Chip from its socket Refer to General Chip Removal and Installation in this manual 3 Install the new Executive ROM Chip into the socket Make certain the notch in the chip is lined up with the notch in the socket and all pins are properly inserted PERSONALITY ROM CHIP REPLACEMENT The Personality ROM Chip must be the proper chip for the particular crane serial number This chip contains calibration data that is unique to each crane 1 Access the Processor Board Refer to pages 8 and 23 of this manual 2 With the power off remove IC7 the Personality ROM Chip from its socket Refer to General Chip Removal and Installation in this manual 3 Install the new Personality ROM Chip into the socket Make certain the notch in the chip is lined up with the notch in the socket and all pins are properly inserted DUTY ROM CHIP R
24. ay at D OUT 1 e Operates the audible alarm and on screen message by controlling the logic level at DIN13 The logic levels are as follows NO ALARM ATB ALARM ATB SWITCH CLOSED OPEN ATB IN LOW HIGH 0 2 VOLT 5 VOLT D OUT 1 LOW HIGH 0 2 VOLT 5 VOLT D IN 13 HIGH LOW 12 VOLT 0 2 VOLT The voltage levels are approximations and small variations are to be expected DIN13 CONTROLS THE AUDIBLE ALARM AND ON SCREEN MESSAGE NO A2B HIGH 12VOLT ALARM LOW 0 2VOLT ATBIN NO A2B LOW O 2VOLT ALARM HIGH 5VOLT SkyAz l Equipment Solutions www skyazul com 19 of 30 DIN13 DIDO IO IO OOO OOO 0 4 DOUT1 CONTROLS THE A2B RELAY RL2 NO A2B LOW 0 2VOLT ALARM HIGH 5 VOLT RL1 LOAD DOUT1 RL2 A2B QO O ajo o BOARD 0v 301 371 6126 PRESSURE TRANSDUCER REPLACEMENT 1 It is recommended that the replacement transducer is closely matched to the sensitivity of the old transducer The sensitivity value is recorded on the serial number plate Remove the connector connecting the transducer to be replaced from the computer box With the boom cylinder completely retracted in the rest or with the boom safely supported remove
25. ayed bits of TX 0 should increase When the boom is fully extended the display should read 400 100 bits for a three section boom and 600 100 bits for a four section boom The values listed are nominal values The actual values will differ according to how the crane is equipped A three section boom will show a smaller value on TX 0 under the same conditions as a four section boom Additional equipment on the main boom such as stowed fly auxiliary head sheaves and hook blocks will give a higher value than the main boom alone If any value is out of range contact your distributor or factory service department before replacing a pressure transducer SkyAz l Equipment Solutions www skyazul com 301 371 6126 Refer to page 20 of this manual for pressure transducer replacement 12 Exit the calibration routine by pressing the EXIT 4 key If the foregoing functional tests indicate faults in the pressure channels proceed with Power Supply Tests and the test for resistance of the bridge of the pressure transducers PRESSURE TRANSDUCER RESISTANCE MEASUREMENT The pressure transducer is a balanced bridge composed of strain gauges bonded to a flexible diaphragm The following resistance tests can be carried out to establish the viability of the pressure transducer Piston Pressure Transducer NOTE Place the boom in rest truck drive or in its lowest position RT s and relieve all pressure to atmosphere on both tra
26. e connector is approximately 12 ft At this point there will be no pre tension Pull the cable out passing it through the cable guides until the end of the cable is 3 ft beyond the boom head Wrap the cable around the boom head anchor a minimum of five times and secure with a wire tie or shipping cable clamp Connect the cable to the connector coming from the Anti Two Block switch Manually turn the large gear connected to the potentiometer fully counterclockwise Observe the length display and turn the large gear at least 3 clicks clockwise until the length display reads the retracted boom length Replace the Extension Reel Cover securing it with the four screws Extend and retract the main boom and ensure that the boom length reading on the display is correct BOOM ANGLE SENSOR REPLACEMENT To replace the Boom Angle Sensor that is fitted inside the extension reel use the following procedure 1 With the power off remove the 4 bolts holding the cover of the extension reel and remove the cover Disconnect the 3 wires connecting the angle sensor to the terminal strip Remove the two SkyAz l Equipment Solutions www skyazul com 301 371 6126 bolts securing the sensor to the extension reel and remove the old angle sensor 3 Install the new sensor in the extension reel in the original location secure it with the mounting bolts and connect the cable 4 Raise the boom to 60 angle and verify the
27. e diagnosed using the display 1 PRESS and HOLD the TEST button to initiate the self test and to identify any faults 2 Continue to PRESS the TEST button NOTE Following the self test faults found will be identified on the display screen and will remain visible as long as the operator continues to press the TEST button 3 Fault information will appear on the screen in the following four groups e GroupA Sensor Faults e GroupB Faults e GroupC Memory Faults e GroupD General Faults FAULT CODES GROUP A ANALOG SENSORS CODE AAA 000 NO FAULTS 001 AINO PISTON PRESSURE TRANSDUCER 002 AIN1 ROD PRESSURE TRANSDUCER 004 AIN2 EXTENSION SENSOR 008 AIN3 BOOM ANGLE SENSOR 016 AIN4 NOT USED 032 5 SWING POTENTIOMETER A 064 6 SWING POTENTIOMETER GROUP INPUTS AND OUTPUTS CODE BB 00 NO FAULTS 01 1 DIGITAL INPUT AND OUTPUT 02 2 ANALOG INPUT AND OUTPUT 04 4 DISPLAY UNIT GROUP C MEMORY CODE CC 00 NO FAULTS 01 1 EXECUTIVE ROM 02 2 DUTY ROM 04 4 SCRATCHPAD RAM 08 8 PERSONALITY ROM GROUP D GENERAL CODE DD 00 NO FAULTS 01 1 NO DUTY FOUND 02 2 CURRENT DUTY BAD 04 4 CONFIGURATION UNCALIBRATED SkyAz l Equipment Solutions www skyazul com 301 371 6126 GROUP A FAULT CODES When a fault is detected by the system a number will appear under one or more of the four group headings A through D shown on the previous page This
28. ed by means of a swing potentiometer mounted in the collector ring If the system does not have input from the swing potentiometer it will not be able to find a duty To check the Swing Potentiometer follow the procedure below 1 SkyAz l Equipment Solutions Access the Termination Board Check the Analog Drive Voltage Refer to page 9 of this manual With a digital voltmeter set for DC volts check the voltage at the connections to the potentiometer located on the Anti Two Block board Connection 1 has a red wire attached to it and connection 3 has a black wire attached to it Connect the black lead of the DVM to connection 3 black wire and the red lead of the DVM to connection 1 red wire The voltage should be 4 125 0 1 volts If this voltage is out of range the Termination Board may need to be replaced With the black lead on any 0 Volt terminal check the voltage at the AIN 5 terminal and AIN 6 terminal The voltage should be 4 50 0 1 maximum and 0 365 0 1 minimum Both of these voltages should rise and fall linearly within this range as the upper is rotated left or right If the Drive Voltage and the Voltage at the connection to the potentiometer were correct and the voltages on AIN 5 and AIN 6 are out of range the swing potentiometer will need to replaced Contact your distributor or your Factory Service Department for procedures on replacing the swing potentiometer www skyazul com 16 of
29. eel Check all connections and plugs between these two components Repair or replace as required Refer to the MicroGuard RCI 500 wiring details in the Installation Manual for the model of crane being tested 12 13 www skyazul com If the negative lead of the voltmeter is connected to the white drive negative and the positive lead of the voltmeter is connected to green angle signal the voltage should be the same as the voltage measured at AIN3 of the analog input group in the computer If this voltage is not the same it is possible that the cable between the extension reel and the computer is faulty or the boom angle sensor is faulty If the above voltage checks are within range and no grounds or opens are found in the wires replace the Boom Angle Sensor as described on pages 20 21 of this manual DRIVE VOLTAGE AIN3 Voltage varies with boom angle 0 40 at 0 deg 3 02 at 60 deg QO QO o 210 010 0 0 0 02 0 9 0 o ojo jojo ojo ojo o GREEN ANGLE SENALTO AN 3 301 371 6126 SWING POTENTIOMETER AIN 5 AND AING The position of the upper structure in relation to the carrier must be determined This is accomplish
30. erse of removal CHIP REMOVAL AND INSTALLATION When removing and installing chips switch off the power Do not touch the chip pins if you are not properly grounded Static electricity can damage chips 1 Ensure that the power is off 2 Remove the chip to be replaced with a chip removal tool NOTE Chip removal and installation tools are available from any electronics store 3 Insert the new chip into the installation tool per the instructions on the package 4 Insert the new chip into the socket ensuring that the notch in the chip 1 lines up with the notch in the socket 2 5 Double check that all pins are properly inserted into the chip socket These pins are very easily bent Failure to have all pins inserted can cause damage to the System and the chip 301 371 6126 22 of 30 122 LAYOUT OF COM PUTER BOARD Ic 2 EXECUTIVE ROM r3 DUTY ROM 127 PERSONALIY CHIP 128 RAM CHIP NOT REMOVABLE PROCESSOR BOARD LAYOUT SkyAz l Equipment Solutions www skyazul com 301 371 6126 23 of 30 9ZL9 LLE LOE 0 40 vc woo InzeAys mmm suonnjos jueuudinb3 InzvAXs LAO 109 NOLLON AVM y 8 1191 Y Ino aiv AO MVC
31. ese two components Repair or replace as required Refer to the MicroGuard RCI 500 wiring details in the Installation Manual for the model of the crane being tested Continued on the next page BLUE SGNAL TO AN 2 301 371 6126 BOOM EXTENSION SENSOR AIN2 cont 12 With the negative lead of the voltmeter connected to the white drive DR and the DRIVE DRy positive lead of the voltmeter connected to VOLTAGE AINO AIN2 VOLTAGE the blue AIN2 extension signal the voltage 9 VARIES WITH should be the same as the voltage D BOOM EXTENSION measured at AIN2 of the analog input group ov 9 computer If this voltage is not the DR same it is possible that the cable between 9 DR AIN2 the reel and the computer is faulty DR AIN3 TXO AIN4 VP NOTE The blue and white wires at the reel Saxo Dore 9 REVERSE at the connector of the reel Sov 11919 y Therefore the white DR at the reel is blue pR 9 9 yp DR in the computer The blue signal S or ams 91910 ov Extension AIN2 at the reel is white AIN2 S rxte amns S S oy in the computer Una Dre oy Soy 19191 oy SkyAz l Equipment Solutions ww
32. nsducers 1 With the power to the computer off disconnect the piston pressure transducer from the terminal blocks DR TX0 and TXO within the computer 2 With the DVM set to the Ohms range measure the resistance between red and blue wires The resistance should be 3500 100 3 With the DVM set to the Ohms range measure the resistance between yellow and green wires The resistance should be 3500 100 4 With the DVM set to the Ohms range measure the resistance between pins Each of the open wires red blue green yellow and the case of the transducer There should be no connection between the case and any of the pins Rod Pressure Transducer NOTE Place the boom in rest truck drive or in its lowest position RT s and relieve all pressure on both transducers to atmosphere BLUE DRIVE 1 With the power to the computer off disconnect the piston pressure transducer from the terminal block DR DR TX0 and TXO within the computer 2 With the DVM set to the Ohms range measure the resistance between the yellow and green wires The resistance should be 3500 100 3 With the DVM set to the Ohms range measure the resistance between pins each of the open wires red blue green yellow and the case of the transducer There should be no connection between the case and any of the pins PRESSURE TRANSDUCER RED BLUE N N N A 4 4 IN GREEN I
33. nt until the system is fully calibrated At the completion of calibration a code is automatically inserted into the memory which enables the system to carry out the self test If the fault code occurs in normal service it could indicate either a failure of IC7 or the loss of data in the device It will be necessary to obtain a copy of the Personality ROM that was made at the completion of the initial calibration or carry out a complete recalibration of the system Contact your Distributor or Factory Service Department for details SCRATCHPAD RAM The Scratchpad Ram fault code indicates the failure of IC6 on the Processor Board This item is not user serviceable and requires the replacement of the Processor Board DUTY ROM This fault is associated with the failure of the Duty Chip on the Processor Board lt can be replaced without the need for recalibration lt contains the load chart data for the crane on which it is fitted and must be identical to the load chart on the crane CURRENT DUTY BAD This fault indicates failure of the Duty Chip on the Processor Board The Duty chip can be replaced without the need to re calibrate This chip contains the load chart data for the crane on which it is fitted and must be identical to the load chart on the crane CONFIGURATION UNCALIBRATED When a crane is initially calibrated its duty chip may contain more configurations than are to be sold with that particular crane Fl
34. on Page 9 of this manual NOTE FOR TECHNICIANS FAMILIAR WITH SkyAz l Equipment Solutions www skyazul com UNLIKE THE MG3A SERIES THE MG4 SERIES DOES NOT HAVE A DUAL CHANNEL PRE AMPLIFIER ANALOG VOLTAGES RELATIVE TO PRESSURE CANNOT BE MEASURED IN THE COMPUTER AINO AND AIN1 HAVE DIFFERENT FUNCTIONS IN THE MG4 SYSTEM AND ARE NOT TO BE USED TO MONITOR PRESSURE VOLTAGES DR DRIVE ANO 8 528 01 DR S oV DR L DR AN2 9 S DR AN3 TX0 AN4 S S VP TX0 DR SIG VP S oV oV S S VP DR DR S S VP 9 DR AN5 S S OV S lTX1 AN6 S TX1 DR S S OV oV oV S S OV The anabg drive voltage can be m easured betw een any DR tem naland any DR tem nal Eis 5 25 vols DC 0 1 vols Faulks T any or sensor can cause the anabg drive volage to be fauly 301 371 6126 12 of 30 BOOM EXTENSION SENSOR 2 To check the Boom Extension Sensor Voltage follow the procedure below 1 2 10 11 SkyAz l Equipment Solutions Fully retract the boom Access the Computer and Termination Boards NOTE Measure the analog sensor drive voltage Refer to page
35. the transducer to be replaced Install the new transducer on the boom hoist cylinder Run the cable to the computer box and connect it to the appropriate computer box connector Pick a known weight to verify the accuracy of the system If the load reading is not within tolerance after the replacement of a pressure transducer first carry out Command 03 zero sensors for the appropriate sensor only Check accuracy again If the system is still out of tolerance carry out Command 6 Pressure and Command 7 Radius Moment This should correct any inaccuracy in the RCI 500 Calibration procedure EXTENSION REEL REPLACEMENT To replace the Extension Reel Assembly use the following procedure 1 2 Fully retract the main boom Disconnect the connector to the Anti Two Block switch and remove the cable from the main boom head anchor Allow the cable to retract onto the reel Take care not to let the cable retract too rapidly Remove the Extension Reel Cable connector 10 1 12 13 Remove the four mounting bolts 5 securing the Extension Reel to the boom Remove the reel Mount the new reel to the boom secure with the mounting bolts and connect the Extension Reel Cable Connector Remove the shipping cable clamp from the new cable and allow it to slowly rewind onto the reel until there is no pre tension Continue to rewind the reel in the same direction until the distance between the boom head and th
36. the wires to the ATBIN terminal 3 Remove the four cover screws from the extension reel located on the left side of the main boom and remove the cover 4 Remove the brown wire from the terminal strip The system should now show an Anti Two Block warning If it does not the brown wire or its connections between the Terminal Board and the extension reel are shorted to ground If the system shows an Anti Two Block warning there is a short circuit to ground in the wiring or connections between the extension reel and the Switch at the boom head 5 Check all wires and connections between the computer and the reel and switches and repair or replace as required SYSTEM SHOWS TWO BLOCK WHEN CRANE IS NOT TWO BLOCKED 1 Check that the selection switch of the Two Block switch located at the main boom head is correctly set 2 Ensure that the Anti Two Block weight is attached to the boom head switch 3 Access the Termination Board Refer to page 8 of this manual 4 Connect a jumper wire from the O volt terminal to the ATBIN terminal leaving the brown and violet wires in place in the ATBIN terminal The Anti Two Block warning should no longer be displayed e If the Anti Two Block warning remains the problem is in the Termination Board assembly e fthe Anti Two Block warning goes away with O volt connected to ATBIN the problem is in the external wiring or switches 5 Remove the jumper wire connected in Step 4
37. to the Termination Board via the glands J in the wall of the box The key switch F controls three wires that connect the Processor Board to the Termination Board THE COMPUTER BOX Continued on next page SPARE RELAY 7 MODE TB3 5 TB6 DR CI On 5 pouTo O E Aino 11 DIN2 7 0 1 0 DOUT1 O 1 OVERLOAD Aina O1 DIN3 1 1 DOUT2 geil DR DI DINA 11 1 1 DOUT3 NO 11 ov On DINS 3 1 DJ DOUTA NC 1 RL2 R EI DIN 10 00 bouts c 3 ATE 15 08 AIN2 ET 1 DIN7 DJ DOUT6 NO 31 MC DR 11 184 pins 11 Gl Dou T7 NC m 15 AINI T D vp ping 0 000 ov FS1 1 0 DRO 1 L VP pinto 0 0 L1 5VA 0711 1O 1 Dlov 1 Oe DIN11 1 LJ 5 1 B 0101 08 DR L1 0 1 L1 VP DIN12 07 0 T CO DA COMPUTER tols 1 ams Ol Clov DIN13 3 1 00 DB AB BOX AND C B DJ TX4 amne 1 Olov DIN44 CT 1 DJ RES BOARD FS2 t DL B L DJTX4 DRO 0 DIN15 1 0 0 LAYOUT OF THE 11 1 010 atem O 0 1 J ATBOUT TER
38. turn to 15V 0 1 15V 0 1 5V 0 1 If the voltages are out of range it may be necessary to replace the computer SkyAz l Equipment Solutions www skyazul com Before replacing the computer call the Product Support Department at the Greer Company Telephone 714 259 9702 Internal Power Terminals olololololololololo Internal Power Terminals LI N O Ground 5 volts dc 15 volts fl i 15 volts 301 371 6126 7 of 30 THE PROCESSOR BOARD AND THE TERMINATION BOARD 1 Remove the four screws B that secure the lid A to the computer box Remove the lid and set it aside Warning The lid is NOT hinged Be careful not to allow the lid to slide off the box 2 Below the lid is the Processor Board E This board contains the microprocessor and its related components This unit is held in place by two screws D located at the left and right ofthe Processor Board mounting plate C The Processor Board is connected to the Termination Board H via 2 ribbon cables K positioned side by side that carry signals to and from the Termination Board All of the cables from the various sensors and the display console connect
39. ut Power Supply Voltage checks before checking individual sensors SkyAz l Equipment Solutions www skyazul com 301 371 6126 6 of 30 VOLTAGE CHECKS POWER SUPPLY VOLTAGES The Computer Unit contains 2 major boards the Processor Board and the Termination Board Both ofthese assemblies are located in an aluminum box that is usually located on the rear wall ofthe cab and can be inside or outside the cab depending on crane model All of the cables from the various sensors and the display are connected to the Termination Board To access the Termination Board refer to Page 8 of this manual INPUT POWER The computer operates from an input voltage in a range from 9 to 36 volts DC This input voltage is measured across the B and B terminals on the Termination Board and corresponds to the battery voltage of the crane At voltages below 9 and above 36 volts the system will power down until correct voltage is restored If the INPUT POWER is not within these limits check the battery and or alternator before servicing the computer INTERNAL POWER SUPPLIES The computer generates its own internal power from the incoming battery voltage This power can be monitored at the test points inside the computer adjacent to the fuses and Battery Input Terminals To monitor the internal power supplies use a digital voltmeter set to the appropriate DC voltage range Connect the black ve lead to GND Connect the red ve lead in
40. w skyazul com 301 371 6126 14 of 30 BOOM ANGLE SENSOR AIN 3 1 10 11 SkyAz l Equipment Solutions Place the main boom at a 0 angle Verify that it is 0 angle with an inclinometer Access the Termination Board Check the Analog Drive Voltage Refer to page 9 of this manual 3 With a digital voltmeter set for DC volts connect the negative lead of the meter to 0 zero volt terminal of the Analog Input Group Connect the positive lead to the AIN 3 terminal of the Analog Input Group With the boom horizontal the voltage should be 0 4 0 1 volts Raise the main boom to a 60 angle Verify that the main boom is at a 60 angle with an inclinometer With the boom at a 60 angle the voltage should be 3 02 0 1 volts If this is out of range remove the cover from the extension reel located on the left side of the main boom Under the cover on the right side of the extension reel is a terminal strip This terminal strip has six wires connected to the bottom screws With a digital voltmeter set to read DC voltage place the negative lead on the terminal with the white wire Drive and the positive lead on the terminal with the red wire Drive The voltage should be 5 25 0 1 volts NOTE If this voltage is out of range and the Analog Drive Voltage checked in step 2 is OK it is possible that the extension reel cable is open or grounded between the computer and the extension r
41. y or jib options that are not supplied with the crane will not show up in the Crane Set Up menu Refer to the Calibration Procedure Command 13 to hide or show attachments DIGITAL I O amp ANALOG I O Digital and Analog faults are not user serviceable When this fault code is detected it will be necessary to replace the Processor Board DISPLAY UNIT This unit is not user serviceable When this fault code is detected it will be necessary to replace the Display Unit This can be done by removing the four screws securing the display to the dashboard and unscrewing the cable from the back of the display Connect the display cable to the new display install it into the dashboard and secure with the four mounting screws SkyAz l Equipment Solutions www skyazul com 301 371 6126 ANTI TWO BLOCK SYSTEM SYSTEM WILL NOT SHOW TWO BLOCK WHEN THE CRANE IS TWO BLOCKED 1 Access the Termination Board Refer to page 8 of this manual 2 Remove and separate the violet and brown wires connected to the ATB IN terminal of the digital input group The system should now show an Anti Two Block warning e Ifthe Anti Two Block warning does not occur with the wires removed from the terminal strip the problem is in the Termination Board Anti Two Block warning occurs with the wires removed from the terminal strip the problem is outside of the computer and is in the 2 switches and or cables Reconnect
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