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Microguard 434 Service Manual

1. OPERATOR CAB Display Console 1 1 l 1 I Power Motion Disconnect 1 Connection Cable 7 I 1 i 1 Connector 8 s od l 1 1 7 ALARM i Connector 6 I Bargraph Display Optional 5 5 5 1 uU Swing Pot I Connection Cable 3 Inside Collector Column 3 Cable 2 Pressure Transducer Connector 2 Rod Side Connector 1 Computer Unit Mounted at rear of Cab Ground Strap to 777 Superstructure UPPER STRUC TURE l l Cable 1 Pressure Transducer Piston Side l li Cranes with Serial Number Prefix D3 E9 F1 F2 amp F3 SkyAz l Equipment Solutions www skyazul com 301 371 6126 F Section IV SYSTEM COMPONENTS AND ASSOCIATED 31 THE COMPUTER UNIT u uuu uuu u uuu Lh e dec te Ore etl et re teat yaaa 32 COMPUTER UNIT COMPONENT S tecta ln 32 ACCESSING THE COMPUTER BOARD AND THE TERMINATION 34 CHECKING THE COMPUTER UNIT tle a ny cae terre vg pts 34 CONNECTORS ceti estet tidie ced dem eee dent hate ut dta 34 UNIT GOVERS SE E
2. TESTING THE COMPUTER UNIT POWER SUPPLY VOLTAGES INPUT VOLTAGE The input voltage for the Computer has a range of 11 to 36 Volts DC This input voltage is measured across the and u A E B terminals on the Termination Board i see Figure 4 3 and corresponds to the battery voltage of the crane Voltages below 10 5 will cause the System to power down until the correct voltage is restored If the INPUT VOLTAGE is not within the above FIGURE 4 3 BATTERY INPUT TERMINALS AND range check the battery and or alternator INTERNAL POWER SUPPLY TEST POINTS before servicing the Computer Unit INTERNAL POWER SUPPLY VOLTAGES The Computer Unit derives its own internal power supply voltages from the incoming battery voltage These voltages can be monitored at Test Points inside the Computer Unit adjacent to the fuses and Battery Input Terminals on the Termination Board see Figure 4 3 1 Seta Digital Multimeter DMM to the appropriate DC voltage range SkyAz l Equipment Solutions www skyazul com 301 371 6126 35 2 Turn the power 3 Connect the negative lead to the GND Test Point 4 Place the positive lead in each of the following test points e 5V Test Point 4 90V 5 10V e 15V Test Point 14 90V 15 10V e 15V Test Point 14 90V 15 10V The above voltages indicated for each point are in the acceptable range If any of these voltage points are out of range it may be necessary to repl
3. DR AIN3 HED AM ES l B B 1 0 DRI 1 B DR AIN5 l B TX1 AIN6 FS2 B TX1 DR ov ov SkyAz l Equipment Solutions B GND VP 5V RES 15V 15V www skyazul com VP VP VP DIN1 DIN2 DIN3 DIN4 DINS DING DIN7 DIN8 DIN9 DIN10 DIN11 DIN12 DIN13 DIN14 DIN15 ATBIN DOUTO DOUT1 DOUT2 DOUT3 DOUT4 DOUT5 DOUT6 DOUT7 0v 5VA 5VB DA DB RES ov ATBOUT FIGURE 4 2 COMPUTER BOX AND LAYOUT OF THE TERMINATION BOARD CL NC NO NC NO NC NO SPARE RELAY TB7 MODE OVERLOAD SPARE RL2 ATB RHAY2 RHAY1 A2B BOARD 301 371 6126 ACCESSING THE COMPUTER BOARD AND THE TERMINATION BOARD 1 Refer to Figure 4 1 To access the Computer Board remove the four screws B that secure the cover A to the Computer Box Carefully remove the lid from the Computer Box Set the lid and the four screws aside 2 Toaccess the Termination Board H remove the screws D located at eac
4. co ou al SkyAzul Equipment Solutions www skyazul com 301 371 6126 43 44 9 LAMPS The lamps are Light Emitting Diodes LED s They are more reliable than standard incandescent bulbs and consume far less power LED operation can be checked at any time by the operator using the Lamp Test feature Always replace the entire Bar Graph Unit if it is found to be faulty With the System powered there should always be at least one GREEN LED lighted the one furthest from the Brightness Control push button even when there is no load suspended The Remote Bar Graph LED s should track or echo the Bar Graph on the Operator s Display Console at all times BRIGHTNESS CONTROL BRIGHTNESS CONTROL Brightness Selection There are four levels of brightness Holding the Brightness Control button continuously will cause the Unit to automatically cycle through the available levels Release the button at any time to select the desired setting Alternately pressing and releasing the button will cause the cycle to progress through the four levels in sequence It is not possible to switch off the LED s using this control The currently selected brightness level is not stored within the MicroGuard System when the power is switched off Therefore the brightness desired will have to be set again manually when the System is next used The Remote Bar Graph always starts with the LED s set to
5. g ul EQUIPMENT SOLUTIONS MicroGuard 434 SERVICE MANUAL SkyAz l makes no warranty of any kind with regard to this material including but limited to the implied warranties of merchantability and or its fitness for a particular purpose SkyAzul 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 SkyAzul SkyAzul 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 r SkyAz l Inc gal 200 W Main Street Suite 2A Middletown MD 21769 EQUIPMENT SOLUTIONS Fax 301 371 0029 info skyazul com SkyAz l Equipment Solutions www skyazul com 301 371 6126 TABLE OF CONTENTS MicroGuard 434 Rated Capacity Limiter System TROUBLESHOOTING MANUAL Introduction SERVICE DEDICATION eene INSIDE FRONT COVER WHERE TO GO FOR 2 200100
6. 1 YELLOW YELLOW PISTON GREEN TXO B CONNECTOR 2 RED RED DR fex s EN BLUE BLUE N CABLE 2 DR py 55 YELLOW E YELLOW ROD TX1 B E GREEN GREEN 7 TX1 lt FIGURE 4 18 THE PRESSURE SENSOR CONNECTED TO THE COMPUTER SkyAz l Equipment Solutions www skyazul com 301 371 6126 PRESSURE SENSOR REMOVAL AND INSTALLATION PRESSURE SENSOR REMOVAL 1 We recommend that a new sensor being installed closely matches the sensitivity of the old sensor The sensitivity value is recorded on the serial number plate Figure 4 19 2 Remove the connector from the faulty sensor in the computer box 3 With the boom cylinder completely retracted in the rest position or with the boom safely supported remove the sensor from the boom hoist cylinder PRESSURE SENSOR INSTALLATION 1 Install the new sensor on the boom hoist cylinder 2 Run the cable to the computer box and connect it to the appropriate computer box connector 3 Pick a known weight to verify the accuracy of the system If the load reading is not within tolerance after installing the new pressure sensor carry out Command 6 Pressure in the MicroGuard 434 Calibration procedure Morganite Electronic Instruments Limited Part No 4002300 Ser 838 20286 15 07 PRESS TXDR 2S0BAR mV OUTPUT 127 FIGURE 4 19 SENSOR SERIAL NUMBER PLATE ANTI TWO BLOCK FUNCTION LOGIC LEVELS The signal from the Anti Two Block ATB switches at the boom
7. DETAILED DESCRIPTION SEE SECTION IV PAGE 53 SkyAz l Equipment Solutions www skyazul com 301 371 6126 18 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 CONNECTOR 1 IS THE TXO CHANNEL ON THE INTERFACE BOARD PROBLEM INDICATOR OUT OF SERVICE Alarm Power from the computer to the transducer is missing Input TXO or is missing or incorrect The transducer or cable has failed Connector to Terminal block open ACTION Press and hold the TEST button Measures the 5 25v supply on the Termination Board Measures TXO inputs on the Termination Board Unplug the cable and measure the resistance Measure the connections from terminal block 2 to connector 1 RESULTS Fault Code AAA 001 Terminal block 2 Pin 1 5 25 Terminal block 2 PIN 3 TXO 2 625v PIN 4 TXO 2 625v Pin C to D 340 to 360 Ohm Pin B to E 340 to 360 Ohm Pin B C D amp E open to the shield Pin C to TB2 DR gt 1 Ohm Pin D to TB2 DR gt 1 Ohm Pin B to TB2 gt 1 Ohm Pin E to TB2 TX gt 1 Ohm NOTE The System will need to be re calibrated if a new sensor is installed FOR A
8. MORE DETAILED DESCRIPTION SEE PRESSURE SENSOR SEC IV PAGE 54 SkyAz l Equipment Solutions www skyazul com 301 371 6126 19 PRESSURE TRANSDUCERS CONTINUED CONNECTOR 2 IS THE TX1 CHANNEL ON THE INTERFACE BOARD PROBLEM INDICATOR OUT OF SERVICE Alarm Power from the computer to the transducer is missing Input TX1 or is missing or incorrect The transducer or cable has failed Connector to Terminal block open ACTION Press and hold the TEST button Measures the 5 25 supply on the Termination Board Measures TX1 inputs on the interface board Unplug the cable and measure the resistance Measure the connections from terminal block 2 to connector 2 RESULTS Fault Code AAA 002 Terminal block 2 Pin 6 5 25 Pin 7 DR 0 volts Terminal block 2 PIN 8 1 2 625 PIN 9 TX1 2 625v Pin C to D 340 to 360 Ohm Pin B to E 340 to 360 Ohm Pin B C D amp E open to the shield Pin C to TB2 DR gt 1 Ohm Pin D to TB2 DR gt 1 Ohm Pin B to TB2 TX1 gt 1 Ohm Pin E to TB2 TX1 gt 1 Ohm NOTE The System will need to be re calibrated if a new sensor is installed SkyAz l Equipment Solutions www skyazul com 301 371 6126 20 The Remote Bar Graph is connected to the computer with 4 wires DA Serial Communication Line DB Serial Communication Line 5v Power Ground Power Return PROBLEM ACTION RES
9. Remove the Computer Board See Computer Board Removal page 37 2 Disconnect all cable connectors from the Computer Box 3 Remove the four screws securing the Computer Box 4 Remove the Computer Box Note The Termination Board must always be replaced with the Aluminum Box due to the wiring looms between the board assembly TERMINATION BOARD AND BOX INSTALLATION 1 Install the new Computer Box securing it with the four mounting screws 2 Follow the steps in Computer Board Installation page 37 38 Numbers 2 7 3 Reconnect all other cables to appropriate connectors Note Connectors 1 and 2 are SIMILAR These connectors are color coded Ensure that the color on the connecting cable matches the color on the socket COMPUTER CHIPS The computer Unit contains three replaceable computer chips identified below and illustrated in Figure 4 6 on the next page For any computer chip replacement follow directions in Computer Chip Removal and Installation page 39 The Computer Chips include The Program ROM Chip identified as IC2 on the Computer Board includes information specific to the System and contains the main program data needed for the computer to function Installation of the Program ROM Chip does NOT necessitate recalibration of the System The Personality ROM Chip identified as IC7 on the Computer Board contains calibration data unique to each crane The Personality ROM Chip must correspond to the prefix serial number on the cr
10. and fly tips is a switched ground The ground signal is sourced 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 ATBIN 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 Unit SkyAz l Equipment Solutions www skyazul com 301 371 6126 59 E The ATB board shown on the Termination Board Figure 4 20 operates e 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 CLOSED OPEN LOW 0 2 VOLT HIGH 5 VOLT LOW 0 2 VOLT HIGH 5 VOLT HIGH 12 VOLT LOW 0 2 VOLT FIGURE 4 20 LOGIC LEVELS DOUT1 CONTROLS THE A2B RELAY RL2 NO A2B LOW 0 2VOLT ALARM HIGH 5VOLT Sis LOAD IN13 CONTROLS THE UBIBLE ALARM AND SCREEN MESSAGE 1O A2B lt HIGH 12VOLT LARM LOW 0 2VOLT RL2 A2B o e ala o ala o ojo DIN13 ATB BOARD ATBI FIGURE 4 21 TERMINATION BOARD SkyAz l Equipment Solutio
11. are properly inserted into the chip socket These pins are very easily bent Warning Failure to have all pins inserted properly into the chip socket can cause damage to the System and the chip SkyAz l Equipment Solutions www skyazul com 301 371 6126 39 40 OPERATOR DISPLAY CONSOLE The Operator s Display Console Figure 4 7 allows the user to see the crane values Angle Radius Load etc and crane configuration selection The Display also provides calibration functions used for testing and Fault diagnosis DISPLAY CONSOLE MODELS There are two Operator s Display Consoles The in dash horizontal and MicroGuard 434 in dash vertical mounts The consoles are identified by Serial Number Prefixes on the unit label or the LBCE Parts Manual Parts within the Operator s Display Console cannot be serviced in the field MicroGuard 434 DP 4 4 E E v I U 4 4 4 A E 9 FIGURE 4 7 OPERATOR S DISPLAY CONSOLE COMPUTER UNIT CONNECTOR 7 DISPLAY CONSOLE CONNECTOR TB6 MS3475W14 15PW YELLOW DISPLAY CONSOLE 7 MS3475W14 15SW INTERFACE BOARD SCREW TYPE BANANA CONNECTOR IN DASH MOUNTED DISPLA ONSOLES ONLY To Machine Battery Positive IN CAB AUDIBLE ALARM EXTERNAL TO DISEUAY CONSOLEON FIGURE 4 8 OPERATOR S DISPLAY CONSOLE CONNECTION TO COMPUTER SkyA
12. boom is extended the displayed number of TX 0 should increase 15 When the boom is fully extended the Display should read 400 100 for a three section boom and 600 100 for a four section boom 16 Exit the calibration test by pressing the BOTTOM RIGHT ARROW The values listed are nominal values The actual values will differ according to how the crane is equipped e Athree section boom will show a smaller value on TX 0 under the same conditions as a four section boom e Additional equipment on the main boom such as stored fly auxiliary head sheaves and hook blocks will give a higher value than the main boom alone e If any value is out of range contact your distributor or factory service department before replacing a pressure sensor If the foregoing functional tests indicate faults in the pressure channels proceed with Sensor Resistance Measurements on the next page and or Measuring Analog Sensor Drive Voltage on page 36 SkyAz l Equipment Solutions www skyazul com 301 371 6126 iw nr rr mmrsemFTrs 7 T t U SENSOR RESISTANCE MEASUREMENT The Pressure Sensor is a balanced bridge composed of strain gauges bonded to a flexible diaphragm The following resistance tests can be performed to establish the condition of the Pressure Sensor PISTON PRESSURE SENSOR 1 Turn off the computer Disconnect the piston pressure sensor cable from connector 1 on the Computer Unit 2 With the Digital Multimeter DMM set to the Ohms
13. etc 3 Faults discovered during Self Test will cause the red and yellow lights to turn on The Graphics Display will read OUT OF SERVICE 4 The Operator then presses and holds the TEST button causing the Fault to be identified with a FAULT CODE NUMBER See Section V in the Graphics Display CAUSES FOR COMMUNICATION FAILURE A Bad connections between the Display Console and the Computer B Incorrect voltage from the Computer to the Display Console C Failure of the serial Transmit Receive IC in either the Computer Display Console or Remote Bar Graph Unit D Failure of the Reset IC in either the Computer or Display Console E The Computer is locked up and not working F The Display is locked up and not working SkyAz l Equipment Solutions www skyazul com 301 371 6126 gt _L_ gt _ r LSSS ea COMPUTER DISPLAY COMMUNICATION Communication problems are difficult to isolate because of the interaction between the Display Console and the Computer Failure of either unit causes malfunction of the Display Console Such problems need resolution before using the Problem Finding Tables Six wires identified below and shown in the following diagram connect the Computer to the Display Console See Figure 4 8 page 40 DA Differential serial communication line VP 2 Operator s Display onsole DB Differential serial communication line 0V Common return RES Reset line from the displ
14. on replacing the swing potentiometer SkyAz l Equipment Solutions www skyazul com 301 371 6126 64 DR Drive Voltage jm AINS amp AING Voltage varies with rotation of the upper structure DR 4 2V maximum 0 36V minimum 0V when the upper structure is rotatin TB2 DR L DR CI DR AIN3 4 Li TX0 AINA VP L J TXO DR VP Lov ov VP DR VP AIN5 ov LI TX1 AING 0V LJ TX1 DR 0V FIGURE 4 25 SWING POT CONNECTIONS Voltage measured between 2 and 4 5 25 Volts Voltage measured between 1 and 3 4 125 Volts FIGURE 4 26 ANTI TWO BLOCK BOARD SkyAz l Equipment Solutions www skyazul com 301 371 6126 65 66 SECTION V FAULT CODES FAULT REPORTING AND FAULT 5 67 FAULT DIAGNOSTIC PROCEDURES 4 I 67 FINDING AND UNDERSTANDING FAULT CODES esee 68 SkyAz l Equipment Solutions www skyazul com 301 371 6126 FAULT REPORTING AND FAULT CODES Group AAA Analog Sensors System Fault Codes provide one of the most important 000 NO FAULTS ways to quickly locate and assess problems i
15. power not the engine 4 Referto FIGURE 27 page 74 Press and hold the CRANE SETUP BUTTON CS and the TEST BUTTON T on the OPERATOR S DISPLAY CONSOLE The GRAPHICS DISPLAY GD will request the SECURITY ENTRY CODE 5 To enter the SECURITY CODE press the TOP LEFT ARROW followed immediately by the SkyAz l Equipment Solutions www skyazul com 301 371 6126 55 56 BOTTOM RIGHT ARROW Then quickly press the BOTTOM LEFT ARROW followed by the TOP RIGHT ARROW Complete this sequence in 5 seconds if not the SECURITY CODE will have to be entered again 6 The GRAPHICS DISPLAY will read RUN Press the ARROW next to MENU UP or MENU DOWN in the GRAPHICS DISPLAY and scroll to Command 03 ZERO SENSOR To continue PRESS THE TOP LEFT ARROW 7 The SELECTION BOX should read ZERO TX 0 followed by 0 ZERO plus or minus 20 Press the TOP LEFT ARROW 8 Press the ARROW next to MENU UP and scroll to ZERO TX 1 followed by 0 ZERO plus or minus 20 Press TOP LEFT ARROW to continue 9 Retighten the fittings on the sensors 10 Raise the boom up to a 60 degree angle 11 Access the Zero of TX 0 described in step 7 The Display should read 200 100 12 Access the Zero of TX 1 described in step 8 The Display should read 5 25 13 Boom down As the boom is moving down the displayed number of TX 1 should increase 14 Place the retracted boom at a 60 degree angle Access the Zero of TX 0 described in step 7 Extend the boom As the
16. range measure the resistance between pins C an D of connector MS3475W14 5PZ see Figure 4 17 The resistance should be 350 0 12 3 With the DMM set to the Ohms range measure the resistance between pins of connector MS3475W 14 5PZ The resistance should be 350 2 10 0 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 PRESSURE SENSOR CONNECTOR MS3475W14 5PZ B TO 3500 100 D TO 3500 100 FIGURE 4 17 PRESSURE CONNECTOR SkyAz l Equipment Solutions www skyazul com 301 371 6126 57 58 ROD PRESSURE SENSOR 1 Turn off the power Disconnect the rod pressure sensor cable from connector 2 on the Computer Unit 2 With the Digital Multimeter DMM set to the Ohms range measure the resistance between pins an D of connector MS3475W14 5PZ see Figure 4 18 The resistance should be 350 0 100 3 With the DMM set to the Ohms range measure the resistance between pins B an E of connector MS3475 214 5PZ The resistance should be 350 2 100 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 CONNECTOR 1 RED RED DR Calle S DR BLUE D BLUE
17. 0 e Anti Two Block Function See Anti Two Block Function page 52 SkyAz l Equipment Solutions www skyazul com 301 371 6126 47 CHECKING THE VOLTAGE OF THE BOOM EXTENSION SENSOR To check or test an Extension Sensor check the voltage Follow the steps outlined below 1 Fully retract the boom 2 Access the Termination Board see Figure 4 12 Measure the Analog Sensor Drive Voltage Refer to page 36 Figure 4 4 3 With a Digital Multimeter set to read DC voltage place the negative lead on 0 Volt terminal of the Analog Input group 4 Place the positive lead of the meter on the AIN2 terminal of the Analog Input group The voltage should be 0 1 Volts 5 Extend the boom as far as is safe to do so The boom need not be horizontal for this test 6 The voltage should be less than 4 9 Volts when the boom is fully extended NOTE During extension the voltage should increase linearly During retraction the voltage should decrease linearly If the voltage is out of range remove the four screws securing the cover on the Extension Reel Assembly located on the left side of the main boom section and remove 7 Under the cover on the right side of the Extension Reel locate the terminal strip see Figure 4 11 This terminal strip has six wires connected to the bottom screws 8 With a Digital Multimeter set to read DC Voltage place the negative lead on the terminal with the blue wire DRive and the positive le
18. 01 016 amp 032 Faults 002 016 amp 032 Faults 001 002 016 amp 032 P gt S n 301 371 6126 69 70 AAA Fault Codes continued FAULT No DESCRIPTION 053 Faults 001 004 016 Faults 002 004 016 Faults 001 002 004 016 amp 32 N N Faults 008 016 amp go N Faults 001 008 016 amp 032 Faults 002 008 016 Faults 001 002 008 016 amp 032 Faults 004 008 016 amp 032 Faults 001 004 008 016 amp 032 Faults 002 004 008 016 amp 032 Faults 001 002 004 008 016 amp 032 SWING POT B 067 Faults 001 002 amp 064 Faults 001 004 amp 064 070 Faults 002 004 amp 064 071 Faults 001 002 004 Figure 5 2 AAA Analog Sensor Fault Codes Numbers 1 127 continued 063 AAA Fault Codes continued FAULT No DESCRIPTION 072 Faults 008 amp 64 073 Faults 001 008 amp 64 074 Faults 002 008 amp 064 075 Faults 001 002 008 amp 064 076 Faults 004 008 amp 064 077 Faults 001 004 008 amp 064 078 Faults 002 004 008 amp 064 079 Faults 001 002 004 008 amp 064 080 Faults 016 amp 064 Faults 001 016 amp 064 Faults 002 016 amp 064 Faults 001 002 016 amp 064 084 Faults 004 016 amp 064 Faults 001 004 016 amp 064 086 Faults 002 004 016 amp 064 087 Faults 001 002 004 016 amp 064 088 Faults 008 016 amp 064 089 Fault
19. 2 amp 064 ERE e Faults 001 002 008 032 amp 064 Faults 004 008 032 amp 064 Faults 001 004 008 Figure 5 2 AAA Analog Sensor Fault Codes Numbers 1 127 continued SkyAz l Equipment Solutions www skyazul com 301 371 6126 71 FAULT No DESCRIPTION FAULT No DESCRIPTION No Faults Digital Input and Analog Input and Output WEINE a Faults 1 2 amp 4 Figure 5 3 Fault Codes sl UN Tv 7 Faults 01 amp 02 FAULT No DESCRIPTION No Faults Current Duty Bad Faults 01 amp 02 Figure 5 5 DD General Fault Codes Faults 01 02 04 amp Figure 5 4 CC Memory Fault Codes SkyAz l Equipment Solutions www skyazul com 301 371 6126 72 SkyAz l Equipment Solutions www skyazul com 301 371 6126 73 MicroGuard 434 SELECTION BOX MENU UP MENU DOWN TES O 1 Q MU MENU UP B BAR GRAPH MD MENU DOWN GD GRAPHICS DISPLAY WINDOW SB SELECTION T TEST BUTTON BOX CS CRANE SETUP BUTTON EX EXIT SEL APPROVE 8 CONTINUE CALIBRATE FIGURE 27 OPERATOR S DISPLAY CONSOLE Refer to Section IV page 40 SkyAz l Equipment Solutions www skyazul com TA TO SCROLL TO DESIRED COMMAND shown in SELECTION BOX 301 371 6126 WVYOVIC WALSAS 97 34nolJ u
20. 8 senten 4 SYSTEM DIAGRAM e om E Eee 75 Section PPEPABATION L L NN NR am aaa a asukuy 5 Section ll PROBLEM FINDER TABLES ferae HER papspa ALL MI tv 7 Section III SYSTENIINSTALPATIONS T M 23 Section IV SYSTEM COMPONENTS AND ASSOCIATED FUNCTIONS eee 27 Section V FAULT E 66 SECTION VI SYSTEM Ze da qo Cre o 73 SkyAz l Equipment Solutions www skyazul com 301 371 6126 3 When field repairs cannot be made without replacement of a part when troubleshooting advice is needed or when corrections to memory chips are reported one of the following support numbers should be called SkyAz l Inc 200 W Main Street Suite 2A Middletown MD 2176 Phone 301 371 6126 Fax 301 371 0029 www skyazul com info skyazul com SkyAz l Equipment Solutions www skyazul com 301 371 6126 SECTION I PREPARATION This Troubleshooting Manual for the MicroGuard 434 Rated Capacity Limiter System manufactured by the Greer Company and installed on Link Belt Construction Equipment Company LBCE cranes provides information and methods for isolating problems that may arise during operation of the System Some of these problems can be corrected in the field Other problems may require replacement of parts or a return of a part to the factory for servicing Persons servi
21. D 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 Access the Termination Board see Figure 4 25 Check the Analog Drive Voltage Refer to Measuring Analog Sensor Drive Voltage page 36 With a Digital Multimeter DMM set for DC Volts check the voltage at the connections to the potentiometer located on the Anti Two Block Board see Figure 4 26 A red wire is attached to Connection 1 a black wire is attached to Connection 3 Connect the black negative lead of the DMM to Connection 3 with the black wire and the red positive lead of the DMM to connection 1 with the red wire The voltage should be 4 125 0 1 Volts 4 025V 4 225V is within range If the 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 AIN5 terminal and AIN6 terminal The voltage should be 4 50 0 1 maximum and 0 365V 0 1V 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 AIN5 and AIN6 out of range the Swing Potentiometer will need to replaced Contact your distributor or your Factory Service Department for procedures
22. FIGURE 5 1 DISPLAY CONSOLE WINDOW IDENTIFYING FAULT CODES AAA Fault Codes FAULT No DESCRIPTION NO FAULTS DETECTED PISTON PRESSURE SENSOR Faults 001 amp 008 Faults pul 002 amp Faults 004 amp 008 013 Faults pdt 004 amp FAULTS 001 amp 002 EXTENSION SENSOR FAULTS 001 amp 004 Figure 5 2 AAA Analog Sensor Fault Codes Numbers 1 127 Faults 002 004 amp 008 Faults 001 002 004 amp 008 ROD PRESSURE SENSOR Superstructure Angle Sensor Faults 001 amp 016 SkyAz l Equipment Solutions www skyazul com 301 371 6126 AAA Fault Codes continued FAULT No DESCRIPTION Fault 002 amp 016 Fault 001 002 amp 016 Fault 004 amp 016 Fault 001 002 004 amp 016 027 Fault 001 002 008 amp 016 Fault 001 004 008 amp 016 Fault 002 004 008 amp 016 Fault 001 002 004 008 amp 016 Du bi in os diea fos E ns 5 Figure 5 2 AAA Analog Sensor Fault Codes Numbers 1 127 continued SkyAz l Equipment Solutions www skyazul com AAA Fault Codes FAULT No DESCRIPTION Faults 004 8 32 037 Faults 001 004 8 032 Faults 002 004 8 032 039 Faults 001 002 004 8 032 jos vu Faults 001 008 amp 032 Faults 002 008 amp 032 Faults 001 002 008 amp 032 Faults 004 008 amp 032 Faults 001 004 008 amp 032 Faults 002 004 008 amp 032 047 Faults 001 002 004 008 amp 32 Faults 0
23. ISCONNECT amp BOOM MODE FUNCTIONS 62 REPLACEABLE PARTS Suman ea qi aska aote restes ien EU AE eta As E a a Eat 63 SWING SENSOR uuu u a be eee eate La e 64 SWING POTENTIOMETER s d iret be t e e a ee i eb ot edd raa 64 AN SAND AIN O ds ares es eT 64 CHECKING THE SWING POTENTIOMETER 0 00010 nnne nn ant rrenan 64 SkyAz l Equipment Solutions www skyazul com 301 371 6126 29 30 SkyAz l Equipment Solutions THIS PAGE SHOULD BE BLANK www skyazul com 301 371 6126 Section IV SYSTEM COMPONENTS AND ASSOCIATED FUNCTIONS This section provides detailed information on the MicroGuard 434 System components and associated functions System components include the Computer Unit Operator s Display Console Remote Bar Graph Extension Reel and Pressure Sensor Functions include the Anti Two Block Function the Power Motion Disconnect and Boom Mode Functions and the Swing Sensor Possible problems are outlined in this section as well as methods for testing checking and replacing System components SkyAzul Equipment Solutions www skyazul com 301 371 6126 31 32 FIGURE 4 0 THE COMPUTER UNIT THE COMPUTER UNIT The Computer Unit shown in Figure 4 0 is the center of the MicroGuard 434 System The Computer Unit provides all the necessary functions to read the sensors create System c
24. LLATION When all tests have been completed and it has been determined that parts must be replaced rather than repaired locate the appropriate section below and follow the steps as directed ANGLE SENSOR REMOVAL 1 Refer to Figure 4 11 Access the Angle Sensor by removing the cover from the Extension Reel Assembly 2 Disconnect the three wire leads at the terminal block from the Angle Sensor 3 Loosen the cable clamps so the Angle Sensor cable can be removed from the triangle plate 4 Remove the Angle Sensor from the Extension Reel Assembly by removing the two mounting nuts and washers SkyAz l Equipment Solutions www skyazul com 301 371 6126 i smO os s Ta ANGLE SENSOR INSTALLATION 1 Install the new Angle Sensor and secure it loosely with the two mounting nuts and washers See Figure 4 11 2 Secure the Angle Sensor cable to the triangle plate with the three cable clamps 3 Installthe three wire leads from the Angle Sensor to the terminal block 4 Raise the boom to a 60 degree angle and verify the angle with an inclinometer While viewing the Display position the Angle Sensor until the Display reads 60 degrees Tighten the mounting nuts 5 Place the boom in horizontal position and verify that it is at zero degrees with an inclinometer 6 Verify that the displayed boom angle is reading zero degrees 0 5 degrees 7 the cover on the Extension Reel Assembly EXTENSION REEL RE
25. MAXIMUM brightness VIEWING DIFFICULTIES Always adjust the LED Brightness first Then reposition the Remote Bar Graph slightly The most commonly encountered problem with this type of Display is that of reflective light It may not be possible to correct this problem completely especially with Units exposed to bright sunlight CABLE AND CONNECTOR The Remote Bar Graph uses a single cable to communicate with the Computer Unit and to carry power The cable is nonremovable and is a fixed length Excess cable should be stored not discarded when the Unit is installed Extending this cable is not recommended There is a single connector on the far end of this cable This connector carries power and various signals between the Computer Unit and the Remote Bar Graph Because of the nature of connectors itis possible for the pins and sockets within the connector halves to be damaged A pin may be bent broken or pushed back inside the housing MOISTURE The Remote Bar Graph offers adequate protection against dust and water when correctly installed It is not possible however to fully protect the sensitive electronic assembly inside against pressure washing or heavy rainfall If this occurs the Remote Bar Graph should be replaced SkyAz l Equipment Solutions www skyazul com 301 371 6126 BAR GRAPH REMOVAL AND INSTALLATION REMOVAL OF A REMOTE BAR GRAPH 1 Turn off the power 2 Disconnect the Remote Bar Graph cable from
26. MOVAL 1 Fully retract the main boom 2 Disconnect the cable for the Two Block switch and release the cable from the boom head anchor 3 Without letting the cable retract too rapidly allow the cable to retract onto the Reel 4 Disconnect the electrical cable from the plug on the Extension Reel Assembly 5 Remove the Extension Reel Assembly Retain the mounting hardware for reuse EXTENSION REEL INSTALLATION 1 Installthe new Extension Reel Assembly and secure it with the mounting hardware Remove the cover 2 Reconnect the electrical cable to the plug on the Extension Reel Assembly 3 Remove the shipping cable clamp from the new cable Slowly rewind the cable onto the Reel to avoid tension Continue to rewind the Reel in the same direction until the distance between the boom head and the connector is approximately 12 ft 4 Pullthe cable out passing it through the cable guides until the end of the cable is 3 ft beyond the boom head 5 Wrap the cable a minimum of five times around the boom head anchor and secure the line with a wire tie or the shipping cable clamp SkyAz l Equipment Solutions www skyazul com 301 371 6126 53 6 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 boo
27. NECTOR 8 I I RED 2 METRI PAK CONNECTOR MS3475W14 5PW I i SPARE CONTACT E BLUE A BLUE BOOM MODE Bo SPARE NO MODE l RED WHITE WHITE WHITE FEED NES 2 RL1 CONTACT p GREEN GREEN E ORANGE OUTPUT ROVERLOAH RED 7 RED RED POWER ls A RL2 CONTACT s CABLE 8 BLACK POWER TB1 2428 D D I BLACK BLACK Be RL2INO I mssa7awik ssw B ov I i 1 1 B SUPPRESSOR DIODE LATER EO q 9 VERSIONS CONNECTED ON 1 H A UNDERSIDE OF TERMINATION I BYPASS BOARD I BYPASS KEY N NORMAL 1 TBS MOUNTED ON UHPER 1 MOUNTING PLATE YELLOW I 1 FIGURE 4 24 POWER AND FUNCTION DISCONNECT REPLACEABLE PARTS The Power Motion Disconnect amp Boom Mode functions are all part of the Computer unit and system wiring Cable 8 connecting to the machine wiring harness The only items that may need to be replaced are Cable 8 or wiring within the computer unit associated with this function Relays within the Computer unit are not independently replaceable since they are directly soldered to the Termination Board In the event that a relay contact is found to be damaged the Computer unit may need to be replaced SkyAz l Equipment Solutions www skyazul com 301 371 6126 63 SWING SENSOR SWING POTENTIOMETER 5 AN
28. S ar a 34 COMPUTER BOARD ASSEMBLY sariini 34 COMPUTER BOX WIRING TERMINATION BOARD ASSEMBLY 34 WIRE LENG TA uu 2 n l ha ER TU ERES 34 INSULATION 22220200 00000 00000000000 nana aa a aa 35 FUSES P 35 TESTING THE COMPUTER UNIT POWER SUPPLY VOLTAGES 35 INPUT VOLTAGE MEI 35 INTERNAL POWER SUPPLY VOLTAGE cnet eere acre 35 MEASURING THE ANALOG SENSOR DRIVE 36 REMOVING AND INSTALLING THE COMPUTER ASSEMBLIES 37 COMPUTER BOARD REMONVAL tr ette et teet t eed pet rs da ER 37 COMPUTER BOARD INSTALLATION a nennen nnn nn nn 37 TERMINATION BOARD AND BOX 38 TERMINATION BOARD AND BOX INSTALLATION eene 38 COMPUTER CHIPS iei rana ah ara 38 PROGRAM ROM GHIP 12 uuu u s duce terne e nora 38 PERSONALITY ROM GHIP 3 3 Iit nas dnu aza 38 deda a aaa OT n 39 COMPUTER CHIP REMOVAL AND INSTALLATION sss 39 SkyAz l Equipment Solutions www skyazul com 301 371 6126 27 COMPUTER CHIP REMOVAL 39 COMPUTER CHIP IN
29. STALEEATIGON iiio tea kan th tc e tha teen b 39 OPERATON S DISPLAY CONSOILE Uu atte patulo ava pua aad 40 DISPLAY CONSOLE MODELS ttt n a e EE aa ea aa 40 CHECKING THE OPERATOR S DISPLAY CONSOLE seen 41 READING THE LIQUID CRYSTAL 41 BUTTONS THAT DON T RESPOND ski nokia etn taber rn 41 GONNEGT ORS i r beet LI ME LL 41 HORN sa u u h silus 42 MOIS TURE a A a 42 OPERATOR S DISPLAY CONSOLE REMOVAL AND INSTALLATION 42 REMOVAL OF HORIZONTAL AND VERTICAL FLUSH MOUNT CONSOLES 42 INSTALLATION OF HORIZONTAL AND VERTICAL FLUSH MOUNT CONSOLES 42 REMOVAL OF HORIZONTAL BRACKET MOUNT CONSOLES 42 INSTALLATION OF HORIZONTAL BRACKET MOUNT CONSOLES 42 REMOTE BAR entro ration ime 43 CHECKING THE REMOTE BAR GRAPH 43 Nim ay 44 BRIGHTNESS CONTROL ss nato rabat P c 44 VIEWING DIEFICULTIES 44 CABLE AND 44 MOISTURE hores eden eg tena ene LLL MI LL MINA s 44 REMOTE BAR GRAPH REMOVAL AND INSTALLATION seem 45 REMOVAL OF A REMOTE BAR GRAPH tente tht nne re th 45 INSTALLATION OF A REMOTE BAR GRAPH 45 SkyAz l Equipment So
30. T button is pushed this line goes Hi about 4 5v and resets the computer In normal operation the reset line is Low about Ov SkyAz l Equipment Solutions www skyazul com 301 371 6126 11 12 iii it COMPUTER DISPLAY COMMUNICATION continued VP RED WIRE IS OPEN DISPLAY COMPUTER REMOTE BAR GRAPH Entire Operator s Display Console Relays turn on and allow crane Normal does not respond motions Relay clicks when TEST button is pushed SkyAzul Equipment Solutions www skyazul com 301 371 6126 DISPLAY OF FAULT CODES When the System detects a problem it is identified in the System as a Fault and given a Fault Code Number At the same time a warning is activated Fault Codes are displayed by holding down the TEST button 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 button SkyAz l Equipment Solutions www skyazul com 301 371 6126 13 CRANE MOTIONS ARE DISABLED Problem Unable to boom down extend boom or hoist up Reason The crane Motion Cut Solenoids aren t powered Theory The MicroGuard 434 System protection circuit has 2 relays in series between the Battery and Motion Cut Solenoids of the crane Refer to the MicroGuard 434 System Diagram on the inside back cover of this Manual Relay 1 cuts power when a Load Limit has been exceeded or a System failure has bee
31. ULT No lights Unplug cable 5 Measure Not getting power the 5 volt on connector 5 of the computer Pin 5 volts Pin C 0 volts All lights remain on after Self Test No serial communication Unplug cable 5 and measure the resistance from Pin D to Pin E on the cable connector Pin D to E measures between 210 and 230 ohms If not the cable is open or shorted Lights pulsating Unplug cable 5 and DA or DB is missing measure the resistance from Pin D to Pin E on the cable connector Pin D to E measures between 210 and 230 ohms If not the cable is open Loose connection inside Measure the resistance Pin C to TB9 gt 1 ohm the computer from from connector 5 to E connector 5 to terminal block 6 inside the Pin Ato TB10 gt 1 ohm terminal block 6 computer Pin D to 12 gt 1 ohm Pin E to TB13 gt 1 ohm NOTE The Remote Bar Graph unit must always be returned to the Service Center for repair Call your Service Representative SEE COMPUTER DISPLAY COMMUNICATION BLOCK DIAGRAM PAGE 9 AND REMOTE BAR GRAPH PAGE 43 SkyAz l Equipment Solutions www skyazul com 301 371 6126 21 22 SkyAz l Equipment Solutions THIS PAGE SHOULD BE BLANK www skyazul com 301 371 6126 Section III SYSTEM 65 23 SELECTING THE RIGHT SYSTEM INSTALLATION ILLUSTRATION 24 SYSTEM LAYO
32. UTS WITH CORRESPONDING SERIAL NUMBER PREFIX 25 1 SYSTEM INSTALLATION 25 2 SYSTEM INSTALLATION D3 ES F1 F2 amp F3 26 SkyAz l Equipment Solutions www skyazul com 301 371 6126 23 24 SELECTING THE RIGHT SYSTEM INSTALLATION ILLUSTRATION The information in this section is meant to familiarize the user with the major components and System setup for most models of the MicroGuard 434 System To locate the correct illustration for your needs match the first two digits of the serial number of your crane to the serial number prefix in column 1 of the following table Column 2 will identify the appropriate illustration for your needs in the following pages Serial No Prefix System Installation FIGURE 3 0 CRANE SERIAL NUMBERS WITH CORRESPONDING ILLUSTRATION NUMBERS SkyAz l Equipment Solutions www skyazul com 301 371 6126 SYSTEM LAYOUTS WITH CORRESPONDING SERIAL NUMBER 1 SYSTEM INSTALLATION 1 Mounted on attachment Head 1 l Anti Two Block HU Reel Off Cable to Boom Head i Anti Two Block Switch Ti Switch Attachment Main Boom I Mounted at Boom Head Extension Drum am
33. ace the Computer Box Before replacing the Computer Box please call for support Refer to Where to Go for Help page 4 MEASURING THE ANALOG SENSOR DRIVE VOLTAGE Analog Sensor Drive Voltages are measured at the Drive Voltage i i DR SOON Analog Input Group Terminals on the Termination AINO Board in the Computer Unit The drive voltage for all AIN1 The analog drive voltage ma DR be measured between any analog sensors is measured between any DR and DR amp DR terminal TB2 DR the Analog Input group LJ DR AIN2 cin Refer to Figure 4 4 The voltage should read DR AIN3 DR VP ue lov 0 VP 1 Seta Digital Multimeter DMM to an appropriate vb DC voltage range C3 DR AIN5 ov TX4 AING ov 4 DR 2 Turn on power ny ny ny x 3 Place the black negative lead on any FIGURE 4 4 MEASURING THE ANALOG DR and the red positive lead on any SENSOR DRIVE VOLTAGE DR Drive terminal 4 The voltage should be 5 25 0 1 Volts 5 Ifthe Analog Drive Voltage is not within this range shut off the power and disconnect all of the external sensor cables including the pressure sensors cables 1 5 6 Recheck the Analog Drive Voltage If the v
34. ad on the terminal with the red wire DRive 9 The voltage should be 5 25 0 1 Volts If this voltage is out of range and the Analog Drive Voltage measured in the computer is within range the cable may be open between the Computer Unit and the Extension Reel Assembly Check all connections and plugs between these two components Repair or replace as required 10 With the negative lead of the multimeter connected to the terminal with the white wire and the positive lead of the multimeter connected to the terminal with the blue wire extension signal the voltage should be the same as the voltage measured at AIN2 of the Analog Input group in the Computer Unit If this voltage is not the same the cable between the Extension Reel Assembly and the Computer Unit may be faulty SkyAzul Equipment Solutions www skyazul com 301 371 6126 S39V 110A dl4LS TVNINYAL g yoejg SIIOA 0 S HOA 0 9 15b 5 UMOJE 5 0 g V 9919 ENIV r d enig q SHUM HQ 6 SION 6086 4G L YOLOANNOO d a LS TIVNIIAH3 L 1334 NOISN31X3 NS 301 371 6126 www skyazul com SkyAz l Eguipment Solutions 49 CHECKING THE VOLTAGE OF THE BOOM ANGLE SENSOR Follow the steps below to check the voltage of the boom 1 Using an inclinometer for verification place the main boom at a zero degree angle 2 Access the Termination Board se
35. age 42 CONNECTORS A single circular connector common to all Display Models is positioned on the rear of the Display Console On the bracket mounted style it is clearly visible on the rear of the housing On the flush mounted versions it is hidden behind the panel within the dash assembly This connector carries power and signals from the Computer Unit to the Display Console Examine this connector carefully It is possible for the pins and sockets within the connector halves to bend break or pushed back inside the housing e On flush mounted Display Consoles vertical model one additional connection besides the circular connector is required The Horn Drive Wire is a single black lead that should be attached to the black terminal on the rear of the Display Console housing SkyAz l Equipment Solutions www skyazul com 301 371 6126 41 iz HORN On bracket mounted Display Consoles the Horn is inside at the rear of the housing On flush mounted Consoles the Horn is outside the housing If there is a problem with the horn ensure that the Horn Drive Wire is connected correctly to the black terminal on the rear of the Display Console housing Release the Display from its connections and pull the Display gently forward If the wire is intact and connected correctly and the horn is still not operating correctly the horn may need to be replaced If possible test the horn operation by temporarily installing another horn know
36. ane Installation of the Personality ROM Chip does not necessitate recalibration of the System if the new Personality ROM Chip is an exact duplicate of the original If a copy of the Personality ROM Chip is not available the System will need to be completely recalibrated SkyAz l Equipment Solutions www skyazul com 301 371 6126 m rr Y s WOrdV r rr fYFR Ribbon Cable 2 Ribbon Cable 1 Calibration Switch IC7 IC4 Personality Program Duty EPROM EPROM 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 COMPUTER CHIP REMOVAL AND INSTALLATION Warning When removing and installing chips ensure that the power is off Do not touch the chip pins unless you are properly grounded Static electricity can damage chips Warning Before removing or installing computer chips refer to Computer Chips page 38 COMPUTER CHIP REMOVAL 1 Turn the power off 2 Refer to Figure 4 6 above Remove chip from Computer Board with a chip removal tool Note Chip removal and installation tools can be obtained from any electronics store COMPUTER CHIP INSTALLATION 1 Following package instructions use the installation tool to insert new chip into socket 2 Ensure that the notch in the chip lines up with the notch in the socket 3 Ensure that all pins
37. ay to the computer 0V Common return DA REMOTE BAR GRAPH COMPUTER DISPLAY CONSOLE TRANSCEIVER 1 6 TRANSCEIVER 5 5 VOLT POWER SUPPLY 5 VOLT REGULATOR RELAYS TEST Button FIGURE 2 1 COMMUNICATION DISPLAYS BUTTONS BLOCK DIAGRAM SkyAz l Equipment Solutions www skyazul com 301 371 6126 9 iu COMPUTER DISPLAY COMMUNICATION NORMAL OCCURRENCES WHEN SYSTEM IS TURNED ON OR WHEN TEST BUTTON IS PUSHED OPERATOR S DISPLAY COMPUTER REMOTE BAR GRAPH CONSOLE READS After Self Test the relays All lights turn on during Self Test This is a SELF TEST turn on and allow crane and then return to normal motions Lamps on during Self Test Audio alarm sounds during Self Test Bar Graph spans full window TEST button resets both Listen for the relay Click Computer and Display Console The following tables describe the reactions of the Operator s Display Console Computer and Remote Bar Graph when 1 of the 6 wires has a simulated failure The wires were disconnected one at a time and the results recorded These tables are intended to help identify a faulty wire or circuit EITHER DA OR DB IS OPEN TO THE DISPLAY OPERATOR S DISPLAY COMPUTER REMOTE BAR GRAPH CONSOLE Shows everything remaining Resets every 5 seconds All lights on after Self Test Lamps r
38. cing this System should have prior training and experience in the procedure for operation and setup of this System Please refer to the MicroGuard 434 Operating Instructions in the LBCE Operator s Manual and or the MicroGuard 434 Calibration Manual regarding questions relating to the operation or calibration of this System Accurate methods must be used to locate a problem We recommend using the PROBLEM FINDER TABLES in Section II to help locate and define a problem The procedures in this manual where possible are based on crane operation and function A basic tool kit consisting of wrenches and screwdrivers flat and Phillips blades will be required to remove covers and units for inspection A digital multimeter DMM may be required The DMM must be capable of measuring DC voltage with a range of 0 volts to 50 volts and resolution of 0 1 volts Resistance range is 0 Ohms to 2 Megohms Low cost analog meters are not appropriate since the input impedance of these meters can give false readings SkyAz l Equipment Solutions www skyazul com 301 371 6126 5 THIS PAGE SHOULD BLANK SkyAz l Equipment Solutions www skyazul com 301 371 6126 nor 3 Dm D E09855 S S EASSSSSISZI SECTION II PROBLEM FINDER TABLES These Problem Finder Tables are designed to aid in determining the location and type of problem experienced It is important to review these Tables carefully before contacting us SYSTEM SELE TEST tre eet beet lend
39. d oed Me a e de dua 8 COMPUTER DISPLAY COMMUNICATION 2 22 2 033 00000000000000000000 000000000 43 9 12 DISPLAY OF FAULT CODES ic preteen rou 13 CRANE MOTIONS ARE DISABLED nennen nnne nnn 14 ANTI TWO BLOCK CIRCUIT 15 SWINGIPOT SENSO methode vorum O 16 BOOM EXTENSION SENSOR uuu teret ut Ce aaa re ERR a 17 BOOM ANGLE SENSOR Eu 18 PRESSURE TRANSDUCERS ptura qut gak Da 19 20 REMOTE BAR de C doe ua uo Ce 21 SkyAz l Equipment Solutions www skyazul com 301 371 6126 7 mu I3 05 U 5 15 5S JO9905SY SYSTEM SELF TEST The Computer and Operator s Display Console do a Self Test when the power is turned on or during operation when the TEST button is pressed The Self Test verifies that the Computer Display Console cables and all remote sensors are working properly TEST SEQUENCE FOR DISPLAY CONSOLE 1 Push TEST BUTTON T BLACK BAR GRAPH B spans entire window All lights and all 7 SEGMENT DISPLAYS turn on and the ALARM sounds Graphic Display GD reads This is a Test MicroGuard 434 FIGURE 2 0 LIQUID CRYSTAL DISPLAYS 2 If no Fault problem is found the System will start displaying Load Radius Angle
40. e Figure 4 12 Measure the Analog Drive Voltage Refer to page 36 Figure 4 4 3 With a Digital Multimeter set for DC Volts connect the negative lead of the meter to any 0 Volt terminal of the Analog Input group 4 Connect the positive lead to the AIN3 terminal of the Analog Input group 5 With the boom horizontal the voltage should be 0 4 0 1 Volts 0 3V 0 5V is within range 6 Raise the main boom to a 60 degree angle Verify that it is at a 60 degree angle with an inclinometer 7 With the boom at a 60 degree angle the voltage should be 3 02 0 1 Volts 2 92V 3 12V is within range If voltage is out of range return boom to the horizontal position Remove the cover from the Extension Reel on the left side of the main boom 8 Locate the terminal strip see Figure 4 11 on the right side of the Extension Reel This terminal strip has six wires connected to the bottom screws 9 With a Digital Multimeter 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 10 The voltage should be 5 25 0 1 Volts If this voltage is out of range and the Analog Drive Voltage checked in step 2 was within range the Extension Reel cable may be open between the Computer Unit and the Extension Reel Assembly Check all connections between these two components Repair or replace as required 11 With the negative lead of the multimeter connec
41. emain on Relays click with every reset Audio alarm remains OFF TEST button resets both the TEST button clicks the Computer and the Display relays SkyAz l Equipment Solutions www skyazul com 301 371 6126 10 L L _ _ _ _ _ _ _ _ gt EE_ _ _ L_ _ E COMPUTER DISPLAY COMMUNICATION DA AND DB ARE OPEN TO THE DISPLAY OPERATOR S COMPUTER REMOTE BAR GRAPH DISPLAY CONSOLE Graphics Display Reset repeats every 5 seconds All lights on READS Serial comms Failure Lamps are on Relays click with every reset Audio alarm on TEST button resets both TEST button clicks the relays Resets when the TEST button is Computer amp Display in pressed about 14 seconds Wires DA and DB going to the Display unit can be checked with an Ohm meter Unplug Connector 7 atthe Computer and connect a meter to pins A and E on the cable It should read between 210 and 230 ohms RESET 15 OPEN TO THE COMPUTER OPERATOR S COMPUTER REMOTE BAR GRAPH DISPLAY CONSOLE Operator s Display Relays turn on and allow crane Normal Console is normal motions after Self Test Graphics Display Relay clicks Resets remains blank when when TEST button is pushed when TEST button is pushed TEST button is pushed The reset line comes from the Display Console and connects to the Computer through Connector 7 Pin D and then connects to TB6 14 RES on the Termination Board When the TES
42. h end of the Computer Board Mounting Plate Swing the plate up and out of the way Warning Ensure that the electrical components do not contact the aluminum box or the cab walls This is especially important if the power is left on for test purposes 3 Take care not to damage the ribbon cables If the Computer Board must be removed from the Computer Box refer to COMPUTER BOARD REMOVAL page 37 4 Figure 4 2 shows the Computer Box and the layout of the Termination Board CHECKING THE COMPUTER UNIT When operated for extended periods of time under extreme conditions the computer can become damaged and that damage may or may not be apparent The following sections identify areas in the computer unit that should be checked for prevention and or repair of possible problems e Connectors There are up to 8 connectors on the computer box These connectors control all of the signals and power distribution within the System The pins and sockets within the connector halves can become damaged or a pin may be bent broken or pushed back inside the housing e Unit Cover The computer unit cover must be secured carefully to prevent water or dust from entering the computer unit A very small amount of water inside the housing could cause the System to malfunction or fail completely This is quite possible when the vehicle is pressure washed on a regular basis e Computer Board Assembly The Computer Board has a number of parts that are plugged in
43. k Wire gt Relay 1 Terminal Block TB7 PIN 8 e Yellow Wire gt DIN10 Terminal Block TB5 PIN 10 5 Remove the Computer Board Assembly with attached ribbon cables 6 Carefully remove the necessary computer chips IC 2 3 amp 7 from the defective Computer Board COMPUTER BOARD INSTALLATION 1 Immediately transfer the computer chips IC 2 3 amp 7 from the defective Computer Board to the new Computer Board Assembly Refer to Computer Chip Installation page 39 2 Ensure that the ribbon cables on the Computer Board are fully engaged and locked Refer to Termination Board and Box Installation page 38 CAL 3 Position the new Computer Assembly above the computer box and OFFb the key switch wires to the correct terminals of the Termination Board see Step 4 above 4 Reconnect the two ribbon cables to the Termination Board Ensure the connectors are fully engaged and locked FIGURE 4 5 CALIBRATION 5 Insert and tighten the two screws that secure the Computer Board to the EE IN Mounting Plate Ensure that the ribbon cables are not trapped or pinched POSITION and are away from the edge of the box when installing the cover SkyAz l Equipment Solutions www skyazul com 301 371 6126 37 38 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
44. lutions www skyazul com 301 371 6126 EXTENSION REEL ie ood et od rada na s 46 CHECKING TESTING EXTENSION REEL FUNCTIONS a 47 CHECKING THE VOLTAGE OF THE BOOM EXTENSION SENSOR 48 CHECKING THE VOLTAGE OF THE BOOM ANGLE 50 ANTETWO BEOCK PFUNCGT QN sarta u k u a ei ra eere ansa 52 EXTENSION REEL PARTS REMOVAL AND 1 52 ANGLE SENSOR REMOVAL ose eds dened verter ie ev ere tees 52 ANGLE SENSOR INSTALLAT QUI ctt ote nante dio notre en eu ted eee dite laso 53 EXTENSION REEL REMOVAL redet eet e aedi 53 EXTENSION REEL INSTALLATION ott et tt te tct doe te deett 53 PRESSURE SENSOR ete eite tte deae dr d ptg c cea 54 PRESSURE CHANNEL FAULT GUIBE ce eta under a e de eius 55 FUNCTIONAL TESTS kap 55 SENSOR RESISTANCE MEASUREMENT nennen nennen nnns 57 PISTON PRESSURE SENSONR uu uu u Pete ta 57 50 5 50 lu a 58 PRESSURE SENSOR REMOVAL AND INSTALLATION 59 ANTI TWO BLOCK FUNCTION essent nennen 59 LOGIC LEVELS e aet c ede e x rte 59 POWER MOTION D
45. m length 9 Replace and secure the Extension Reel Cover 10 Extend and retract the main boom Ensure that the boom length reading on the Display is correct PRESSURE SENSOR The Pressure Sensor Figure 4 14 is based around a strong metal PRESSURE SENSOR diaphragm which when subjected to hydraulic pressure bends in a predictable and repeatable way This diaphragm is totally enclosed within the body of the sensor The body provides strong mechanical MS347SW14 5PZ and environmental protection for the sensitive measuring elements within The body cavity is filled with resin to prevent moisture FIGURE 4 14 PRESSURE SENSOR penetration A fixed cable line exits from the rear end of the sensor body The Pressure Sensor has four electrical connections Figure 4 15 These connections transmit power and information via the cable line to the Termination Board within the Computer Box Two of the connections provide power or Drive for the PRESSURE SENSOR CONNECTOR strain gauge to operate The other two carry the MS3475W14 5PZ signal representing the amount of hydraulic TO E 3500 100 pressure being measured by the sensor There are two Pressure Sensors installed on a MicroGuard 434 System One is fitted to the Piston side of the Boom Hoist Cylinders the other to the Rod side The Sensor on the Piston side is subject to the hydraulic pressure necessary to support the weight of the Boom any attachments and the L
46. n detected Relay 2 cuts power when the Anti two Block limit switch is opened ACTION Press and release the TEST button on the Press and Hold the TEST button Press and Hold the ALARM OVERRIDE button for 5 seconds Measure the DC voltages on Terminal Block 7 on the Termination Board Measure the resistance from Terminal Block 7 to Check the wiring from the computer to the Motion Check the ATB Board connections SkyAz l Equipment Solutions 14 RESULT The System will perform a Self Test Fault codes will be displayed until the button is Relay 1 and Relay 2 will be forced on by the computer to provide power to the Motion Cut Solenoids TB7 7 13 8V battery in TB7 8 13 8V jumper TB7 10 13 8V jumper TB7 7 to C8 B gt 5 Ohms TB7 11 to C8 E gt 5 Ohms Cable 8 supplies 13 8v to the Motion Cut Solenoids All wires are making contact www skyazul com DETAILED INFORMATION Please refer to page 8 Please refer to Fault Codes pages 66 72 See the System Diagram the inside back cover of this Manual to see the voltage path from the battery through the relays to the solenoids See the System Diagram on the inside back cover of this Manual and the Termination Board layout in Figure 4 24 page 63 See Figure 4 21 page 60 See Figure 4 21 page 60 301 371 6126 Ez sMV_m ANTI TWO BLOCK CIRCUIT The ANTI TWO BLOCK switch is normally closed connec
47. n the 001 PISTON PRESSURE SENSOR MicroGuard System Please review this section carefully FAULT DIAGNOSTIC PROCEDURES 002 ROD PRESSURE SENSOR Each time the System is turned on it goes through a self 004 EXTENSION SENSOR testing process lasting two to three seconds that automatically detects any Faults in the System During 008 BOOM ANGLE SENSOR normal operation a Self Test can be initiated at any time 016 S STRUCTURE ANGLE SENSOR by pressing the TEST button on the Display Console Fault conditions in external sensors are detected without a 032 SWING FOTENTIOMETERSA System Self Test oa SWING POTENTIOMETER Faults detected in the System during Self Test are indicated on the Display Console in the following way GROUP B IO FAULTS e The RED LAMP will illuminate and the NO FAULTS AUDIBLE ALARM will sound Diagnosis of a Fault is obtained by PRESSING and HOLDING the TEST button The System will then go ANALOG AND CUTER through a Self Test followed by the appearance of a Fault DIGITAL INPUT AND OUTPUT DISPLAY UNIT Code screen The Fault Code screen will remain visible as long as the TEST button is pressed Information will be GROUP MEMORY FAULTS displayed on the screen in the four groups shown in Figure 5 0 Note Always repair Analog Sensor Faults AAA prior to 01 PROGRAM 00 NO FAULTS investigating other fault
48. n to operate correctly MOISTURE The Display Consoles both bracket and flush mounted designs offer adequate protection against dust and water when correctly installed However they are unlikely to fully protect the sensitive electronic assemblies inside against pressure washing or heavy rainfall In this case replace the Console especially if moisture is visible behind the Display windows OPERATOR DISPLAY CONSOLE REMOVAL AND INSTALLATION REMOVAL OF HORIZONTAL AND VERTICAL FLUSH MOUNT CONSOLES 1 Remove and set aside the four mounting screws on the defective Operator s Display Console 2 Disconnect the cable and ground wire from the connector on the rear of the defective Operator s Display Console INSTALLATION OF HORIZONTAL AND VERTICAL FLUSH MOUNT CONSOLES 1 Attach the electrical cable to the electrical connector on the new Console 2 Attach the new Operator s Display Console to the cab with the four mounting screws REMOVAL OF HORIZONTAL BRACKET MOUNT CONSOLES 1 Disconnect the electrical cable from the electrical connector on the rear of the Operator s Display Console 2 Remove the defective Operator s Display Console from the bracket in the cab by removing the knob on each side of the Console Retain the knobs for future use INSTALLATION OF HORIZONTAL BRACKET MOUNT CONSOLES 1 Install the new Operator s Display Console on the bracket in the cab by positioning it between the bracket legs and inserting and tightening
49. ns B and G of the cable and lift the ATB WEIGHT The resistance is low during normal operation and should switch to OPEN when the weight is lifted SkyAz l Equipment Solutions www skyazul com 301 371 6126 15 16 SWING POT SENSOR FAULT CODE AAA 096 The Swing Pot Sensor is 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 to D 2 5k 20 Measure the wiper arms from pin B to E 1 88k 200 If power going to the Swing Pot is cut or if either wiper arm opens the System will report a Fault Refer to Section IV SWING SENSOR page 64 SkyAz l Equipment Solutions www skyazul com 301 371 6126 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 If the voltage is missing or out of range the System will send forth an alarm The Boom Extension Sensor is located inside the Boom Extension Box PROBLEM ACTION RESULT INDICATOR OUT OF Press and hold the TEST Fault Code AAA 004 SERVICE Alarm button AIN2 is not getting voltage Measure AIN2 on the Retracted ABOUT 2v or is out of range Termination Board The vol
50. ns www skyazul com 301 371 6126 EXTENSION REEL 2 BLOCK SWITCH AT 2 BLOCK SWITCH AT MAIN JIB HEAD BOOM HEAD CABLE 3 4 1 ATBLO OV VP I ATB 28 BOARD COMPUTER UNIT FIGURE 4 22 gt ANTI TWO BLOCK FUNCTION SkyAz l Equipment Solutions www skyazul com 301 371 6126 61 POWER DISCONNECT amp 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 amp B of the machine Note Some models may not use a power cable but have the connector on the wire harness MODEL BOOM MODE D3 AIB E1 AIB E9 AIB F1 F2 MAIN MANUAL FIGURE 4 23 TABLE SHOWING BOOM MODES SEE THE SYSTEM DIAGRAM ON THE INSIDE BACK COVER FOR A TYPICAL MOTION DISCONNECT CIRCUIT SkyAz l Equipment Solutions www skyazul com 301 371 6126 62 1 COMPUTER UNIT MEN gs reg eg py O E SH TE E PEE EE 1 1 1 TB6 I DOUT4 ORANGE SPARE CL 79 1 5VA YELLOW SPARE CL I 1 CON
51. oad The other Sensor monitors the D TOC SBD SS ug pressure necessary to control the position of the Boom The Computer Unit uses this information FIGURE 4 15 PRESSURE SENSOR CONNECTOR along with that from other sensors such as Extension Length and Angle to compute the weight of the suspended load Continued on page 55 SkyAz l Equipment Solutions www skyazul com 301 371 6126 1 RED RED DR gs x BLUE S BLUE gt CABLE 1 YELLOW YELLOW Z PISTON TX0 2 GREEN E 2 SS RED DR s BLUE BLUE N CABLE 2 DR D S YELLOW YELLOW 2 ROD TX1 B z GREEN GREEN TEE E FIGURE 4 16 PRESSURE SENSOR CONNECTION TO THE COMPUTER The maximum continuous working pressure for these devices is 250 Bar 3625 psi There are no user serviceable parts within the Pressure Sensor A defective unit should be replaced Refer to Pressure Sensor Removal and Installation page 59 PRESSURE CHANNEL FAULT GUIDE A fault in a pressure sensor can cause an apparent fault in the other channel It is necessary therefore to test both channels and both sensors together in order to determine which sensor is at fault FUNCTIONAL TESTS PRESSURE CHANNEL FAULT GUIDE FUNCTIONAL TEST 1 Boom down all the way ensuring that the boom hoist cylinders are fully retracted Switch off the engine 2 Loosen the pressure sensor fittings to ensure that no pressure remains 3 Turn on the
52. oltage is still out of range the Computer 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 T f after reconnecting any one of the sensor cables the Analog Drive Voltage goes out of range the wiring to the sensor is probably grounded or the sensor itself is faulty 8 Check all wiring and the sensor itself Repair the faulty wiring or replace the defective sensor SkyAz l Equipment Solutions www skyazul com 301 371 6126 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 See Accessing the Computer Board and the Termination Board page 34 2 Release the two screws located at opposite ends of the Computer Board Mounting Plate Carefully swing the Computer Board Mounting Plate up and out of the way 3 Disconnect both ribbon cables at the Termination Board connectors by pushing the locking tabs outwards The connectors will automatically eject 4 Disconnect the following three wires that connect the key switch on the Computer Board Mounting Plate to the Termination Board see Figure 4 2 e RedWire gt Relay 1 C Terminal Block TB7 PIN 7 e Blac
53. omputations control the disconnect functions and communicate with the Display Console Certain crane functions require different wiring within the Computer Unit The Computer Unit is manufactured with and identified by Serial Number Prefix Please refer to the label on the Unit or the LBCE Parts Manual COMPUTER UNIT COMPONENTS The Computer Unit contains two major assemblies the Computer Board E and the Termination Board H shown in Figure 4 1 These boards are in an aluminum box G usually located on the rear wall of the cab On some crane models they are outside of the cab The Computer Board containing the microprocessor and its related components is held in place by screws D located on each end of the Computer Board Mounting Plate C The Computer Board is connected to the Termination Board via two ribbon cables K that carry signals to and from the Termination Board All of the cables from the various sensors and the Display Console connect to the Termination Board via the connectors J in the wall of the box The key switch F controls three wires that connect the Computer Board to the Termination Board SkyAz l Equipment Solutions www skyazul com 301 371 6126 FIGURE 4 1 COMPUTER UNIT COMPONENTS DR AINO AIN1 DR ov DR DR
54. p Angle Sensor l l 22 1 1 1 1 1 9993335355 P endete EE SEE Enn sac OT TE TS ix MATT EUN Cable 8 Display Console I i Power Motion Disconnect 1 Connection A j Cable 7 I rm 1 Connector 8 L d Connector 7 1 0 1 Gonnector e Bargraph Display Optional i Cable 5 7 Connector 5 28 1 acre EE ESO I Swing Pot Cable 6 Connection 1 Inside Collector Column 1 Cable 3 Connector 3 T I Cable 2 Pressure Transducer Connector 2 j Rod Side 1 iod Cable 1 Pressure Transducer Piston Side 1 1 Computer Unit 1 Mounted behind seat in Cab 1 1 UPPER STRUCTURE Cranes with Serial Number E1 SkyAz l Equipment Solutions www skyazul com 301 371 6126 25 26 SYSTEM LAYOUTS WITH CORRESPONDING SERIAL NUMBER PREFIX CONTINUED 2 SYSTEM INSTALLATION Mounted on attachment Head 80 Anti Two Block Anti Two Block Reel Off Cable to Boom Head Switch Switch Mounted at Boom Head BOOM tension Drum amp Angle Sensor
55. s A complete listing of all possible 02 DUTY ROM Fault Codes and the description of each is listed on the 04 SCRATCHPAD RAM following pages 08 GROUP DD GENERAL FAULTS 00 NO FAULTS 01 NO DUTY FOUND 02 FIGURE 5 0 FAULT CODES SkyAz l Equipment Solutions www skyazul com 301 371 6126 67 68 FINDING AND UNDERSTANDING FAULT CODE S A Display Console window shown below shows how the various Fault Codes will be exhibited The following tables have been created to simplify the identification of Faults detected by the Computer Some Faults involve a combination of Code Numbers indicating that there may be more than one problem or that a single problem is affecting other operations Each Fault Code Number has been identified in the following pages on the left side of the tables and described in the column to the right For Example If Code Number 009 appears in the Fault Code window the Operator would check the table below under 009 in the left column To the right the Operator would see the description as Faults 001 and 008 Looking again in the left column we see that 001 indicates a Piston Pressure Sensor problem and 008 indicates a Boom Angle Sensor problem Read the sections relating to these operations in Section IV of this Troubleshooting Manual and report the findings to the Service Representative AAA Fault Codes FAULT No DESCRIPTION BOOM ANGLE SENSOR
56. s 001 008 016 amp 064 d ios SkyAz l Equipment Solutions www skyazul com 301 371 6126 AAA Fault Codes continued AAA Fault Codes continued FAULT No DESCRIPTION FAULT No DESCRIPTION Faults 002 004 008 032 amp 064 Faults 001 002 004 008 032 amp 064 Faults 016 032 amp 064 Faults 001 016 032 amp 064 Faults 002 016 032 amp 064 Faults 001 002 016 032 amp 064 Faults 004 016 032 amp 064 117 Faults 001 004 016 032 amp 064 Faults 002 004 016 032 amp 064 Faults 001 002 004 016 032 amp 064 Faults 008 016 032 amp 064 Faults 001 008 016 032 amp 064 Faults 002 008 016 032 amp 064 Faults 001 002 008 016 032 amp 064 Faults 004 008 016 032 amp 064 Faults 001 004 008 016 032 amp 064 Faults 002 004 008 016 032 amp 064 127 Faults 001 002 004 Faults 001 002 008 016 amp 064 Faults 004 008 016 amp 064 Faults 001 004 008 016 amp 064 Faults 002 004 008 016 amp 064 Faults 001 002 004 008 016 amp 064 Faults 032 amp 064 e E Faults 001 032 amp e e Faults 002 032 amp 064 Faults 001 002 032 amp 064 Faults 004 032 amp Faults 001 004 032 amp 064 Faults 002 004 032 amp 064 Faults 001 002 004 032 amp 064 Faults 008 032 amp 064 Faults 001 008 032 amp 064 Faults 002 008 03
57. s 2 AV1dSIG e AO 2 9 81 13539 9 s Alddns Em noe va G4vog NO SLOWSY A va gt NG A8 v Je g 0 8 077 Age E gt AS 552 AGC G 9NIV 5 gt SNIMS o AGL HW m 09 GION3 10S ALITVNOSUJd 29l aud aiv Yr 3GonN WHO 095 p 04 74 NSSIYd j A NO LSId S yd 2 D VN m 4 221 51 N 086 Are 34 NSSIUJd st zal GON 1 0X1 7 81 Mare zt gt 0XL 2 AS 82 zal s ST J4vds T 3s NVYOVIG real ud 2 2 HOLIMS SSVd AB 4 1 AXONS YAW E SNOLLISOd g tul 21 691 VASON NI NMOHS TY N ZNIV NOISN3 LLX3 HOLIMS SSVd A8 ANY SAVTHH JHL ONILVAZdO IVNYON HL 01 281 L 1nog NIG NMOHS SSHOLIMS E1v dS dn ONALXA NMOG 2 e 1SIOH wood woos c Ta ino 13 e A0 b t quvog W XVOO A X9078 NOOE NIYIN gif Anya SIION31OS 3NVNO 4 89 301 371 6126 www skyazul com SkyAz l Eguipment Solutions 75 SkyAz l Inc 200 W Main Street Suite 2A Middletown MD 21769 Phone 301 371 6126 EQUIPMENT SOLUTIONS Fax 301 371 0029 www sk
58. tage increases as the boom is extended The Extension Sensor is Measure the 5 25v on the not getting 5 25v from the terminal strip inside the computer Extension Reel Check cable 3 NOTE The computer may need to be re calibrated when the Extension Sensor is replaced or adjusted Please refer to the MicroGuard 434 System Diagram on the inside back cover of this manual Also review Section IV in this Manual for a detailed discussion of the Extension Sensor SkyAz l Equipment Solutions www skyazul com 301 371 6126 17 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 3 on the Termination Board The voltage on is about 437v when the Boom is at 0 and 4 375v at 90 If the voltage is missing or out of this range the System will display a Fault The Angle Sensor is located inside the Boom Extension box PROBLEM ACTION RESULT System Overload Press and hold the Alarm TEST button AIN3 not getting Measure AIN3 on the Boom angle 0 lt 437v voltage or is out of Termination Board Boom angle 30 1 750v range Boom angle 60 3 062v Boom angle 90 4 375v The Angle Sensor is Measure the 5 25v on not getting 5 25v from the terminal strip the computer inside the Extension Reel Check cable 3 NOTE The computer may need to be re calibrated when the angle sensor is replaced or adjusted FOR A MORE
59. ted to white DRive and the positive lead of the multimeter 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 the cable between the reel and the computer or the boom angle sensor SkyAz l Equipment Solutions www skyazul com 301 371 6126 50 Drive Voltage Ain2 voltage varies with Boom lengt AIN3 Voltage varies with Boom angle 0 4V at 0 deg 3 02V at 60 deg TB4 FIGURE 4 12 TERMINATION BOARD AIN2 LENGTH WHITE WIRE BLUE GREEN DR ANGLE SIGNAL TO AIN3 FIGURE 4 13 EXTENSION REEL TERMINAL STRIP SkyAz l Equipment Solutions www skyazul com 301 371 6126 91 52 may be faulty ANTI TWO BLOCK FUNCTION The Anti Two Block Function is a safety function that signals an impending collision between the hook block or ball and head sheaves When the distance between these points is within an acceptable range there is a zero voltage reading As distance changes to a dangerous zone a voltage registers and releases a warning and or a danger alert Refer to Anti Two Block Function page 59 EXTENSION REEL PARTS REMOVAL AND INSTA
60. the Computer Box 3 Remove the Remote Bar Graph from its bracket by loosening and removing the knob at each end of the Remote Bar Graph Retain the knobs for reuse INSTALLATION OF A REMOTE BAR GRAPH 1 Putthe new Remote Bar Graph in position Reconnect and tighten the two knobs 2 Route the cable to the computer box and connect the cable Store excess cable line 3 Turn on the power and ensure that the Remote Bar Graph operates correctly SkyAz l Equipment Solutions www skyazul com 301 371 6126 45 46 iz a THE EXTENSION REEL The primary operation of the Extension Reel is to measure the extension of the telescoping sections of the boom The Extension Reel includes an Anti Two Block function that provides an electrical path for transmission of a signal to the Computer Unit The Computer transmits this signal to the Operator s Display Console warning the operator of an impending Two Block problem 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 horizon SkyAz l Equipment Solutions www skyazul com 301 371 6126 iu s ia RES yAw I CHECKING TESTING THE EXTENSION REEL FUNCTIONS To check or test the following e Boom Extension Sensor See Checking the Voltage of the Boom Extension Sensor page 48 e Boom Angle Sensor See Checking the Voltage of the Boom Angle Sensor page 5
61. the knob on each side of the Operator s Display Console continued on next page SkyAz l Equipment Solutions www skyazul com 301 371 6126 42 2 Connect the electrical cable to the electrical connector on the rear of the Operator s Display Console Refer to Figure 4 8 REMOTE BAR GRAPH The Remote Bar Graph shown below monitors the percentage of rated capacity in use The Remote Bar Graph is normally mounted near the operator for easy viewing Four user selectable levels of brightness are available on the device which is designed for reading under all lighting conditions Defective Remote Bar Graphs cannot be serviced Refer to Remote Bar Graph Removal and Installation page 45 FIGURE 4 9 REMOTE BAR GRAPH The Remote Bar Graph is optional and is not used on all cranes CHECKING THE REMOTE BAR GRAPH The Remote Bar Graph is normally very reliable However when operated for extended periods under extreme conditions the device 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 D LL rd ka aa 1 COMPUTER UNIT I T ce t l l CONNECTOR 5 MS3474W14 5SY OPNS BARGRAPH UNIT CABLE 5 MS3475W14 5PY l FIGURE 4 10 BAR GRAPH UNIT 1 TERMINATION BOARD CONNECTION TO COMPUTER 1 L
62. ting 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 The ATB board opens Relay 2 disabling crane motions The ATB board also sends a signal to the computer through DIN 13 allowing the computer to display an ATB alarm on the Operator s Display Console The ANTI TWO BLOCK limit switch connects to the computer through a coax cable slip rings inside the Reeling Drum Assembly and through cable 3 Please refer to EXTENSION REEL Section IV PROBLEM CRANE MOTION REASON DISABLED There is an ATB ALARM The ANTI TWO BLOCK circuit is open Check but there isn t a TWO the connectors cables and slip rings for BLOCK condition on the continuity The slip rings are inside the crane Extension Reel Check the position of the Selection Switch mounted on the Anti Two Block Switch It can be set at Main Both or Jib and should be set to reflect the configuration of the crane There is an ATB ALARM CRANE MOTION The ATB board is not holding DIN 13 Hi but there isn t a TWO Check the wire from the ATB board to the BLOCK problem on the Termination Board crane There is NO ATB ALARM CRANE MOTION OK The ANTI TWO BLOCK circuit is shorted to when the weight is lifted ground Unplug cable 3 to disconnect the ATB switch This generates an ATB ALARM With an Ohm meter measure pi
63. to sockets The parts that are most prone to incorrect insertion are the four largest IC chips IC2 IC3 IC7 amp IC4 The pins on these devices are very easily bent and may not be connecting to the socket underneath Carefully inspect the board under a good light looking down at the space between each chip and its socket to detect a bent pin e Computer Box Wiring Termination Board Assembly Cable ends must conform to the following requirements and must be carefully inserted o Wire Length Measure wire length carefully Wires that are too long get trapped or pinched when the Termination Board Assembly is replaced or when SkyAz l Equipment Solutions www skyazul com 301 371 6126 34 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 Too much exposed wire may mean that a short circuit could occur between adjacent conductors Warning Ensure that all of the strands of a stripped wire are inside the Terminal Block Loose strands of wire sometimes short to adjacent Terminal Blocks or even to other cables e Fuses Two fuses on the Termination Board protect INTERNAL POWER the equipment during abnormal or extreme TEST POINTS conditions Fuse failure is usually due to excessive current
64. yazul com info Gskyazul com
65. zul Equipment Solutions www skyazul com 301 371 6126 HO U OO CHECKING THE OPERATOR S DISPLAY CONSOLE The Operator s Display Console is normally very reliable However when operated for extended periods under extreme conditions the Console can become damaged The damage is not always apparent To help identify subtle faults that are sometimes difficult to find or that may be attributed mistakenly to other kinds of problems please review the following comments READING THE LIQUID CRYSTAL DISPLAYS Always adjust the Display contrast first On bracket mounted models only reposition the Display Console slightly The most commonly encountered problem is caused by reflections Note It may not be possible to correct this problem completely especially on flush mounted Display Consoles exposed to bright sunlight If the problem concerns the contents of one or more of the Display Screens refer to the Problem Finder Flow Charts in this Manual BUTTONS THAT DON T RESPOND All button options are not available for use at all times Ensure that the non responsive button is programmed to respond at that point in the operation of the System Press the button in the center Pressing the printed symbol at one end may not activate the switch underneath Buttons that are damaged or have a surface that is worn may cause the switch underneath to operate improperly In this case refer to Operator s Display Console Removal and Installation p

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