Microguard 424 Operators Manual PDF

Greer Company
Crane Systems
MICROGUARD 424
RATED CAPACITY INDICATOR SYSTEM
OPERATION/TROUBLESHOOTING
MANUAL
TELESCOPIC BOOM CRANES
HORIZONTAL DISPLAY
1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel:(714) 259-9702 Fax:(714) 259-7626
MICROGUARD 424 OPERATION/TROUBLESHOOTING MANUAL PN W424103 REV A 02/13/01
Greer Company
Crane Systems
The Greer Company is dedicated to the design and

manufacture of electronic parts created to aid in crane
operation and in the protection of crane operators and
associated personnel. This manual has been
developed to assist in helping Service Personnel to
understand, locate, and identify problems that may
arise during the operation of the MicroGuard®424
Rated Capacity Indicator System. Persons using this
Manual must be familiar with the MicroGuard®424
System and with Electrical Servicing. Use of
calibration routines without consultation with the Greer
Company will invalidate the warranty.
MicroGuard 424 Operation/Troubleshooting Manual Horizontal Display Hydraulic Cranes
Page 2 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
MICROGUARD 424
RATED CAPACITY INDICATOR SYSTEM
OPERATION/TROUBLESHOOTING MANUAL
TABLE OF CONTENTS
SECTION 1: OPERATION
MICROGUARD 424 SYSTEM DESCRIPTION...............................................................................................4
DISPLAY WINDOWS ....................................................................................................................................5-6
PUSH BUTTONS - ICONS - LAMPS - ALARMS.........................................................................................7-10
MICROGUARD 424 SYSTEM OPERATION ................................................................................................11
CONFIGURATION SELECTION ...............................................................................................................12-15
EXAMPLES OF CRANE SET UP .................................................................................................16-20
MAIN BOOM .............................................................................................................................16
MAIN BOOM PLUS 35' OFFSETTABLE FLY...........................................................................17
MAIN BOOM PLUS 48' TELESCOPING FLY...........................................................................18
ON TIRES .................................................................................................................................19
RIGGING/TRAVEL MODE........................................................................................................20
OPERATOR SETTABLE ALARMS ...........................................................................................................21-24
METHOD OF SETTING.....................................................................................................................22
EXAMPLES OF SETTING ALARMS ............................................................................................23-24
CANCELING ALARMS ......................................................................................................................24
PERIODIC INSPECTIONS ........................................................................................................................25-26
CHECKING THE ANTI TWO-BLOCK SYSTEM...........................................................................25-26
ROUTINE MAINTENANCE ...............................................................................................................26
SECTION 2: TROUBLESHOOTING .....................................................................................27-51
Page 3 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
MICROGUARD 424 SYSTEM DESCRIPTION

This manual describes the function and operation of the MicroGuard 424 Rated Capacity Indicator (RCI)
System for telescopic boom cranes. The MicroGuard 424 System is intended to aid the crane operator in
efficient crane operation by continuously monitoring the load and warning of an approach to an overload or a
two-block condition. This System, which monitors crane functions by means of high accuracy sensors,
continuously compares the load suspended below the boom head with data from a copy of the crane capacity
chart, stored in the computer memory. If an overload is approached, the MicroGuard 424 System warns the
operator by means of audible and visual alarms and can be configured to cause function kick-out.
M icroG uard 424

TEST
W
100%
M AX
C RA N E STO W ED W O RKIN G
SET U P D ED U CT A REA
D ED U CT
EREC TED STO W ED
W IN FO RM A TIO N
V IEW SET C LEA R DO W N UP
O PERA TO R A LA RM S C O N TRA ST
SELEC T
The MicroGuard 424 indicator provides the operator with a continuous display of:
♦ Rated Capacity
♦ Actual Load
♦ Percentage of Rated Capacity
♦ Radius of the Load
♦ Angle of the Main Boom
♦ Working Area
♦ Crane Configuration
And by means of alternate display push buttons, it provides the operator with:
♦ Length of the Main Boom
♦ Height of the Boom Head
On-screen messages provide the operator with visual indications of the various alarms, which may occur
during normal operation of the MicroGuard 424 System. These values are displayed on the left and upper
right display. The lower right display gives information about the currently selected crane configuration.
Page 4 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
DISPLAY WINDOWS
LEFT DISPLAY WINDOW
1 MAXIMUM RATED CAPACITY is a digital

display of the maximum permitted capacity.
M icroG uard 424 It is derived from the crane's capacity chart.
A copy of this chart is stored in the computer
TEST
memory and is the reference capacity for
W
100% 2 any lifting operation. Maximum Rated
M AX
Capacity is dependent on the configuration

1 3
5.82 60% currently selected. This configuration, shown
in the lower right display, determines the
5 3.46 A TB A LA RM 4
section of the capacity chart to be used as
W IN FO RM A TIO N the capacity reference. If maximum rated
capacity is limited by parts of line, then the
V IEW SET CLEA R DO W N UP displayed MAXIMUM RATED CAPACITY is
the rope capacity and the message, "ROPE
O PERA TO R A LA RM S CO N TRA ST LIMIT" is displayed in the information area.
2 The BAR GRAPH is an analog bar graph in the upper display that gives a visual indication of how much
of the crane capacity is being used and the rate at which an overload is being approached. This
bar graph in conjunction with the 100% capacity marker gives a visual indication of when the overload
point is reached.
3 PERCENTAGE OF RATED CAPACITY is a part of the bar graph display. A digital readout
within the bar graph display expresses Actual Load as a percentage of Maximum Rated Capacity.
For percentages of less than 100%, the display will be at the right side of the bar graph.
For percentages over 87%, the display will move to the center of the bar graph in order to make
space for the leading edge of the bar graph.
4 The INFORMATION AREA provides the operator with a visual indication of the various alarms, which
may occur during normal operation of the MicroGuard 424 System. For example, PRE-ALARM or
OVERLOAD, ATB ALARM, and ROPE LIMIT.
5 ACTUAL LOAD is a digital display that shows total load suspended below the boom or jib head. It
includes the load, slings, pins or tackle used to secure the load and the hook block.
Page 5 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
DISPLAY WINDOWS
RIGHT SIDE DISPLAYS

1 The RADIUS/HEIGHT display gives a
2
3 continuous indication of the radius of the load,
which is the horizontal distance from the
57.2 8 F 49.1
1 4 centerline of rotation to the centerline of the
OUTRIGGERS 360° hook. When the Radius/Height push button is
6
CRANE STOWED WORKING
5 pressed, the display will give a momentary
SET UP DEDUCT AREA readout of the height of the boom head above
DEDUCT ground level i.e., the vertical distance from the
ERECTED STOWED
ground to the boom/jib head. Information about
MAIN BOOM height is only displayed while the Radius/Height
7
push button is pressed and held.
2 The PARTS OF LINE display shows the parts

SELECT
of line currently selected. If the parts of line
selected has a lower safe working strength than
the actual capacity, the MAXIMUM RATED
CAPACITY display will show the reduced
capacity and the message, "ROPE LIMIT" will appear in the information area.
3 The WINCH IN USE display indicates the selected winch. "F" indicates front; "R" indicates rear.
4 The ANGLE/LENGTH display gives a continuous indication of the angle of the main boom relative to
horizontal. When the angle/length push button is pressed and held, the display will give a momentary
readout of the length of the Main Boom from the boom foot pin to the shaft of the head machinery.
Information about length is shown only while the Angle/Length push button is pressed and held.
5 The WORKING AREA is located in the lower right of the middle display. Descriptions conform to the
current configuration selected and to the swing position of the crane upper. For example, the following
messages will appear:
Front, Side, Rear, 360°
Line, Track (between tracks)
6 The OUTRIGGERS or TIRES display is locateded in the lower left of the middle display. Readout is
determined by the current duty selection.
7 The LIFTING POINT is continuously shown in the lower display. If an attachment such as a fly
is erected but is not the lifting point, the DEDUCT (see Push Buttons, Icons, and Lamps) light
will be illuminated.
Page 6 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
PUSH BUTTONS - ICONS - LAMPS - ALARMS
LEFT DISPLAY
1 2 3 4 1 TEST is a push button used to initiate a system

self-test; it is also used to display fault codes.
TEST
2 CANCEL ALARM is a push button used to silence
100%
8
W
MAX 5 the audible alarm when the alarm has occurred as
a result of either an Overload, an Anti Two-Block
LEFT DISPLAY alarm, or an Operator Settable alarm. CANCEL
ALARM is also used to reset the function kick-out
7
W
INFORMATION 6 relay when it is necessary to by-pass function
kick-out.
VIEW SET CLEAR DOWN UP
3 The PRE-ALARM (AMBER) indicator illuminates
at a pre-set value of 90% of Maximum Rated
9 10 11 12 13 Capacity and provides a visual indication of an
approach to an overload.
4 The OVERLOAD INDICATOR (RED) illuminates at a pre-set value of 100% of Maximum Rated Capacity
and provides a visual indication of Maximum Allowed Load. The OVERLOAD INDICATOR will also
illuminate whenever an anti two-block (A.T.B.) alarm occurs or a wire rope limit is exceeded or an
operator SETTABLE alarm has been reached or exceeded. When the crane is equipped with function
kick-out, this will occur simultaneously for an Overload, Wire Rope Limit, or an Anti Two-Block condition,
but function kick-out will not occur when exceeding an operator set alarm.
5 The BAR GRAPH ICON is a part of the analog bar graph in the upper display. This display bar graph
gives a visual indication of how much of the crane's capacity is being used and the rate at which an
overload is being approached. The leading edge of the bar graph aligns with three colored bands in the
bar graph indicator. Red indicates an overload. Between the red and amber is a black notch, which
indicates 100% of rated capacity. The 100% RATED CAPACITY indicator is above the bar graph in the
upper display and marks the point at which 100% of the rated capacity of the crane has been reached.
When the value of 100% has been reached, it corresponds to the Maximum Rated Capacity in the upper
display.
6 The INFORMATION AREA indicates the area of the upper display that provides the operator with a visual
indication of the various alarms, which may occur during normal operation of the system.
7 The ACTUAL LOAD ICON indicates the area of the display that shows the total load suspended below
the boom, fly, or jib head. It includes the load, any slings, pins or tackle used to secure the load and also
includes the weight of the hook block.
8 The MAXIMUM RATED CAPACITY icon indicates the area of the upper display that gives a readout of
maximum rated capacity for the currently selected configuration.
Page 7 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
OPERATOR ALARM BUTTON
BUTTONS
S AND CONTRAST
9 VIEW is a push button used during the setting of operator alarms. It is used to start the routine and to
view the current alarm settings.
10 SET is a push button used during the setting of operator alarms to set a new alarm setting.
11 CLEAR is a push button used during the setting of operator alarms to clear the current alarm setting.
12 CONTRAST (DOWN) is a push button used to decrease the display contrast.
13 CONTRAST (UP) is a push button used to increase the display contrast.
Page 8 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
UPPER RIGHT DISPLAY
1 The RADIUS/HEIGHT icon

2 3
indicates the area of the display
4
that gives a readout of radius
1
and height. This icon is also a
push button used to select the
alternate display of height.
UPPER RIGHT DISPLAY HEIGHT is displayed only when
the push button is pressed and
held. When this push button is
not pressed, the display
7 5 readout is always the radius of
SET UP DEDUCT AREA
the load.
6 2 The PARTS OF LINE icon
indicates the area of the display
that gives a read-out of the parts of line currently selected. This icon is also a push button used to select
the parts of line in use on the selected winch.
3 The WINCH SELECT icon indicates the area of the display that gives a readout of the winch currently
selected. This icon is also the push button used to select the Front or Rear winch. When switching
between winches, the parts of line previously selected for the other winch is recorded and displayed
whenever the alternate winch is selected.
4 The ANGLE/LENGTH icon indicates the area of the display that gives a read-out of angle or length. This
icon is also a push button used to select the alternate display of Length. Length is displayed only when
the push button is pressed and held. When this push button is not pressed, the display will always show
the Angle of the main boom.
5 WORKING AREA indicates the part of the display where messages can be displayed. Messages in this
area will conform to the current duty selection and the swing position of the crane upper.
6 STOWED DEDUCT is a push button that is used to start the selection of deducts for stowed attachments.
The first press of the button will start the menu, after which it will function as a down-arrow for scrolling.
7 CRANE SET UP indicates the area of the display showing a read-out of the currently selected crane
configuration (on OUTRIGGERS or TIRES). CRANE SETUP is also a push button used to start the
selection of configurations.
Page 9 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
LOWER RIGHT PUSH BUTTONS AND ICONS
2
3
1
DEDUCT
ERECTED STOWED
SELECT 4
6
1 and 3 UP/DOWN ARROWS are push buttons used as arrows for scrolling.
2 DEDUCT INDICATOR is an icon that contains two amber lamps, which indicate stowed and
erected deducts. When a deduct is selected, the appropriate lamp will illuminate to warn the
operator that a deduct has been applied.
4 and 6 RIGHT and LEFT ARROW are push buttons used in calibration routines.
5 SELECT is a push button used to terminate all selection and calibration routines.
Page 10 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
MICROGUARD 424 SYSTEM OPERATION
At start-up, the MicroGuard 424 System automatically performs a self-test. Upon completion of the self-test,
the System goes directly to the normal working screen. The self-test can be initiated at any time during
normal operation by pressing the TEST button.
TEST
One press (press and release) will cause the system to execute a self-test routine during which all lamps,
audible alarms, and digital displays will be functionally tested, and all memory areas will be checked for
accuracy. If faults in the system are detected during a test, the information area in the upper display will show
the word FAULT. If the word FAULT occurs, press and hold the TEST button. This will cause the display to
change to the FAULT mode. In this mode, information about the fault condition will be displayed in the middle
display by means of an error code.
CANCEL ALARM
CANCEL ALARM is used to cancel the audible alarm when the alarm has occurred as a result of either an
Overload, an Anti Two-Block alarm (A.T.B.) or an Operator Settable alarm. The audible alarm may be
canceled by pressing and releasing the CANCEL ALARM button. The audible alarm remains canceled
until the condition, which caused the alarm, has been removed. For example, if the audible alarm was
canceled because of an overload condition, it will remain canceled until the overload condition is removed.
However, if a different alarm (e.g., an anti two-block condition) was to occur when the audible alarm was still
canceled for an earlier overload condition, the new alarm condition would cause the audible alarm to be
restarted.
CANCEL ALARM is also used to reset the function kick-out relay when it is necessary to by-pass a function
kick-out that has occurred as a result of either an overload or an A.T.B. alarm. The relay is reset by first
canceling the audible alarm [as described above] and then pressing and holding the CANCEL ALARM button
for about 3 seconds, after which the function kick-out relay will be set to normal operation. However, should
another different alarm condition occur when the relay had previously been overridden, then the newly
occurring alarm condition would cause the motion cut to be restarted.
CANCEL ALARM is a temporary function. The audible alarm or function kick-out is automatically reset when
the condition that caused the alarm is no longer present.
WARNING
WHEN FUNCTION KICK-OUT IS RESET BY MEANS OF THE CANCEL ALARM BUTTON YOU ARE NO
LONGER PROTECTED AGAINST THE CONDITION THAT CAUSED THE FUNCTION KICK-OUT.
Page 11 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
CONFIGURATION SELECTION
In the normal operational mode, the MicroGuard 424 System is programmed to retain the configuration last
selected. Each time the system is powered up, it will automatically choose that configuration. Only when the
crane is rigged differently must a new configuration be selected.
CRANE SET UP
The menu for the crane set up consists of up to 7 consecutive steps. Steps that are not available are
automatically skipped by the program during the Crane Set Up procedure.
1. Select Outriggers, Tires, Rigging/Travel mode.
2. Select Counterweight configuration (If available).
3. Select Boom configuration or Telescope Mode (If available).
4. Select Auxiliary Head fitted or not fitted.
5. Select Lifting Attachments.
6. Select Lifting Point for Front Winch.
7. Select Lifting Point for Rear Winch.
AFTER THE SELECTIONS MADE DURING CRANE SET UP, IT IS ONLY NECESSARY TO USE THE
WINCH PUSH BUTTON TO SELECT THE LIFTING POINT. ALL OF THE INFORMATION REQUIRED BY
THE SYSTEM IS ENTERED DURING CRANE SET-UP. THE PARTS OF LINE IN USE FOR EACH WINCH
MUST ALSO BE SET FOR THE SYSTEM TO OPERATE CORRECTLY.
FOR SPECIFIC EXAMPLES OF CRANE SET-UP, REFER TO PAGES 16-20.
PARTS-
PARTS-OF- OF-LINE
Press and hold the PARTS-OF-LINE push button to scroll through the available parts of line. The new value
is automatically registered when the button is released. The number chosen applies only to the winch
currently selected and a value must be programmed for both winches.
WINCH
The current selection is shown in the display by use of the letter F for front winch and the letter R for rear
winch. To change the selection, press the WINCH select push button. Successive pressing of the button will
change the selection from one to the other. After the initial setup, the system retains the Parts-of-Line and
Lifting Point and Deducts for each winch.
RIGGING TRAVEL MODE

The Rigging /Travel mode is selected as part of the carrier options. This mode is used to facilitate the rigging
and travel of the crane by inhibiting motion-cut and audible alarm while selected. The information screen is
restricted to the display of radius, length, angle, height and precautionary messages during the time that the
mode is selected. To return to normal operation, press CRANE SET UP.
Page 12 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
STOWED DEDUCTS
When attachments such as flys are stowed, it is necessary to make a reduction in the rated capacity of the
crane. This reduction, also called a deduct, is specified in the capacity chart. The MG424 has the ability to
store this data and to make the deduct from the chart.
This reduction is applied by use of the DEDUCT controls as follows.
Start the selection by pressing the STOWED push button. The display will change to show the current
selection in the center display. Use the UP or DOWN arrow to scroll through the selection menu. When at the
required Deduct, press the SELECT push button to complete the selection of the new Deduct and return to
the normal working screen. In order to remind the operator that a DEDUCT is applied, a lamp is illuminated in
the deduct information panel, which is below the Stowed push button. To view the current selection, when
indicated by the illuminated lamp, press the Stowed push button. After confirming or changing the selection,
press the SELECT push button to complete the selection and return to the normal working screen.
ALTERNATE DISPLAYS
The primary position displays are those of RADIUS and ANGLE. There are alternate displays of HEIGHT and
LENGTH available for display but these are only displayed during the time that the alternate display push
buttons are pressed. Height alternates with Radius, and Length alternates with Angle.
HEIGHT DISPLAY
Height Display is a push button, used to select the alternate display of Height. Height is displayed only when
the push button is pressed and held. When the push button is not pressed, the display always indicates
Radius.
LENGTH DISPLAY
Length Display is a push button used to select the alternate display of Length. Length is displayed only when
the push button is pressed and held. When this push button is not pressed, the display always indicates the
Angle of the main boom.
Page 13 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
CONFIGURATION SELECTION (Link-Belt Model 70 shown)
START THE SELECTION OF CRANE CONFIGURATION BY PRESSING "CRANE SET UP"
CRANE
SET UP
SCROLL TO
CARRIER
× OR Ø OUTRIGGERS
FULLY EXT.
ON TIRES
STATIONARY
PICK AND
CARRY
RIGGING
TRAVEL
SELECT
SCROLL TO
COUNTERWEIGH
T
× OR Ø COUNTERWEIGH
T
COUNTERWEIGH
T
ATTACHED REMOVED
SELECT
SCROLL TO
BOOM
× OR Ø MAIN BOOM MAIN BOOM
+ MANUAL
SELECT
SCROLL TO
AUX. HEAD
× OR Ø AUX. HEAD
FITTED
AUX. HEAD
NOT FITTED
SELECT
SCROLL TO
ATTACHMENT
NO +35' OFSET +35' OFSET +35' OFSET +35' TELE +35' TELE +35' TELE
ATTACHMENT FLY 2° FLY 15° FLY 30° FLY 2° FLY 15° FLY 30°
× OR Ø +48' TELE
FLY 2°
+48' TELE
FLY 15°
+48' TELE
FLY 30°
+61' TELE
FLY 2°
+61' TELE
FLY 15°
+61' TELE
FLY 30°
+45' TUBE +45' TUBE +45' TUBE +45' TUBE +60' TUBE +60' TUBE
JIB 5° JIB 17.5° JIB 30° JIB 45° JIB 5° JIB 17.5°
JIB 30° JIB 45° JIB 5° JIB 17.5° JIB 30° JIB 45°
SELECT
SCROLL TO
FRONT WINCH
LIFTING POINT
× OR Ø +48' TELE
FLY 2°
+48' TELE
FLY 15°
+48' TELE
FLY 30°
+61' TELE
FLY 2°
+61' TELE
FLY 15°
+61' TELE
FLY 30°
SELECT
(CONTINUED ON NEXT PAGE)
Page 14 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
SCROLL TO
REAR WINCH
LIFTING POINT
× OR Ø +48' TELE
FLY 2°
+48' TELE
FLY 15°
+48' TELE
FLY 30°
+61' TELE
FLY 2°
+61' TELE
FLY 15°
+61' TELE
FLY 30°
SELECT
FOLLOWING THE SELECTION OF CRANE SET UP, USE THE WINCH PUSH BUTTON TO SELECT THE
LIFTING POINT. SET THE PARTS OF LINE IN USE FOR EACH WINCH USING THE PARTS OF LINE
PUSH BUTTON.
Page 15 of 52 W424103 REV A 02/13/01
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Crane Systems
CRANE SET-
SET-UP EXAMPLES
MAIN BOOM
♦ FULLY EXTENDED OUTRIGGERS
♦ COUNTERWEIGHT ATTACHED
♦ PICKING FROM THE MAIN BOOM WITH THE FRONT WINCH, 6 PARTS OF LINE
♦ PICKING FROM THE AUXILIARY HEAD WITH THE REAR WINCH, 1 PART OF LINE
♦ THE 35-61' TELE FLY IS STOWED ON THE BOOM
START THE SELECTION BY PRESSING THE

M icroG uard 424 CRANE SET UP BUTTON (ITEM 1)
TEST
3 2
W
M AX
100%
1 4 SELECT "FULLY EXTENDED OUTRIGGERS"
SET U P D ED U CT A REA SELECT "COUNTERWEIGHT ATTACHED"
D ED U CT
EREC TED STO W ED
W IN FO RM A TIO N
SELECT "MAIN BOOM"
V IEW SET C LEA R DO W N UP SELECT "AUX. HEAD" FITTED

SELEC T
SELECT "NO ATTACHMENT"
SELECT LIFTING POINT FOR FRONT

WINCH, "MAIN BOOM"
SELECT LIFTING POINT FOR REAR WINCH, "AUXILIARY HEAD"
PRESS WINCH SELECT (ITEM 2) TO SELECT

FRONT WINCH "F"
PRESS PARTS OF LINE (ITEM 3) TO SELECT 6 PARTS OF LINE

REAR WINCH "R"
PRESS PARTS OF LINE (ITEM 3) TO SELECT

1 PART OF LINE
PRESS STOWED DEDUCT (ITEM 4) TO SELECT

35-61' TELE FLY
THE SYSTEM IS NOW SET UP, AS DESCRIBED ABOVE, AND THE ONLY SELECTION TO BE MADE IS
FRONT OR REAR WINCH FOR THE LIFTING POINT. THE LOAD AND RADIUS WILL BE FOR THE
SELECTED LIFTING POINT.
Page 16 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
CRANE
RANE SET-
SET-UP EX
EXAMPLES
AMPLES
MAIN BOOM PLUS 35' OFFSETTABLE FLY

♦ COUNTERWEIGHT REMOVED
♦ MAIN BOOM + MANUAL, THE AUXILIARY HEAD IS FITTED BUT IS NOT BEING USED
♦ PICKING FROM THE MAIN BOOM + MANUAL WITH THE FRONT WINCH, 6 PARTS OF LINE
♦ PICKING FROM THE 35' OFFSETTABLE FLY AT 15° OFFSET WITH THE REAR WINCH, 1 PART OF
LINE
♦ NO STOWED ATTACHMENTS ON THE BOOM

CRANE SET UP BUTTON (ITEM 1)
M icroG uard 424
TEST
3 2
SELECT "FULLY EXTENDED OUTRIGGERS"
W
100% 4
1
SELECT "COUNTERWEIGHT REMOVED"
M AX
D ED U CT SELECT "MAIN BOOM + MANUAL"

EREC TED STO W ED
W IN FO RM A TIO N
SELECT "AUX. HEAD" FITTED
SELECT "35' OFSET FLY, 15° OFFSET"
SELEC T
SELECT LIFTING POINT FOR FRONT

WINCH, "MAIN BOOM + MANUAL"
SELECT LIFTING POINT FOR REAR WINCH, "35' OFSET FLY, 15° OFFSET"
PRESS WINCH SELECT (ITEM 2) TO SELECT FRONT WINCH "F"

6 PARTS OF LINE

REAR WINCH "R"

1 PART OF LINE
Page 17 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
CRANE SET-
SET-UP EXAMPLES
MAIN BOOM PLUS 48' TELESCOPING FLY

♦ COUNTERWEIGHT ATTACHED
♦ MAIN BOOM, THE AUX. HEAD IS NOT FITTED
♦ PICKING FROM THE 48' TELESCOPING FLY AT 30° WITH THE REAR WINCH, 1 PART OF LINE
♦ NO STOWED ATTACHMENTS ON THE BOOM

CRANE SET UP BUTTON (ITEM 1)
M icroG uard 424
TEST
3 2
SELECT "FULLY EXTENDED OUTRIGGERS"
W
100% 4
1
SELECT "COUNTERWEIGHT ATTACHED"
M AX
D ED U CT SELECT "MAIN BOOM"

EREC TED STO W ED
W IN FO RM A TIO N
SELECT "AUX. HEAD"
V IEW SET C LEA R DO W N UP NOT-FITTED
SELEC T
SELECT "48' TELE FLY, 30° OFFSET
SELECT LIFTING POINT FOR FRONT WINCH, "MAIN BOOM"
SELECT LIFTING POINT FOR REAR WINCH, "48' TELE FLY, 30° OFFSET"

4 PARTS OF LINE

REAR WINCH "R"

1 PART OF LINE
Page 18 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
CRANE SET-
SET-UP EXAMPLES
ON TIRES
♦ PICK AND CARRY CENTERED OVER REAR
♦ COUNTERWEIGHT REMOVED
♦ MAIN BOOM
♦ THE AUXILIARY HEAD IS FITTED BUT IS NOT USED ON TIRES (LBCE NOTE 22)
♦ THE 35-61' TELE FLY IS STOWED ON THE BOOM

TEST
3 2
W
100%
1 4
SELECT "PICK AND CARRY, CENTERED
M AX
REAR"
D ED U CT SELECT "COUNTERWEIGHT REMOVED"

EREC TED STO W ED
W IN FO RM A TIO N
SELECT "MAIN BOOM"
SELEC T
SELECT "AUX. HEAD" FITTED
SELECT "NO ATTACHMENT"
SELECT LIFTING POINT FOR FRONT WINCH, "MAIN BOOM"
SELECT LIFTING POINT FOR REAR WINCH, "AUXILIARY HEAD"

4 PARTS OF LINE

REAR WINCH "R"

1 PART OF LINE
PRESS STOWED DEDUCT (ITEM 4) TO SELECT

35-61' TELE FLY
FRONT WINCH FOR THE LIFTING POINT. THE LOAD AND RADIUS WILL BE FOR THE SELECTED
LIFTING POINT.
Page 19 of 52 W424103 REV A 02/13/01
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Crane Systems
CRANE SET-
SET-UP EXAMPLES
RIGGING/TRAVEL MODE
The Rigging /Travel mode is selected as part of the carrier options. This mode is used to facilitate the rigging
and travel of the crane by inhibiting motion-cut and audible alarm while selected. The information screen is
restricted to the display of radius, length, angle, height and precautionary messages during the time that the
mode is selected.

TEST
3 2
100%
SELECT "RIGGING/TRAVEL MODE"
W
1 4
M AX
C RA N E STO W ED W O RKIN G THE LOWER RIGHT DISPLAY WILL READ:

D ED U CT
EREC TED STO W ED
W IN FO RM A TIO N Rigging/Travel Mode

SELEC T
THE LEFT DISPLAY WILL READ:
To Resume, press
CRANE SETUP
CAUTION!
THE RIGGING TRAVEL MODE INHIBITS ALL MOTION CUT AND AUDIBLE ALARMS FOR ALL ALARM
CONDITIONS. IT IS TO BE USED ONLY FOR THE RIGGING OR TRAVEL OF THE MACHINE DURING
WHICH TIME ALARMS AND MOTION CUT ARE NOT REQUIRED.
BEFORE RESUMING ANY LIFTING OPERATIONS SELECT THE APPROPRIATE CONFIGURATION BY

PRESSING CRANE SETUP.
THE SYSTEM IS NOW SET UP, AS DESCRIBED ABOVE. RADIUS, ANGLE, AND ALTERNATES
LENGTH AND HEIGHT WILL DISPLAYED IN THE RIGGING /TRAVEL MODE BUT LOAD INFORMATION
IS NOT DISPLAYED.
Page 20 of 52 W424103 REV A 02/13/01
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Crane Systems
OPERATOR SETTABLE ALARMS

An additional feature of the MicroGuard 424 System is the provision of Operator Settable Alarms. These
alarms, when properly set by the operator, provide a method of obstacle avoidance. This is achieved by
means of minimum and maximum angle, maximum length and maximum height alarms. These alarms can be
programmed for each job site and set rapidly for the prevailing site conditions, thereby aiding the operator in
the safe operation of the crane.
Most alarms will occur automatically as a result of limitations imposed by the capacity chart. The operator has
control over additional alarms, which are set to define the working range of the machine for particular site
requirements, and which will provide a measure of obstacle avoidance.
Four alarms are available for operator use.
MINIMUM ANGLE
M icroGuard 424 MAXIMUM ANGLE
TEST M A X LENGTH 92.0 MAXIMUM

LENGTH
W
100% M A X HEIGHT 98.5
M AX
CRA NE STO W ED W O RKING

MAXIMUM
M IN ANGLE 31.5 SET-UP DEDUCT AREA HEIGHT
DEDUCT
M A X ANGLE 75.4 ERECTEDSTO W ED
W INFO RM ATIO N
VIEW SET CLEAR DOW N UP
O PERA TO R A LA RM S CO NTRAST SELECT
Page 21 of 52 W424103 REV A 02/13/01
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Crane Systems
METHOD OF SETTING
WARNING
THE FOLLOWING EXAMPLES ARE GIVEN TO ILLUSTRATE METHODS OF SETTING ALARMS. THE
ACTUAL VALUES GIVEN SHOULD NOT BE USED WITHOUT FIRST CHECKING THE CAPACITY CHART
TO ENSURE SAFE, STABLE OPERATION UNDER THE CONDITIONS DESCRIBED.
NOTE
OPERATOR ALARMS WILL BE STORED IN THE COMPUTER MEMORY, EVEN IF THE CRANE IS
SHUTDOWN. THE FOLLOWING PROCEDURES WILL DESCRIBE THE METHOD OF SETTING OR
CANCELING ALARMS.
Alarms can only be SET or CLEARED from within the alarm

LEFT DISPLAY screen. From the main working screen, press VIEW to access the
Operator Alarm screen. The cursor is an arrow that points to the
W INFORMATION alarm, which may be set or cleared and is always at the first
position when entering the alarm screen. It may be moved to any
VIEW SET CLEAR DOWN UP position on the alarm screen by use of the UP/DOWN arrows.
When the cursor is pointing to an alarm, the numerical value
displayed will be the current position of the crane except when that alarm has previously been SET. In this
case, the SET value will be indicated and will alternate with the word, "SET." Alarms which are set but to
which the cursor is not pointing indicate the previously set value. Other alarms, which are NOT SET, are
indicated by the word, "OFF."
The functions of the push buttons when in the alarm screen are:
♦ VIEW Used to access the alarm screen in order to view the currently set alarms.
♦ SET Used to SET the alarm value. The alarm value is determined by the position of the crane at the
time the SET button is pressed.
♦ CLEAR Used to clear a previously SET alarm. Alarms can only be CLEARED when the cursor is
pointing to the item to be cleared. Use the UP/DOWN arrows to move the cursor to the desired alarm.
Press CLEAR to cancel that alarm.
♦ UP/DOWN ARROWS Used to move the cursor up or down the screen to the alarm that is to be
viewed, SET or CLEARED.
♦ SELECT Used to return to the normal operating screen.
Page 22 of 52 W424103 REV A 02/13/01
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Crane Systems
EXAMPLES OF SETTING THE ALARMS
Setting the alarm point is achieved by positioning the crane at the point at which the alarm is to sound and
then, when in the operator alarm screen, using the SET push button to set the alarm. The following examples
illustrate the use of the procedures.
EXAMPLE A
To have an alarm whenever the boom is below a 30° angle, use the following procedure:
1. Press VIEW to access the alarm screen. The cursor will be at MIN. ANGLE.
2. Move the boom to 30° angle.
3. Press SET to enter the alarm. The displayed value will be the alarm setting, and it will alternate with the
word SET.
4. When the alarm is set, press SELECT to return to the working screen. The red lamp and the audible
alarm will operate whenever the boom is below 30°. The message MIN. ANGLE will appear in the
INFORMATION area on the left display.
EXAMPLE B
To have an alarm whenever the boom is above 60° angle, use the following procedure:
1. Press VIEW to access the alarm screen. The cursor will be at MIN. ANGLE. Press the DOWN ARROW
to move the cursor to MAX. ANGLE.
2. Move the boom to 60° angle.
3. Press SET to enter the alarm. The displayed value will be the alarm setting and it will alternate with the
word SET. Press SELECT to return to the working screen. The red lamp and the audible alarm will
operate whenever the boom is above 30°. The message MIN. ANGLE will appear in the INFORMATION
area on the left display.
EXAMPLE C
To have an alarm whenever the boom length exceeds 50 feet, use the following procedure:
to move the cursor to MAX. LENGTH.
2. Extend the boom to 50 feet.
operate whenever the boom is extended beyond 50 feet. The message, MAX. LENGTH will appear in the
Page 23 of 52 W424103 REV A 02/13/01
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Crane Systems
EXAMPLE D
To have an alarm whenever the boom tip height exceeds 75 feet, use the following procedure:
1. Extend the boom and/or adjust the boom angle so that the tip height is 75 feet.
to move the cursor to MAX. HEIGHT.
operate whenever the boom tip height exceeds 75 feet. The message MAX. HEIGHT will appear in the
CANCELING ALARMS
CLEAR is used to cancel a previously SET alarm. Alarms can only be CLEARED when the cursor is pointing
to the item to be cleared. Canceling of alarms can be carried out regardless of the position of the crane.
1. Press VIEW to access the alarm screen.
2. Move the cursor to point to the alarm to be canceled.
3. Press CLEAR to cancel the alarm. The displayed value will be the current position of the crane and the
word SET will no longer be displayed.
4. Move the cursor to point to the next alarm to be canceled.
5. When all the chosen alarms are canceled, press SELECT to return to the working screen.
Page 24 of 52 W424103 REV A 02/13/01
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Crane Systems
PERIODIC INSPECTIONS
CHECKING THE ANTI TWO BLOCK SYSTEM
MAIN SWITCH
1. Lower the boom so that the A.T.B. switches can be reached by hand.
2. Set the Selector Switch located on the Main Switch housing to the "Main" position and check that raising
the weight to trip the switch causes the A.T.B. alarm to operate.
JIB SWITCHES
If the crane is equipped with additional Jib switches, check as follows.
1. Connect the cable from the Jib switch to the receptacle on the Main Switch.
2. Set the Selector Switch to "Both".
3. Check that raising the weight and tripping the switch on EITHER the Main OR the Jib switch causes the
A.T.B. alarm to operate.
4. Set the Selector Switch to "Jib".
5. Check that raising the weight on the Jib switch only and tripping the switch causes the A.T.B. alarm to
operate.
FUNCTION KICK-
KICK-OUT
If the crane is equipped with Function Kick-Out, check the operation of the system as follows:
1. With the crane in any normal working configuration, raise the hook block sufficiently to cause the A.T.B.
switch to operate.
2. Check that when the audible alarm sounds the following functions are stopped:
♦ Main Winch Up
♦ Aux. Winch Up
♦ Boom Hoist Lower
♦ Telescope Out (all cylinders)

3. Check that when the CANCEL ALARM by-pass system is enabled or the RIGGING/TRAVEL MODE is
selected, the audible alarm is silenced and the motions are restored.
CAUTION
WHEN CARRYING OUT THIS TEST THE FUNCTION KICK-OUT CIRCUITS DO NOT PROTECT THE
CRANE. TAKE CARE THAT THE CRANE IS NOT PUT INTO AN ACTUAL TWO-BLOCK CONDITION
INADVERTENTLY.
DO NOT OPERATE THE CRANE UND

UNDER
ER THE ABOVE CONDITIONS.
Page 25 of 52 W424103 REV A 02/13/01
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Crane Systems
SYSTEM CHECKS
♦ Check that the displayed boom angle agrees with the measured angle.
♦ Check that the displayed radius agrees with the measured operating radius.
♦ Check that the displayed boom length agrees with the actual boom length.
♦ If a known test weight is available, check that the displayed weight agrees with the test load. The
displayed load includes the hook block and any lifting attachments such as slings, pins and shackles.
♦ If the capacity chart is rated for specific areas e.g., side, front or rear, the system should be checked
by swinging the boom into the permitted areas and checking that the Rated Capacity reading agrees
with the crane Capacity Chart.
ROUTINE MAINTENANCE
The MicroGuard 424 System has built-in self-test facilities and checks itself each time the system is
switched on. Only a minimum level of preventive maintenance is required. This is restricted to visual
inspections of cables and sensors for obvious signs of wear and tear and inspection of mechanical parts,
such as extension reels and anti two-block switches.
Page 26 of 52 W424103 REV A 02/13/01
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Crane Systems
MICROGUARD 424
OPERATION/TROUBLESHOOTING
OPERATION/TROUBLESHOOTING MANUAL
TABLE OF CONTENTS
SECTION 2: TROUBLESHOOTING
FAULT DIAGNOSTIC PROCEDURES............................................................................................................ 29
GROUP "A" FAULT CODES..............................................................................................................30-31
POWER SUPPLY VOLTAGES........................................................................................................................ 32
INPUT POWER....................................................................................................................................... 32
INTERNAL POWER SUPPLIES ............................................................................................................. 32
ACCESSING THE COMPUTER AND TERMINATION BOARDS ................................................................... 33
CHECKING ANALOG DRIVE VOLTAGE........................................................................................................ 33
PRESSURE CHANNEL FAULT GUIDE .....................................................................................................34-36
FUNCTIONAL TESTS............................................................................................................................. 34
TRANSDUCER RESISTANCE MEASUREMENT .................................................................................. 35
PISTON PRESSURE TRANSDUCER ........................................................................................... 35
ROD PRESSURE TRANSDUCER............................................................................................35-36
ANALOG DRIVE VOLTAGE...........................................................................................................36
BOOM EXTENSION SENSOR AIN2 ...................................................................................................... 37
BOOM ANGLE SENSOR AIN3............................................................................................................... 38
SWING POTENTIOMETER AIN5 AND AIN6 ......................................................................................... 39
NO DUTY FOUND .................................................................................................................................. 40
OTHER SYSTEM FAULTS ..................................................................................................................... 40
EXECUTIVE ROM.......................................................................................................................... 40
PERSONALITY ROM ..................................................................................................................... 40
SCRATCHPAD RAM...................................................................................................................... 40
DUTY ROM .................................................................................................................................... 40
CURRENT DUTY BAD................................................................................................................... 40
CONFIGURATION UNCALIBRATED ............................................................................................ 40
DIGITAL I/O AND ANALOG I/O .....................................................................................................40
DISPLAY UNIT ............................................................................................................................... 40
ANTI TWO-BLOCK SYSTEM.......................................................................................................................... 41
ANTI TWO-BLOCK LOGIC LEVELS ...................................................................................................... 42
1918 EAST GLENWOOD PLACE, SANTA ANA CA 92705 Tel: (714) 259 9702 Fax: (714) 259 7626
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PARTS REPLACEMENT ............................................................................................................................43-45
PRESSURE TRANSDUCERS .............................................................................................................. 43
EXTENSION REEL............................................................................................................................... 43
BOOM ANGLE SENSOR HTC8660 ONLY .......................................................................................... 43
BOOM ANGLE SENSOR...................................................................................................................... 44
EXECUTIVE ROM CHIP....................................................................................................................... 44
PERSONALITY ROM CHIP .................................................................................................................. 44
DUTY ROM CHIP ................................................................................................................................. 44
COMPUTER BOARD............................................................................................................................ 44
COMPUTER BOX ................................................................................................................................ 45
CHIP REMOVAL AND INSTALLATION................................................................................................ 45
GLOSSARY ................................................................................................................................................46-48
COMPUTER BOARD LAYOUT ....................................................................................................................... 49
TERMINATION BOARD LAYOUT ................................................................................................................... 50
EXTENSION REEL LAYOUT .......................................................................................................................... 51
1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 Tel: (714) 259 9702 Fax: (714) 259 7626
28 of 52 W424103 REV A 02/13/01
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Crane Systems
FAULT CODES
TROUBLESHOOTING GROUP “A” ANALOG SENSORS
CODE
FAULT DIAGNOSTIC PROCEDURES
AAA
Faults in the MicroGuard 424 System are detected
000 NO FAULTS
automatically. Each time the MicroGuard 424 System is
switched on it goes through a start up self-test which 001 AIN0 PISTON PRESSURE TRANSDUCER
lasts about 2-3 seconds. During normal operation a self- 002 AIN1 ROD PRESSURE TRANSDUCER
test can be initiated by pressing the TEST button on the
004 AIN2 EXTENSION SENSOR
display.
008 AIN3 BOOM ANGLE SENSOR
Fault conditions in external sensors are detected without
016 AIN4 S’STRUCTURE ANGLE SENSOR
the need for a system self-test.
SWING POTENTIOMETER “A”
Faults detected in the MicroGuard 424 System during 032 AIN5
self-test are indicated on the display as follows: 064 AIN6 SWING POTENTIOMETER “B”
• The word FAULT will appear in the information area

GROUP “B” INPUTS AND OUTPUTS
of the left display.
CODE
• The RED LAMP will illuminate and the AUDIBLE BB FAULT
ALARM will sound.
00 NO FAULTS
When faults occur in the system they can be diagnosed 01 1 DIGITAL INPUT AND OUTPUT
using the display. 02 2 ANALOG INPUT AND OUTPUT
04 4 DISPLAY UNIT
Details of the fault locations are obtained by pressing and
holding the test button. Holding the test button will cause
GROUP “C” MEMORY
the system to go through a self-test during which faults CODE
will be detected.
CC
Following completion of the self-test: 00 NO FAULTS
If the test button continues to be pressed, the fault screen 01 1 EXECUTIVE ROM
will appear. The fault screen will remain visible for as 02 2 DUTY ROM
long as the test button is pressed. Information will be 04 4 SCRATCHPAD RAM
displayed on the screen in four groups. 08 8 PERSONALITY ROM
• Group A Sensor faults

GROUP “D” GENERAL
• Group B I/O faults CODE
DD
• Group C Memory faults
00 NO FAULTS
• Group D General faults 01 1 NO DUTY FOUND
02 2 CURRENT DUTY BAD
04 4 CONFIGURATION UNCALIBRATED
08 8 2 HZ OSCILLATOR
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MicroGuard
TEST 414 AAA B CC DD
W
MAX
100% 000 0 00 0 0
SET UP DEDUCT A REA
PRESS AND HOLD DEDUCT
ERECTED STOW ED
W
INFORMATION FAULT CODES
VIEW SET CLEA R DOWN UP SELECT

OPERATOR A LARMS CONTRAST
GROUP ‘A’ FAULT CODES 016 Sensor 4 S’structure Angle

If a fault is detected by the system, a number will appear 032 Sensor 5 Swing Pot’r “A”
under one or more of the four group headings A through 064 Sensor 6 Swing Pot’r “B”
D. This number will correspond to one or more fault
When there are no faults detected in the system, ‘000’
diagnostic numbers. The meaning of these numbers can
will appear under all group headings indicating that there
be determined by looking at the appropriate code in the
are no detected faults in the system. When there are
fault interpretation table.
faults in only one sensor, the code will be one of the
Group A fault codes relate to analog sensors. Each codes listed above. When there are faults in more than
sensor is allocated a number and this number is also the one sensor, the codes indicated will be the sum of the
number of the channel to which it is connected in the fault codes.
system.
• Sensor 0 Piston Pressure
EXAMPLES OF FAULT CODES
• Sensor 1 Rod Pressure Fault 0
• Sensor 2 Extension Sensor AAAB CC DD
• Sensor 3 Boom Angle 000 0 00 00
• Sensor 4 Superstructure Angle No faults detected.
• Sensor 5 Swing Potentiometer “A”
Fault 1
• Sensor 6 Swing Potentiometer “B”
AAAB CC DD
Each sensor is allocated a FAULT CODE and this is the
001 0 00 00
number that appears under the group heading in the fault
Piston pressure transducer.
code display.
001 Sensor 0 Piston Pressure Fault 2
002 Sensor 1 Rod Pressure AAAB CC DD
004 Sensor 2 Extension Sensor 002 0 00 00
Rod pressure transducer
008 Sensor 3 Boom Angle
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Fault 3 Fault 10
AAAB CC DD AAAB CC DD
003 0 00 00 010 0 00 00
Piston pressure transducer Boom angle sensor
Rod pressure transducer Rod pressure transducer
Fault 4 Fault 11
004 0 00 00 009 0 00 00
Extension Sensor Boom angle sensor
Piston pressure transducer
Fault 5
AAAB CC DD
005 0 00 00 Fault 32
Piston pressure transducer AAAB CC DD
Extension sensor 032 0 00 00
Swing potentiometer “A”
Fault 6
AAAB CC DD Fault 64
006 0 00 00 AAAB CC DD
Rod pressure transducer 064 0 00 00
Extension sensor Swing potentiometer “B”
Fault 96
Fault 7 AAAB CC DD
AAAB CC DD 096 0 00 00
007 0 00 00 Swing potentiometer “A”
Piston pressure transducer Swing potentiometer “B”
Rod pressure transducer This sequence continues up to the maximum fault code
Extension sensor of 127 that is the sum of all group “A” fault codes.
Fault 8 Fault 127

008 0 00 00 127 0 00 00
Boom angle sensor All analog sensors.
This fault condition is seldom caused by the
Fault 9
simultaneous failure of all sensors. It is more usually the
AAAB CC DD result of the failure of the analog drive voltage, which is
009 0 00 00 the supply voltage for all sensors. This power supply fault
Piston pressure transducer may be due to the failure of the power supply or may be
Boom angle sensor due to damage to the cable that connects the sensor to
the computer.
When this fault occurs, carry out Power Supply Voltage
checks before checking individual sensors.
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POWER SUPPLY VOLTAGES

The Computer Unit contains 2 major boards, the
B attery +
Terminal Connection Board and the Computer Board.
Both of these assemblies are located in an aluminum
box that is usually located on the rear wall of the cab or
can be inside or outside the cab depending on crane
B attery -
model. All of the cables from the various sensors and the
display are connected to the Terminal Connection Board.
To gain access to the Terminal Connection Board, refer
to Page 33 of this manual.
INPUT POWER
The computer operates from an input voltage in the

range 11 to 36 volts DC. This input voltage is measured
across the B+ and B- terminals on the Terminal
Connection Board and corresponds to the battery voltage
InternalPow er
of the crane. At voltages below 10.5 and above 38 volts Term inals
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.
InternalPow er
To monitor the Internal Power Supplies, use a Digital Term inals
Voltmeter set to the appropriate DC voltage range.
Connect the black (-ve) lead to GND G round
Connect the red (+ve) lead in turn to
+15V +/- 0.1 + 5 volts
-15V +/- 0.1
+ 15 volts
+5V +/- 0.1
If the voltages are out of range, it may be necessary to
-15 volts
replace the computer.
Before replacing the computer, refer to
Greer Company
Product Support Department
714-259-9702
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Crane Systems
ACCESSING MAIN COMPUTER BOARD each cable, one at a time, checking the Analog Drive
AND TERMINATION BOARD Voltage after each cable is connected.
7. If after reconnecting any one of the sensors the

1. Remove the four screws (1) securing the computer
Analog Drive Voltage goes out of range, it is
lid to the computer box. This lid is NOT hinged. Take
probable that the wiring to the sensor is grounded or
care not to allow the lid to fall from the box. Set the
the sensor itself is faulty.
lid aside.
Check all wires and the sensor itself and repair or
2. Under the lid you will see the Main Computer Board.
replace as required.
This board contains the microprocessor and its
related components. This unit is held in place by two
screws (2) located at the left and right of the Main
Computer Board backing plate and is connected to
+ DR
the Terminal Connection Board via 2 ribbon cables.
D RIV E A IN 0
These cables carry the signals to and from the V O LTA G E
A IN 1
Termination Board. These will be to the top of the 5.25 + /- 0.1
Main Computer Board. -D R
0V
3. If you are going to check voltages on the Termination
+ DR
Board, remove the two screws located at the left and
+ D R A IN 2
right of the Main Computer Backing Plate and swing
-D R A IN 3
the assembly up. Take care not to damage the
TX 0+ A IN 4 + VP
ribbon cables. These ribbon cables must remain
TX 0- -D R + VP
connected to the Main Computer Board for voltage
0V 0V + VP
checks.
+ DR + DR + VP
CHECKING ANALOG DRIVE VOLTAGE -D R A IN 5 0V
To check the Analog Sensor Drive Voltage, use the TX 1+ A IN 6 0V
following procedure: TX 1- -D R 0V
0V 0V 0V
1. Access the Termination Board.
2. With the system power on and a digital volt meter set The analog drive voltage can be
to read DC voltage, place the negative lead on any - m easured betw een any D R+ term inal
DR (- Drive) terminal (1) of the Analog Input Group. and any D R- term inal. It is 5.25volts
3. Place the positive lead of the meter on any +DR D C + /- 0.1 volts.
(+ Drive) terminal (2).
4. The voltage should be 5.25+/-0.1volts.
5. If the 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 voltage is

still out of range, the Computer Board will need to be
replaced. If the voltage is within range, reconnect
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PRESSURE CHANNEL FAULT GUIDE transducers. With no pressure, the upper display
FUNCTIONAL TESTS should indicate 0+/-20 bits.
A fault in a pressure transducer is such that a fault on 6. Press the Left Arrow (5) and then use the Up (3) or
one channel can cause an apparent fault in the other Down (4) arrow keys to select TX1 (pressure
channel. It is necessary to test both channels and both transducer rod side). With no pressure in the
transducers together in order to determine which cylinder, the upper display should read 0+/- 20 bits.
transducer is at fault.
7. If the transducers were disconnected in step 5,
tighten the fittings. With the boom fully retracted,
MicroGuard 414 boom up to a 60° angle.
2 TEST
W 100%
8. Access the Zero of TX 0, as described in step 5.
MAX
CRANE
SET UP
STOWED
DEDUCT
WORKING
AREA
The upper display should read 200+/-100 bits.
DEDUCT
3 4
ERECTED STOWED
9. Access the Zero of TX 1, as described in step 7.
W
INFORMATION The upper display should read 5+/-25 bits.
VIEW SET CLEAR DOWN UP 5 SELECT 6

10. Boom down. As the boom is moving down, the
OPERATOR ALARMS CONTRAST 1 displayed bits of TX 1 should increase.
11. Place the retracted boom at a 60° angle. Access the

1. Access the calibration routine by simultaneously
Zero of TX 0, as described in step 4, and extend the
pressing and holding
boom. As the boom is extended, the displayed bits of
SELECT (1) and TEST (2) keys
TX 0 should increase. When the boom is fully
The display will request entry of the calibration extended, the display should read 400+/-100 bits for
security code. a three-section boom and 600+/-100 bits for a four-
section boom.
2. The security code is entered by the consecutive
pressing of the calibration arrow keys which MUST The values listed are nominal values. The actual
be in the following sequence: values will differ according to how the crane is
Up, (3), Down (4), equipped. A three-section boom will show a smaller
value on TX 0 under the same conditions as a four-
Left (5), Right (6),
section boom. Additional equipment on the main
SELECT (1) boom, such as stowed fly, auxiliary head sheaves
If the wrong sequence is used, or if the entry is not and hook blocks will give a higher value than the
completed within 5 seconds, the calibration entry will main boom alone. If any value is out of range,
be aborted and must be re-entered. After accessing contact your distributor or factory service department
the calibration routine, the system alarm will sound before replacing a pressure transducer. Refer to
as a reminder that the calibration routine is active. page 43 of this manual for pressure transducer
3. Use the Up (3) or Down (4) Arrow keys to scroll to replacement.
command 06 Zero. Press Select (1). 12. Exit the calibration routine by pressing the TEST (2)
4. Press the Left Arrow (5) and then use the Up (3) or key.
Down (4) Arrow keys to select TX 0 (pressure If the foregoing functional tests indicate faults in the
transducer 0 piston side). Press Select (1). pressure channels, proceed with Power Supply
5. With the boom in the rest or the boom hoist cylinder Tests and the test of the resistance of the bridge of
fully retracted, relieve all pressure from both the pressure transducers.
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PRESSURE CHANNEL FAULT GUIDE

TRANSDUCER RESISTANCE MEASUREMENT PRESSU RE TRA N SD U CER CO N N ECTO R
M S3475W -5PZ
The pressure transducer is a balanced bridge composed “B” TO “E” 350Ω + /- 10Ω
of strain gauges bonded to a flexible diaphragm. The
following resistance tests can be carried out to establish
the viability of the pressure transducer.
A
Piston Pressure Transducer E B
1. With the power to the computer off, disconnect the D C
piston pressure transducer from connector 1 on the

computer.
2. With the DVM set to the Ohms range, measure the

“D ” TO “C” 350Ω = + /- 10Ω
resistance between pins “C” an “D” of connector
MS3474W14-5PZ.
The resistance should be 350Ω +/- 10Ω

resistance between pins “B” an “E” of connector
MS3474W14-5PZ. YELLO W , SIG N A L +
PIN “D ”
The resistance should be 350Ω ± 10Ω

350Ω + /-10
resistance between pins B, C, D, E, and the case of
the transducer. Measure the resistance between B,
G REEN , SIG N A L-
C, D, E and the case of the connector. PIN”E”
There should be no connection between the case 350Ω + /-10
and any of the pins. BLU E, D RIVE-

PIN “D ”
RED , D RIV E +
PIN “C ”
Rod Pressure Transducer

NON-CONNECTOR TYPE PRESSURE TRANSDUCER
1. With the power to the computer off, disconnect the
rod pressure transducer from connector 2 on the
computer.

resistance between pins “C” an “D” of connector PRESSU RE TRA N SD U CER
MS3474W14-5PZ.

resistance between pins “B” an “E” of connector
MS3474W14-5PZ.
M S3475W 14-5PZ
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resistance between pins B, C, D, E, and the case of + DR
the transducer. Measure the resistance between B, D RIV E A IN 0
C, D, E and the case of the connector. There should V O LTA G E
A IN 1
5.25 + /- 0.1
be no connection between the case and any of the -D R
pins. 0V
PRESSURE CHANNEL FAULT GUIDE + DR
ANALOG DRIVE VOLTAGE + D R A IN 2
– D R A IN 3
Analog sensor voltages are measured at the analog
TX 0+ A IN 4 + VP
input group terminals.
TX 0- -D R + VP
The drive voltage for all analog sensors is measured 0V 0V + VP
between any +DR and -DR in the analog input group and
+ DR + DR + VP
is 5.25volts DC ± 0.1 0V
-D R A IN 5
To measure this voltage use a Digital Voltmeter set to TX 1+ A IN 6 0V
the DC voltage range. TX 1- -D R 0V
0V 0V 0V
1. Connect the black (negative) lead of the DVM to any
DR- terminal in the analog input group.
The analog drive voltage can be m easured
2. Connect the red (positive) lead of the DVM to any betw een any D R+ term inaland any D R–
DR+ terminal in the analog input group. term inal. It is 5.25 volts D C + /– 0.1 volts.
3. Measure the drive voltage. Faults in any cable or sensor can cause the
analog drive voltage to be faulty.
5.25 volts DC ± 0.1
4. If the voltage is out of range, disconnect all of the NOTE: FOR TECHNICIANS FAMILIAR WITH MG3
analog sensors by disconnecting the sensor UNLIKE THE MG3A SERIES, THE MG4 SERIES DOES
connectors from the computer in order to determine NOT HAVE A DUAL CHANNEL PRE-AMPLIFIER.
if any sensor or its cabling is causing the drive THERE IS NO POINT IN THE COMPUTER WHERE
voltage to be incorrect. ANALOG VOLTAGES RELATIVE TO PRESSURE CAN
5. If the drive voltage is correct with all of the sensors BE MEASURED.
disconnected, connect each sensor in turn to AIN0 AND AIN1 HAVE DIFFERENT FUNCTIONS IN
determine which sensor is causing the drive voltage THE MG4 SYSTEM AND ARE NOT THE POINT AT
to incorrect. WHICH TO MONITOR PRESSURE VOLTAGES.
6. If any sensor is causing the drive voltage to be
incorrect, carry out the trouble shooting 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 on Pages 32-33 of this manual.
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BOOM EXTENSION SENSOR AIN2 Refer to the MicroGuard 414 wiring details in the
Installation Manual for the model of crane under test.
Use the following procedure to check the Boom
Extension Sensor Voltage. 12. With the negative lead of the voltmeter connected to
blue, drive negative and the positive lead of the
1. Fully retract the boom.
voltmeter connected to white, extension signal, the
2. Access the Relay and Termination Board. voltage should be the same as the voltage measured
Measure the analog sensor drive voltage (refer to at AIN2 of the analog input group in the computer. If
page 36 of this manual). this voltage is not the same, it is possible that the
3. With a digital voltmeter set to read DC voltage place cable between the reel and the computer is faulty.
the negative lead on any 0 Volt terminal of the
Analog Input Group. + DR
D RIV E
4. Place the positive lead of the meter on the AIN2 2 V O LTA G E A IN 0 A IN 2, V O LTA G E
terminal of the Analog Input Group. The voltage A IN 1 V A RIES W ITH
should be 0.25 volts ± 0.1volt. -D R BO O M EX TEN SIO N
5. Extend the boom as far as safe to do. The boom 0V
need not be horizontal for this test. + DR
+ D R A IN 2
6. The voltage should be less than 5 volts. (Usually
-D R A IN 3
around 2.5 volts depending on the boom length).
TX 0+ A IN 4 + VP
7. During extension the voltage should increase linearly TX 0- -D R + VP
and during retraction the voltage should decrease
0V 0V + VP
linearly.
+ DR + DR + VP
8. If the voltage is out of the range listed above, remove -D R A IN 5 0V
the four screws securing the cover on the extension TX 1+ A IN 6 0V
reel located on the left side of the main boom section TX 1- -D R 0V
and remove the cover.
0V 0V 0V
9. Under the cover on the right side of the extension
reel you will see a terminal strip. This terminal strip
has six wires connected to the bottom screws.
BLU E, SIG N A L TO
10. With a digital voltmeter set to read DC Voltage, place
A IN 2
the negative lead on the terminal with the blue wire
attached to it (- Drive) and the positive lead on the
terminal with the red wire attached to it (+Drive).
11. 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 was OK then it is possible
that the cable is open or grounded between the RED W H ITE
Computer and the Extension Reel. Check all DR + D R-
connections and plugs that may be between these
two components. Repair or replace as required.
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BOOM ANGLE SENSOR AIN3 12. With the negative lead of the voltmeter connected to
blue, drive negative and the positive lead of the
1. Place the main boom at a 0° angle. Verify that it is at
voltmeter connected to green, angle signal, the
a 0° angle with an inclinometer.
voltage should be the same as the voltage measured
2. Access the Terminal Connection Board. Check the at AIN3 of the analog input group in the computer. If
Analog Drive Voltage. Refer to page 36 of this this voltage is not the same it is possible that the
manual. cable between the reel and the computer is faulty or
the boom angle sensor is faulty.
3. With a digital voltmeter set for DC Volts, connect the
negative lead of the meter to any 0 Volt terminal of 13. If the above voltage checks are within range and no
the Analog Input Group. grounds or opens are found in the wires, replace the
Boom Angle Sensor as described on page 44 of this
4. Connect the positive lead to the AIN 3 terminal of the
manual.
Analog Input Group.
5. With the boom horizontal, the voltage should be

0.4 ± 0.1 volts. + DR
D RIV E A IN 3, V oltage
V O LTA G E. A IN 0 varies w ith
6. Raise the main boom to a 60° angle. With an
A IN 1 boom angle.
inclinometer, verify that the main boom is at a 60°
-D R 2.6 at 0 deg.
angle. 3.5 at 60 deg.
0V
7. With the boom at a 60° angle, the voltage should be + DR
3.02 ± 0.1 volts. + D R A IN 2
-D R A IN 3
8. If this is out of range, remove the cover from the
TX 0+ A IN 4 + VP
reeling drum located on the left side of the main
TX 0- -D R + VP
boom.
0V 0V + VP
9. Under the cover on the right side of the extension + DR + DR + VP
reel you will see a terminal strip. This terminal strip -D R A IN 5 0V
has six wires connected to the bottom screws. TX 1+ A IN 6 0V
10. With a digital voltmeter set to read DC Voltage, place TX 1- -D R 0V

the negative lead on the terminal with the blue wire 0V 0V 0V
attached to it (- Drive) and the positive lead on the
terminal with the red wire attached to it (+Drive).
G REEN , A N G LE
11. The voltage should be 5.25 ± 0.1 volts. If this voltage SIG N A L TO A IN 3
is out of range and the Analog Drive Voltage
checked in step 2 was OK, then it is possible that the
reeling drum cable is open or grounded between the
Computer and the Extension Reel. Check all
connections and plugs between these two
components. Repair or replace as required. Refer to
RED BLU E
the MicroGuard 414 wiring details in the Installation DR + D R-
Manual for the model of crane under test.
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SWING POTENTIOMETER
AIN5 AND AIN6 A IN 5 and A IN 6,
+ DR
D RIV E V oltage varies
The position of the upper structure in relation to the V O LTA G E. A IN 0
carrier must be determined. This is accomplished by w ith rotation of
A IN 1 upper.
means of swing potentiometer mounted in the collector -D R 4.2 m axim um .
ring. If the system does not have an input from the swing 0.36 m inim um
0V
potentiometer it will not be able to find a duty. w hen the upper is
+ DR
To check the Swing Potentiometer, use the following rotating.
+ D R A IN 2
procedure: -D R A IN 3
1. Access the Relay and Termination Board. TX 0+ A IN 4 + VP
Check the Analog Drive Voltage. Refer to page 33 of TX 0- -D R + VP
this manual. 0V 0V + VP
2. With a digital voltmeter set for DC volts check the + DR + DR + VP
voltage at the connections to the potentiometer -D R A IN 5 0V
located on the Anti Two-Block board. Connection 1 TX 1+ A IN 6 0V
has a red wire attached to it and connection 3 has a TX 1- -D R 0V
black wire attached to it.
0V 0V 0V
3. 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 will need to be replaced.
4 2
4. With the black lead on any 0 Volt terminal, check the
voltage at 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 3 1
correct and the voltages on AIN 5 and AIN 6 are out
of range the swing potentiometer will need to V oltage m easured betw een 2 and 4 = 5.25 volts.
replaced. V oltage m easured betw een 1 and 3 = 4.125 volts.
Contact your distributor or your Factory Service
Department for procedures on replacing the swing
potentiometer.
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NO DUTY FOUND CURRENT DUTY BAD
The system needs the same information that the This fault indicates failure of the Duty Chip IC3 on the
operator would need in order to read a load chart. If for Main Computer Board. It can be replaced without the
any reason this information is not available the fault “ No need for re-calibration. It contains the load chart data for
Duty Found “ will result. This fault could occur if either the crane on which it is fitted and must be the exact type
the Boom Angle Sensor, or Extension Sensor inputs are for the load chart on the machine.
faulty. The system uses all of these inputs to determine CONFIGURATION UNCALIBRATED
the duty selection. Upon correction of the Sensor fault
the system will again be able to find a duty. When a machine is initially calibrated its duty chip may
contain more configurations than are to be sold with that
OTHER SYSTEM FAULTS particular machine. Fly or jib options that are not supplied
with the machine will not show up in the Crane Set Up
EXECUTIVE ROM
menu. Refer to the Calibration Procedure, Command 13
The Executive ROM fault code indicates failure of IC2 on for details of hiding or showing attachments.
the main computer board. This chip can be replaced
DIGITAL I/O & ANALOG I/O
without the need for re-calibration. The chip is labeled
M414150. Digital and Analog I/O faults are not user serviceable.
When this fault code is detected it will be necessary to
PERSONALITY ROM
replace the Main Computer Board.
The Personality ROM fault code will be present until the
DISPLAY UNIT
system is fully calibrated. At the completion of calibration
a code is automatically inserted into the memory which This unit is not user serviceable. When this fault code is
enables the system to carry out the self-test. If the fault detected it will be necessary to replace the Display Unit.
code occurs in normal service it could indicate either a This can be done by removing the four screws securing
failure of IC7 or the loss of data in the device. It will be the display into the dash and unscrewing the cable from
necessary to obtain a copy of the Personality ROM that the back of the display. Connect the display cable to the
was made at the completion of the initial calibration or new display, install it into the dash and secure with the
carry out a complete re-calibration of the system. four mounting screws.
Contact your Distributor or Factory Service Department
for details.
SCRATCHPAD RAM
The Scratchpad Ram fault code indicates the failure of

IC6 on the Main Computer Board. This item is not
user serviceable and requires the replacement of the
Main Computer.
DUTY ROM
This fault is associated with the failure of the Duty Chip

IC3 on the Main Computer Board. It can be replaced
without the need for re-calibration. It contains the load
chart data for the crane on which it is fitted and must be
the exact type for the load chart on the machine.
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ANTI TWO BLOCK SYSTEM 4. Remove the brown wire connected to ATB in
terminal of the digital input group. The system should
SYSTEM WILL NOT SHOW TWO-
TWO-BLOCK WHEN
show a Two-Block warning.
CRANE IS TWO-
TWO-BLOCKED:
BLOCKED
5. Connect a jumper wire from the 0 volt terminal to the
1. Access the Termination Board (refer to page 33 of
ATBIN terminal. The Two-Block warning should no
this manual).
longer be displayed. If the Two-Block warning
2. Make certain that the Anti Two-Block weight is remains the problem is in the Termination Board
attached to the boom head switch and that the assembly. If not, the problem is in the external wiring
selector switch is properly positioned. or switches.
3. Remove the brown wire connected to the ATBIN 6. Remove the jumper wire and reconnect the brown
terminal of the digital input group (see page 42). The wire to ATB in terminal. Remove the four screws
system should show a Two-Block warning. from the extension reel located on the left side of the
4. Connect a jumper wire from the 0 volt terminal to the main boom.
ATBIN terminal (seepage 42). The Two-Block 7. Connect a jumper wire between the black wire and
warning should no longer be displayed. If the Two- the brown wire on the terminal strip. The Two-Block
Block warning remains the problem is in the warning should no longer be displayed. If it remains,
Termination Board. the brown wire is open between the Termination
5. Remove the jumper wire and reconnect the brown Board and the Extension Reel. If the warning is no
wire to the ATBIN in terminal. Remove the four cover longer displayed the problem is somewhere between
screws from the extension reel located on the left the extension reel and the boom head switch. Check
side of the main boom and remove the cover. all wires and connections between these two
components and repair or replace as required.
6. Remove the brown wire from the terminal strip. The
system should show a Two-Block warning. If it does
not, the brown wire or its connections between the REELIN G D RU M TERM IN A L
Terminal Board and the extension reel are grounded. STRIP
If the system does show a Two-Block warning there
is a ground in the wiring or connections between the
extension reel and the Switch at the boom head.
Check all wires and connections between these two
components and repair or replace as required.
SYSTEM SHOWS TWO-

TWO-BLOCK
BLOCK WHEN CRANE
IS NOT TWO-
TWO-BLOCKED
1. Check that the selection switch of the Two-Block
BRO W N BLA C K
switch located at the main boom head is correctly A 2B SIG N A L 0V O LT
set.
2. Make certain that the Anti Two-Block weight is

attached to the boom head switch.
3. Access the Termination Board.

(Refer to page 33 of this manual).
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ANTI TWO-
TWO-BLOCK LOGIC LEVELS
D O U T1 C O N TRO LS TH E A 2B
The signal from the ATB switches at the boom and fly RELA Y RL2
N O A 2B = LO W , 0.2V O LT
tips is a switched ground. The ground signal is sourced A LA RM = H IG H , 5V O LT
in the computer at the 0 volt terminal of the digital input

group. RL1
D O U T1 LO A D
When there is no ATB alarm, the switches at the boom D IN 13 C O N TRO LS TH E
head are closed allowing the ground to be returned to the A U BIBLE A LA RM A N D
RL2
O N SCREEN M ESSA G E.
A 2B
computer at the ATBIN terminal. N O A 2B = H IG H 12V O LT
A LA RM = LO W 0.2V O LT
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 D IN 13
A TB BO A RD
Function Disconnect.
0V
A TBIN
The ATB alarm and Function Disconnects are controlled
A TBIN
separately by the ATB board in the computer. N O A 2B = LO W
O .2V O LT
The ATB board, located in the computer box: A LA RM = H IG H
5V O LT
• Operates the function disconnects by controlling the

coil of RL2, ATB relay, at D OUT 1.
• 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.
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PARTS REPLACEMENT approximately 12 ft. At this point there will be no pre-

tension.
PRESSURE TRANSDUCER REPLACEMENT
7. Pull the cable out passing it through the cable guides
1. It is recommended that the replacement transducer
until the end of the cable is 3 ft. beyond the boom
is closely matched to the sensitivity of the old
head.
transducer. The sensitivity value is recorded on the
serial number plate. 8. Wrap the cable around the boom head anchor a
minimum of five times and secure with a wire tie or
2. Remove the connector connecting the transducer to
the shipping cable clamp.
be replaced from the computer box.
9. Connect the cable to the connector coming from the
3. With the boom cylinder completely retracted, in the
Two-Block switch.
rest, or with the boom safely supported, remove the
transducer to be replaced. 10. Manually turn the large gear connected to the
potentiometer fully counter-clockwise.
4. Install the new transducer on the boom hoist
cylinder. 11. Observe the length display and turn the large gear at
least 3 clicks clockwise until the length display reads
5. Run the cable to the computer box and connect it to
the retracted boom length.
the appropriate computer box connector.
12. Replace the Extension Reel Cover, securing it with
6. Pick a known weight to verify the accuracy of the
the four screws.
system. If the load reading is not within tolerance
after the replacement of a pressure transducer, carry 13. Extend and retract the main boom and see that the
out Command 6 (Pressure) of the MG414 Calibration boom length reading on the display is correct.
procedure. BOOM ANGLE SENSOR REPLACEMENT
EXTENSION REEL REPLACEMENT HTC8660 ONLY
To replace the extension Reel assembly, use the To replace the Boom Angle Sensor use the following
following procedure: procedure:
1. Fully retract the main boom. 1. With the power off, disconnect the Boom Angle
Sensor cable from the sensor located on the left side
2. Disconnect the connector to the Two-Block switch
of the boom near the boom extension reel.
and remove the cable from the main boom head
anchor. Allow the cable to retract onto the reel, be 2. Remove the two bolts securing the sensor to the
careful not to let the cable retract too rapidly. boom and remove the old sensor.
3. Remove the Extension Reel Cable connector. 3. Install the new sensor on the boom, secure it loosely
with the mounting bolts and connect the cable.
4. Remove the four mounting bolts (5) securing the
Extension Reel to the boom and remove the reel. 4. Raise the boom to a 60° angle and verify the angle
with an inclinometer. While viewing the display adjust
5. Mount the new reel to the boom, secure with the
the sensor until the display reads 60° and tighten the
mounting bolts and connect the Extension Reel
mounting bolts.
Cable Connector.
5. Place the boom horizontal, verify that it is at 0° with
6. Remove the shipping cable clamp from the new
an inclinometer.
cable and allow it to slowly rewind onto the Extension
Reel until there is no pre-tension. Continue to re- 6. Verify that the displayed boom angle
wind the reel in the same direction until the distance is reading 0° +/- 0.5°.
between the boom head and the connector is
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BOOM ANGLE SENSOR REPLACEMENT 2. With the power off, remove IC7 (the Personality
To replace the Boom Angle Sensor that is fitted inside ROM Chip) from its socket. Refer to General Chip
the reeling drum, use the following procedure: Removal and Installation (page 45) in this manual.
1. With the power off, remove the 4 bolts holding the 3. Install the new Personality ROM Chip into the socket.
cover of the reeling drum and remove the cover. Make certain the notch in the chip is lined up with the
notch in the socket and all pins are properly inserted.
2. Disconnect the 3 wires connecting the angle sensor
to the terminal strip. Remove the two bolts securing DUTY ROM CHIP REPLACEMENT
the sensor to the reeling drum and remove the old The Duty ROM Chip must be specific to the load chart
angle sensor. used in the machine. This chip contains a copy of the
3. Install the new sensor in the reeling drum in the load chart and must match the load chart in the machine.
original location, secure it with the mounting bolts 1. Access the Main Computer Board. Refer to page 33
and connect the cable. of this manual.
4. Raise the boom to a 60° angle and verify the angle 2. With the power off, remove IC3 (the Duty ROM Chip)
with an inclinometer. While viewing the display adjust from its socket. Refer to General Chip Removal and
the sensor until the display reads 60° and tighten the Installation (page 45) in this manual.
mounting bolts.
3. Install the new Duty ROM Chip into the socket. Make
5. Place the boom horizontal, verify that it is at 0° with
certain the notch in the chip is lined up with the notch
an inclinometer.
in the socket and all pins are properly inserted.
6. Verify that the displayed boom angle is
NOTE: Replacement of the Executive or Duty ROM
reading 0° +/- 0.5°.
Chip does NOT necessitate the re-calibration of the
EXECUTIVE ROM CHIP REPLACEMENT system.
The Executive ROM Chip contains the main program NOTE: Replacement of the Personality ROM Chip
data that the computer uses to function and must be does NOT necessitate re-calibration of the system
specific to the system. if the new Personality ROM Chip is an exact
duplicate of the original. If a copy of the Personality
1. Access the Main Computer Board. Refer to page 33
Chip is not available the system will need to be
of this manual.
completely re-calibrated.
2. With the power off remove IC2, the Executive ROM
Chip from its socket. Refer to General Chip Removal COMPUTER BOARD REPLACEMENT
and Installation (page 45) in this manual. 1. With the power off, access the Computer Board.
Refer to page 33 of this manual.
3. Install the new Executive ROM Chip into the socket.
Make certain the notch in the chip is lined up with the 2. Locate the two ribbon cables connecting the
notch in the socket and all pins are properly inserted. Computer Board to the Termination Board.
PERSONALITY ROM CHIP REPLACEMENT 3. The ribbon cables are held in place by two locking
tabs on each cable end. These locking tabs must be
The Personality ROM Chip must be the proper chip for
pushed away from the cable to disconnect the
the particular crane serial number. This chip contains
cable. As the locking tabs are pushed the
calibration data that is unique to each machine.
connector will come loose from the Main
1. Access the Main Computer Board. Refer to page 33 Computer Board.
of this manual.
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4. Loosen the two screws holding the Computer 5. Install the new computer and secure with the four
backing plate to the box. mounting screws.
5. Remove the Computer Board Assembly. 6. Reconnect all cable connectors.
NOTE THAT CONNECTORS 1 AND 2 ARE SIMILAR

There are three computer chips on the Main Computer
AND THEY ARE COLOR-CODED AND MUST BE
Board that must be of the correct type. These three chips
CONNECTED WITH THE COLOR ON THE CABLE
are:
MATCHING THE COLOR ON THE SOCKET.
IC2 Executive ROM
CHIP REMOVAL AND INSTALLATION
IC3 Duty ROM
When removing and installing chips be certain the power
IC7 Personality ROM
is switched off. Do not touch the chip pins unless you are
The Executive ROM must be specific to the system. properly grounded. Static electricity can damage chips.
The Duty ROM contains a copy of the load chart and 1. Make certain the power is off.
must correspond to the Load Chart Number of the
2. Remove the chip to be replaced with a chip removal
particular serial number machine.
tool.
The Personality ROM contains data that is unique to the
NOTE: Chip removal and installation tools are
particular serial number machine.
available from any electronics store.
6. Install the:
3. Insert the new chip into the installation tool per the
• Executive ROM Chip. instructions on the package.
• Duty ROM Chip. 4. Insert the new chip into the socket, making certain
that the notch in the chip (1) lines up with the notch
• Personality ROM Chip.
in the socket (2).
7. Place the Main Computer Assembly into the
5. Double check that all pins are properly inserted into
computer box and tighten the two mounting screws,
the chip socket. These pins are very easily bent.
make certain to allow access to the ribbon cables.
Failure to have all pins inserted can cause damage
8. Reconnect the two Ribbon Cables being certain to to the system and the chip.
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

COMPUTER BOARD FROM THE ORIGINAL BOX.
1. Remove the Main Computer Board.
2. Disconnect all cable connectors from the Computer

Box.
3. Remove the four screws securing the Computer Box.
4. Remove the Computer Box.
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GLOSSARY OF TERMS
ABORT The premature termination of a data entry procedure.
ALARM A signal that warns or alerts such as a flashing light or loud noise.
AMPLIFIER A device which takes an input and produces an output of greater magnitude (as in the case of a pressure
transducer where a signal in the millivolt range is amplified to the level of up to ten volts).
AMPLIFIER GAIN The factor used to express the level of amplification.
ANALOG A mechanism in which data is represented by continuously variable physical quantities.
ANGLE SENSOR A device which measures the inclination of a boom.
ANNULAR Relating to, or forming a ring. e.g. the pressure around the rod of a boom hoist cylinder.
ANNULAR GAIN 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 bore.
BACK-UP Move data from the working area of memory to a microchip that is stored elsewhere e.g. in a service
department.
BOOM DEFLECTION The change of radius due to the bending of a boom under load.
BOOM MOMENT The turning moment around the boom pivot caused by the moment of the unladen boom.
BORE The piston side of a boom hoist cylinder.
CALIBRATION The adjustment of the graduation of sensors.
CAPACITY CHART A table showing the rating of a crane.
CENTER OF GRAVITY 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.
COMMISSIONING Preparing to be put into service.
CONFIGURATION An arrangement of the lifting elements of a crane.
CURSOR A pointer on a display which indicates the position where data is to be entered.
DATA Factual information used as a basis for calculation.
DECREMENT The action of decreasing a number or value.
DEDUCT A reduction in rated capacity for an unused stowed or erected attachment.
DEFLECTION The bending of a boom or the stretching of pendant lines within the elastic limits of the boom or
pendants.
DIGITAL Operating with numbers expressed directly as digits.
DIGITAL INPUTS Computer inputs which usually are either on or off as determined by external switches.
DIRECTION The direction of rotation of the superstructure.
DUTY A working configuration on a crane usually contained in a single column of a capacity chart.
EEPROM Electrically erasable and programmable "read only" memory. (ROM)
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Greer Company
Crane Systems
ELASTIC Capable of recovering size or shape after deformation.
ERECTED An attachment on the main boom fitted in its working position.

ATTACHMENT
EXTENSION SENSOR A device which measures the extension of the telescoping sections of a boom.
FLY/JIB Something attached by one edge such as a lattice fly or jib on a crane boom.
FORCE Energy exerted, in this case by the suspended weight of an object.
GEOMETRY A branch of mathematics that deals with the measurement and relationships of points, lines, angles,
surfaces and solids.
GRADUATED Marked with degrees of measurement.
HEIGHT The vertical distance from the ground to the tip of the boom or attachment.
HITE An abbreviation of the word height. The height of the boom pivot above ground level.
HORIZONTAL Parallel to the horizon.
HYDRAULIC Operated using the pressure of oil.

CRANES
INCREMENT The action of increasing a number or value.
INITIALIZE Erase all data from a memory prior to a new calibration.
INTEGRATED A tiny complex of electronic components and connections on a small slice of material (such as
CIRCUITS silicon).
MEASURE HEIGHT The vertical distance below the boom pivot at which radius measurements are to be made
when calibrating.
MICROPROCESSOR A computer processor contained on an integrated chip.
MILLIVOLT One thousandth of a volt.
MOMENT The product of force and distance to a particular axis or point.
OUT OF DUTY A point which is either longer than the longest permitted radius or lower than the lowest
permitted angle on a capacity chart
OUTRIGGER A projecting support run out from a main structure to provide additional stability or support.
PERSONALITY Data stored in the calibration EEPROM.
PRESSURE Hydraulic pressure in the boom hoist cylinder
RADIUS The horizontal distance from the center line of rotation to the center of the hook.
RATED CAPACITY The lifting capacity of a crane as determined by the published capacity chart.
RATED CAPACITY The load that a crane can safely handle based on factors such as strength, stability and rating.
RATING A factor determined by legislation that limits the proportion of a cranes capabilities which may
be utilized in a lifting operation. Usually expressed as a percentage of strength or stability.
RESTORE Move data from a back-up chip into the working personality.
47 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
ROM "Read only" memory from which data can only be read, i.e. not changed after programming.
ROPE LIMIT The maximum permitted single line pull determined by the construction and diameter of a wire
rope.
SAVE Move data from the working personality to a write protected area of memory.
SCALE The use of a factor to set the scaling of analog sensors.
SCALE Something graduated when used in measurement.
SENSITIVITY A measure of the capacity of a sensor to respond to physical stimulus.
SENSOR A device that responds to a physical stimulus and transmits a resulting impulse.
SHEAVE A grooved wheel or pulley.
SLEW OFFSET The horizontal distance from the boom pivot to the center of rotation
SPAN An extent or spread between two limits.
SPAN The calibration of an analog sensor between zero and maximum span.
STOWED An attachment usually stowed on the main boom when not in use.
ATTACHMENT
SUPERSTRUCTURE The structural part of a crane above the carrier, usually rotating.
SWING The rotation of a crane upper around its center line.
SWL (%SWL) Percentage of safe working load. The proportion of the crane capacity which is being utilized at
any one time expressed as a percentage of rated capacity
TRANSDUCER A device which 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).
TX.0 The piston side pressure transducer.
TX.1 The rod side pressure transducer.
UNLADEN A boom which has no additional stowed or erected attachments and which is not supporting a
load.
VOLT Unit of electrical potential difference and electromotive force.
WEIGHT The amount that a body weighs or the poundage to be carried by a horse in a handicap race.
WRITE PROTECTED An area of memory to which a microprocessor cannot write data.
ZERO The point from which graduation of a scale begins.
48 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
COMPUTER BOARD LAYOUT
IC2 IC3 IC8 IC7

EX EC D U TY RA M PERS
LA YO U T O F M A IN CO M PU TER BO A RD
IC2 EX ECU TIV E RO M
IC3 D U TY RO M
IC7 PERSO N A LITY CH IP
IC8 RA M CH IP (N O T REM O V A BLE).
49 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
TERMINATION BOARD
+DR DIN1 DOUT0 RL1

AIN0 DIN2 DOUT1
DIN3 O'LOAD
AIN1 DOUT2
-DR DIN4 DOUT3
0V DIN5 DOUT4 NC RL2
+DR DIN6 DOUT5 C RL1
+DR AIN2 DIN7 DOUT6 NO ATB
-DR AIN3 DIN8 DOUT7 NC
TX0+ AIN4 +VP DIN9 0V C RL2
TX0- -DR +VP DIN10 +5VA NO
0V 0V +VP DIN11 +5VB
FS1
+DR +DR +VP DIN12 DA ATB
-DR AIN5 0V DIN13 DB
BOARD
+B TX1+ AIN6 0V DIN14 RES
-B TX1- -DR 0V DIN15 0V
FS2
0V 0V 0V ATBIN ATBOUT
Cable 1 Cable 2 Cable 3 Cable4 Cable 5 Cable 6 Cable 7 Cable 8
50 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
EXTENSION REEL LAYOUT
A ngle Sensor D ata Pot’r Term inal

A 220210 P010110 Strip
51 of 52 W424103 REV A 02/13/01
Greer Company
Crane Systems
1918 East Glenwood Place
Santa Ana, CA 92705
Telephone: (714) 259-9702
Fax (714) 259-7626
1918 East Glenwood Place

Santa Ana, CA 92705
Telephone: (714) 259-9702
Fax: (714) 259-7626
52 of 52 W424103 REV A 02/13/01

Microguard 424 Operators Manual PDF

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Greer Company

TELESCOPIC BOOM CRANES

The Greer Company is dedicated to the design and

MICROGUARD 424 SYSTEM DESCRIPTION...............................................................................................4

DISPLAY WINDOWS ....................................................................................................................................5-6

PUSH BUTTONS - ICONS - LAMPS - ALARMS.........................................................................................7-10

MICROGUARD 424 SYSTEM OPERATION ................................................................................................11

CONFIGURATION SELECTION ...............................................................................................................12-15

EXAMPLES OF CRANE SET UP .................................................................................................16-20

MAIN BOOM .............................................................................................................................16

MAIN BOOM PLUS 35' OFFSETTABLE FLY...........................................................................17

MAIN BOOM PLUS 48' TELESCOPING FLY...........................................................................18

OPERATOR SETTABLE ALARMS ...........................................................................................................21-24

EXAMPLES OF SETTING ALARMS ............................................................................................23-24

CANCELING ALARMS ......................................................................................................................24

PERIODIC INSPECTIONS ........................................................................................................................25-26

CHECKING THE ANTI TWO-BLOCK SYSTEM...........................................................................25-26

ROUTINE MAINTENANCE ...............................................................................................................26

SECTION 2: TROUBLESHOOTING .....................................................................................27-51

MICROGUARD 424 SYSTEM DESCRIPTION

M icroG uard 424

V IEW SET C LEA R DO W N UP

♦ Percentage of Rated Capacity

♦ Radius of the Load

♦ Angle of the Main Boom

♦ Length of the Main Boom

♦ Height of the Boom Head

LEFT DISPLAY WINDOW

1 MAXIMUM RATED CAPACITY is a digital

Capacity is dependent on the configuration

RIGHT SIDE DISPLAYS

2 The PARTS OF LINE display shows the parts

Front, Side, Rear, 360°

Line, Track (between tracks)

PUSH BUTTONS - ICONS - LAMPS - ALARMS

1 2 3 4 1 TEST is a push button used to initiate a system

UPPER RIGHT DISPLAY

1 The RADIUS/HEIGHT icon

LOWER RIGHT PUSH BUTTONS AND ICONS

MICROGUARD 424 SYSTEM OPERATION

1. Select Outriggers, Tires, Rigging/Travel mode.

2. Select Counterweight configuration (If available).

3. Select Boom configuration or Telescope Mode (If available).

4. Select Auxiliary Head fitted or not fitted.

5. Select Lifting Attachments.

6. Select Lifting Point for Front Winch.

7. Select Lifting Point for Rear Winch.

FOR SPECIFIC EXAMPLES OF CRANE SET-UP, REFER TO PAGES 16-20.

RIGGING TRAVEL MODE

This reduction is applied by use of the DEDUCT controls as follows.

(CONTINUED ON NEXT PAGE)

♦ THE 35-61' TELE FLY IS STOWED ON THE BOOM

START THE SELECTION BY PRESSING THE

V IEW SET C LEA R DO W N UP SELECT "AUX. HEAD" FITTED

SELECT LIFTING POINT FOR FRONT

SELECT LIFTING POINT FOR REAR WINCH, "AUXILIARY HEAD"

PRESS WINCH SELECT (ITEM 2) TO SELECT

PRESS PARTS OF LINE (ITEM 3) TO SELECT 6 PARTS OF LINE

PRESS WINCH SELECT (ITEM 2) TO SELECT