Dover TWG GC ELEMENT II Programming manual

Operation, Calibration &
Troubleshooting Manual
For Greer LMI System
With MG5 Computer
& Element II Display
by

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TABLE OF CONTENTS
Section 1: Operation.................................................................................................................................6
1. Introduction.........................................................................................................................................6
2. Technical Support...............................................................................................................................6
3. Outline of Operation............................................................................................................................6
3.1 System Components .................................................................................................................7
3.1.1 Element II Display Unit................................................................................................7
3.1.2 MG5 Computer Unit ....................................................................................................7
3.1.3 Pressure Transducers.................................................................................................7
3.1.4 Reeling Drum Assembly..............................................................................................7
3.1.5 Boom Angle Sensor ....................................................................................................7
3.1.6 Extension Sensor ........................................................................................................7
3.1.7 Swing Sensor ..............................................................................................................8
3.1.8 Anti-Two-Block (ATB)..................................................................................................8
3.1.9 Function Kick-Out (FKO).............................................................................................8
3.1.10 Operator Programmable Alarms..................................................................................8
3.1.11 Outrigger Position Sensing (If Equipped)....................................................................8
3.1.12 Electronic Frame-Level Sensor (If Equipped)..............................................................8
4. System Self-Test.................................................................................................................................9
4.1 System Power Up Self-Test ......................................................................................................9
4.2 Calibration Mode Self-Test......................................................................................................10
5. System Setup....................................................................................................................................11
5.1 Frame-Level Screen (If Equipped) ..........................................................................................11
5.2 Accessing the Configuration Screen .......................................................................................13
6. The Configuration Screens ...............................................................................................................14
6.1 Pick Point.................................................................................................................................15
6.2 Parts of Line (POL)..................................................................................................................16
6.3 Aux Head.................................................................................................................................17
6.4 Jib............................................................................................................................................18
6.5 Boom Mode.............................................................................................................................19
6.6 Stow.........................................................................................................................................20
6.7 Counter Weight........................................................................................................................21
6.8 Winch.......................................................................................................................................22
6.9 Home.......................................................................................................................................22

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6.10 Next.........................................................................................................................................23
6.11 Outrigger..................................................................................................................................24
6.11.1 Outrigger Position Sensing (If Equipped)..................................................................24
6.12 Man Basket..............................................................................................................................25
6.13 Tires.........................................................................................................................................25
6.13.1 Rigging Travel (Tires Sub-Menu) ..............................................................................26
7. The Home Screen.............................................................................................................................27
7.1 Adjusting the Brightness of the Display...................................................................................28
7.2 LMI Window.............................................................................................................................29
7.3 Crane Configuration Window...................................................................................................30
7.4Information Window.................................................................................................................30
8. Cancel Alarm Button.........................................................................................................................31
8.1 Reset Function Kick-Out..........................................................................................................31
9. Operator Programmable Alarms.......................................................................................................32
9.1 Accessing the Operator Alarms...............................................................................................32
9.2 Setting the Minimum Boom Angle Alarm.................................................................................33
9.3 Setting the Maximum Boom Angle Alarm................................................................................33
9.4 Setting the Maximum Boom Length Alarm..............................................................................34
9.5 Setting the Maximum Tip Height Alarm...................................................................................35
9.6 Swing Alarms Overview...........................................................................................................36
9.7 Accessing the Swing and Work Area Alarms ..........................................................................37
9.8 Setting the Swing Alarms ........................................................................................................37
9.9 Work Area Alarms Overview ...................................................................................................38
9.10 Setting the Work Area Alarm...................................................................................................39
Section 2: Calibration &Troubleshooting................................................................................................40
10. Introduction.......................................................................................................................................40
11. Overview and Preparation ................................................................................................................40
12. System Self-Test...............................................................................................................................41
12.1 System Power Up Self-Test ....................................................................................................41
12.2 Calibration Mode Self-Test......................................................................................................42
13. Element II Display Console Problems...............................................................................................43
14. Fault Reporting and Fault Codes......................................................................................................44
14.1 Fault Codes for Multiple Faults................................................................................................44
14.2 Group “A” Fault Codes ............................................................................................................45
14.3 Group “B” Fault Codes ............................................................................................................45

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14.4 Group “C” Fault Codes ............................................................................................................46
14.5 Group “D” Fault Codes ............................................................................................................46
15. Problems Not Reported by Fault Code System................................................................................47
15.1 Anti-Two-Block Alarm (ATB)....................................................................................................47
15.2 Displayed Load or Radius Errors.............................................................................................47
15.2.1 Check Boom Extension.............................................................................................47
15.2.2 Check Main Boom Radius.........................................................................................48
15.2.3 Check Boom Angle....................................................................................................48
15.2.4 Check Pressure Transducers....................................................................................49
16. MG5 Computer Unit Overview..........................................................................................................50
16.1 Internal Status Indicators.........................................................................................................50
16.2 Function Kickout Fuse (FUS1) ................................................................................................51
16.3 Replacing the Computer Unit ..................................................................................................51
16.3.1 Computer Removal ...................................................................................................51
16.3.2 Computer Installation ................................................................................................51
17. Element II Display Console Overview...............................................................................................52
17.1 Checking the Display Console.................................................................................................52
17.2 Unresponsive Buttons .............................................................................................................53
17.3 Connectors..............................................................................................................................54
17.4 Horn.........................................................................................................................................55
17.5 Ingress Protection Rating ........................................................................................................55
17.6 Replacing the Display Console................................................................................................55
17.6.1 Removal ....................................................................................................................55
17.6.2 Installation .................................................................................................................55
18. Calibration Mode...............................................................................................................................56
18.1 Entering the Calibration Mode.................................................................................................57
18.2 Calibration Menus....................................................................................................................58
18.3 Inactive Buttons During Calibration Mode ...............................................................................59
18.4 Calibrating the Extension Sensor Zero....................................................................................60
18.5 Calibrating the Angle Sensor Zero ..........................................................................................61
18.6 Calibrating Span of Extension and Angle................................................................................62
18.7 Calibrating the Swing Potentiometer .......................................................................................65
18.7.1 Calibrating Swing Direction .......................................................................................66
18.7.2 Setup for Cranes With Cranes with Swing Switches.................................................66
18.8 Calibrating the Outrigger Position Sensors .............................................................................67

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18.8.1 Enabling and Disabling the Outrigger Position Sensors............................................69
18.9 Calibrating the Frame-Level Sensor (If Equipped) ..................................................................70
18.10 After the Calibration Routine ...................................................................................................72
19. Reeling Drum Overview....................................................................................................................73
19.1 Checking the Reeling Drum Cable Layering ...........................................................................74
19.2 Sensor Baseplate Assembly....................................................................................................75
19.3 Reeling Drum Voltage Checks ................................................................................................76
19.4 Anti-Two-Block Function Overview..........................................................................................77
19.5 Checking the Reeling Drum Cable ..........................................................................................77
19.6 Checking the Anti-Two-Block Circuit.......................................................................................77
20. Swing Potentiometer Overview (If Equipped) ...................................................................................79
20.1 Checking the Swing Potentiometer Drive Voltage...................................................................80
20.2 Checking the Swing Potentiometer Output Voltage ................................................................80
20.3 Checking the Swing Potentiometer Resistance.......................................................................80
21. Frame-Level Sensor Overview (If Equipped)....................................................................................81
22. Revision History................................................................................................................................82

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Section 1: Operation
1. Introduction
The Greer LMI System with MG5 Computer & Element II Display is an aid to crane operation. It is
hereinafter referred to as the "system".
Do not use this system without a properly trained operator. The operator must be knowledgeable in
safety guidelines, crane capacity information, and the crane manufacturer’s specifications.
This manual describes the operation of the system. Please read, understand, and follow the contents
and instructions contained in this manual.
2. Technical Support
For technical support specifically relating to the Greer LMI System, please contact the Greer/TWG
Service Department:
Phone: [phone]
Fax: [phone]
Address: 11135 S James Ave, Jenks, OK, 74037
3. Outline of Operation
The system is an aid to crane operation. Crane functions are monitored by a variety of sensors.
The system compares the load suspended below the boom head to the crane capacity chart stored
within the computer’s memory.
At approach to overload, the system sends audible and visual warning signals. The system can be
configured to cause function kick-out by sending a signal to function disconnect solenoids.

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3.1 System Components
•Element II Display Unit
•MG5 Computer Unit with Integrated Pressure Transducers
•Reeling Drum Assembly, with Extension and Angle Sensors
•Swing Sensor
•Anti-Two-Block Switches
•Cables
•Audible Alarm
•Operation Manual & Calibration/Troubleshooting Manual
3.1.1 Element II Display Unit
The display unit provides the operator with:
•Rated Capacity
•Actual Load
•Bar graph representation of Actual Load vs. Rated Capacity
•Radius of the Load
•Boom Angle
•Main Boom Length
•Working Area
•Crane Configuration
•Frame-Level Sensor Screen (If Equipped)
3.1.2 MG5 Computer Unit
The MG5 Computer is the center of the system. It reads the sensors, controls computations and
disconnect functions, and communicates with the display.
3.1.3 Pressure Transducers
Two hydraulic pressure transducers are contained in the computer unit. One sensor measures the rod-
side pressure in the boom hoist cylinder and one sensor measures the piston-side pressure. They are
factory calibrated at production and cannot be replaced in the field.
3.1.4 Reeling Drum Assembly
The reeling drum assembly consists of the reeling drum and reeling drum cable, the boom angle
sensor, and the extension sensor.
3.1.5 Boom Angle Sensor
The boom angle is measured by a potentiometer/pendulum assembly. It provides a voltage proportional
to boom angle. This sensor is mounted inside the cable reeling drum assembly.
3.1.6 Extension Sensor
The extension sensor provides a voltage proportional to the extension of the boom. The extension
sensor is mounted inside the cable reeling drum assembly.

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3.1.7 Swing Sensor
The swing sensor measures the angle of the boom relative to the chassis.
3.1.8 Anti-Two-Block (ATB)
The ATB switch monitors the approach of the hook block or overhaul ball to the boom head. The switch
is held in the normal position until the hook block or overhaul ball raises a weight that is mounted
around the hoist rope. When the weight is raised it opens the switch. The resultant switch open signal is
sent to the computer via the reeling drum. This results in the ATB alarm operating and a function kick-
out to occur.
3.1.9 Function Kick-Out (FKO)
Electrically-operated hydraulic solenoids disable the functions for boom hoist lower, telescope out, and
winch up when an overload or ATB alarm condition occurs.
3.1.10 Operator Programmable Alarms
These alarms, when properly set by the operator, define the operating range. These alarms are
programmable for each job site and allow the operator to work in a defined area.
•Minimum Boom Angle Alarm
•Maximum Boom Angle Alarm
•Maximum Boom Length Alarm
•Maximum Tip Height Alarm
•Left and Right Swing Alarm
•Work Area Alarm
3.1.11 Outrigger Position Sensing (If Equipped)
This alarm alerts the operator, audibly and visually, when the selected outrigger position does not
match the detected outrigger position.
3.1.12 Electronic Frame-Level Sensor (If Equipped)
The sensor and display screen show the crane’s position on the X-axis and Y-axis relative to the 0.0°
preset at the factory.

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4. System Self-Test
Immediately following system power up, or upon entering calibration mode, the system executes a self-
test. The following sections describe the self-test in each case.
4.1 System Power Up Self-Test
Immediately following system power up, the system performs a self-test which verifies that the
computer, display console, cables, and sensors are working properly. The test lasts for approximately
10 seconds. During this time, crane motions are disabled by the system function kick-out. The display
shows the crane model, load chart number, and units of measurement.
When the home display message appears, press the Press to Continue button to acknowledge the
message and allow the system to start normal operation.
When the display shows the following message, read it and press any key to continue.
If the above does not occur, see the Calibration & Troubleshooting Manual section Element II
Display Console Problems.

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4.2 Calibration Mode Self-Test
Immediately following entering calibration mode, the system performs a self-test lasting approximately
10 seconds.
During this time the numerical display segments and bar graph segments are all turned on, the audible
alarm will sound and alarm indicator lights are illuminated.
NOTE: Display message is crane dependent. This is a generic example.
If the above does not occur, see the Calibration & Troubleshooting Manual section Element II
Display Console Problems.

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5. System Setup
5.1 Frame-Level Screen (If Equipped)
If the machine is equipped with a Frame-Level sensor, press the Menu button to access the Menu
screen. NOTE: This option will not appear on machines without a Frame-Level sensor installed.
Use the Frame-Level screen to ensure the machine is properly leveled.
Machine angle from level
Dot Indicator
0°-0.9° on either axis
Green
1°-1.9° on either axis
Yellow
2°+ on either axis
Red

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If the Frame-Level sensor (or its connection) malfunctions, the home screen grid will display in red.
The grid on the Frame-Level screen will also display in red.
To exit the screen, press the Home button in the lower right corner.

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5.2 Accessing the Configuration Screen
NOTE: Press the Configuration button to access the Configuration screen.
The system will remember all previously set data, including after the system is powered off and
powered on.
After the configuration has been set, the operator must choose the winch in use. Changing the winch
will automatically change the lifting point and the parts of line to the previously set data for the selected
winch.
NOTE: Always check the point of lift and parts of line following selection of the winch.
WARNING! THE DISPLAYED LOAD AND CAPACITY ARE BASED UPON THE CURRENT
SELECTED POINT OF LIFT. NEITHER THE GREER LMI SYSTEM, NOR THE CRANE
CAPACITY CHART ALLOWS FOR LIFTING FROM MORE THAN ONE HOOK AT A TIME.

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6. The Configuration Screens
The CONFIGURATION screens represent the current setup of the system with green indicators. Each
area contains a group of one or more green indicators and a button to change the setup selection.

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6.1 Pick Point
The Pick Point button contains three green indicators. A single green indicator will illuminate to show
the point of lift. Press the Pick Point button to scroll through the available options.

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6.2 Parts of Line (POL)
The POL button (Parts of Line) changes the current number of parts of line in use.

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6.3 Aux Head
Press the Aux Head button when the aux head is fitted.

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6.4 Jib
Press the Jib button to access the different options. The Jib group contains 6 green indicators. They
indicate the length and offset of the jib in use.

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6.5 Boom Mode
The Boom Mode group contains one green indicator for machines with pinned extensions or active
boom tip options. Choose the boom mode in use.

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6.6 Stow
The Stow (Stowed Jib) group indicator illuminates when a jib is stowed on the boom.