Dover TWG GC MicroGuard 586 Manual

MicroGuard® 586
Rated Capacity Indicator System
for Truck-Mounted Cranes
Miller Operation
Setup
Maintenance

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MG586 Introduction 1 W450030S 0/
Introduction
The MicroGuard 586 System (hereinafter referred to as “the system”) is designed for use as an aid to
crane operation. This system is not to be used in the place of an operator who is knowledgeable in
safety guidelines, crane capacity information, and the crane manufacturer’s specications.
This manual describes operation, setup, and troubleshooting procedures for the system. Please make
sure to read, understand, and follow the contents and instructions contained within this manual. By
doing so, the operator will have a more clear indication of rated capacity, approach to overload, and
two-block conditions.

MG586 Introduction 2 W450030S 0/
System Description
The MG586 Rated Capacity Indicator/Limiter System is a visual and audible system used in the
operation of the MR30 Miller recovery vehicle.
The system includes a computer, an operator’s display console, an extension reel, and various types of electrical
cables and sensors, and is designed to measure and display load weight, calculate and display maximum capacity,
percentage of rated capability, crane conguration numbers, parts-of-line, and warn of an approaching overload
or two-block condition for each crane conguration.
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MG586 Introduction 3 W450030A 09/09
The &RPSXWHU provides all of the functions necessary to read the system sensors, process
computations, and control the disconnect functions. Information dening the physical
characteristics of the crane has been loaded during factory setup to reliably calculate crane
parameters, such as load rated capacity, and interpret the crane capability chart and conguration
numbers.
The ([WHQVLRQ5HHOmeasures the extended length of the telescoping sections of the boom and
enables calculation of crane radius, load weight, and percent of rated capacity. The reel-o cable
provides a path from the boom head to the computer via the extension reel computer cable. This
path is used to signal a possible two-block condition. The boom angle sensor measures the angle of
the boom.
The 5HHO2II&DEOH provides a path from boom head, to the computer by way of the extension reel
cable. This path is used to send a two-block signal to the computer.
The operator’s 'LVSOD\&RQVROH translates data received from the computer and displays the actual
load weight and percent of rated capability in the display windows. Visual and audible warning
alarms activate when capability limits are approaching or exceeded, or when a two-block condition is
encountered.
The $QWL7ZR%ORFN6ZLWFK$VVHPEO\ consists of the switch without the lockout pin, and the
chain and weight assembly. The anti-two-block switch provides data to the computer which is
transmitted to the operator’s display through electrical cables. Visual and audible warning alarms
activate when a two-block condition is encountered.
Two +\GUDXOLF3UHVVXUHsensors, housed within the computer assembly, measure the pressure in
both sides of the boom hoist cylinder. Other system sensors, mounted elsewhere on the crane, are
connected to the computer via electrical cables.
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MG586 Introduction 4 W450030A 09/09
Operator’s Display Console
Warning/Alarm Indicators
The red two-block lamp will illuminate when a two-
block condition occurs.
The yellow pre-warning lamp will illuminate at 90% of
rated capacity.
When the load reaches or exceeds 100% of rated
capacity, the red overload warning lamp will
illuminate along with the yellow pre-warning lamp,
when this occurs, the computer will implement a
function kick-out, which in turn, disables the boom
down, winch up, and extend out functions.
Display Windows
The current rated capacity for the crane in the current conguration will be displayed in the rated capacity
window as well as the percent of rated capacity shown as a meter which progresses to the right as the load
increases. Refer to“Normal Operation” Section of this manual.
The setup codes have been pre-congured to match the setup of the crane. The setup codes are shown as
well as the parts-of-line. Refer to “Conguration Selection” Section of this manual.
The information window shows crane specic information regarding boom length, boom angle, and working
radius, along with the load on hook. In addition, information regarding any warnings or alarms will be
displayed in this window. If the system has any internal faults, it will display “!WARNING! SYSTEM FAULT” in the
information window. The specic fault messages can be viewed by pressing the 83$552: or '2:1$552:
key. Refer to“System Fault Messages” Section of this manual.
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MG586 Introduction 5 W450030A 09/09
Main Boom-
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Push Buttons
The SETUP key enables the operator to
congure the system to match the actual setup
of the crane.
Codes are present for:
Crane conguration
Number of parts of line, up to three parts of
line with a maximum of three parts
The ALARM OVERRIDE key is used to disable
the audible warning and to override the
function kick-out for the current alarm
condition. The boom will continue to move as
long as the button is on hold after the reset. To
reconnect the function kick-out, simply allow
the button to return.
The CONTRAST keys are used to adjust the
lightness or darkness of the display area.
The DISPLAY MODE/SELECT keys are used to
switch to dierent display formats showing
various combinations of boom angle, boom
length, and radius. They can also be used as an
UP ARROW or DOWN ARROW to scroll through
menu selections.
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MG586 Operation 6 W450030A 09/09
System Operation
System Self-Test
When the system is turned on, it goes through a brief self-testing process.
All three alarm indicators will light up, all display windows will appear black, and the audible alarm will
sound.
The information display will then show the crane model and capacity chart number for the system
congured.
Following self-test, the information display will now show Miller MR3 and capacity chart numbers
2916-2917 for the System. The setup code window will display the same setup code used when the
system was last powered o. Check that the correct setup code is displayed before operating the
crane.
The rst selection will be blinking “1” and is the only available boom selection. Pressing the setup key
will go to the next selection, “Parts of Line” as in the illustration below. In order to achieve maximum
load on the unit, the load line must be three parted.
After the selection on Parts of line is made, the display will go into the“Normal Operation” mode.
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MG586 Operation 7 W450030A 09/09
Conguration Selection
Conguration selection is required upon system power up; however, it can also be entered anytime by
pressing the 6(7832. key.
The rst part of the conguration selection allows for jib selection. Since there are no jib options for
this model, the system defaults to the main boom.
Main Boom-
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6HOHFW
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Press the 6(7832. key to continue.
The current number of parts-of-line is now ashing.
To change the parts-of-line, press the 83$552: or '2:1$552: key to select the desired number
and press the 6(7832. key to continue.
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MG586 Setup 8 W450030A 09/09
Calibrating the Unit for Proper Operation
The MG586 system contains a setup/calibration mode that operates through the system display
console. The setup mode provides a means of ensuring that the system sensors are correctly
positioned and adjusted following system installation or parts replacement.
It is important that each step of this procedure is properly followed for the system to accurately
provide load, rated capacity, warnings, and function kick-outs.
WARNING!
AT ALL TIMES, OBSERVE SAFE PRACTICES. MAKE SURE THAT CRANE CAPACITY LIMITATIONS
ARE UNDERSTOOD, AND THAT THE CRANE CAPACITY PLATE IS FOLLOWED. DO NOT EXCEED
MANUFACTURER’S SPECIFIED LIFTING LIMITATIONS.
Recommended Tools
• Phillips Screwdrivers
• Digital Level – Accurate to 0.1° at level
• Digital Voltmeter
• Measuring tape (at least 100 feet, 200 feet preferable) – ber-type in tenths of feet
Crane Conguration
Before starting the system setup, position the crane on rm and level ground with the outriggers
properly extended and set.
Fully retract the boom and set it to zero degrees (±0.1°) using a digital level.
Remove the reeling drum cover to expose the length and angle sensors.
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MG586 Setup 9 W450030A 09/09
Entering Setup Mode
The display will step through each setup operation, as required by the user. The setup mode is
activated by the following procedure:
1. With the screen showing a normal working screen mode of operation, hold down “Setup”and
“up arrow” on the display for 5-10 seconds at any time to start the self test.
2. The setup screen should appear as in the graphic below when the calibration mode is
complete.
3. Boom Angle Zero
Fully retract the main boom and use an inclinometer or accurate bubble level to
ensure the boom is completely level.
4. Ensure that the inclinometer reading is made on the top at surface of the boom.
Take several readings in alternate locations to verify a true“0 °” reading.
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MG586 Setup 10 W450030A 09/09
For new reeling drum installations, once the free end of the cable coil to boom tip has been attached, the
shipping clamp should be removed to avoid damage to the cable. When the reeling drum is shipped
from the factory, it is preset to “Extension “0,”and a shipping clamp is applied to the cable.
Boom Length Zero and Span Function
After completion of the angle “0” functions the MG586 will display the screen below for Extension Zero.
NOTE The value beside the Exten = 0.0, should equal “0” ± .2, if the reading is correct, remove the cogbelt and
rotate the sensor clockwise until it hits the clutch stop. If the reading is incorrect, move the pulley
counterclockwise exactly one turn, or until the display reads within .2 of“0.” Replace the belt on the pulley.
NOTE
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MG586 Setup 11 W450030A 09/09
Angle Calibration
With the boom still at 60 °, the Length Trim procedure can be performed. The boom should be
extended to the full extension limit of the cylinder. The screen should appear as the illustration
below. If this length is o at all, you will be oered the chance to trim the length, and span the
length sensor. The Trim procedure is accomplished by pressing the Setup button once. The
length number should then be changed to match what was measured and previously stored
When the UP arrow key is pressed again, the display will return to the normal display operation
mode, and will be restored, utilizing the newly calibrated dimensions for the angle and length.
When this procedure is completed, the user should record a physical radius measurement, and
compare the measurement to the MG586 display.
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Presss the UP arrow to select the Angle Span screen. Set the boom elevation to exactly 60 ° using the digital level.
While the display in the Angle Span mode, pressing the setup button will cause the system to span the angle at
exactly 60 °. Pressing the UP arrow will allow the user to advance to the Extension Trim screen.
The console displays the boom angle sensor inside the ex tension reel. If the display reads “0.0 °,”the angle sensor
is correctly adjusted. If the display does not read“0.0 °,” angle sensor adjustment is necesssary. To adjust the Boom
Angle “0” press the setup button one time and the numbers beside the ANGLE OK= will display a zero. Boom Angle
function is now calibrated. Press the UP arrow button and the setup screen will take the user to the next step of
setup, Boom Extension “0.”
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MG586 Setup 12 W450030A 09/09
System Maintenance
It is recommended that the following checks be performed on the system prior to each shift or crane
operation to help prevent errors or malfunctions:
Crane Conguration and System Setup
The crane conguration denes the physical setup of the crane. The system setup denes the load
parameters for each conguration. The data for these calculations are loaded in the capacity chart and
installed in the crane’s computer prior to factory shipment.
WARNING!
ENSURE THAT THE CONFIGURATION CODE NUMBER IN THE DISPLAY CONSOLE WINDOW IDENTIFIES THE
CRANE’S CONFIGURATION FOR THE CURRENT OPERATION. IF IN DOUBT, SELECT THE CODE NUMBER
AGAIN FOLLOWING THE STEPS OUTLINED IN THE CRANE OPTIONS AND SETUP CODES OUTLINED IN THIS
MANUAL.
Extension Reel, Reel-O Cable to Boom Tip, Extension Reel Cable to Computer
The extension reel houses the reel-o cable to the boom tip, a cable from the extension reel to the
computer, and the boom angle sensor. The extension reel provides the following signals that are sent
directly to the computer via the extension reel computer cable:
• The Boom Extension Signal is generated within the extension reel, and controlled by the reel-o cable,
as the boom is extended or retracted. The extension reel measures the boom extension and provides a
signal, which enables the computer to calculate the operating radius of the crane, the weight of the actual
load, and the percent of rated capacity.
•The Two-Block Signal is transmitted from the boom head, through the reel-o cable, to the extension reel,
and the extension reel cable to the computer. This signal JTJOUFSSVQUFEwhen the anti-tXo block switch
opens, indicating a two-blocLDPOEJUJUJPO8IFOUIJTTJHOBMJOUFSSVQUJPOSFBDIFTUIFDPNQVUFSJUDBVTFTBO
immediate display of ashing light, an alarm on the operator’s display console sounds, and
the motion cutouts are activated.
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MG586 Setup 13 W450030A 09/09
System Maintenance (Continued),
•The Boom Angle Signal is generated within the extension reel, and designed to measure the angle of the boom
relative to the horizon.
•The Reel-O Cable (Extension Cable), extends from the extension reel to the boom tip. The reel-o cable provides
an electrical path for passage of the two-block warning signal from the boom tip to the computer cable in the
extension reel. Check the following:
•Carefully examine the reel-o cable for damage.
•Fully telescope the boom in and out. As you extend or retract the boom, ensure that the reel-o cable is smoothly
fed on and o the extension reel without drooping along the boom or jumping, especially as the boom is retacted.
WARNING!
THE EXTENSION REEL SETTING IS FACTORY PRESET. IF THE REEL-OFF CABLE HAS BEEN BROKEN, CALL YOUR SERVICE
REPRESENTATIVE. DO NOT ATTEMPT TO REPAIR A BREAK IN THE REEL-OFF CABLE WITHOUT CONSULTING WITH
YOUR SERVICE REPRESENTATIVE.
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MG586 Setup 14 W450030A 09/09
Hydraulic Connections
The two hydraulic pressure sensors mounted within the computer, measure the pressure within each side of the
boom hoist cylinder. The pressure sensors are connected to the boom hoist cylinder valve block by two exible
hoses. Both hoses are subject to the full hydraulic pressure contained within the upper and lower sides of the
boom hoist cylinder.
•Ensure that there are no hydraulic leaks at either connection end of both hoses. Check for signs of wear or damage
along the length of each hose.
Anti-Two Block Weight
•Ensure that the anti-two block weight and its parts are undamaged, in proper position, and correctly connected.
•Ensure that the switch cable is secured to the strain relief thimble, and that the thimble is on the mounting post
behind the switch.
•Ensure that all electrical cables and connectors are free from damage and correctly connected. Please refer to the
Anti-Two Block Switch Installation Section of this manual.
Checking the Two-block Warning Signals and Cutout of Machine Motions
The following test activates the anti-two-block warning signals and the valve controlling cut out of crane motions
to ensure proper operation. No other pre-existing alarm conditions may be active when performing this test.
WARNING!
Before performing this test, turn the crane power o and then on again to ensure that an existing
two-block warning and/or motion cut has not been overridden.
During this test, do not press the alarm override key to disable the audible alarm.
During this test, do not winch the hook block into the boom tip, in case the system does not cut
the crane motions.
Slowly raise the hook block until it lifts the anti-two-block weight and deactivates the anti-two block
switch. This action should cut out the winch up motion as well as the boom down, and boom extend
motions. Audible and visual alarms on the operator’s display console should become active. Lower the hook block
by winching down. This action should disable the audible and visual alarms on the operator’s display console and
activate the boom motions.
Note
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MG586 Setup 15 W450030A 09/09
Computer Cable
The extension reel cable to the computer acts as a channel for passage of signals to the system computer.
• Ensure that the cable exiting from the extension reel and running down the boom and around its pivot to
the computer is free from damage. If this cable has been damaged in any way, it should be carefully tested
and may need to be replaced to ensure accurate transmission of signals.
Load Test
The best way to identify a possible problem in the system is to do a load test. The accuracy of the load test is
dependent upon accurate operation of all of the sensors in the system and the correct code number setting for
the conguration of the crane. If no stowed deduct conguration is provided by the system, perform this test with
stowed attachments removed.
It is recommended that a load test be performed monthly.
Load Test Steps
• Calculate the weight of the total load, including the slings and hook block.
• Lift the weight, and record the load weight displayed on the display console. The load weight on the console
should be between 0 to 10% higher than the load that was lifted. EXAMPLE: When lifting 5000 lbs., the display
console window should read between 5000 and 5500 lbs. WARNING!
A LOAD READING ON THE DISPLAY CONSOLE THAT FALLS OUTSIDE OF A 10% RANGE MAY INDICATE A SENSOR
PROBLEM. CALL YOUR SERVICE REPRESENTATIVE.
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MG586 Troubleshooting 16 W450030A 12/10
Troubleshooting
System Fault Messages
When the system detects a fault, the red warning lamp will illuminate and the message, “WARNING:
SYSTEM FAULT” will ash on the display. When a more serious fault is detected, the message,
“WARNING: SYSTEM OUT OF SERVICE” will ash.
To determine the fault, press the 83$552: or '2:1$552: key once or twice. The information
window will display the related fault message. This message will appear for up to 20 seconds before
the display returns to its normal display mode. If the 83$552: or '2:1$552: key is pressed
before the 20 seconds have elapsed, the display will automatically return to its normal display mode.
Fault messages that can appear on the display and the required corrective action follow:
Fault Message Corrective Action
Reselect Crane Setup
This message indicates that there is an error in
the crane setup selection, or there is an internal
computer fault. Reselect the correct crane setup
code; the error should correct itself. If not, replace the
computer.
Refer to“Computer Replacement,”page 2.
Check Extension
This message indicates a problem with the boom
extension sensor.
1. Inspect/check cabling and connections from
computertoextensionreelonthesideoftheboom.
2. Inspect/check the extension reel-o cable for
damage.
3. Remove the extension reel cover to verify
operation of the extension reel. Refer to
“Extension Reel Voltage Checks,” page .
Check Angle
This message indicates a problem with the boom angle
sensor.
1. Inspect/check cabling and connections from
computertoextensionreelonthesideoftheboom.
2. Refer to “Adjusting the Sensors”located within
this manual.
3. Remove the extension reel cover to verify
operation of the extension reel. Refer to
“Extension Reel Voltage Checks,” page .
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MG586 Troubleshooting 17 W450030A 12/10
Fault Message Corrective Action
Check ATB Wiring
This message indicates an Anti Two-Block wiring
problem usually due to an electrical short to the
boom or a damaged cable.
1. Inspect/check cabling and connections from
computertoextensionreelonthesideoftheboom.
2. Inspect/check reel-o cable from extension reel to
boom tip and Anti Two-Block switch connections.
3. Verify electrical signals for the two-block drive
and signal within the extension reel. Refer to
“Extension Reel Voltage Checks,” page .
Check FKO
This message indicates a Function Kick-Out wiring
problem that is usually caused by a fuse or crane
circuit breaker failure. Remove the computer unit lid
and check the 10A fuse.
Replace the Computer
This message indicates an internal fault in the
computer. In some cases, it may not be necessary to
replace the computer unit.
1. Remove the computer unit lid and check the
Internal LED status indicators located on the
computer circuit board.
2. Refer to “Computer Internal Status Indicators,”
page .
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