GREER Company Insight Programming manual

Terex Calibration and
Troubleshooting Manual

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W450311 Rev C 2/13
TABLE OF CONTENTS
Introduction..............................................................................................................................3
1.1 Overview and Preparation..................................................................................................3
2.1 System Self-Test ...............................................................................................................4
2.2 Display Console Problems.................................................................................................5
2.3 Fault Reporting and Fault Codes .......................................................................................6
2.3.1 Group “A” Fault Codes..............................................................................................7
2.3.2 Group “B” Fault Codes..............................................................................................7
2.3.3 Group “C” Fault Codes..............................................................................................8
2.3.4 Group “D” Fault Codes..............................................................................................8
2.4 “No Fault Code” Problems .................................................................................................9
2.4.1 Anti-Two-Block Alarm (ATB)......................................................................................9
2.4.2 Displayed Load or Radius Errors...............................................................................9
3.1 Computer Unit Overview..................................................................................................12
3.2 Computer Unit Layout ................................................................................................12
3.3 Internal Status Indicators............................................................................................13
3.4 Function Kickout Fuse (FUS1) ...................................................................................14
3.5 Replacing the Computer Unit.....................................................................................14
4.1 Display Console Overview...............................................................................................15
4.2 Checking the Display Console....................................................................................15
4.3 Unresponsive Buttons................................................................................................15
4.4 Connectors.................................................................................................................16
4.5 Horn...........................................................................................................................16
4.6 Moisture.....................................................................................................................16
4.7 Replacing the Display Console...................................................................................17
5.1 Calibration Mode..............................................................................................................18
5.2 Entering the Calibration Mode....................................................................................19
5.3 Calibration Menus......................................................................................................20
5.4 Calibrating the Extension Zero...................................................................................22
5.5 Calibrating the Angle Sensor Zero .............................................................................23
5.6 Calibrating Span of Extension and Angle...................................................................24
5.7 Calibrating the Swing Potentiometer ..........................................................................26
5.7.1 Calibrating Swing Direction................................................................................26
5.7.2 Cranes with Swing Switches..............................................................................27
5.8 Calibrating the Outrigger Position Sensor ..................................................................28
5.9 After the Calibration Routine ......................................................................................30
6.1 Reeling Drum Overview...................................................................................................31
6.2 Checking the Reeling Drum Cable Layering...............................................................32
6.3 Sensor Baseplate Assembly ......................................................................................33
6.4 Anti-Two-Block Function Overview.............................................................................35
6.5 Checking the Reeling Drum Cable.............................................................................35
6.6 Checking the Anti-Two-Block Circuit ..........................................................................35
7.1 WAD/ISS .........................................................................................................................37
7.2 WAD/ISS Troubleshooting Table................................................................................38
7.3 Replacing the Swing Sensor ......................................................................................39
7.4 Replacing the Conditioning Box .................................................................................40

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W450311 Rev C 2/13
Introduction
The Greer Insight system is an aid to crane operation. The operator must be knowledgeable in safety
guidelines, crane capacity information, and the crane manufacturer’s specifications.
This manual describes the setup, operation, and maintenance of the system. Read the instructions in
this manual.
1.1 Overview and Preparation
This manual provides general information and methods for isolating problems that may happen during
operation. Service personnel should have previous training and experience in the procedure for setup
and operation of this system. Some problems may require replacing or returning parts to the factory for
servicing.
Tools necessary:
•Tool kit consisting of wrenches and screwdrivers (flat and Phillips’)
•Digital level accurate to 0.1°
•150-200 ft tape measure graduated in tenths of a foot
•Digital multimeter
NOTE: Low-cost analog multimeters are not appropriate; their input impedance may give inaccurate
readings.

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W450311 Rev C 2/13
2.1 System Self-Test
When the power is turned on, the system performs a self-test. This verifies the computer, display
console, cable, and sensors are working properly. During the self-test, the display will show the
expected crane model, load chart number and units of measurement.
When the display shows the following message, press the “PRESS TO CONTINUE” button.
If the above does not occur, refer to Display Console Problems.

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W450311 Rev C 2/13
2.2 Display Console Problems
Display console problems can be difficult to isolate due to the interaction between the display and the
computer unit. Failure of either unit or the cabling connecting the units can cause a malfunction.
To solve problems using the display indications, observe the display at power up and through the self-
test. Use the following chart to help with the diagnosis:
Problem
Action
There are no display indications in any of the
windows when the power is turned on.
Or a “No Communications” message appears.
Refer to Internal Status Indicators.
The display unit does not cycle through the
self-test. The data in the display windows
appears jumbled with missing segments.
Replace the display unit.

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W450311 Rev C 2/13
2.3 Fault Reporting and Fault Codes
System fault codes provide ways to locate and assess problems within the Insight system. Each time
the system is turned on, it performs a self-test that lasts approximately 6 seconds. Faults detected
during the self-test are indicated on the display console:
•“WARNING SYSTEM FAULT!” will display at the bottom of the text window.
To view the fault codes, press and hold the (i) button as shown.
The faults will be listed across the bottom of the text window.

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W450311 Rev C 2/13
2.3.1 Group “A” Fault Codes
Group “A” fault codes represent faults detected for analog sensors.
NOTE: Check and repair “B” and “C” group faults before investigating group “A” faults.
The following chart details all the available codes in the left column and the actions to take in the right
column.
FAULT
CODE SWING
SENSOR
BOOM
ANGLE
SENSOR
EXTENSION
SENSOR
TDX 1
ROD
PRESSURE
TDX 0
PISTON
PRESSURE
ACTION
000
No Fault Found
None
001
X
Refer to Replacing the
Computer
002
X
003
X
X
004
X
Refer to Calibrating the
Extension Sensor Zero,
Calibrating Span of Extension
and Angle, and Reeling Drum
Voltage Checks.
008
X
Refer to Calibrating the Angle
Sensor Zero, Calibrating Span
of Extension and Angle, and
Reeling Drum Voltage
Checks.
012
X X
Refer to Calibrating the Angle
Sensor Zero, Calibrating the
Extension Sensor Zero,
Calibrating Span of Extension
and Angle, and Reeling Drum
Voltage Checks.
016
X
Refer to Calibrating the Swing
Potentiometer, and Reeling
Drum Voltage Checks.
2.3.2 Group “B” Fault Codes
Group “B” fault codes represent faults detected for internal analog functions and power feeds to the
function kickout and anti-two block switches.
FAULT
CODE
FKO
POWER
FEED
A2B
POWER
FEED
DISPLAY
CONSOLE
ADC 2
INTERNAL
FAULT
ADC 1
INTERNAL
FAULT
ACTION
000
No Fault Found
008 X
Refer to sections 6.5 and
6.6 for Troubleshooting
Information.
016 X
Check Crane Circuit
Breakers

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W450311 Rev C 2/13
2.3.3 Group “C” Fault Codes
NOTE: Group “C” fault codes represent faults detected for internal computer memories.
The following chart details all the available codes in the left column and the actions to take in the right
column.
FAULT
CODE
SERIAL
EEPROM
CRANE
DATA
RAM
DUTY
DATA
PROGRAM
ACTION
000
No Fault Found
NONE
001
X
Reprogram the MG5 computer.
008
X
Erase Crane Data
016
X
Replace Computer
2.3.4 Group “D” Fault Codes
NOTE: Group “D” fault codes represent faults detected for capacity chart selection.
The following chart details all the available codes in the left column and the actions to take in the right
column.
FAULT
CODE
WRONG
SWING
AREA
WRONG
BOOM
LENGTH
CHART
NOT
FOUND
ACTION
000
No Fault Found
NONE
001 X
Check other sensor faultsfirst,
Reselect CRANE SETUP
002 X
Boom length is out of range for selected chart.
Check crane setup, boomlength and extension.
003 X X
Check other sensor faultsfirst,
Reselect CRANE SETUP
004 X
Swing to correct working area to select chart.
Check swing sensor zero position.
005 X X
Swing to correct working area to select chart.
Check swing sensor zero position.
006 X X
Check other sensor faultsfirst,
Reselect CRANE SETUP
007 X X X
Check other sensor faultsfirst,
Reselect CRANE SETUP

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W450311 Rev C 2/13
2.4 “No Fault Code” Problems
This section addresses problems not reported by the computer fault code system.
2.4.1 Anti-Two-Block Alarm (ATB)
This section gives aides diagnosing ATB alarm problems. For detailed information, schematic, and
voltages, refer to ANTI-TWO-BLOCK FUNCTION OVERVIEW.
PROBLEM:
• The Anti-Two-Block alarm is continuously ON. Operating the switch at the boom head does not
deactivate the alarm.
This problem suggests an open circuit between the computer ATB input and the ATB switch, or an
open circuit between the computer ATB feed and the ATB switch. Check the reeling drum cable for
damage. Ensure the two-block switches are correctly connected. Check the slip-ring and wiring inside
the extension reel. Check the reel-to-computer cable. Check the connectors.
PROBLEM:
• The Anti-Two-Block alarm is continuously OFF (safe). Opening the switch at the boom head, by
lifting the A2B weight does not activate the alarm.
This problem suggests a short circuit between the computer ATB input and the computer ATB feed
somewhere between the computer and the ATB switch. Check the reeling drum cable for damage.
Ensure the two-block switches are correctly connected. Check the slip-ring and wiring inside the
extension reel. Check the reel-to-computer cable. Check the connectors.
2.4.2 Displayed Load or Radius Errors
This section gives direction to fault diagnosis of load and radius errors. Load or radius errors can cause
early or late tripping of overload alarms. Accuracy of load is governed by the radius accuracy, and the
extension, angle, and pressure sensors. Accuracy of radius (unloaded) is governed by the extension
and angle sensors.
Ensure there are no system faults before continuing.
2.4.2.1 Check Boom Extension
1. Ensure the boom is fully retracted.
2. Ensure the reeling drum cable is correctly layered as a single layer across the extension reel
surface. Any stacking of the cable will cause extension errors. This will cause the System to
exceed the 0.5 ft tolerance allowed by the computer for boom mode selection. If the reeling
drum cable is stacking on the reel, refer to CHECKING THE REELING DRUM CABLE
LAYERING.

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W450311 Rev C 2/13
3. Check the zero of the extension sensor with the boom fully retracted. Enter the Calibration
Mode and use the “SPAN” command. Select sensor No. 2 to view the extension value in feet.
The value of extension must be between -0.2 and +0.2, with the boom fully retracted. If the
extension value is incorrect, refer to ENTERING THE CALIBRATION MODE. Fully telescope
the boom and ensure the displayed boom length value matches the maximum length of the
boom. If the length value is incorrect, follow the EXTENSION SPAN procedure in
CALIBRATING SPAN OF EXTENSION AND ANGLE.
2.4.2.2 Check Main Boom Radius
NOTE: The required accuracy of taped radius measurements is within 0.1 feet. When taking radius
measurements use a good quality tape that does not stretch. The tape should be graduated in feet
and tenths of a foot. Always measure between the swing center of the crane and the hook line,
using a single part of line with the crane centered over front (rough terrain) or centered over rear
(truck crane).
1. Fully retract the boom and ensure the crane configuration is correctly set up.
2. Raise the boom to about 45° and measure the radius. The measured radius must match the
displayed radius within + 0.5 ft. If it does not match, refer to CALIBRATING THE ANGLE
SENSOR ZERO.
3. Raise the boom to a high angle (at least 70°) and measure the angle with the inclinometer.
Ensure the displayed angle matches the inclinometer reading within 0.2°. If the displayed angle
is incorrect, follow the angle span calibration procedure in CALIBRATING SPAN OF
EXTENSION AND ANGLE.
2.4.2.3 Check Boom Angle
NOTE: The required accuracy of measured angles is within 0.2°. When taking boom angle
measurements use a good quality inclinometer. Many inclinometers are only accurate at 0° (level).
Ensure the digital inclinometer is securely mounted to the boom.
1. Fully retract the boom.
2. Using an inclinometer, set the boom to 0° (zero) and ensure the displayed boom angle value is
0.0°. If the angle value is not 0.0°, refer to CALIBRATING THE ANGLE SENSOR ZERO.
3. Raise the boom to a high angle (at least 70°) and measure the angle with the inclinometer.
Ensure the displayed angle matches the inclinometer reading within 0.2°. If the displayed angle
is incorrect, refer to CALIBRATING SPAN OF EXTENSION AND ANGLE.