GREER Company MicroGuard 500R Installation guide

Greer Company Crane Systems
GREER COMPANY 1918 E. Glenwood Place, Santa Ana, CA 92705 MicroGuard® 500R Computer Training Manual
Telephone: [phone] Fax: [phone] PN: W000014- 10/04/02
1 of 11
MicroGuard®500R Computer
Training Manual

Greer Company Crane Systems
GREER COMPANY 1918 E. Glenwood Place, Santa Ana, CA 92705 MicroGuard® 500R Computer Training Manual
Telephone: [phone] Fax: [phone] PN: W000014- 10/04/02
2 of 11
Table of Contents
MicroGuard®500R Computer.............................................................................3-4
Cab Plug Operation ...............................................................................................4
Cab Wiring Harness Legend...............................................................................4-5
Console Wiring Harness Plug................................................................................6
Circuit Breaker Protection......................................................................................6
Anti Two-Block and Function Kickout ....................................................................7
Grouped Error Codes ......................................................................................8-10

Greer Company Crane Systems
GREER COMPANY 1918 E. Glenwood Place, Santa Ana, CA 92705 MicroGuard® 500R Computer Training Manual
Telephone: [phone] Fax: [phone] PN: W000014- 10/04/02
3 of 11
The MicroGuard®500R Computer
With the introduction of the MG® 500R Computer, there was a major change in the
interaction between the Greer computer and theelectrical systemofthe crane.Besides
monitoring crane load functions, the MG® 500R Computer is responsible for routing the
main electrical current for the computer, as well as supplying the electrical circuitry for the
crane.
The photograph below shows the added Terex-RO components. Anything above or outside
of the heavy black line is considered the load moment function and is addressed in the
Greer Company Maintenance and Setup Manual (Part No. W458200 Rev. B 01/14/02).
MicroGuard®500R Computer Assembly
This publication contains schematic information, as well as troubleshooting material for the
MicroGuard®500R Computer Assembly. Please read this material carefully before
undertaking any maintenance or troubleshooting tasks on this system.
Warning: Proper maintenance and troubleshooting procedures for electrostatic
devices must be utilized or the system components may be damaged.

Greer Company Crane Systems
GREER COMPANY 1918 E. Glenwood Place, Santa Ana, CA 92705 MicroGuard® 500R Computer Training Manual
Telephone: [phone] Fax: [phone] PN: W000014- 10/04/02
4 of 11
The MicroGuard®500R Computer continued
Thefollowingpagesaddressthe MicroGuard®500R system partsand function.The purpose
of this system is to ensure that no power reaches the crane or load moment functions until
the PTO is engaged in preparation for crane operation. The picture below identifies the
wiring of system components.
CAB Plug Operation
The cab plug supplies the main power to the computer and crane wiring. The circuit
incorporates Relay # 4, located inside the computer enclosure. Relay # 4 is a power relay
designed to control the main current flow from the battery to the computer and from the
crane electronics through a wiring panel.
The power for the coil in Relay # 4 is supplied by ignition power when the truck ignition
switch is turned on. The ground side of the coil is attached to the PTO ground switch and
will not allow the relay to function until the PTO on the crane is engaged. When this ground
connection is made, the coil on the relay pulls the contacts closed and supplies
battery power to the system. The relay will make a clicking sound as it engages, indicating
that the coil has pulled the contacts closed, which will then activate the PTO light in the
truck cab, indicating that the system is powering up.
Cab Wiring Harness Legend
Pin# 1 The black wire is connected tothe engine fuel shut-offsolenoid and is routed
through the shutdown relay to ignition power.
Pin# 2 The grey wire is connected topower for the PTOlight.When the circuitis
powered, it will cause the PTO light to glow in the cab.
Pin# 3 The redwire interminalposition #3isconnected toabatterysource. As
always, the power should be fused at the source even though the power is directed
to the computer module through a “resettable “circuit breaker on the
terminal board. This is a direct power connection, which is then directed to
position BLD17 on the circuit board.
ATB Plug Console
Plug CAB Plug
Display Harness Reel Drum Harness

Greer Company Crane Systems
GREER COMPANY 1918 E. Glenwood Place, Santa Ana, CA 92705 MicroGuard® 500R Computer Training Manual
Telephone: [phone] Fax: [phone] PN: W000014- 10/04/02
5 of 11
To Ignition On
(engine Compartment
Engine Shutdown Solenoid
(Engine Compartment)
PTO Limit Switch
PTO Light
12V
Battery
Supply
Grey
White
Black
Blue
Red
Red
Blue
White
Black
Grey
Computer Enclosure
Terminal Color/Terminal Function
1Black/Bld15 Fuel Solenoid
2 Grey/Bld16 PTO Light
3 Red/Bld17 Power (Battery Source)
4 Blue/Bld18 Ignition Power
5 White/Bld19 PTO Ground
**6 Red/NA Engine Start (from Crane
Console
**7 Brown/NA Signal Horn (From Crane
Console) Bottom View of Computer
** These two connections are wiring junctions between the CAB and Console receptacles. There is no
connection to the computer board assembly.
Pin# 4 The bluewire isthe ignitionpower thatusually provides power tothe fuel solenoid.
The wire is never “hot” unless the key is on. This wire also supplies the power for the
coil in relay# 3.
Pin# 5 The white wire is the completion ofthe “power on” circuit.This wire is mostoften
connected tothe ground switchon the shiftcover of thePTO.When the PTO is
engaged, the ground is then passed on tothe ground side ofthe powerrelaycoil,
becoming the main power supplyfor the computer.
Pin# 6 The red wire is power from the Start/Stop switch at the operator display console.
When the switchis pushed in the start direction, currentissupplied tothe truck
starter solenoid to start thetruck.
Pin# 7The brown wire is the power signal sent to the chassiswarning horn, activated by
pushing the operator warning horn device atthe operator displayconsole.

Greer Company Crane Systems
GREER COMPANY 1918 E. Glenwood Place, Santa Ana, CA 92705 MicroGuard® 500R Computer Training Manual
Telephone: [phone] Fax: [phone] PN: W000014- 10/04/02
6 of 11
Console Wiring Harness Plug
The power for all of the previously mentioned functions is supplied from the terminal
connections in the computer enclosure as listed in the Color/Terminal column in the table
below.
Circuit Breaker Protection
The main power signal supplied from the main
power relay is divided up into a series of three
self-resetting circuit breakers on the board.
These circuit breakers work when a short circuit
in a wire causes the power signal to go to
ground, thus heating up the circuit breaker. It
would then go again into the working mode
when it cooled off.In the caseof a function that
loses and then regains power intermittently, any
of the power wires supplied to the console or
FKO could be suspect for a short. CB1 and CB2
are for console options, and CB3 is for the FKO
circuit.
If the short circuit is so severe that the circuit
breaker has to be replaced, the unit must be
returned to the factory for repair.
Terminal
Number
Function Color of Wire/
Terminal#
1 Engine Start/Stop Black/Bld1
2 Engine Stop Green/Bld2
3 O/R Limit Switches Brown/Bld3
4 Signal Device Yellow/Bld4
5 2 Spd. Winch Orange/Bld5
6 Angle Switch Red/Bld6
7 Aux. OR Switch Grey/Bld7
8 Signal Limit Switch Black/Bld8
9 Limit Switch Power Blue/Bld9
Console Plug

Greer Company Crane Systems
GREER COMPANY 1918 E. Glenwood Place, Santa Ana, CA 92705 MicroGuard® 500R Computer Training Manual
Telephone: [phone] Fax: [phone] PN: W000014- 10/04/02
7 of 11
Anti 2-Block and Function Kick-Out Plug
Terminal
ColorWire/
Terminal
Connection
Function
1 Blue/BLD22 FKO Solenoid
2 Green/BLD23 Warning Horn
ATB Plug and Connections
The Anti 2-Blockfunction is associated withthe ATBplug and islocated on theleftside of
the computer enclosure, as shown in the above illustration. This plug contains 2 wires: a
green wire that connects to the warning horn, located on the crane console, and a blue
wire that is connected to the function kick-out solenoid. The resulting output signals are a
result of the feeds from the FKO relay. When the signal from the extension reel indicates a
2-Block condition, the FKO relay switches the condition; the currents between the FKO
solenoid and the warning horn are then reversed. The schematic below shows
the following circuit.
FKO Relay
(Mounted on computer board)
Common
NO
NC
Green
BLD 23
Blue
BLD 22

Greer Company Crane Systems
GREER COMPANY 1918 E. Glenwood Place, Santa Ana, CA 92705 MicroGuard® 500R Computer Training Manual
Telephone: [phone] Fax: [phone] PN: W000014- 10/04/02
8 of 11
Grouped Error Codes
The MicroGuard®586 Display used in conjunction with the MicroGuard®500R
Computer has the capability of producing Grouped Error Codes for use as a troubleshooting
tool and guide. The error codes assist in pinpointing problem areas.
There are four basic groups of fault codes:
Group A is designed for all analog sensor inputs. These functions must
operate within a specific range of output; if not within the expected range as
called for in the program instructions, the computer will produce a fault code
“A XXX.” When the fault code is compared to the error code chart, a specific
sensor will be identified for checking.
Group B monitors internal voltage feeds, such as the ATB Input/Output
circuit, and transducer inputs.
Group C monitors the computer memory modules. The only part of this group that would
be user serviceable is the Executive Program Chip, which is changeable.
Group D refers to Load Chart (or Duty Chart) as it applies to specific sensor inputs. If
one of the analog sensors is producing signals that are out of the specific volt-
age criteria, the computer will not be able to find a specific load chart to match
this criteria. This code is usually accompanied by an analog or “A” code.
When an error is detected, the
display will first emit a warning on
the screen as viewed in this
graphic .

Greer Company Crane Systems
GREER COMPANY 1918 E. Glenwood Place, Santa Ana, CA 92705 MicroGuard® 500R Computer Training Manual
Telephone: [phone] Fax: [phone] PN: W000014- 10/04/02
9 of 11
When the warning occurs, press the
Up arrow button to display the
specific problem in words. It may
read: “Extension Sensor,”or
“Check FKO” as shown here.
Most of the time an error can be located and defined by using the above definitions,
however, a more completedefinition mayberequired for diagnosis. Inthiscase,press
the “SETUP” button on the display.The codeswill appear on the screen bygroup with a
code number to define the fault. Refer to the 586 Repair Manual for proper voltages
and testing.
Setup
OK
The MicroGuard®586 Display Console showing the four error code groups
For definition of these codes, refer to the chart on the following page.
Grouped Error Codes cont.

Greer Company Crane Systems
GREER COMPANY 1918 E. Glenwood Place, Santa Ana, CA 92705 MicroGuard® 500R Computer Training Manual
Telephone: [phone] Fax: [phone] PN: W000014- 10/04/02
10 of 11
Grouped Error Codes continued
Group A Fault Codes
A1 TXO Piston Side Pressure Out of Range
A2 TX1 Rod Side Pressure Out of Range
A4 Extension Sensor Ain2, Out of Range
A8 Boom Angle Sensor, AIN3, Out of Range`
Group B Fault Codes
B1 ADC1 (Piston Pressure) Not Responding
B2 ADC2 (Rod Pressure) Not Responding
B8 Bad ATB Feed
B16 Bad FKO Feed
Group C Faults
C1 Bad Executive EPROM Checksum
C2 Bad Duty ROM Checksum
C4 Bad RAM Test
C16 Bad Serial EEPROM Test
Group D Faults
D1 No Duty Found
D2 No Duty Because of Bad Extension Match