RCI 777 Calibration and

Troubleshooting Manual
 TABLE OF CONTENTS
Introduction ................................................................................................................................ 3
1.1 Overview & Preparation ....................................................................................................... 4
2.1 System Self-Test ................................................................................................................. 5
2.2 Display Console Problems ................................................................................................... 7
2.3 Fault Reporting and Fault Codes ......................................................................................... 8
2.3.1 Group “A” Fault Codes ................................................................................................ 9
2.3.2 Group “B” Fault Codes ................................................................................................ 9
2.3.3 Group “C” Fault Codes ................................................................................................ 10
2.3.4 Group “D” Fault Codes ................................................................................................ 10
2.4 “No Fault Code” Problems ................................................................................................... 11
2.4.1 Anti-Two-Block Alarm (ATB)........................................................................................ 11
2.4.2 Displayed Load or Radius Errors ................................................................................. 11
3.1 Computer Unit Overview ...................................................................................................... 14
3.2 Internal Status Indicators ..................................................................................................... 14
3.3 The COMM Indicator............................................................................................................ 15
3.4 Function Kickout Fuse ......................................................................................................... 15
3.5 Replacing the Computer Unit ............................................................................................... 16
4.1 Display Console Overview ................................................................................................... 17
4.2 Checking the Display Console ............................................................................................. 17
4.2.1 Reading the LCD......................................................................................................... 17
4.2.2 Unresponsive Buttons ................................................................................................. 17
4.2.3 Connectors.................................................................................................................. 17
4.2.4 Horn ............................................................................................................................ 18
4.2.5 Moisture ...................................................................................................................... 18
4.3 Replacing the Display Console ............................................................................................ 18
5.1 Calibration Mode .................................................................................................................. 19
5.2 Entering the Calibration Mode .............................................................................................. 20
5.3 Calibration Menus ................................................................................................................ 21
5.4 Zeroing the Extension and Angle Sensors ........................................................................... 22
5.5 Spanning the Boom Extension and Angle ............................................................................ 24
5.6 Calibration of Swing Zero ..................................................................................................... 26
5.6.1 Changing the Direction of the Swing Count ................................................................. 26
5.7 Cylinder Span Dimension..................................................................................................... 27
6.1 Reeling Drum Overview ....................................................................................................... 29
6.2 Checking the Reeling Drum Cable Layering......................................................................... 30
6.3 Sensor Baseplate Assembly ................................................................................................ 31
6.4 Anti-Two-Block Function Overview ...................................................................................... 33
6.5 Checking the Reeling Drum Cable ....................................................................................... 33
6.6 Checking the Anti-Two-Block Circuit .................................................................................... 33

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Introduction
The Greer Company is dedicated to the design and manufacture of electronic parts created to aid in
crane operation. This manual has been developed to assist Service Personnel understand, locate, and
identify problems that may arise during the operation of the RCI 777 Rated Capacity Limiter System.
Do not use this system in place of an operator who is knowledgeable in safety guidelines, crane
capacity, information, and the crane manufacturer’s specifications. Use of calibration routines without
consultation with the Greer Company invalidates the warranty.

Where to go for help

When field repairs cannot be made without replacement of a part, or when troubleshooting advice is
needed, the following support number should be called.

Greer Company
Service: Jenks, OK
Telephones: (918) 298-8300
Fax: (918) 298-8301

Information provided to support personnel must be accurate and complete. Have your crane Model
Number and Serial Number ready. Carefully describe the problem, noting any unusual system
responses that may help us to quickly and effectively solve your problem.

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1.1 Overview & Preparation
The Troubleshooting Manual for the RCI 777 Rated Capacity Limiter System, manufactured by the
Greer Company provides information and methods for isolating problems that may arise during the
operation of the system. Some of these problems can be corrected in the field. Other problems may
require replacement of parts or the return of a part to the factory for servicing. Service personnel should
have prior training and experience in the procedure for operation and setup of this system.
For inspection and calibration, the service technician will need a basic tool kit consisting of wrenches
and screwdrivers (flat and Phillips blades), a digital multimeter (DMM) capable of measuring DC voltage
with a range of 0 volts to ± 50volts and resolution of 0.1 volts with a resistance range of 0 ohms to 2
megaohms. Low-cost analog meters are not appropriate since the input impedance of these meters
may give false readings.

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2.1 System Self-Test
When the power is turned on or when the “TEST” button is pressed during operation, the computer and
operator’s display console perform a “SELF-TEST,” verifying the computer, display console, cables,
and all remote sensors are working properly.
During the SELF-TEST, all display functions are activated, allowing the operator to check whether or
not all indicators are functional.
NOTE: It is important that the indicators displayed during the SELF-TEST are recognized and
fully understood by the operator to aid in correctly determining computer and display
communication problems.

MAX

SET

TEST

Immediately following electrical power up or press the “TEST” button, the system performs a self-test.
During this time the numerical display segments and bar graph segments are illuminated, the audible
alarm will sound and alarm indicator lights are illuminated. The information window displays the
machine model and load chart number.

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2.1 System Self-Test (cont.)

MAX

SET

TEST

Following the Power-Up Self-Test, the information window will display as shown. During this time, crane
motions are disabled by the system function kickout.
Press the “PRESS TO CONTINUE” button to acknowledge the information display message and allow
the system to begin normal operation.

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2.2 Display Console Problems
Display Console Problems are difficult to isolate because of the interaction between the display console
and the computer unit. Failure of either unit, or the cabling between the two units, causes malfunction of
display console indications. Diagnosis of some system problems can be carried out without the proper
function of the display console and it’s communication with the computer unit.
To solve problems using display console indications, carefully observe the display console at “power-on”
and through the self-test. Next, use the following chart to help decide the course of action.

PROBLEM ACTION
There are no display indications at all when power Refer to Section 3.3
is turned on. All displays remain blank and no
lights are illuminated
The load, angle, radius, length, and rated capacity Replace the display console.
display windows do not show “188.8” or the bar
graph display window has missing black segments
during the self-test.
The red or yellow indicator lights do no illuminate Replace the display console.
during the self-test.
The display console does not do the self-test. No Replace the display console.
words or logical numbers ever appears after the
power is turned on. The displays look jumbled,
with missing segments.
The display console lights are illuminated. Load, Display console is OK.
angle, radius, length, and rated capacity show Check connectors on the back of the display
“188.8” or 888,8000 for load and capacity, but the console.
information window displays: Refer to Section 3.5
“Bad Communications with main computer”

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2.3 Fault Reporting and Fault Codes
System Fault Codes provide one of the most important ways to quickly locate and assess problems
within the RCI 777 system. Review this section carefully.
Each time the system is turned on, it goes through a brief self-testing process that detects most faults in
the system. During normal operation, a self-test can be initiated at any time by pressing the TEST
button on the display console.
Many fault conditions are detected without a system self-test.
Faults detected in the system during the self-test are indicated on the display console in the following
ways:
• The RED OVERLOAD LED will illuminate.
• The ALARM will sound.
• “WARNING SYSTEM FAULT!” will be displayed at the bottom of the text window.
Fault codes may be displayed on the display console. To view the codes, press and hold the TEST
button and wait for the system to complete the self-test. The system will reboot, keep holding the TEST
button until the screen displays the codes, as shown.
The user may also view fault codes after entering the Calibration Menu and accessing the “00 Error
Codes” menu.

SET

TEST

NOTE: During this time, the system may display prompts such as “CHECK CONFIGURATION
BEFORE YOU CONTINUE”. Select the appropriate response while keeping the TEST button
pressed. Do not release the TEST button. Fault codes will be shown in the lower portion of the
window as long as the TEST button is depressed.

There are four groups of FAULT CODES: A, B, C & D. The function of these groups and a complete
listing of each code is provided on the following pages.
NOTE: It is important to always investigate Faults in the “B” and “C” groups before continuing
with “A” and “D” group faults.

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2.3.1 Group “A” Fault Codes
NOTE: Group “A” fault codes represent faults detected for analog sensors. Check and repair “B”
and “C” group faults before proceeding with group “A” fault finding sensors.
This chart details the available codes in the left column and the corrective actions to take.

Fault Swing Boom Extension Tdx 1 Tdx 0 Action

Code Sensor Angle Sensor Rod Piston
Sensor Pressure Pressure
000 No Fault Found None
001 X
002 X Replace Computer.
003 X X
004 X Check Extension
Calibration. If Recalibration
does not fix the problem,
replace the Sensor
Baseplate Assembly.
008 X Check Angle Calibration. If
recalibration does not fix the
problem, replace the Sensor
Baseplate Assembly.
016 X Replace Swing Sensor.

2.3.2 Group “B” Fault Codes

NOTE: Group “B” fault codes represent faults detected for internal analog functions and power
feeds which go to the function kickout and anti-two-block switches.
This chart details the available codes in the left column and the actions to take in the right column.
Fko A2b Display ADC 2 ADC 1
Fault
Power Power Console Internal Internal ACTION
Code
Feed Feed Fault Fault
Check Crane Circuit
016 X Breakers.
Check the FKO fuse.

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2.3.3 Group “C” Fault Codes
NOTE: Group “C” fault codes represent faults detected for internal computer memories.
This chart details the available codes in the left column and the actions to take in the right column.
Fault Serial Crane RAM Duty Program Action
Code EEprom Data Data
000 No Fault Found NONE
001 X
002 X Replace the Duty File. Refer to section 3.5.2.
003 X X
004 X Replace the computer.
005 X X
006 X X Replace the Duty File. Refer to section 3.5.2.
007 X X X
016 X Corrupt calibration. Replace computer.

2.3.4 Group “D” Fault Codes

NOTE: Group “D” fault codes represent faults detected for capacity and chart selection.
This chart details the available codes in the left column and the actions to take in the right column.

Wrong Wrong Chart

Fault
Swing Boom Not Action
Code
Area Length Found
000 No Fault Found NONE
001 X Re-select crane setup. Check other sensor faults first.
Boom length is out of range for selected chart. Check crane
002 X
setup, boom length, and extension.
003 X X Re-select crane setup. Check other sensor faults first.
Swing to correct working area to select chart. Check swing
004 X
sensor zero.
Swing to correct working area to select chart. Check swing
005 X X
sensor zero.
006 X X Re-select crane setup. Check other sensor faults first.
007 X X X Re-select crane setup. Check other sensor faults first.
DataLogger Malfunction – Error detected in the
016 daughterboard chip. It should be replaced or updated with
a compatible version.

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2.4 “NO FAULT CODE” Problems
This section addresses problems which may occur and may not be reported by the computer fault code
system.

2.4.1 Anti-Two-Block Alarm (ATB)

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 switches, or an
open circuit between the computer ATB feed and the ATB switch(es). Check the reeling drum cable for
damage. Ensure the Anti-Two-Block switches are correctly connected. Check the slip-ring and wiring
inside the reeling drum. Check the signal cable from the reeling drum to the computer. Check the
connectors.

Problem:
• The Anti-Two-Block alarm is continuously OFF (safe). De-operating the switch at the boom
head by lifting the ATB weight does not activate the alarm.
This problem suggests a short circuit between the computer ATB input and the computer ATB feed
between the computer and the ATB switch(es). Check the reeling drum cable for damage. Ensure the
Anti-Two-Block switches are correctly connected. Check the slip-ring and wiring inside the extension
reel. Check the signal cable from the reeling drum to the computer. Check the connectors.

2.4.2 Displayed Load or Radius Errors

This section aids in 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. The accuracy of the radius (unloaded) value 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 when the boom is fully retracted.
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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 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, continue to the CALIBRATING THE
ANGLE SENSOR ZERO procedure.
3. Raise the boom to a high angle (at least 60°) and measure the angle with the inclinometer.
Ensure the displayed angle matches the inclinometer reading within 0.1°. 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 near 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° 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 0.1°. If the displayed angle
is incorrect, refer to CALIBRATING SPAN OF EXTENSION AND ANGLE.

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2.4.2.4 Check Pressure Sensors
There are two pressure sensors installed as part of the system. Both pressure sensors are mounted
within the computer unit. One is connected to the piston side of the boom hoist cylinder via flexible hose;
the other is connected to the rod side of the boom hoist cylinder via flexible hose. Both hoses are
protected by velocity fuses within the boom hoist cylinder valve block on the end of the cylinder.
The pressure sensor located on the piston side, is subject to the hydraulic pressure needed to support
the weight of the boom, any attachments, and the load. The pressure sensor on the rod side monitors
the pressure necessary to control the down motion of the boom. The computer unit uses this
information (along with other sensors such as extension, length, and angle), to compute the weight of
the suspended load. The maximum continuous working pressure for the sensors is 250 bar (3625 PSI).
The pressure sensing system is calibrated at the factory. Pressure sensors may not be individually
replaced. Any serious problem will necessitate changing the entire computer unit.
1. Lower the boom until the boom hoist cylinder is fully retracted and on its stop.
2. Loosen the hydraulic connections to the pressure sensors to ensure zero pressure is present on
the sensors.
3. Enter the calibration mode and press “Menu Up” button to access “15 PRESSURE MONITOR”
to view both sensor pressures and net pressure.
4. Check the pressure values of both sensors. The pressure values should be between -75 and
+75 PSI. If not, replace the computer unit.
5. Check the nett pressure value. This should be between -35 and +35 psi. If not, replace the
computer unit.

MAX

SET

TEST

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3.1 Computer Unit Overview
The Computer Unit provides all necessary functions to read the sensors, control computations,
disconnect functions, and communicate with the display console/internal bar graph.
NOTE: Due to differences in computer unit configurations, the locations of various board
components may vary.

3.2 Internal Status Indicators

The computer unit contains a row of LED indicators for checking computer operation. During normal
operation, all LEDs will be illuminated with the COMM indicator blinking. If not, please contact technical
support for assistance. Use the following chart and preceding image for LED location.
LED Indicator Function
D7 Communication Indicator TST0
D8 Battery Power_POS
D9 Communication Indicator TST1
D10 +VP
D11 +10V
D12 COMM (Communication Indicator)
D13 +8V2
D14 +5V
D17 +3V3

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3.3 The COMM Indicator
The COMM Indicator provides an indication of the communication with the display console and of the
running state of the computer program. Carefully observe the COMM Indicator and the display console
at power on and through the self-test, then use the following chart to assist in diagnosing the problem.

COMM Indicator at Power On Action

From the moment the power is applied, the The computer is not running.
COMM indicators do not illuminate. During and Check status indicators.
after the brief self-test, the COMM Indicators Try to reset the system by powering off and on.
remain off. Listen to the computer for the relays to click. If
they do not click, replace the system chip. If not
successful, replace the computer.
From the moment system power is applied, the Communication with the display has not been
COMM Indicators flash at a fast rate and never made.
stop. The display console never goes to normal Check connector at rear of the display console.
display and displays “188.8” or 888,000 in the
number display windows.
At the moment power is applied, the COMM This is the normal operation of the communication
Indicators flash briefly, and then switches off. After between the computer and display console. If
a few seconds, the COMM Indicators start to flash there are any problems with indications on the
quickly and never stop. display console, go to section 2.2.

3.4 Function Kickout Fuse

The computer unit contains a standard 10-Amp replaceable fuse, identified as FUS1 on the computer
board, which protects the function kickout circuit and relay contacts.
Replace the fuse if these three conditions are present:
• System error codes indicate the FKO power feed is missing.
• The crane circuit break is closed.
• Power from the crane is present.

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3.5 Replacing the Computer Unit
Computer Removal
1. Lower the boom until the boom hoist cylinder is completely retracted and on its stop or the boom
is firmly in the boom rest.
2. Disconnect the hydraulic connections at the computer unit. Cap the end of the hydraulic hoses.
3. Disconnect both electrical connectors at the computer unit.
4. Remove the hardware securing the computer to the cab wall.
Computer Installation
1. Secure the computer unit to the cab wall with the mounting hardware.
2. Ensure the electrical connections face downward.
3. Connect the electrical connectors.
4. Remove the protective caps from the hydraulic ports.
5. Connect the base-side pressure (green band) hose to the piston pressure port.
6. Connect the rod-side pressure (red band) hose to the rod pressure port.

Power-Up and Calibration

NOTE: Switch the crane power ON and ensure all LED check lights within the computer unit are
illuminated. Ensure the COMM LEDs are flashing and the display console is operating.
Checks:
1. Use an inclinometer to check the accuracy of the boom angle and use the tape to measure the
radius at four or five points.
2. Ensure the hydraulic connections are secure and not leaking.
3. Secure the computer lid.
4. Move to Section 5.1 to begin calibration of the new computer.

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4.1 Display Console Overview
The Operator’s Display Console allows the user to see the crane values (angle, radius, load, etc.) and
crane configuration selection. The display also provides calibration functions used for testing and fault
diagnosis.

4.2 Checking the Display Console

It is important to note the Operator’s Display Console may become damaged when operated under
extreme conditions. The damage is not always apparent. To identify faults, review the following
sections.

4.2.1 Reading the LCD

Always adjust the display contrast first. For bracket-mounted models only, reposition the display
console slightly. The most commonly encountered problem is caused by reflections.
NOTE: It may not be possible to correct this problem completely, especially on flush-mounted
display consoles which may be exposed to bright sunlight.

4.2.2 Unresponsive Buttons

Not all button options are available at all times. It is important to verify that the non-responsive button is
programmed to respond during the operation of the system. Press the button in the center. Pressing the
printed symbol ‘at one end’ may not activate the switch underneath. Buttons that are damaged or have
a surface that is worn may cause the switch underneath to operate improperly. In this case, refer to
Operator’s Display Console – Removal and Installation.

4.2.3 Connectors
A Singular Circular Connector, common to all display models, is positioned on the rear of the rear of the
display console. For bracket-mounted styles, it is clearly visible on the rear of the housing. On flush-
mounted versions, it is ‘hidden’ behind the panel within the dash assembly. Handle this connector
carefully, it is possible for the pins and sockets within the connector halves to bend, break, or ‘be
pushed back’ inside the housing.
On Flush-Mounted Display Consoles (Vertical Model), the Horn Drive Wire must also be connected. It
is a single black lead that should be attached to the black terminal on the rear of the display console
hearing.

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4.2.4 Horn
On vertical Flush-Mounted Display Consoles, the Horn is outside the housing. If there is a problem with
the horn, ensure the Horn Drive Wire is correctly connected to the black terminal on the rear of the
display console housing. If the wire is intact, connected correctly, and the horn is still not operating
properly, it is possible the horn may need to be replaced.

4.2.5 Moisture
The Display Console offers protection against dust and water, when correctly installed.

4.3 Replacing the Display Console

Removal
1. Disconnect the electrical cable from the electrical connector on the rear of the Operator’s
Display Console.
2. Remove the knob on each side of the console and retain.
3. Remove the defective display console from the bracket in the cab.

Installation
1. Put the Operator’s Display Console on the bracket located in the cab by positioning it between
the bracket legs.
2. Insert and tighten the knob on each side of the console.
3. Connect the electrical cable to the electrical connector on the rear of the console.

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5.1 Calibration Mode
The Greer Insight system is an aid to crane operation. Use this system with an operator trained in
safety guidelines, crane capacity information, and the crane manufacturer’s specifications.

When the computer is new, it has no zero or span calibrations. It is necessary to enter zero and span
settings for accurate length and angle calculations.

Tools Needed:
• Digital level accurate to 0.1°
• 150-200ft. tape measure graduated in 1/10ths
• Digital multimeter
Pre-Requisites for Calibration
• The crane must be properly set on level ground per the manufacturer’s specifications.
• Maximum boom height will be necessary for calibration. Ensure the area is free of overhead
obstructions.
• All options such as jibs, fly’s, auxiliary heads, etc. must be setup in the computer.

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5.2 Entering the Calibration Mode
NOTE: This instruction is intended for OEM units on the assembly line or units in the field where
a replacement computer has been installed. When the computer is new, it does not contain zero
and span information for the crane.
In order for the computer to measure length and angle, zero points must be entered into the system.
Before proceeding to the calibration screens, the display must be properly configured for the actual
crane setup. It is permissible to have Stowed Jib and Auxiliary Head, Multi Part Line, etc. but they must
be noted in the crane setup before calibration.
Follow these steps to ensure proper calibration. The actual crane setup must be reflected on the
display. Check the Greer Insight Operator’s Manual for proper setup of the display unit.
1. To enter Calibration Mode, the display must be in “Normal Operating” mode.
2. Press the TEST and the OPERATOR ALARM BUTTON simultaneously.

SET

TEST

3. Enter the Security Code within 5 seconds, or the system will revert to the “Normal Operating”
mode. The numbers indicate the proper order to press the buttons.

1 SET 4

3 TEST 2

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5.3 Calibration Menus
After entering the calibration menu, scroll through the menu options by pressing the “Menu Up” or
“Menu Down” buttons. To select an item, press the button adjacent to the menu listing as shown in the
example.

SET

TEST

The main menu items used to calibrate the system are:

• 02 Zero Sensors
• 03 Span Sensors

The only calibrations needed are for the boom extension function and the boom angle function. They
must be properly set to zero. Boom extension and angle readings are dependent on the correct span
values to be entered into the system. These span values are determined by using a digital level on the
boom angle, and measuring the span of boom extension.

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5.4 Zeroing the Extension and Angle Sensors
NOTE: Prior to zeroing the sensors, remove the reeling drum cover to reveal the length and
angle sensors.

1. Fully retract the boom and place at 0.0°. Verify with a digital inclinometer.
2. Rotate the extension sensor gear clockwise until it stops against the clutch in the potentiometer.
3. Rotate the gear counter-clockwise 1/2 turn and let the spring pull it back to engage with the
drum gear.
4. Press the “Menu Up” button until the “02 Zero Sensor” option is on the screen.

SET

TEST

5. Press the “02 Zero Sensor” button.

6. Press the “Zero No. 2 = ” button to zero the extension sensor. This will change the display to
read “Zero No. 2 = 0”.

SET

TEST

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 7. With the boom still at 0.0°, press the “Menu Up” button.
8. The screen will advance to “Zero No. 3 = ”.
9. Press the “Zero No. 3 = ” button to zero the angle sensor. The display will now read “Zero No. 3
= 0”.

SET

TEST

10. Zero calibration is now complete.

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5.5 Spanning the Boom Extension and Angle
WARNING!
THE AREA OVERHEAD ABOVE THE CRANE MUST BE CLEAR OF OBSTRUCTIONS
PRIOR TO CALIBRATING SPAN OF EXTENSION AND ANGLE!

Spanning the sensors defines in the computer the angle and extension of the boom. In order to set the
angle span, the information from the digital level must be used to enter the number. The boom
extension span number, is the Extended Length – Retracted Length = Span. The above graphic
demonstrates how to properly measure the span.

1. Fully extend the boom and raise the boom to at least 60°.
2. From the Calibration Menu, press the “Menu Up” button to display the “03 Span Sensors”
option.

SET

TEST

3. Press the “03 Span Sensors” button.

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 4. Press the “Span No 2= X.XX” button to access the number entry screen.

SET

TEST

SET

TEST

5. The lower left and right buttons move the cursor left or right for number selection. The upper left
button enters each digit inside the brackets.
6. Enter the Extension Span (Extended Length – Retracted Length = Extension Span).
7. Press the upper right button when the number is complete. This will save the number to the
system memory.
8. The extension span is now complete.
9. Press the “Menu Up” button to display “Span No 3=X.XX”.
10. Press the “Span No 3=X.XX” button to access the number entry screen.

SET

TEST

SET

TEST

11. The lower left and right buttons move the cursor left or right for number selection. The upper left
button enters each digit inside the brackets.
12. Enter the angle from the digital level on the boom.
13. Press the upper right button when the number is complete. This will save the number to the
system memory.
14. The angle span is now complete.
NOTE: All numbers can be changed if entered incorrectly. If 9.99 is entered mistakenly
instead of 99.9, the sensor can be re-calibrated and the information will be overwritten.

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5.6 Calibration of Swing Zero
The system uses a 360° circle for determining the location of the swing. The swing must have a Zero
point set, so the system knows where to begin counting. The stowed boom position is over the front of
the vehicle. When the boom is placed over front, set the house lock. This is important because the pick
and carry tolerance is very close. If the house lock is not set, the user may not be able to gain the “LINE”
work area needed to pick and carry.
1. From the Calibration Menu, press the “Menu Up” button to display “04 Swing Potentiometer”.
2. Press the “04 Swing Potentiometer button.
3. The --- lines mean the potentiometer is not recognized by the system and had not had the Zero
point set.

SET

TEST

4. Press the “Zero = ___” button to set the Zero point. The system will recognize the swing pot and
have the needed “starting point.”
5. Lift the boom and rotate to the right (clockwise). The numbers should count up, 1°, 2° to 360°. If
the numbers are not going up, change the direction of the swing.
6. The Swing zero has been set. Press the “Exit” button.

5.6.1 Changing the Direction of the Swing Count

1. While still in the “04 Swing Potentiometer”, press the “Menu Up” button until “Direction = +/-“ is
displayed.

SET

TEST

2. Press the “Direction = +/-” button to change the direction of the swing.

The system is now calibrated. Normal production test procedures may be used on the unit.

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5.7 Cylinder Span Dimension Calibration
The cylinder span dimension calibration allows the crossover point between the two boom extension
cylinders. Begin the routine with the boom fully retracted.
1. Press the Boom Mode button.
2. Press the Mode 1 button.

SET

TEST

3. Enter the calibration menu.

4. Press Menu Up until “18 Span Cylinders” is displayed.
5. Press the Disabled button to enable the cylinder span dimension.

SET

TEST

6. With the routine enabled, extend the boom until it stops. Press the Span = XX.XX button. The
span for “Cylinder 1” has now been calibrated. Fully retract the boom.

SET

TEST

7. Exit the 18 Span Cylinders menu. Then exit the calibration menu.
8. Press the Boom Mode button.
9. Press the Mode 2 button.
10. Enter the calibration menu.
11. Press the Menu Up until “18 Span Cylinders” is displayed.
12. Press the 18 Span Cylinders button.

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 13. The system will now prompt the user to set the span for Cylinder 2.

SET

TEST

14. Fully extend the boom until it stops.

15. Press the Span = XX.XX button.
16. The span cylinder routine is complete.

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6.1 Reeling Drum Overview
The primary operation of the reeling drum is to measure the extension of the telescoping sections of the
main boom. The reeling drum also includes an angle sensor to measure the main boom angle along
with an electrical slip-ring which transfers the two-block signal from the reeling drum cable to the
system computer. It is important the setup these devices is performed correctly. Incorrect maintenance
can result in system calculation errors.

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6.2 Checking the Reeling Drum Cable Layering
The extension reel is designed to provide accurate measurement of boom extension. To provide
accurate measurement, the reeling drum cable must form a single flat layer across the surface of the
extension reel as the boom is telescoped in and out. Any stacking of the cable will cause extension
errors as the boom retracts.
1. Telescope the boom fully out and then fully in.
2. Ensure the reeling drum cable forms a flat single layer across the surface of the extension reel,
with each successive turn of cable lying next to the last.
NOTE: If any stacking or build-up of the cable occurs, ensure the first cable guide at the top of the
boom root section is correctly aligned with the outside edge of the extension reel. Clean the reeling
drum cable and lubricate it with a silicone spray.

Reeling Drum Viewed from Above

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6.3 Sensor Baseplate Assembly
The sensor baseplate assembly supports and connects the extension and angle sensors. It also
supports the two-block switch signal and signal cable to the computer.
Electrical or mechanical failure of either the angle sensor or the extension sensor potentiometers
cannot be repaired in the field. The angle sensor pendulum is set during production on the
potentiometer shaft; and the extension potentiometer gear contains a protection clutch, both are difficult
to replace in the field. In the event of failure of either item, replace the entire sensor baseplate
assembly.
The terminal block (TB1) mounted on the assembly provides wiring connection for all internal parts of
the reeling drum and Reel-to-Computer cable. Most electrical diagnoses of the boom sensors can be
made at this terminal block.
If problems occur with the two-block alarm operation, angle, or extension sensor, refer to the following
chart. Follow the Boom Position/Action column before performing any voltage checks. Measure all
voltages with a digital voltmeter set to DC volts range.

BOOM VOLTAGE VOLTMETER CONNECTION

SIGNAL POSITION/
MIN MAX RED (+) BLACK (-)
ACTION
SENSOR
- +4.7V +5.3V TB1/4 - RED TB1/1 - BLUE
DRIVE
ANGLE
TB1/2 -
SENSOR 0 degrees 0.4V 0.6V TB1/1 - BLUE
GREEN
OUTPUT
EXTENSION
0 ft. FULL
SENSOR 0.15V 0.35V TB1/3 - WHITE TB1/1 - BLUE
RETRACTED
OUTPUT
A2B WEIGHT TB1/6 -
5.5V 7.5V TB1/1 - BLUE
TWO-BLOCK DOWN BLACK
DRIVE A2B WEIGHT TB1/6 -
9.5V 10.5V TB1/1 - BLUE
UP BLACK
A2B WEIGHT TB1/5 -
5.5V 7.5V TB1/1 BLUE
TWO-BLOCK DOWN BROWN
SIGNAL A2B WEIGHT TB1/5 -
0V 2V TB1/1 - BLUE
UP BROWN

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32
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6.4 Anti-Two-Block Function Overview
The computer supplies a protected positive feed to the Anti-Two-Block switches at the boom/jib head
via the reeling drum cable, slip-ring, and reel-to-computer cable. With the Anti-Two-Block weight
hanging freely on the switch, the switch contact is closed and the signal return to the computer is high.
When the weight is lifted by the hook block, the switch contact is opened, and the computer will sense a
low signal input from the ATB signal return.
Since the computer checks the protected feed voltage internally, the system is capable of detecting a
short circuit of the feed (or the ATB signal return when the switch is closed) to the crane chassis. Fault
codes are defined in FAULT REPORTING AND FAULT CODES.
Most problems with the ATB circuit may be identified through inspection of cables, switches, and the
reeling drum. Damage to these parts may result in continuous or intermittent ATB alarms.

6.5 Checking the Reeling Drum Cable

The outer braid of the cable carries the Anti-Two-Block feed to the switches. If the cable sheath is
damaged, this may cause a short circuit to the boom/chassis and indicate a fault code of “B008”(Refer
to GROUP “B” FAULT CODES). The same fault code will be indicated if the ATB switch is closed and
the inner core of the cable is shorted to the chassis at some point in the wiring.
1. Carefully inspect the reeling drum cable for wear.
2. Check for signs of damage to the outer sheath of the cable.
3. Check for any signs of severe “kinking” or crushing of the cable.

6.6 Checking the Anti-Two-Block Circuit

Before continuing, ensure the connections are correct at the ATB switches on the boom head/jib. This
procedure checks the ATB circuit when no power is applied to the circuit, use the diagram on the
following page.
1. Remove the extension reel cover.
2. Disconnect the slip-ring arm from the plug by pulling it away from the center of the reel.
3. Close the ATB switch at the boom head by suspending the weight from it or pulling on the chain.
4. Measure the resistance between TB2-1 & TB2-2 terminal connections on the sensor arm.
5. With the ATB switch closed, the resistance should be less than 300 ohms. If not, inspect the
reel-off cable, ATB switch, and the boom head connectors for an open circuit.
6. Open the ATB switch at the boom head by lifting the weight.
7. Measure the resistance between TB2-1 & TB2-2 terminal connections on the sensor arm.
8. With the ATB switch open, the resistance should be greater than 10,000 ohms. If not, inspect
the reeling drum cable, ATB switch, and the boom head connectors for a short circuit.

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34
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 11135 South James • Jenks, OK 74037
Phone: (918) 298-8300
Fax: (918) 298-8301

www.team-twg.com

Greer Company is a part of TWG.

As a leader in product innovation, Greer Company is committed to the ongoing improvement of its equipment.
We reserve the right to make changes to our products without notice.

©2012 TWG. All rights reserved.

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