3B6 Mtech Service Manual

Revisione 23/01/2002

Revisione 23/01/2002

Complies to the MACHINES DIRECTIVE Standards: EN60204-1, EN954, EN12077-2

Complies to the MACHINES DIRECTIVE Standards: EN60204-1, EN954, EN12077-2

EMC

EMC according to the “ Heavy Industrial Environmenaccording to the “ Heavy Industrial Environment” category: EN50081-2, EN50082-2t” category: EN50081-2, EN50082-2

 Service Manual

 Service Manual

for FRANNA Cranes

for FRANNA Cranes

PAGE PAGE  ACCESS PROCEDUR  ACCESS PROCEDURES ES 33 DESCRIPTION DESCRIPTION C COOMMPPOONNEENNTTS S LLOOCCAATTIIOON N OON N TTHHE E MMAACCHHIINNE E 44 MAI

MAIN N UNIUNIT T AND AND CONCONTROTROL L PANPANEL EL CODCODE: E: U2MU2MIC-IC-2/42/41 1 55 G

GEENNEERRAAL L CCHHAARRAACCTTEERRIISSTTIICCS S 66 M

MAAIIN N CCOONNTTRROOL L UUNNIIT T CCOONNNNEECCTTIIOONNS S AANND D SSIIGGNNAALLS S 77  AC MCP ANGLE/EXTENSION S

 AC MCP ANGLE/EXTENSION SENSORS ENSORS CODE : AC MCP236A/2PCODE : AC MCP236A/2P 88 E

EXXTTEENNSSIIOON N SSEENNSSOOR R CCOODDE E : : CCIITT--11PPAACCWW//1100 99--1100--1111 PRESSURE TRANSDUCERS

PRESSURE TRANSDUCERS CCOODDE E : : YY111 1 44774455--335500 1122 CONTROL

CONTROL PANEL PANEL DESCRIPTION DESCRIPTION 1313 DETECTION

DETECTION T

TRROOUUBBLLEESSHHOOOOTTIINNGG 1144

 ALARM CODES AND ACTIONS TO TA

 ALARM CODES AND ACTIONS TO TAKEKE 15-16-1715-16-17

 ALARM CODE

 ALARM CODE 1 1 : MEMORY DATA NOT RELIABLE: MEMORY DATA NOT RELIABLE 1818  ALARM CODE

 ALARM CODE 2 : ANGLE READING < MINIMUM VALUE2 : ANGLE READING < MINIMUM VALUE 1919  ALARM CODE

 ALARM CODE 3 : ANGLE READING > MAXIMUM VALUE3 : ANGLE READING > MAXIMUM VALUE 1919 CABLE

CABLE REEL REEL POWER POWER SUPPLY SUPPLY VERIFYING VERIFYING 2020  ANGLE POTENTIOMETER VERIFYING

 ANGLE POTENTIOMETER VERIFYING 2121

 ALARM CODE

 ALARM CODE 6 : EXTENSION READING < MINIMUM VALUE6 : EXTENSION READING < MINIMUM VALUE 2222  ALARM CODE

 ALARM CODE 7 : EXTENSION READING > MAXIMUM VALUE7 : EXTENSION READING > MAXIMUM VALUE 2222 CABLE

CABLE REEL REEL POWER POWER SUPPLY SUPPLY VERIFYING VERIFYING 2323 B

BOOOOM M LLEENNGGTTH H PPOOTTEENNTTIIOOMMEETTEER R VVEERRIIFFYYIINNGG 2244  ALARM CODE 8 : MAIN CYLINDER (BOTTOM SIDE ) < MINIMUM VALUE

 ALARM CODE 8 : MAIN CYLINDER (BOTTOM SIDE ) < MINIMUM VALUE 2525  ALARM CODE 9 : MAIN CYLINDER (BOTTO

 ALARM CODE 9 : MAIN CYLINDER (BOTTOM SIDE ) > MAXIMUM VALUEM SIDE ) > MAXIMUM VALUE 2626  ALARM CODE 10 : MAIN CYLINDER (ROD SID

 ALARM CODE 10 : MAIN CYLINDER (ROD SIDE ) < MINIMUM VALUEE ) < MINIMUM VALUE 2727  ALARM CODE 11 : MAIN CYLINDER (ROD SID

 ALARM CODE 11 : MAIN CYLINDER (ROD SIDE ) > MAXIMUM VALUEE ) > MAXIMUM VALUE 2828  ALARM CODE

 ALARM CODE 14 : EXTENSION READING < MINIMUM VALUE14 : EXTENSION READING < MINIMUM VALUE 2929  ALARM CODE

 ALARM CODE 15 : EXTENSION READING > MAXIMUM VAL15 : EXTENSION READING > MAXIMUM VALUEUE 2929 CABLE

CABLE REEL REEL POWER POWER SUPPLY SUPPLY VERIFYING VERIFYING 3030 B

BOOOOM M LLEENNGGTTH H PPOOTTEENNTTIIOOMMEETTEER R VVEERRIIFFYYIINNGG 3311 ACTION ACTION E EPPRROOM M aannd d EEEEPPRROOM M RREEPPLLAACCEEMMEENNTT 3322 P POOTTEENNTTIIOOMMEETTEERRS S AALLIIGGNNMMEENNTT 3333 S SYYSSTTEEM M LLAAYY--OOUUT T ANAND D CCOONNNNEECCTTIIOONNSS 3344 E EXXTTEERRNNAALL WWIIRRIINNGG 3355 R REECCOOMMMMEENNDDEED D SSPPAARRE E PPAARRTTS S LLIISSTT 3366

INDEX

INDEX

INDEX

INDEX

PAGE PAGE  ACCESS PROCEDUR  ACCESS PROCEDURES ES 33 DESCRIPTION DESCRIPTION C COOMMPPOONNEENNTTS S LLOOCCAATTIIOON N OON N TTHHE E MMAACCHHIINNE E 44 MAI

MAIN N UNIUNIT T AND AND CONCONTROTROL L PANPANEL EL CODCODE: E: U2MU2MIC-IC-2/42/41 1 55 G

GEENNEERRAAL L CCHHAARRAACCTTEERRIISSTTIICCS S 66 M

MAAIIN N CCOONNTTRROOL L UUNNIIT T CCOONNNNEECCTTIIOONNS S AANND D SSIIGGNNAALLS S 77  AC MCP ANGLE/EXTENSION S

 AC MCP ANGLE/EXTENSION SENSORS ENSORS CODE : AC MCP236A/2PCODE : AC MCP236A/2P 88 E

EXXTTEENNSSIIOON N SSEENNSSOOR R CCOODDE E : : CCIITT--11PPAACCWW//1100 99--1100--1111 PRESSURE TRANSDUCERS

PRESSURE TRANSDUCERS CCOODDE E : : YY111 1 44774455--335500 1122 CONTROL

CONTROL PANEL PANEL DESCRIPTION DESCRIPTION 1313 DETECTION

DETECTION T

TRROOUUBBLLEESSHHOOOOTTIINNGG 1144

 ALARM CODES AND ACTIONS TO TA

 ALARM CODES AND ACTIONS TO TAKEKE 15-16-1715-16-17

 ALARM CODE

 ALARM CODE 1 1 : MEMORY DATA NOT RELIABLE: MEMORY DATA NOT RELIABLE 1818  ALARM CODE

 ALARM CODE 2 : ANGLE READING < MINIMUM VALUE2 : ANGLE READING < MINIMUM VALUE 1919  ALARM CODE

 ALARM CODE 3 : ANGLE READING > MAXIMUM VALUE3 : ANGLE READING > MAXIMUM VALUE 1919 CABLE

CABLE REEL REEL POWER POWER SUPPLY SUPPLY VERIFYING VERIFYING 2020  ANGLE POTENTIOMETER VERIFYING

 ANGLE POTENTIOMETER VERIFYING 2121

 ALARM CODE

 ALARM CODE 6 : EXTENSION READING < MINIMUM VALUE6 : EXTENSION READING < MINIMUM VALUE 2222  ALARM CODE

 ALARM CODE 7 : EXTENSION READING > MAXIMUM VALUE7 : EXTENSION READING > MAXIMUM VALUE 2222 CABLE

CABLE REEL REEL POWER POWER SUPPLY SUPPLY VERIFYING VERIFYING 2323 B

BOOOOM M LLEENNGGTTH H PPOOTTEENNTTIIOOMMEETTEER R VVEERRIIFFYYIINNGG 2244  ALARM CODE 8 : MAIN CYLINDER (BOTTOM SIDE ) < MINIMUM VALUE

 ALARM CODE 8 : MAIN CYLINDER (BOTTOM SIDE ) < MINIMUM VALUE 2525  ALARM CODE 9 : MAIN CYLINDER (BOTTO

 ALARM CODE 9 : MAIN CYLINDER (BOTTOM SIDE ) > MAXIMUM VALUEM SIDE ) > MAXIMUM VALUE 2626  ALARM CODE 10 : MAIN CYLINDER (ROD SID

 ALARM CODE 10 : MAIN CYLINDER (ROD SIDE ) < MINIMUM VALUEE ) < MINIMUM VALUE 2727  ALARM CODE 11 : MAIN CYLINDER (ROD SID

 ALARM CODE 11 : MAIN CYLINDER (ROD SIDE ) > MAXIMUM VALUEE ) > MAXIMUM VALUE 2828  ALARM CODE

 ALARM CODE 14 : EXTENSION READING < MINIMUM VALUE14 : EXTENSION READING < MINIMUM VALUE 2929  ALARM CODE

 ALARM CODE 15 : EXTENSION READING > MAXIMUM VAL15 : EXTENSION READING > MAXIMUM VALUEUE 2929 CABLE

CABLE REEL REEL POWER POWER SUPPLY SUPPLY VERIFYING VERIFYING 3030 B

BOOOOM M LLEENNGGTTH H PPOOTTEENNTTIIOOMMEETTEER R VVEERRIIFFYYIINNGG 3311 ACTION ACTION E EPPRROOM M aannd d EEEEPPRROOM M RREEPPLLAACCEEMMEENNTT 3322 P POOTTEENNTTIIOOMMEETTEERRS S AALLIIGGNNMMEENNTT 3333 S SYYSSTTEEM M LLAAYY--OOUUT T ANAND D CCOONNNNEECCTTIIOONNSS 3344 E EXXTTEERRNNAALL WWIIRRIINNGG 3355 R REECCOOMMMMEENNDDEED D SSPPAARRE E PPAARRTTS S LLIISSTT 3366

This systems has been conceived and developed to offer two different levels of

This systems has been conceived and developed to offer two different levels of functionalityfunctionality of access to internal data, according to the

of access to internal data, according to the actions to be done.actions to be done.

The basic access level (Operator) does not required any password; this one, in fact, is The basic access level (Operator) does not required any password; this one, in fact, is required for possible interventions, exclusively by Technical Service Personnel (failure required for possible interventions, exclusively by Technical Service Personnel (failure detecting and repairing).

detecting and repairing). 1° LEVEL:

1° LEVEL:

OPERATOR: OPERATOR:

Without needing PASSWORD (also see OPERATOR MANUAL) all working information of  Without needing PASSWORD (also see OPERATOR MANUAL) all working information of  the machine are available through several monitoring given by the display panel; starting the machine are available through several monitoring given by the display panel; starting from basic working data: lifted load, max admitted load, outreach, working conditions, tilting from basic working data: lifted load, max admitted load, outreach, working conditions, tilting percentage;

percentage;

Just pressing the GREEN button key, it is possible to show machine working data in a Just pressing the GREEN button key, it is possible to show machine working data in a graphic way.

graphic way.

The aim to give to the Operator the possibility of entering these readings, allowing to The aim to give to the Operator the possibility of entering these readings, allowing to communicate them to the Technical Assistance Department, giving relevant data, possibly communicate them to the Technical Assistance Department, giving relevant data, possibly avoiding

avoiding a direct a direct Service oService on site.n site.

The Operator can also find some information to solve easy troubles in his OPERATOR The Operator can also find some information to solve easy troubles in his OPERATOR MANUAL

MANUAL 2

2°° LEVEL: (PASSWORD) LEVEL: (PASSWORD) SENSORS REPLACEMENTSSENSORS REPLACEMENTS ::

TECHNICAL ASSISTANCE DEPT. AND

TECHNICAL ASSISTANCE DEPT. AND AUTHORIZED DEALERS AUTHORIZED DEALERS 

The second level corresponds to the

The second level corresponds to the information contained in this information contained in this TROUBLE SHOOTINGTROUBLE SHOOTING MANUAL, where all details referred to system components are included (Main Unit,

MANUAL, where all details referred to system components are included (Main Unit, Transducers

Transducers, Display Panel), , Display Panel), troubleshooting codes introductiontroubleshooting codes introduction, and , and the useful informationthe useful information to remove the problems without specific tools (except a

to remove the problems without specific tools (except a voltmeter).voltmeter).  As far as Pressure Tran

 As far as Pressure Transducers are consducers are concerned, please nocerned, please note that they do not need anyte that they do not need any calibration, as they are

calibration, as they are totally interchangeable.totally interchangeable.

FINE CALIBRATION. FINE CALIBRATION.

This means the complete machine calibration, that is done at

This means the complete machine calibration, that is done at the first start-up of the first start-up of thethe machine.

machine. To this aim a

To this aim a PASSWORDPASSWORD is given, allowing to enter into the functions of the program, as is given, allowing to enter into the functions of the program, as the fine

the fine calibration of geometricacalibration of geometrical data and lifted load, and to perfol data and lifted load, and to perform their on-siterm their on-site calibration. These calibrations need the use of a PC.

calibration. These calibrations need the use of a PC.

ACCESS PROCEDURES

ACCESS PROCEDURES

LOAD MONITORING SYSTEM (LMI)

LOAD MONITORING SYSTEM (LMI)

LOAD MONITORING SYSTEM (LMI)

LOAD MONITORING SYSTEM (LMI)

COMPONENTS LOCATION ON THE MACHINE

COMPONENTS LOCATION ON THE MACHINE

Control Panel : into the cabin

MAIN CONTROL UNIT

MAIN CONTROL UNIT

CODE: U2MIC-2/XX

CODE: U2MIC-2/XX

U2MIC-2/41 Main Control Unit is equipped with memories for Data

and program storage not erasable EPROM type or erasable

EEPROM type for calibration parameters storage.

INPUT/OUTPUT circuits are self-protected against overloads and

short circuits.

Power supply internal circuits are designed to operate at low voltage

and are provided with all protection for hard environment.

U2MIC-2/41 Main Control Unit is provided with all EMC necessary

components.

GENERAL CHARACTERISTICS

o POWER SUPPLY 

• From vehicle battery :10-28 V

• Current consumption, without loads : ~0,35A

o INPUT / OUTPUT 

• 14 Digital Inputs

• 14+1 Digital Outputs • 6 (+2) Analog Inputs

• Watch Dog Dynamic Output

• Voltage working range : 10-28 VCC

• Output Current : 2A

• Analogue Inputs Voltage : 0- 5V • Serial Links RS232, CAN BUS

• Clock and Buffer Battery

• Epoxy Resin Coating

• 32 Kb E2prom for Data Recording

MECHANICAL CHARACTERISTICS

o MECHANICAL DIMENSIONS 

• Case Dimension : 260 x 160 x 91 mm

• Fixing holes : 240 x110 mm

o  VIBRATIONS 

• Continuous : 5g’s from 20 to 400Hz Over 3 AXIS

• Shock : 10g’s

o ENVIROMENTAL

• Salt spray resistance over 48 Hours

o TEMPERATURE 

• Working range :-30 -+70°C

"MV 231-346" MORS. 16C. C.S. CV a FILO 1,5mmq.    "    M    V    2    3    1   -   3    4    6    "    M    O    R    S .    1    6    C .    C .    S . "MV 231-346" MORS. 16C. C.S.

MAIN CONTROL UNIT

MAIN CONTROL UNIT ::

CONNECTIONS and SIGNALS

CONNECTIONS and SIGNALS

D35, D39, D43, D47, D51, D55, D59, D63 = RED LED’s They show the INPUT status

ON = ACTIVE INPUT

D68, D71, D74, D77, D80, D83, D86, D89, D101 =RED LED’s

They show the OUTPUT status ON = ACTIVE OUTPUT D2 = RED LED

When lit means that +15V Voltage is active

D1 = RED LED When lit means that +5V Voltage is active

Note :

D1 et D2 always have to be lit when the system is ON

NOTE:

CODE DIODE PIN FUNCTION

DI0 D35 17 Articulation signal (On when +/- 10 deg) DI1 D39 18 Anti two block (On when not 2blocked) DI2 D43 19 Engine Oil Pressure (On when OK) DI3 D47 20 Engine Water Temp (On when OK) DI4 D51 21 Crane/Travel Mode (On in crane mode) DI5 D55 22 Water Level (On when level low)

DI6 D59 23 Ignition key signal (On when key on) DI7 D63 24 Optional Seat Switch (Off= empty seat)

EEPROM: CALIBRATION DATA, BLACK BOX EEPROM: PROGRAM AND LOAD TABLES NOTE:

CODE DIODE PIN FUNCTION

DO0 D68 25 Not used

DO1 D71 26 Not used

DO2 D74 27 Not used

DO3 D77 28 Not used

DO4 D80 29 Alarm Buzzer   DO5 D83 30 Stop Function

DO6 D86 31 Not used

 AC MCP cable reel is used where the A2B function is required (i.e.: MAC25).

The length transducer (or transducers) is formed by drum cable servo-winders on which a cable is wound that is attached to the boom head (or to intermediate elements).

When the boom is telescoped, the wire unwinds measuring the boom length through a potentiometer sensing device.

During crane operations, it is always necessary to carefully check the cable unwinding along the boom, as it can be subjected to accidental break if collided.

The replacement of this element is to be done by qualified personnel only.

The angle transducer (inside to cable reel) detects the absolute angle of the crane boom through an accelerometer sensing device.

The signal is used by the limiter to compute the geometry.

The replacement of this element is delicate and for this reason it must be done by qualified personnel. 180 M mm 11 F mm 495 G mm 0 H mm  AC MCP214I/3P MODEL 420 460 60 323 100 3,8 32000 3x0,22 shields. 3 E mm D mm C mm B mm  A mm Diam mm Length mm Type Slip Rings

AC MCP ANGLE / EXTENSION SENSOR

EXTENSION SENSOR

EXTENSION SENSOR

CODE :

CIT-CODE : CIT-1PACW/10

1PACW/10

The boom and angle sensor is formed by a cable reel having a pulley

on which a cable is wound; the other side is attached to the boom head

(or to the first telescopic element in case of proportional extension).

Extending the boom, the cable unwinds (max. 12 mt.) measuring the

extension length signal through 10-turns servo potentiometer.

While using the machine, it is always necessary to carefully check the

length cable along the boom, because it can be subject to accidental

break if collided.

The replacement of this element has to be done by Qualified Personnel

only.

The angle sensor (inside the cable reel) detects the absolute angle of 

the boom referred to the vertical gravity reference through an

accelerometer sensing device.

 Analogue signals from above potentiometers are used by the LMI to

compute the boom geometric data.

OVERALL DIMENSION

8-1 6 6-1 2 7-2 7 7-1 8 12 1 4 10 9 5 5-1 11 3 7 Angle accelerometer  7-1 Not Used 7-2 Not Used 8 Pulley 8-1 Cap 9 Strain relief  10 Breather   11 Spring 12 Cable

DESCRIPTION

1 Case 2 Base 3 Circuit board 4 Step 5 Pinion 5-1 Shaft 6 Clutch 6-1 10-turns Potentiometer 

EXTENSION SENSOR

EXTENSION SENSOR

EXPLODED VIEW

Pressure transducers detect the pressure into boom lifting cylinders; typically 2 sensors are required for measuring the differential pressure on lifting cylinders : they must be installed on the two cylinder  chambers.

By these values, weight computing is taken. These sensing devices detect the pressure by means of a sensor, which transforms the measured pressure into a direct voltage proportional to the pressure itself.

 An on-board amplifier is included in the transducer itself.

 Any possible replacement of these elements is very easy because of their complete compatibility.

PRESSURE TRANSDUCERS CODE : Y11 4745-350

PRESSURE TRANSDUCERS CODE : Y11 4745-350

TECHNICAL SPECIFICATIONS

PIN CONNECT IONS 

PIN 3 Wires 1 +VB

2 output signal 0,5 .. 5,5 V 3 GND

INPUT DATA

• Measuring ranges 350 bar 

• Overload ranges 800 bar 

• Max pressures 2000 bar 

• Parts in contact with oil Stainless steel ; Viton seal

OUTPUT DATA

• Output Signal 0,5 ... 5,5V

• Temperature compensation Max ≤0,15%/10K Typ.≤0,08%/10K

• Accuracy Max ≤0,3%FS Typ.≤0,1%FS

• Hysteresis Max ≤0,1%FS Typ.≤0,05%FS

• Repeatability ≤0,05%FS

ENVIRONMENTAL CONDITIONS 

• Nominal temperature range -25 ...+85°C

• Operating temperature range -40 ...+85°C

• Storage temperature range -40 ... +100°C

• Fluid temperature range -40 ... +100°C

• Protection class IP65 OTHER DATA

• Supply voltage 12 ...30V

• Current consumption ca.15mA

• Life expectancy 106_{load cycle}

CONTROL PANEL DESCRIPTION

1) SAFE WORKING LOAD Displaying “Tonnes”, with a decimal point. 2) ACTUAL LIFTED LOAD Displaying “Tonnes”, with a decimal point. 3) JIB LENGTH Displaying “Meters”, with a decimal point. 4) JIB OFFSET ANGLE Displaying “Degrees”, with a decimal point. 5) TIP HEIGHT FROM GROUND Displaying “Meters”, with a decimal point. 6) BOOM LENGTH Displaying “Meters”, with a decimal point. 7) WORKING RADIUS Displaying “Metres”, with a decimal point 8) MAIN BOOM ANGLE Displaying “Degrees”, with a decimal point. 9) PARTS OF LINE Manually selectable with F1 & F2 buttons.

10) OPERATING MODE Corresponds to the Duty of the load charts table. 11) REAR AXLE LOAD Weight on the rear axle (Refer Notes)

12) FRONT AXLE LOAD Weight on the front axle (Refer Notes)

1

2

3

4

5

6

7

8

The first step to seek a fault is to identify the problem that has occurred, and

to advise the crane Operator.

The auto-diagnostic procedures are able to identify transducers failures,

cable breakages and internal electronic faults; alarm codes are automatically

shown on the display to the Operator, providing him with a certain ability to

locate the fault, and also to better inform the Technical Assistance even from

a remote location.

When an alarm occurs, the LMI puts itself in a safe condition (shut down)

blocking the dangerous movements and, at the same time, the display shows

the alarm corresponding message on the display lower row.

Depending on the message, the fault can then be identified.

 Alarm codes are listed in the following pages.

The list also includes some hints able to solve the problems and get back to

normal working conditions.

TROUBLESHOOTING

TROUBLESHOOTING

Not Used 4

Not Used 5

• Verify that the cable or the connector wiring is not open

If the alarm persists, please, contact Technical  Assistance :

• Verify the length transducer integrity Reading of the

boom length sensor 1 higher  than the maximum value

7 Page 22, 23,

24, 32

• Verify that the wiring and the connectors are not in short circuit

If the alarm persists, please, contact Technical  Assistance:

Verify the length transducer integrity Reading of the

boom length

sensor 1 lower than the minimum value 6

Page 22, 23,

24, 32

•Verify that the cable or the connector wiring is not open

If the alarm persists, please, contact Technical  Assistance :

• Verify the angle sensor integrity.  Angle sensor 

reading higher than the maximum value 3

Page 19, 20,

21, 32

• Verify that the wiring and the connectors are not in short circuit.

If the alarm persists, please, contact Technical  Assistance :

• Verify the angle sensor integrity.  Angle sensor 

reading lower than the minimum value 2

Page 19, 20,

21,32

• Switch the system off and on.

If the alarm persists, please, contact Technical  Assistance to:

•Verify that E2prom chip is fitted properly in its socket. • Re-enter data and save them again

• Replace the E2PROM chip and recalibrate the machine

Memory data not reliable 1 Page 18,32 What to do Description Alarm code

ALARM CODES AND ACTIONS TO TAKE

ALARM CODES AND ACTIONS TO TAKE

Not used 12

Not Used 13

• Verify that the cable or the connectors wiring are not in short circuit

If the alarm persists, please, contact Technical  Assistance :

• Verify the pressure transducer integrity Reading pressure of 

the main cylinder  (bottom side) lower  than the minimum. 8

Page 25

• Verify that the cable or the connector wiring are not open

If the alarm persists, please, contact Technical  Assistance :

•Verify the pressure transducer integrity Reading pressure of 

the main cylinder  (bottom side) higher  than the maximum. 9

Page 26

• Verify that the cable or the connector wiring is not open

If the alarm persists, please, contact Technical  Assistance :

• Verify the length transducer integrity Reading of the boom

length sensor total higher than the

maximum value 15

Page 29, 30,

31

• Verify that the wiring and the connectors are not in short circuit

If the alarm persists, please, contact Technical  Assistance:

Verify the length transducer integrity Reading of the boom

length sensor total lower than the

minimum value 14

Page 29, 30,

31

• Verify that the cable or the connector wiring are not open

If the alarm persists, please, contact Technical  Assistance :

•Verify the pressure transducer integrity Reading pressure of 

the main cylinder (rod side) higher than the maximum.

11 Page

28

•Verify that the wiring and the connectors are not in short circuit

If the alarm persists, please, contact Technical  Assistance :

•Verify the pressure transducer integrity Reading pressure of 

the main cylinder (rod side) lower than the minimum. 10 Page 27 What to do Description Alarm code

•Apply parking brake prior to opening door or  turning the ignition key off.

•Reset with F9. Parking Brake Not Set

35

•Engine will stop ten seconds after vacating seat, engine will not start if driver not seated.

•Reset with F9. Driver Not Seated

34

•Stop engine and check cooling system when safe to do so, reset with F9.

Low Water Level 33

•Stop the crane as soon as safely possible and shift to N (Neutral). Accelerate the engine to 1200 rpm and allow the temperature to return to normal

(2 or 3 minutes),reset with F9 and resume operation.

High Transmission Oil Temperature

32

•Stop engine and determine cause, reset with F9 High Water Temp.

31

•Stop engine and check oil level, reset with F9 Low Engine Oil Press.

30

Not used 12

Not Used 13

•Please, select the operating mode in use and confirm it.

Table charts not available..

The operating condition selection is missing 18

Engine Monitoring System (reset alarms with F9) Optional What to do Description Alarm code

EEPROM

ALARM CODE

1 : MEMORY DATA NOT RELIABLE

CAUSE:

 All the calibration data are stored in four EEPROM 24C65.

Through the “Check-sum” equation, software checks continuously the result to the original memorised value. When detecting a difference, the display will show the following message : ALARM 1 = memory data not reliable.

ACTION TO TAKE:

1) Switch the system off and on.

2) Verify that the EEPROM chip is fitted properly in its socket.

3) Re-enter data and save again, switch off and on again.

4) If the problem persists, replace the PC board making sure that

software/parameters installed are corresponding to the

ALARM CODE 2 :

ANGLE TRANSDUCER READING

LOWER THAN THE MINIMUM VALUE(*)

CAUSE:

The signal from the angle transducer to the main PC board is lower than the

minimum programmed value.

This can be produced by a short-circuit in the electrical wiring, between the

Main Unit and Sensor or the sensor itself is in interdiction.

ACTION TO TAKE:

• Verify the wiring

• Verify cable reel PC board proper power supply

(refer to “CABLE REEL POWER SUPPLY VERIFYING” section – page 20).

• Verify angle potentiometer 

(refer to “ANGLE POTENTIOMETER VERIFYING” section – page 21).

ALARM CODE 3:

ANGLE TRANSDUCER READING

HIGHER THAN THE MAXIMUM VALUE (*)

CAUSE:

The signal from the angle transducer to the main PC board is higher than the

maximum programmed value.

This can be produced by a break in the electrical wiring, between the Main

Unit and Sensor or the sensor itself is in saturation.

ACTION TO TAKE:

• Verify the wiring

• Verify cable reel PC board proper power supply

(refer to “CABLE REEL POWER SUPPLY VERIFYING” section – page 20).

• Verify angle potentiometer 

(refer to “ANGLE POTENTIOMETER VERIFYING” section – page 21).

(*) : NOTE: Main Unit Processor identifies below and over the signal range a

minimum zone and a maximum zone in order to check the sensor 

1 (+)

3 (GND)

+ GND

CABLE REEL POWER SUPPLY VERIFYING

CABLE REEL POWER SUPPLY VERIFYING

FALSE TRUE

FALSE TRUE

Verify 5Volts between 1(+) and 3(GND) on cable reel board

FALSE TRUE

Verify the Potentiometers

(**)

Cable break down. Check the cable-reel cable

Probably the cable is  in short circuit.

Check cable

Main pc board Is faulty. Replace it with

a new one (*)

(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 32 (**) REFER TO page 21

Verify on the Main PC board 5Volts between

10(+) and 11(GND)

Disconnect wires  10 and 11 from the Main pc board and

2 (CA2) 3 (GND)

CA2 GND The Main pc board is faulty.

Proceed with the replacement (*)

The signal is not correct Problems on the Connection Cable. Probably short circuited.

Check the cable

The signal is correct

Put the machine boom at 0° (horizontal).

Verify voltage between  2(CA2 ) and 3 (GND)

Is +2,5Vdc +/- 5%

 Angle potentiometer

broken (**) Raise the boom slowly. TRUE

Loss of Signal The variation is continuous and linear 

FALSE

Verify with a voltmeter that the signal increases in a linear 

and continuous way.

 Angle potentiometer  broken (**)

(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 32 (**) REFER ALSO TO POTENTIOMETERS ALIGNMENT - page 33

Verify on the Main pc board the potentiometer signal on

ALARM CODE 6 :

BOOM LENGTH TRANSDUCER READING

LOWER THAN THE MINIMUM VALUE(*)

CAUSE:

The signal from the boom length transducer to the main PC board is lower 

than the minimum programmed value.

This can be produced by a short-circuit in the electrical wiring, between the

Main Unit and Sensor or the sensor itself is in interdiction.

ACTION TO TAKE:

• Verify the cabling.

Verify cable reel PC board proper power supply

(refer to “CABLE REEL POWER SUPPLY VERIFYING” section – page 23).

• Verify length potentiometer 

(refer to “EXTENSION POTENTIOMETER VERIFYING” section - page 24).

ALARM CODE 7 :

BOOM LENGTH TRANSDUCER READING

HIGHER THAN THE MAXIMUM VALUE (*)

CAUSE:

The signal from the boom length transducer to the main PC board is higher 

than the maximum programmed value.

This can be produced by a short-circuit in the electrical wiring, between the

Main Unit and Sensor or the sensor itself is in saturation.

.

ACTION TO TAKE:

• Verify the cabling.

• Verify cable reel PC board proper power supply

(refer to “CABLE REEL POWER SUPPLY VERIFYING” section – page 23).

• Verify length potentiometer 

(refer to “EXTENSION POTENTIOMETER VERIFYING” section - page 24).

(*) NOTE: Main Unit Processor identifies below and over the signal range a

+ GND Verify 5Volts between

1(+) and 2(GND) on cable reel board

FALSE TRUE

Verify the Potentiometers

(**)

Verify on the Main PC board 5Volts between

7(+) and 8(GND)

Cable break down. Check the cable-reel cable

Disconnect wires  7 and 8 from the Main pc board and

Check for 5Vdc TRUE

FALSE TRUE

FALSE

Probably the cable is  in short circuit.

Check cable

Main pc board Is faulty. Replace it with

a new one (*) (*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 32 (**) REFER TO pages 24

VERIFYING CABLE

GND CA3

VERIFYING BOOM

VERIFYING BOOM LENGTH

LENGTH POTENTIOMETER

POTENTIOMETER

The boom must be completely retracted.

Voltage higher or at 5V Boom Length potentiometer broken

(**) Verify voltage between

 2(GND ) and 5 (+ ) of app. +250mV

Boom Length Potentiometer broken

(**)

Extend the Boom. TRUE

Loss of Signal The variation is continuous and linear 

Verify on the Main pc board the potentiometer signal on

8(GND) e 12(CA3)

The Main pc board is faulty. Proceed with the replacement

(*) FALSE

Verify with a voltmeter that the signal increases in a linear 

and continuous way.

The signal is not correct Problems on the Connection Cable.Probably short circuited.

Check the cable

The signal  is correct Boom Length

potentiometer broken (**)

(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 32 (**) REFER ALSO TO POTENTIOMETERS ALIGNMENT - page 33

TRUE

FALSE FALSE

Value <0,5Vdc Value >0,5Vdc + GND GND CA0

MAIN CYLINDER (PISTON SIDE) READING

LOWER THAN THE MINIMUM VALUE

NOTE:

Main Unit Processor identifies below and over the signal range a minimum zone and a maximum zone in order to check the sensor.

Verify voltage between 1(+) and  2(GND) on the Main PC board

is +15Vdc

TRUE

Measure the voltage between 2(GND) and 3(CA0) on the Main PC board

The Main PC board  is faulty. Proceed

 with the  replacement(*) Problems on the Connection Cable. Probably short circuited. Check the cable

Broken Pressure Transducer. Proceed With the Replacement FALSE Disconnect wires on 1(+) and 2(GND) and Verify a voltage of +15Vdc

The Main PC board  is faulty. Proceed

 with the  replacement(*) Problems on the Connection Cable. Probably short circuited. Check the cable

Broken Pressure Transducer. Proceed

With the Replacement

+ GND GND CA0

ALARM CODE 9 :

MAIN CYLINDER (PISTON SIDE) READING

HIGHER THAN THE MAXIMUM VALUE

NOTE:

Main Unit Processor identifies below and over the signal range a minimum zone and a maximum zone in order to check the sensor.

Verify voltage between 1(+) and  2(GND) on the Main PC board

is +15Vdc

TRUE

Measure the voltage between 2(GND) and 3(CA0) on the Main PC board

Value >5Vdc Value <5Vdc The Main PC board

 is faulty.Proceed  with the  replacement (*) Broken Pressure Transducer.Proceed With the Replacement FALSE Disconnect wires on 1(+) and 2(GND) and Verify a voltage of +15Vdc TRUE FALSE

The Main pc board  is faulty.Proceed  with the  replacement (*) Problems on the Connection Cable.Probably short circuited. Check the cable

Broken Pressure Transducer.Proceed

With the Replacement

TRUE

+ GND GND CA1

MAIN CYLINDER (ROD SIDE) READING LOWER

THAN THE MINIMUM VALUE

NOTE:

Main Unit Processor identifies below and over the signal range a minimum zone and a maximum zone in order to check the sensor.

TRUE

FALSE FALSE

Value <0,5Vdc Value >0,5Vdc Verify voltage between 1(+) and

 2(GND) on the Main PC board is +15Vdc

TRUE

Measure the voltage between 2(GND) and 6(CA1) on the Main PC board

The Main PC board  is faulty. Proceed

 with the  replacement(*) Problems on the Connection Cable. Probably short circuited. Check the cable

Broken Pressure Transducer. Proceed With the Replacement FALSE Disconnect wires on 1(+) and 2(GND) and Verify a voltage of +15Vdc

The Main PC board  is faulty. Proceed

 with the  replacement(*) Problems on the Connection Cable. Probably short circuited. Check the cable

Broken Pressure Transducer. Proceed

With the Replacement

+ GND GND CA1

ALARM CODE 11 :

MAIN CYLINDER (ROD SIDE) READING HIGHER

THAN THE MAXIMUM VALUE

NOTE:

Main Unit Processor identifies below and over the signal range a minimum zone and a maximum zone in order to check the sensor.

Verify voltage between 1(+) and  2(GND) on the Main PC board

is +15Vdc

TRUE

Measure the voltage between 2(GND) and 6(CA1) on the Main PC board

Value >5Vdc Value <5Vdc The Main PC board

 is faulty.Proceed  with the  replacement (*) Broken Pressure Transducer.Proceed With the Replacement FALSE Disconnect wires on 1(+) and 2(GND) and Verify a voltage of +15Vdc TRUE FALSE

The Main PC board  is faulty.Proceed  with the  replacement (*) Problems on the Connection Cable.Probably short circuited. Check the cable

Broken Pressure Transducer.Proceed

With the Replacement

TRUE

ALARM CODE 14 :

BOOM LENGTH TRANSDUCER READING

LOWER THAN THE MINIMUM VALUE(*)

CAUSE:

The signal from the boom length transducer to the main PC board is lower 

than the minimum programmed value.

This can be produced by a short-circuit in the electrical wiring, between the

Main Unit and Sensor or the sensor itself is in interdiction.

ACTION TO TAKE:

• Verify the cabling.

Verify cable reel PC board proper power supply

(refer to “CABLE REEL POWER SUPPLY VERIFYING” section – page 30).

• Verify length potentiometer 

(refer to “EXTENSION POTENTIOMETER VERIFYING” section - page 31).

ALARM CODE 15 :

BOOM LENGTH TRANSDUCER READING

HIGHER THAN THE MAXIMUM VALUE (*)

CAUSE:

The signal from the boom length transducer to the main PC board is higher 

than the maximum programmed value.

This can be produced by a short-circuit in the electrical wiring, between the

Main Unit and Sensor or the sensor itself is in saturation.

.

ACTION TO TAKE:

• Verify the wiring.

• Verify cable reel PC board proper power supply

(refer to “CABLE REEL POWER SUPPLY VERIFYING” section – page 30).

• Verify length potentiometer 

(refer to “EXTENSION POTENTIOMETER VERIFYING” section - page 31).

(*) NOTE: Main Unit Processor identifies below and over the signal range a

1 (+)

3 (GND)

+ GND

CABLE REEL POWER SUPPLY VERIFYING

CABLE REEL POWER SUPPLY VERIFYING

FALSE TRUE

FALSE TRUE

Verify 5Volts between 1(+) and 3(GND) on cable reel board

FALSE TRUE

Verify the Potentiometers

(**)

Cable break down. Check the cable-reel cable

Probably the cable is  in short circuit.

Check cable

 Main PC board Is faulty. Replace it with

a new one (*)

(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 32 (**) REFER TO page 31

Verify on the Main PC board 5Volts between

10(+) and 11(GND)

Disconnect wires  10 and 11 from the Main PC board and

2 (CA3)

3 (GND)

GND CA4

Retract the boom completely.

Voltage higher or at 5V Boom Length potentiometer broken (**) Verify between  3(GND ) e 5 (CA3 ) a voltage of roughly +250mV Boom Length Potentiometer broken (**)

Extend the Boom. TRUE

Loss of Signal The variation is continuous and linear 

The Main PC board is faulty. Proceed with the replacement

(*) FALSE

Verify with a voltmeter that the signal increases in a linear 

and continuous way.

The signal is not correct Problems on the Connection Cable. Probably short circuited.

Check the cable

The signal  is correct Boom Length

potentiometer broken (**)

(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 32 (**) REFER ALSO TO POTENTIOMETERS ALIGNMENT - page 33

Verify on the Main PC board the potentiometer signal on

EEPROM

EPROM

EPROM and EEPROM REPLACEMENT(*)

EPROM and EEPROM REPLACEMENT(*)

The picture shows the EPROM storing main program data and Load Tables,

and EEPROM storing calibration data, that have to be removed from old to

the new PC board.

Remove the EPROM and EEPROM carefully out of their sockets by means

of electronic components tweezers or adequate tools.

Insert the EPROM and EEPROM in their sockets on the new PC Board in

the correct way, taking care not to damage their pins, and looking to their 

reference mark.

(*) REMARK: Replacement of memories is required in case of failure of Main Control Unit that must be replaced, avoiding any re-programming and

 After the replacement of the potentiometer, it is advisable to verify the comparison between the values shown on the display to a couple of known boom position.

I.E: Boom completely closed / Boom extended and 0° / maximum angle

These displayed values must correspond to the values given by the Manufacturer for this specific machine model.

Referring to the angle, simply check that, with the boom in horizontal position ( o° ) the angle’s reading on the display ( zone 1-5 ) is “0” acting on the potentiometer’s body.

Before fitting the potentiometer, make sure that, the value will increase by lifting the boom.  After the length potentiometer has been replaced, it’s necessary proceed with its alignment.

With the machine’s boom completely retracted,rotate the potentiometer’s body until the length indication on the display (zone 1-6) will be the same at the minimum length value ( please,refer to the load charts table ).

In case of cable reel wire replacement, refer to applicable procedure.

Mechanical alignment of angle and extension sensors

Following the replacement of a potentiometer, even if this has been done carefully, it is suggested to check its alignment.

The following procedure, if properly done, allows the total restoring of the machine behaviour without any calibration operation.

Switch on the machine without load and wait for a few seconds for the main working data page to be shown.

SYSTEM LAY-OUT AND CONNECTIONS

SYSTEM LAY-OUT AND CONNECTIONS

Refer to layout applicable to each model Refer to layout applicable to each model

CENTRAL UNIT: U2MIC-2/41

PRESSURE TRANSDUCERS

INPUT OUTPUT SI GNALS  AND EXTERNAL SUPPLY

(Y11 4745-350)  A B J1 PG1 PG2 PG3 PG4 PG5 PG6  ANGLE/LENGTH SENSOR CONTROL PANEL CMC100/10 CV ATG12/21 CIT- 1PI/13

(USED IN CASE OF BOOM INDIPENDENT SECTIONS)

CV 6X0.35+SCH

F.C.

 AC MCP214I/2A

SHLD SHLD  +15V  AGND  CA0  +15V  AGND  CA1  +5V  AGND  CA2  +5V  AGND  CA3  +5V  AGND  CA4  CA5 MS1 BROWN WHITE GREEN BROWN WHITE GREEN BROWN WHITE PINK SHIELD 1  2   3   3 2  1  SHIELD BROWN GREEN WHITE 1  2  +  PINK WHITE BROWN SHIELD 1   6  1   5  1  2  1   3  1   0   9  1  1  7   5   6  4  2   3   8  1  1  4  4   3   6   5  -A  1   S ₂  A  2   S ₁  +  V  B  OUT6  3 ₁  INP1 1   8  INP0 1  7  OUT5 OUT2 OUT3 OUT4 INP6 INP7 OUT0 INP3 INP4 INP5 OUT1 INP2 2  1  2   0  1   9  2   3  2  2  2  4  2   8  2   6  2   5  2  7  2   9   3   0  OUT7  3 ₂  -V  B  ₃   5   3   3   3 ₄   3   6  -VB +VB WDO -+   G R E  Y  1  2   C _A  2  +   5 _V  W H I   T  E  A   G N D  S _H L  D  6   8 7 5 4 3 2  B  R  O W N PINK BLUE RED BROWN WHITE GREY +5V A  2  B   3  1  SCH SCH MS2 MS3 TX2 4   3  RX2 +VOUT TX1 RX1 +VOUT GND  3 ₇  4   0   3   8   3   9  4  1  4  2  +15V +5V D-D+ GND GND CA7 CA6 -15V  5   0  4  7  4   5  4  4  4   6  4   8 ₄   9   5 ₁   5 ₂   5   3   6   8   9  7 5 4 2 1 7   8 9 4  PENDULUM BOARD  6  R E  D P  I   N K  B  L   U_E  YELLOW GREEN EXT.ALL +V TX1 RX1 GND +VOUT GREY WHITE BROWN A  B   S _H L  D YELLOW GREEN PINK _E   C  D F  BROWN PINK  G R E  E  N Y  E  L  L   O W GREY YELLOW WHITE  G R E  E  N MS4 BROWN WHITE GREEN CIT- 1PI/13 (USED IN CASE OF BOOM

LENGTH SENSOR PRESSURE TRANSDUCERS

(Y11 4745-350)

 ANG LE/L ENG TH S ENS OR  AC M CP214 I/2A  C  M  C ₁   0   0   /  ₁   0   C   O N T  R  O L  P  A  N E  L  INDIPENDENT SECTIONS)

EXTERNAL

EXTERNAL WIRING

WIRING

Refer to applicable schematics Refer to applicable schematics