3B6 Mtech Service Manual

3B6 LMI
Service Manual
for FRANNA Cranes
Revisione 23/01/2002
Complies to the MACHINES DIRECTIVE Standards: EN60204-1, EN954, EN12077-2
EMC according to the Heavy Industrial Environment category: EN50081-2, EN50082-2
INDEX
ACCESS PROCEDURES
PAGE
3
DESCRIPTION
COMPONENTS LOCATION ON THE MACHINE
MAIN UNIT AND CONTROL PANEL
CODE: U2MIC-2/41
GENERAL CHARACTERISTICS
MAIN CONTROL UNIT CONNECTIONS AND SIGNALS
AC MCP ANGLE/EXTENSION SENSORS CODE : AC MCP236A/2P
EXTENSION SENSOR
CODE : CIT-1PACW/10
PRESSURE TRANSDUCERS
CODE : Y11 4745-350
CONTROL PANEL DESCRIPTION
4
5
6
7
8
9-10-11
12
13
DETECTION
TROUBLESHOOTING
ALARM CODES AND ACTIONS TO TAKE
ALARM CODE 1 : MEMORY DATA NOT RELIABLE
ALARM CODE 2 : ANGLE READING < MINIMUM VALUE
ALARM CODE 3 : ANGLE READING > MAXIMUM VALUE
CABLE REEL POWER SUPPLY VERIFYING
ANGLE POTENTIOMETER VERIFYING
ALARM CODE 6 : EXTENSION READING < MINIMUM VALUE
ALARM CODE 7 : EXTENSION READING > MAXIMUM VALUE
BOOM LENGTH POTENTIOMETER VERIFYING
ALARM CODE 8 : MAIN CYLINDER (BOTTOM SIDE ) < MINIMUM VALUE
ALARM CODE 9 : MAIN CYLINDER (BOTTOM SIDE ) > MAXIMUM VALUE
ALARM CODE 10 : MAIN CYLINDER (ROD SIDE ) < MINIMUM VALUE
ALARM CODE 11 : MAIN CYLINDER (ROD SIDE ) > MAXIMUM VALUE
ALARM CODE 14 : EXTENSION READING < MINIMUM VALUE
ALARM CODE 15 : EXTENSION READING > MAXIMUM VALUE
14
15-16-17
18
19
19
20
21
22
22
23
24
25
26
27
28
29
29
30
31
ACTION
EPROM and EEPROM REPLACEMENT
POTENTIOMETERS ALIGNMENT
SYSTEM LAY-OUT AND CONNECTIONS
EXTERNAL WIRING
RECOMMENDED SPARE PARTS LIST
32
33
34
35
36
ACCESS PROCEDURES
LOAD MONITORING SYSTEM (LMI)
This systems has been conceived and developed to offer two different levels of functionality
of access to internal data, according to the actions to be done.
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
detecting and repairing).
1 LEVEL:
OPERATOR:
Without needing PASSWORD (also see OPERATOR MANUAL) all working information of
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
percentage;
Just pressing the GREEN button key, it is possible to show machine working data in a
graphic way.
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
avoiding a direct Service on site.
The Operator can also find some information to solve easy troubles in his OPERATOR
MANUAL
2 LEVEL: (PASSWORD) SENSORS REPLACEMENTS :
TECHNICAL ASSISTANCE DEPT. AND AUTHORIZED DEALERS
The second level corresponds to the information contained in this TROUBLE SHOOTING
MANUAL, where all details referred to system components are included (Main Unit,
Transducers, Display Panel), troubleshooting codes introduction, and the useful information
to remove the problems without specific tools (except a voltmeter).
As far as Pressure Transducers are concerned, please note that they do not need any
calibration, as they are totally interchangeable.
FINE CALIBRATION.
This means the complete machine calibration, that is done at the first start-up of the
machine.
To this aim a PASSWORD is given, allowing to enter into the functions of the program, as
the fine calibration of geometrical data and lifted load, and to perform their on-site
calibration. These calibrations need the use of a PC.
COMPONENTS LOCATION ON THE MACHINE
Control Panel :
into the cabin
SYSTEM LAY-OUT AND CONNECTIONS at page 34-35
MAIN CONTROL UNIT

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
Current consumption, without loads
o
INPUT / OUTPUT
14 Digital Inputs
14+1 Digital Outputs
6 (+2) Analog Inputs
Watch Dog Dynamic Output
Voltage working range
Output Current
Analogue Inputs Voltage
Serial Links RS232, CAN BUS
Clock and Buffer Battery
Epoxy Resin Coating
32 Kb E2prom for Data Recording
:10-28 V
: ~0,35A
: 10-28 VCC
: 2A
: 0- 5V
MECHANICAL CHARACTERISTICS
o
MECHANICAL DIMENSIONS
Case Dimension
Fixing holes
: 260 x 160 x 91 mm
: 240 x110 mm
VIBRATIONS
Continuous
Shock
o ENVIROMENTAL
Salt spray resistance over 48 Hours
o TEMPERATURE
Working range
Storage range
: 5gs from 20 to 400Hz Over 3 AXIS

: 10gs
:-30 -+70C
:-45 - +85C
MAIN CONTROL UNIT : CONNECTIONS and SIGNALS

EEPROM:
CALIBRATION DATA,
BLACK BOX
MORS. 16C. C.S.

"MV 231-346"
EEPROM:
PROGRAM AND
LOAD TABLES
MORS. 16C. C.S.
MORS. 16C. C.S.

"MV 231-346"
"MV 231-346"
CV a FILO 1,5mmq.
D2 = RED LED
When lit means
that +15V Voltage
is active
D35, D39, D43, D47, D51, D55, D59, D63 = RED LEDs
They show the INPUT status
ON = ACTIVE INPUT
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
DI0
DI1
DI2
DI3
DI4
DI5
DI6
DI7
DIODE
D35
D39
D43
D47
D51
D55
D59
D63
PIN
17
18
19
20
21
22
23
24
D68, D71, D74, D77, D80, D83, D86, D89, D101 = RED LEDs
They show the OUTPUT status ON = ACTIVE OUTPUT
FUNCTION
Articulation signal (On when +/- 10 deg)
Anti two block (On when not 2blocked)
Engine Oil Pressure (On when OK)
Engine Water Temp (On when OK)
Crane/Travel Mode (On in crane mode)
Water Level (On when level low)
Ignition key signal (On when key on)
Optional Seat Switch (Off= empty seat)
NOTE:
CODE
DO0
DO1
DO2
DO3
DO4
DO5
DO6
DO7
DIODE
D68
D71
D74
D77
D80
D83
D86
D89
PIN
25
26
27
28
29
30
31
32
FUNCTION
Not used
Not used
Not used
Not used
Alarm Buzzer
Stop Function
Not used
Not used
AC MCP ANGLE / EXTENSION SENSOR Code : AC MCP236A/2P

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.
Slip
Rings
3
Type
Length
mm
3x0,22
shields.
32000
Diam
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
100
323
60
460
420
11
495
180
3,8
MODEL
AC MCP214I/3P
EXTENSION SENSOR
CODE : CIT-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.
10
OVERALL DIMENSION
WIRING DIAGRAM
11
EXTENSION SENSOR
EXPLODED VIEW
7-2
7-1
7
5-1
5
11
3
8-1
6
6-1
8
12
9
10
1
DESCRIPTION
1
2
3
4
5
5-1
6
6-1
Case
Base
Circuit board
Step
Pinion
Shaft
Clutch
10-turns Potentiometer
7
7-1
7-2
8
8-1
9
10
11
12
Angle accelerometer
Not Used
Not Used
Pulley
Cap
Strain relief
Breather
Spring
Cable
12
PRESSURE TRANSDUCERS CODE : Y11 4745-350

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.
TECHNICAL SPECIFICATIONS
PIN CONNECTIONS
PIN
1
2
3
INPUT DATA
Measuring ranges
Overload ranges
Max pressures
Parts in contact with oil
OUTPUT DATA
Output Signal
Temperature compensation
Accuracy
Hysteresis
Repeatability
ENVIRONMENTAL CONDITIONS
Nominal temperature range
Operating temperature range
Storage temperature range
Fluid temperature range
Protection class
OTHER DATA
Supply voltage
Current consumption
Life expectancy
Weight
3 Wires
+VB
output signal 0,5 .. 5,5 V
GND
350 bar
800 bar
2000 bar
Stainless steel ; Viton seal
0,5 ... 5,5V
Max 0,15%/10K Typ.0,08%/10K
Max 0,3%FS Typ.0,1%FS
Max 0,1%FS Typ.0,05%FS
0,05%FS
-25 ...+85C
-40 ...+85C
-40 ... +100C
-40 ... +100C
IP65
12 ...30V
ca.15mA
106 load cycle
145g.
13
CONTROL PANEL DESCRIPTION

9
10
1) SAFE WORKING LOAD

2) ACTUAL LIFTED LOAD
3) JIB LENGTH
Displaying Tonnes, with a decimal point.

Displaying Tonnes, with a decimal point.
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
7) WORKING RADIUS
8) MAIN BOOM ANGLE
Displaying
Displaying
Displaying
Meters, with a decimal point.

Metres, with a decimal point
Degrees, with a decimal point.
9) PARTS OF LINE
10) OPERATING MODE
Manually selectable with F1 & F2 buttons.

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)
14
TROUBLESHOOTING
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.
15
ALARM CODES AND ACTIONS TO TAKE
Alarm
code
Description
What to do
1
Page
18,32
Memory data not

reliable
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
2
Page
19, 20,
21,32
Angle sensor
reading lower than
the minimum value
Verify that the wiring and the connectors are not in

short circuit.
Assistance :
Verify the angle sensor integrity.
3
Page
19, 20,
21, 32
Angle sensor
reading higher than
the maximum value
Verify that the cable or the connector wiring is not

open
Assistance :
Verify the angle sensor integrity.
Not Used
Not Used
6
Page
22, 23,
24, 32
Reading of the
boom length
sensor 1 lower than
the minimum value

short circuit
Assistance:
Verify the length transducer integrity
7
Page
22, 23,
24, 32
Reading of the
boom length
sensor 1 higher
than the maximum
value

open
Assistance :
16
Alarm
code
Description
What to do
Reading pressure of
the main cylinder
(bottom side) lower
than the minimum.
Verify that the cable or the connectors wiring are

not in short circuit
Assistance :
Verify the pressure transducer integrity
Reading pressure of
the main cylinder
(bottom side) higher
than the maximum.
Verify that the cable or the connector wiring are

not open
Assistance :
10
Page
27
Reading pressure of
the main cylinder (rod
side) lower than the
minimum.

short circuit
Assistance :
11
Page
28
Reading pressure of
the main cylinder (rod
side) higher than the
maximum.
Verify that the cable or the connector wiring are

not open
Assistance :
8
Page
25
9
Page
26
12
Not used
13
Not Used
14
Page
29, 30,
31
Reading of the boom

length sensor total
lower than the
minimum value

short circuit
Assistance:
15
Page
29, 30,
31
Reading of the boom

length sensor total
higher than the
maximum value

open
Assistance :
17
Alarm
code
Description
12
Not used
13
Not Used
18
Table charts not

available..
The operating condition
selection is missing
Optional
What to do
Please, select the operating mode in use and

confirm it.
Engine Monitoring System (reset alarms with

F9)
30
Low Engine Oil Press.
Stop engine and check oil level, reset with F9
High Water Temp.
Stop engine and determine cause, reset with F9
32
High Transmission Oil

Temperature
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.
33
Low Water Level
Stop engine and check cooling system when

safe to do so, reset with F9.
Driver Not Seated
Engine will stop ten seconds after vacating seat,

engine will not start if driver not seated.
Reset with F9.
Parking Brake Not Set
Apply parking brake prior to opening door or

turning the ignition key off.
Reset with F9.
31
34
35
18
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.
EEPROM
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
machine characteristics.
19
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 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
20
3 (GND)
1 (+)
Verify 5Volts between

1(+) and 3(GND)
on cable reel board
TRUE
Verify the
Potentiometers
(**)
FALSE
Verify on the Main PC board

5Volts between
10(+) and 11(GND)
TRUE
FALSE
+ GND
Cable break down.

Check the
cable-reel cable
Disconnect wires
10 and 11 from the
Main pc board and
Check for 5Vdc
TRUE
Probably the cable is

in short circuit.
Check cable
FALSE
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
21
ANGLE POTENTIOMETER VERIFYING

Put the machine boom at 0 (horizontal).
2 (CA2) 3 (GND)
Verify voltage between

2(CA2 ) and 3 (GND)
Is +2,5Vdc +/- 5%
FALSE
TRUE
Angle potentiometer
broken (**)
Raise the boom slowly.
Verify with a voltmeter that the

signal increases in a linear
and continuous way.
The variation is continuous

and linear
Loss of Signal
Angle potentiometer
broken (**)
Verify on the Main pc board

the potentiometer signal on
9(CA2) and 11(GND)
CA2 GND
The signal is
not correct
Problems on the Connection

Cable. Probably short circuited.
Check the cable
The signal
is correct
The Main pc board is faulty.

Proceed with the replacement
(*)

(**) REFER ALSO TO POTENTIOMETERS ALIGNMENT - page 33
22
ALARM CODE 6 :
BOOM LENGTH TRANSDUCER READING
CAUSE:
The signal from the boom length transducer to the main PC board is lower
than the minimum programmed value.
ACTION TO TAKE:
Verify the cabling.
Verify length potentiometer
(refer to EXTENSION POTENTIOMETER VERIFYING section - page 24).
ALARM CODE 7 :
CAUSE:
The signal from the boom length transducer to the main PC board is higher
than the maximum programmed value.
Main Unit and Sensor or the sensor itself is in saturation.
.
ACTION TO TAKE:
Verify the cabling.
(*) NOTE: Main Unit Processor identifies below and over the signal range a
minimum zone and a maximum zone in order to check the sensor.
23
VERIFYING CABLE REEL POWER SUPPLY

1(+) and 2(GND)
on cable reel board
TRUE
Verify the
Potentiometers
(**)
FALSE

5Volts between
7(+) and 8(GND)
TRUE
FALSE
Cable break down.

Check the
cable-reel cable
+ GND
Disconnect wires
7 and 8 from the
Main pc board and
Check for 5Vdc
TRUE

in short circuit.
Check cable
FALSE
Main pc board
Is faulty.
Replace it with
a new one (*)

(**) REFER TO pages 24
24
VERIFYING BOOM LENGTH POTENTIOMETER

The boom must be completely retracted.
Verify voltage between

2(GND ) and 5 (+ )
of app. +250mV
TRUE
Voltage higher or
at 5V
Extend the Boom.
Boom Length
potentiometer broken
(**)
FALSE
Boom Length
Potentiometer broken
(**)

and continuous way.

and linear
Loss of Signal
Boom Length
(**)
Verify on the Main pc board

8(GND) e 12(CA3)
The signal is
not correct

Cable.Probably short circuited.
Check the cable
The signal
is correct
GND
The Main pc board is faulty.

(*)

CA3
25
ALARM CODE 8 :
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.
GND CA0
+ GND
TRUE
Verify voltage between 1(+) and

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

2(GND) and 3(CA0)
on the Main PC board
Value <0,5Vdc
Problems on the
Connection
Cable. Probably
short circuited.
Check the cable
Value >0,5Vdc
Broken Pressure
Transducer. Proceed
With the
Replacement
The Main PC board

is faulty. Proceed
with the
replacement(*)
FALSE
Disconnect wires on
1(+) and 2(GND) and
Verify a voltage of +15Vdc
FALSE
The Main PC board

is faulty. Proceed
with the
replacement(*)
TRUE
Problems on the
Connection
Cable. Probably
short circuited.
Check the cable
FALSE
Broken Pressure
Transducer. Proceed
With the
Replacement
26
ALARM CODE 9 :
MAIN CYLINDER (PISTON SIDE) READING
HIGHER THAN THE MAXIMUM VALUE
NOTE:
GND CA0
+ GND
TRUE

is +15Vdc

2(GND) and 3(CA0)
Value >5Vdc
Value <5Vdc
Broken Pressure
Transducer.Proceed
With the
Replacement
The Main PC board

is faulty.Proceed
with the
replacement (*)
FALSE
Disconnect wires on
1(+) and 2(GND) and
FALSE
The Main pc board

is faulty.Proceed
with the
replacement (*)
TRUE
Problems on the
Connection
Cable.Probably
short circuited.
Check the cable
TRUE
Broken Pressure
Transducer.Proceed
With the
Replacement
27
ALARM CODE 10:

MAIN CYLINDER (ROD SIDE) READING LOWER
THAN THE MINIMUM VALUE
NOTE:
GND CA1
+ GND
TRUE

is +15Vdc

2(GND) and 6(CA1)
Value <0,5Vdc
Problems on the
Connection
Cable. Probably
short circuited.
Check the cable
Value >0,5Vdc
Broken Pressure
Transducer. Proceed
With the
Replacement
The Main PC board

is faulty. Proceed
with the
replacement(*)
FALSE
Disconnect wires on
1(+) and 2(GND) and
FALSE
The Main PC board

is faulty. Proceed
with the
replacement(*)
TRUE
Problems on the
Connection
Cable. Probably
short circuited.
Check the cable
FALSE
Broken Pressure
Transducer. Proceed
With the
Replacement
28
ALARM CODE 11 :
MAIN CYLINDER (ROD SIDE) READING HIGHER
THAN THE MAXIMUM VALUE
NOTE:
GND CA1
+ GND
TRUE

is +15Vdc

2(GND) and 6(CA1)
Value >5Vdc
Value <5Vdc
Broken Pressure
Transducer.Proceed
With the
Replacement
The Main PC board

is faulty.Proceed
with the
replacement (*)
FALSE
Disconnect wires on
1(+) and 2(GND) and
FALSE
The Main PC board

is faulty.Proceed
with the
replacement (*)
TRUE
Problems on the
Connection
Cable.Probably
short circuited.
Check the cable
TRUE
Broken Pressure
Transducer.Proceed
With the
Replacement
29
ALARM CODE 14 :
CAUSE:
The signal from the boom length transducer to the main PC board is lower
than the minimum programmed value.
ACTION TO TAKE:
Verify the cabling.
ALARM CODE 15 :
CAUSE:
The signal from the boom length transducer to the main PC board is higher
than the maximum programmed value.
Main Unit and Sensor or the sensor itself is in saturation.
.
ACTION TO TAKE:
Verify the wiring.
(*) NOTE: Main Unit Processor identifies below and over the signal range a
minimum zone and a maximum zone in order to check the sensor.
30
3 (GND)
1 (+)

1(+) and 3(GND)
on cable reel board
TRUE
Verify the
Potentiometers
(**)
FALSE

5Volts between
10(+) and 11(GND)
TRUE
FALSE
+ GND
Cable break down.

Check the
cable-reel cable
Disconnect wires
10 and 11 from the
Main PC board and
Check for 5Vdc
TRUE

in short circuit.
Check cable
FALSE
Main PC board
Is faulty.
Replace it with
a new one (*)

(**) REFER TO page 31
31

Retract the boom completely.
3 (GND)
2 (CA3)
Verify between
3(GND ) e 5 (CA3 )
a voltage of roughly +250mV
FALSE
Voltage higher or
at 5V
TRUE
Boom Length
Potentiometer broken
(**)
Extend the Boom.
Boom Length
(**)

and continuous way.

and linear
Loss of Signal
Boom Length
(**)

11(GND) e 15(CA4)
GND CA4
The signal is
not correct

Cable. Probably short circuited.
Check the cable
The signal
is correct
The Main PC board is faulty.

(*)

32
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.
EEPROM
EPROM
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
re-calibration of the system .
33
POTENTIOMETERS ALIGNMENT
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.
Select the operating mode used as described into the User Manual.
Referring to the angle, simply check that, with the boom in horizontal position ( o ) the
angles reading on the display ( zone 1-5 ) is 0 acting on the potentiometers body.
Before fitting the potentiometer, make sure that, the value will increase by lifting the boom.
After the length potentiometer has been replaced, its necessary proceed with its alignment.
With the machines boom completely retracted,rotate the potentiometers 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.
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.
34
SYSTEM LAY-OUT AND CONNECTIONS

Refer to layout applicable to each model
CONTROL PANEL
CMC100/10
CENTRAL UNIT: U2MIC-2/41
F.C.
ANGLE/LENGTH SENSOR
AC MCP214I/2A
J1
PG1
PG2
PG3
PG4
PG5
PG6
CV ATG12/21
(Y11 4745-350)
INPUT OUTPUT SIGNALS

AND EXTERNAL SUPPLY
CV 6X0.35+SCH
LENGTH SENSOR
CIT- 1PI/13
(USED IN CASE OF BOOM INDIPENDENT SECTIONS)
35
EXTERNAL WIRING
Refer to applicable schematics
SHLD
SHLD
SHIELD
BROWN
WHITE
1 23
BROWN
GREEN
WHITE
GREEN
BROWN
SHIELD
WHITE
PINK
RED
BLUE
PINK
BROWN
WHITE
GREY
LENGTH SENSOR
CIT- 1PI/13
(USED IN CASE OF BOOM
INDIPENDENT SECTIONS)
YELLOW
+VB
CA0
+15V
AGND
CA1
+5V
AGND
CA2
+5V
AGND
CA3
+5V
AGND
CA4
CA5
+5V
17 18 19 20 21 22 23 24 25 26 27 28 2930 31 32
3334 35 36
-VB
+
MS2
INP0
INP1
INP2
INP3
INP4
INP5
INP6
INP7
OUT0
OUT1
OUT2
OUT3
OUT4
OUT5
OUT6
OUT7
MS3
WDO
+VB
-VB
ANGLE/LENGTH SENSOR
AC MCP214I/2A
AGND
SCH
GREEN
+ - A1 A2 S1 S2
1 2 3 4 5 6
PINK
SHIELD
+15V
SCH
GREEN
BROWN
WHITE
MS1
1 2 3 4 5 6 7 8 9 10 11 1213 14 15 16
123
(Y11 4745-350)
BROWN
WHITE
GREEN
BROWN
GREEN
WHITE
2
1
6
5
3
4
9
8
7
+5V
1
CA2
2
AGND
3
4
5
6
7
8
9
37 3839 40 4142 43 44 45 46 47 4849 50 5152
BROWN
GREY
WHITE
RED
PINK
BLUE
GREEN
YELLOW
SHLD
PINK
BROWN
GREY
YELLOW
WHITE
PENDULUM
BOARD
A2B
GREY
YELLOW
PINK
SHLD
GREEN
+VOUT
GND
RX1
TX1
+V
EXT.ALL
CONTROL PANEL
CMC100/10
WHITE
A B C D E F
BROWN
MS4
+VOUT
RX1
TX1
GND
+VOUT
RX2
TX2
GND
D+
D+5V
GND
+15V
-15V
CA6
CA7
36
RECOMMENDED SPARE PARTS LIST
MAIN COMPONENTS
DESCRIPTION
CODE
MAIN UNIT
CONTROL PANEL (in dash)
CONTROL PANEL (out of dash)
U2MIC-2/41
HTD65-01I2/11
HTD65-01O2/11
LENGTH/ANGLE SENSOR (MAC25)

LENGTH/ANGLE SENSOR (AT15/20 & UC15)
AC MCP236A/2P
CIT-1PACW/10
Y11 4745-350
CONNECTING CABLE MAIN UNIT/CONTROL PANEL

CV ATG12/21
CONNECTING CABLE MAIN UNIT/CONTROL PANEL P/SUPPLY CV ATG77-1/10
GENERAL WIRING
CV 4x0,5+SCH
INTERNAL PARTS
DESCRIPTION
CODE
MAIN BOARD WITH BLACK BOX

ELECTRONIC BOARD FOR BOOM LENGTH/ANGLE SENSOR
ANGLE ACCELEROMETER
S U2MIC-6/42
S CIT1PACW/10
ASA*23/180/10
LENGTH POTENTIOMETER
LENGTHCABLE (18.5mt)(MAC25)
LENGTHCABLE (8.5mt)(AT15/20, UC15)
PT 534-2K
CV C0102/18.5
CV CIT-8.5
CABLE REEL MECHANICS WITHOUT INTERNAL

BOARD AND SENSORS
GR CITMEC/10

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3B6 LMI

COMPONENTS LOCATION ON THE MACHINE

SYSTEM LAY-OUT AND CONNECTIONS at page 34-35

MAIN CONTROL UNIT

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

: 5gs from 20 to 400Hz Over 3 AXIS

MAIN CONTROL UNIT : CONNECTIONS and SIGNALS

MORS. 16C. C.S.

MORS. 16C. C.S.

MORS. 16C. C.S.

AC MCP ANGLE / EXTENSION SENSOR Code : AC MCP236A/2P

PRESSURE TRANSDUCERS CODE : Y11 4745-350

CONTROL PANEL DESCRIPTION

1) SAFE WORKING LOAD

Displaying Tonnes, with a decimal point.

4) JIB OFFSET ANGLE

Displaying Degrees, with a decimal point.

5) TIP HEIGHT FROM GROUND

Meters, with a decimal point.

Meters, with a decimal point.

Manually selectable with F1 & F2 buttons.

11) REAR AXLE LOAD

Weight on the rear axle (Refer Notes)

12) FRONT AXLE LOAD

Weight on the front axle (Refer Notes)

Alarm codes are listed in the following pages.

ALARM CODES AND ACTIONS TO TAKE

Memory data not

Switch the system off and on.

Verify that the wiring and the connectors are not in

Verify that the cable or the connector wiring is not

Verify that the wiring and the connectors are not in

Verify that the cable or the connector wiring is not

Verify that the cable or the connectors wiring are

Verify that the cable or the connector wiring are

Verify that the wiring and the connectors are not in

Verify that the cable or the connector wiring are

Reading of the boom

Verify that the wiring and the connectors are not in

Reading of the boom

Verify that the cable or the connector wiring is not

Table charts not

Please, select the operating mode in use and

Engine Monitoring System (reset alarms with

Stop engine and check oil level, reset with F9

High Water Temp.

Stop engine and determine cause, reset with F9

High Transmission Oil

Stop the crane as soon as safely possible and

Low Water Level

Stop engine and check cooling system when

Driver Not Seated

Engine will stop ten seconds after vacating seat,

Parking Brake Not Set

Apply parking brake prior to opening door or

ALARM CODE 1 : MEMORY DATA NOT RELIABLE

CABLE REEL POWER SUPPLY VERIFYING

Verify 5Volts between

Verify on the Main PC board

Cable break down.

Probably the cable is

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

ANGLE POTENTIOMETER VERIFYING