MCS670-6201

Operating Instructions

Version：1.0

Changsha WIDE Science & Technology Co., Ltd. http://www.eacs.cn/ 0731-82842288

 Contents
1 Overview ......................................................................................................................... - 3 -
1.1 Appearance and accessories of MCS670-6201 ...................................................... - 4 -
1.2 Main technical indexes ........................................................................................... - 5 -
1.3 System function overview ....................................................................................... - 5 -
2 Operating instructions ................................................................................................... - 7 -
2.1 Self test and operating mode confirmation during system boot up .......................... - 7 -
2.1.1 Self test ........................................................................................................ - 7 -
2.1.2 OM Confirmation .......................................................................................... - 8 -
2.2 Monitoring Status ................................................................................................... - 8 -
2.2.1 Description of main monitoring screen .......................................................... - 9 -
2.2.2 Panel Display under Monitoring Status and Description of Button Functions- 13 -
2.3 Operation ............................................................................................................. - 14 -
2.3.1 Buzzer button ............................................................................................. - 14 -
2.3.2 Language selection .................................................................................... - 14 -
2.3.3 Quick observation ....................................................................................... - 14 -
2.3.4 Virtual wall .................................................................................................. - 15 -
2.3.5 Alarm of short circuit of output valve ........................................................... - 16 -
2.3.6 Operating mode setting .............................................................................. - 17 -
2.3.7 System debugging ...................................................................................... - 19 -
2.3.8 Time setting ................................................................................................ - 20 -
2.3.9 On-line communication ............................................................................... - 22 -
2.3.10 System configuration ................................................................................ - 25 -
2.3.11 Black box .................................................................................................. - 26 -
2.3.12 System information ................................................................................... - 29 -
2.3.13 Failure inquiry ........................................................................................... - 30 -
2.3.14 Maintenance reminding ............................................................................ - 35 -
3 Debugging instruction ................................................................................................. - 37 -
3.1 Length adjustment ................................................................................................ - 37 -
3.2 Angle adjustment .................................................................................................. - 38 -
3.3 Radius adjustment ................................................................................................ - 39 -
3.4 Main adjustment (empty hook calibration) ............................................................. - 39 -
3.5 Auxiliary adjustment (weight calibration) ............................................................... - 42 -
4. System Maintenance ................................................................................................... - 45 -
5. Basic troubleshooting ................................................................................................. - 46 -
6 Product installation ...................................................................................................... - 52 -
7 After-sale service and warranty period ....................................................................... - 52 -
Appendix 1：Connection method for signal wire ................................................................ - 53 -
Appendix 2: Installation method ......................................................................................... - 54 -
Appendix 3 Table – Error Codes ........................................................................................ - 56 -

2
1 Overview

In case that the actual lifting capacity (lifted load) exceeds the rated range during the
working process of various cranes, the damage (breakage or crack) of main steel structure
components in the crane and even tipping of the crane will occur. The consequences would
be unimaginable. MCS670-6201 intelligent monitoring device for construction machinery
can ensure safety for your lifting equipment, effectively prevent overload operation, avoid
safety accidents and fully exert and utilize the potential of the equipment.

MCS670 intelligent monitoring device for construction machinery integrates the

microelectronic technology, intelligent troubleshooting technology and dynamic system
monitoring technology, blends the mathematical modeling technology for the hydraulic
system, and adopts the industrial-grade high-definition color monitor to comprise the new-
type intelligent safety monitoring system with sensors and control modules. As for the design,
it adopts a large amount of the newest research achievements, absorbs numerous
advantages of similar products, and redesigns on this basis, so as to make performance be
obviously improved and reliability be remarkably enhanced. It is an intelligent monitoring
system for construction machinery in the domestic leading level.

WIDE Science & Technology Co., Ltd. is an enterprise specialized in the research,
development, production and manufacture of the construction machinery control system
with the integration of manufacturing, learning and researching. It is the implementation unit
for the Innovation Fund from Ministry of Science and Technology and the major special
technology projects in the provinces and cities. It possesses multiple independent

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 intellectual property rights involving construction machinery intelligent control, wireless
video, assessment leveling, and remote on-line monitoring. The company is committed to
exploring and innovating the electrification of the construction machinery products in China,
electric and hydraulic integration, network information, and new technology application of
the complete system field on basis of the construction machinery industry, pushes forward
the research, development and industrialization of the critical components in the
construction machinery control system, and continuously reinforces the core
competitiveness of the enterprise in the industry field of technology.

1.1 Appearance and accessories of MCS670-6201

Figure 1.1 Product Appearance

Figure 1.2 Length / angle sensor

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 Figure 1.3 Pressure sensor

1.2 Main technical indexes

Technical requirements for the product conform to the stipulations of GB12602-2009 and
GB7950-1999. EMC/EMI has passed CE certification of EU.
Working voltage: DC24(+10V – 40V)
Relative humidity: ≤95% (25℃)
Working temperature: -20～+70℃
Storage temperature: -30～+80℃
Anti- impulse force: 20g
Rated power: 15W
* GB12602-2009: PRC National Standard Lifting Appliances – Safety Devices against
Overloading
* GB7950-1999: PRC National Standard Jib Type Cranes – Load Moment Limiters –
General Technical Requirements

1.3 System function overview

◼ The intelligent monitoring device collects the working state parameters of the crane in
real time through the pressure sensor, length sensor, angle sensor and detectors for
other status. It can accurately judge whether the crane is within the safe working range
after treatment, and intuitively and truly display parameters for actual operating
conditions of the crane by the characters/graphs in the LCD, including boom length
(length L), boom angle (angle A), working radius (range R), rated lifting capacity (maxt),
actual lifting capacity (t), and load moment percentage, which provide great
convenience for the crane operator to comprehensively understand the working state
of the crane. When the crane is more than 90% of the rated moment, the intelligent
monitoring device will send out the early warning signal. When it reaches the warning
value (factory value is 100%), it will send out the warning signal, and quickly switch off
the movement of the crane towards the dangerous directions through the crane control
mechanism, and limit the crane only acting towards the safety directions till the
dangerous states are removed.
◼ Controlled by the microcomputer, the MCS670 intelligent monitoring device adopts the
modular structure, and achieves significant improvements in aspects of accuracy,
safety, reliability, system operability, debugging method, and standardization.
Especially the installation and debugging adopt the push-button operation, graphs or

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 characters display prompt. The debugging is simple and intuitive with friendly interface.
◼ For the crane with telescopic boom, the monitor for MCS670 intelligent monitoring
devices can automatically enter the previous working monitoring mode without making
any extra choice or adjustment. If the jib is installed on the main boom head for crane
operation, refer to Section 2.3.6.1 for setting.
◼ All the input and output signals are isolated. The analog quantity adopts 4~20mA signal
transmission, and is isolated from the mentor, providing strong ranti-interference
capability.
◼ Based on uses’ need, the MCS670 intelligent monitoring device can be equipped with
the inner current type (4 – 20mA) anemometer for safe work.
◼ PWM output function, closed-loop control and intelligent control are supported.
◼ The BTS drive circuit can directly drive 2A load.
◼ The J1939 protocol and CANOPEN protocol are supported.

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2 Operating instructions

2.1 Self test and operating mode confirmation during system boot

up
2.1.1 Self test

Figure 2.1 Self Test

After the load moment is turned on, the system performs a seft test, including the tests of
status of output valve, sensors, CANBUS and engine.

There are three test results for the output valve: “Normal”, “Open circuit” and “Short circuit”.
The three results indicate the connecting status of output valve circuit. When the test result
is “Open circuit” or “Short circuit”, stop working and test whether the output valve circuit has
open circuit or short circuit to the ground.

There are two test results for the sensors: “OK” and “ERROR”. “ERROR” indicates that the
sensor has open circuit or short circuit.

There are two test results for the CANBUS: “OK” and “ERROR”. “ERROR” indicates that
the CANBUS has communication failure.

There are two test results for the engine: “OK” and “ERROR”. “ERROR” indicates that the
engine is defective.

If no error is found during the test, the monitor shows the screen “OM confirmation”.
Otherwise, the user needs to press the button “ENT” to enter this screen.

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2.1.2 OM Confirmation

Figure 2.2 OM Confirmation

The system selects the operating mode which was active befoe the computer systwas
turned off. The user can modify the OM in this screen. After modification, press the button
“ENT” to save the OM. Press the button “ESC” to enter the main monitoring screen of the
load moment limiter.

2.2 Monitoring Status

If the user does not modify the OM in the “OM Confirmation” screen, the previous OM will
be automatically adopted after the load moment limiter enters the monitoring status. The
system allows normal sound of the buzzer. For monitoring screens, refer to Figure 2.3,
Figure 2.4, Figure 2.5 and Figure 2.6. The image icons + digital identifications indicate the
current working boom: main boom, rooster sheave, jib, extension + jib.

Monitoring includes but not limited to the status below:

○
1 Main boom length

○
2 Main boom angle

○
3 Lifting height

○
4 Working radius

○
5 Rated lifting capacity

○
6 Calculated value of actual lifting capacity

○
7 Load capacity bar (in percentage)

○
8 Engine parameter
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 ○
9 Work range

10
○ Outrigger status

For detailed description of monitoring status, refer to Section 2.2.1.

The load moment limiter mainly monitors whether the load lifted by the construction
machinery exceeds the maximum permissible value. The “Advance warning” icon appears
and the buzzer sends out slow acoustic warning if the current load exceeds the (90%) limit
programmed for advance warning. The “Stop” icon appears, the buzzer sends out fast
acoustic warning and the system outputs the switch-off control signals to switch off all crane
movements towards dangerous directions if the current load exceeds the (100%) limit
programmed in the factory.

2.2.1 Description of main monitoring screen

Figure 2.3 Main Monitoring Screen for Main boom

As shown in Figure 2.3, description of each marked number is as follows:

1) Quick observation
2) Sound status
3) Status of height virtual wall
4) Language selection: Chinese / English
5) Main menu
6) Maintenance reminding: Be highlighted in yellow when it is the time for maintenance.
7) Low speed gear signal: Be highlighted in green when the low speed gear signal is
effective.
8) Alarm of return-line filter element: Be highlighted in red when it is in alarm.
9) Engine failure: Be highlighted in yellow when the engine is defective.
10) CANBUS failure: Be highlighted in red when the CANBUS is defective.
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11) ECO mode: Be highlighted in dark red when the mode is wrong. Be highlighted in red
in power mode, Be highlighted in green in fuel-saving mode. Be highlighted in yellow in
economic mode.
12) Activation of hoisting limit swich for main winch / auxiliary winch: Be highlighted in red
when the hoisting limit switch is activated.
13) Current error code: When the equipment is defective, “Equipment Failure” shows on the
screen. When other failures occur, corresponding error codes highlighted in red show
on the screen.
14) Actual load display area (Unit: tons)
15) Rated load display area (Unit: tons)
16) Height display area: Boom top height above the ground (Unit: meters)
17) Angle display area: Boom angle is displayed. (Unit: °)
18) Working radius display area (Unit: meters)
19) Boom length display area: When the jib is installed on the main boom for crane operation,
the boom angle displays the total length (Unit: meters) of “main boom length + jib length”.
20) Moveable counterweight display area (Unit: tons)
21) – 22) displays the start value and end value of height virtual wall. Caution: the end
value must be larger than the start value.
23) Working area display: The green digit “240” and arc indicate the crane is working within
the 240° region over side and over rear.
24) The arrow indicates the crane is working over side and over rear.
25) Outrigger display area: 1/2 indicates the outriggers are intermediately extended, 2/2
indicates the outriggers are fully extended.
26) Falls display area: displays falls of the main hook.
27) Superstructure working hours display area: Displays working hours of superstructure
(Unit: h).
28) Engine RPM display area: Displays engine RPM (Unit: r/min)
29) Fuel reserve display area: Displays fuel reserve (Unit: %)
30) Instantaneous fuel consumption display area: Display the instantaneous fuel
consumption (Unit: L/h).
31) Engine coolant temperature display area: Displays engine coolant temperature (Unit: ℃)
32) Engine oil pressure display area: display engine oil pressure (Unit: Mpa)
33) Wind speed display area: Displays wind speed (Unit: m/s).
34) Load capacity bar (in percentage) display area: The ratio of actual load moment to rated
load moment.
35) Mandatory input prompt box display area: “LMI override mode” is highlighted in red
when the mandatory signal is input.
36) Displays current date / time.

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 Figure 2.4 Main Monitoring Screen of Jib in an Offset of 0°

1) Jib length display area: Displays length of the currently installed jib (Unit: m).

2) Jib offset display area: Displays offset of the currently installed jib (Unit: °).

Figure 2.5 Main Monitoring Screen of Extension + Jib

1) Extension length + jib length display area: Displays length (Unit: m) of the currently
installed extension and jib.

2) Jib offset display area: Displays offset of the currently installed jib (Unit: °).

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Figure 2.6 Main Monitoring Screen of Rooster Sheave

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2.2.2 Panel Display under Monitoring Status and Description of Button
Functions

Figure 2.6 Panel and Buttons

1. “Advance warning” indicator

2. “Stop” indicator

3. “Hoisting limit switch activated” indicator

4. “Lowering limit switch activated” indicator

5. “The fifth outrigger pressure high” indicator

6. LEFT

7. UP

8. ENT

9. RIGHT

10. DOWN

11. RST

12. ESC

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2.3 Operation
2.3.1 Buzzer button

After the load moment limiter boots up, the icon shows on the monitor under the
monitoring status (Figure 2.3). At this time, normal sound of the buzzer is permitted. Press

the button【▶】, the icon will automatically modified into and the sound of buzzer is

switch off. At this time, press the button【▶】to make buzzer resume normal sound and

the icon will be automatically changed to .

2.3.2 Language selection

After the load moment limiter boots up, press the button【▼】under the monitoring state

(Figure 2.3) to select the language. The icon shows on the screen under Chinese

operation interface, and is displayed under English operation interface.

2.3.3 Quick observation

Press the button【◀】under the monitoring status (Figure 2.3/2.4/2.5/2.6) to enter the quick

observation screen. You can observe status of working radius, rated load, actual load, PWM
and relative parameters of AD value & actual value of various sensors in the quick
observation column. Refer to Figure 2.7.

Figure 2.7 Quick Observation

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2.3.4 Virtual wall
Crane virtual wall: Adopting the virtual wall technology, the user can set the maximum and
minimum height according to the current external environment. When the boom is operated
beyond the set range, the load moment limiter will send out acoustic warning.

Setting of Virtual Wall:

Press the button【▲】in the main screen to enter the virtual wall setting interface. Refer to
Figure 2.8.

Quick setting method: Press buttons【◀】and【▶】to select the required input box. Then

press buttons【▲】and【▼】to set the expected height value. At last, press the save button
to save the value.

Indicating the height setting channel. Press the button to set the start height and
end height. Press the button ON/OFF to switch on / switch off this function.

Indicating the height virtual wall function is activated and can be controlled by sound and light.

Indicating functions of corresponding channels are turned off and cannot be

controlled by sound and light.

Figure 2.8 Virtual Wall Setting

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 Points for attention:
1. The “End height” must be higher than the “Start height” when you set the height channel.

2. After the virtual wall for the boom height has been set, when the boom height approaches
the “upper limit height” or “lower limit height” set by the virtual wall, buzzer on the load
moment limiter panel sends out slow acounstic alarm and the yellow light in the tri-color light
flashes. When the boom height reaches the “upper limit height” or “lower limit height”, the
buzzer on the load moment limiter panel sends out fast acoustic warning and the red light
in the tri-color light flashes.

3. Lower part on the monitoring screen (Refer to Figure 2.3) has four colors.
When the virtual wall is not activated, it is highlighted in grey. After it is activated, it is
highlighted in green. When the boom height reaches the limit value, it is highlighted in yellow.
When it touches the upper limit, it is highlighted in red.

2.3.5 Alarm of short circuit of output valve

When the load moment limiter detects that the output valve is in short circuit, it will timely
cut off the output of the circuit and display corresponding error codes on the monitor and
output the alarm prompt box for short circuit of output valve. Refer to Figure 2.9. After the
output valve cuts off the output, the cut-off can only be bypassed after the load moment
limiter is restarted.

Figure 2.9 Alarm for Short Circuit of Output Valve

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2.3.6 Operating mode setting
Under monitoring status (Figure 2.3), press the button【ENT】to enter the main menu screen
(Figure 2.10). Press buttons【▲】and【▼】to select the item that is required to be set and
press the button 【ENT】to enter the screen of adjustment setting of system parameters.
You should enter the password to set some of the items (Figure 2.11).

Figure 2.10 Main menu

Figure 2.11 Enter the password

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Note:

Make sure the crane is under normal working status before debugging and setting. The set
OM should be the same as the actual OM. The load moment limiter does not have automatic
detection and setting function. The incorrect the setting will directly affect calculation of
actual load and rated load, thus accident may occur.

Under the main menu screen (Figure 2.10), select the icon【Basic State】to enter the OM
setting screen (Figure 2.12). Press buttons【▲】and【▼】to select the set item and press

buttons【◀】and【▶】to adjust OM parameters.

You can set falls at values between 1-20.

Work boom status setting: you can set among main boom, jib, rooster sheave or extension
+ jib.

When the work boom is set at jib or extension + jib, set the jib length and then select different
jib lengths set for different vehicle models. The jib offset can be set among 0°, 5°, 15° and
30°.

Outrigger status setting: you can set among status of fully extension, intermediate extension
and fully retraction.

The 5th outrigger status setting: you can set among status of fully extension and fully
retraction.

Moveable counterweight status setting: you can set among different counterweight weights.

Low-speed gear current setting: The preset adjustment range for load moment limiter is
350mA to 500mA. The preset value is 395mA and the adjustment value is increased by
5mA.

After setting, press the button【ENT】to save the value. Press the button【ESC】to exit and
return to the main menu screen. If you do not press the button【ENT】before exiting, the
modified results will not be saved.

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 Figure 2.12 Basic OM Setting

Caution:

Make sure the crane is under normal working status before debugging and setting. When
the adjusted falls of hoist rope is smaller than the design falls of the crane and the lifting
capacity provided by the lifting capacity table is larger than the weight that can be borne by
the hoist rope with the current set falls. The rated lifting capacity displayed in the intelligent
monitoring device is the weight that can be borne by the current hoist rope rather than the
weight that can be provided by the lifting capacity table. In the actual operation process, the
selected falls should be the same as the actual falls. Otherwise, accident may occur.

2.3.7 System debugging

Under the main menu screen (Figure 2.10), press the icon【System Debug】to enter the

system debugging screen (Figure 2.13). Press buttons【◀】and【▶】to select the function

items that is required to be set. Press buttons【▲】and【▼】to modify value of the selected
function item (For detailed debugging method, refer to Chapter 3.).

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 Figure 2.13 System Setting

2.3.8 Time setting

Under the main menu screen (Figure 2.10), press the icon【Time & Date】 to enter the time

source selection screen (Figure 2.14). Press buttons【◀】and【▶】 to switch over between

“Local time” and “GPS time”. Press the button【ENT】to select and confirm the currently
selected time source. The time in the monitoring interface adopts the selected time source.

When the time source is selected to “Local time”, press the button【ENT】again to set the

local time. Press buttons【◀】and【▶】to select the item that is required to be set. Press

buttons【▲】and【▼】to adjust the value of value of the selected item (Figure 2.15). Press
the button【ENT】to save when the setting is done. Press the button【ESC】to exit and
return to the main menu screen.

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Figure 2.14 Time Source Selection

Figure 2.15 Time and Date Setting

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2.3.9 On-line communication
Under the main menu screen (Figure 2.10), press the icon【Communication】to enter the
on-line debugging interface (Figure 2.16). Press buttons【▲】and【▼】to select the function
items. Press the button 【 ENT 】 to enter the selected function item (Refer to Figures
2.17/2.18/2.19/2.20/2.21). Press the button【ENT】again to enter the required operation.

Figure 2.16 O-line Communication

Figure 2.17 Parameter Export

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 Figure 2.18 Parameter Import

Figure 2.19 Data Sample

If the SD card has been inserted, you can select “Black box records export”. Under the
screen shown in Figure 2.20, press the button【ENT】to export records into the SD card.

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 Figure 2.20 Black Box Records Export

If the SD card has been inserted, you can select “Historical work records export”. Under the
screen shown in Figure 2.21, press the button【ENT】to export the historical work records
into the SD card.

Figure 2.21 Historical work records export

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2.3.10 System configuration
Under the main menu screen (Figure 2.10), press the icon【System Config.】to enter the
system configuration screen (Figure 2.22). This function item can select and modify
percentage (in the setting range of 95% to 110%) of overload switching off and bypass. You
can select the anemometer function and switch over between Metric system and British
system according to actual conditions. You can also select the empty hook modes of 0 or 1.
You can select “OFF” or “ON” of filtration control and compensation control.

The default slewing current is 380mA. You can set between the maximum current and the
minimum current. The setting value can be increased or decreased by 5mA.
The maximum default current is 500mA. You can set to 650mA at the maximum. The setting
value can be increased or decreased by 10mA.
The minimum default current is 350mA. You can set to 300mA at the minimum. The setting
value can be increased or decreased by 10mA.
Upper collision warning point, lower collision warning point and upper switch-off point buffer
zone and lower switch-off point buffer zone can be used for the setting of height virtual wall.

When the height virtual wall is activated:

1. Height display <= lower collision warning point, red light in the tricolor light flashes and
buzzer sends out fast acoustic warning.

2. Lower collision warning point < height display <= （lower collision warning point +
lower switch-off point buffer zone), yellow light in the tricolor light flashes and buzzer
sends out slow acoustic warning (under normal conditions —— without overloading,
overhoisting and overlowering, etc.).

3. (Lower collision warning point + lower switch-off point buffer zone) < height display <
(upper collision warning point - upper switch-off point buffer zone), green light in the
tricolor light flashes (under normal conditions —— without overloading, overhoisting and
overlowering, etc.).

4. (Upper collision warning point - upper switch-off point buffer zone) <= height display <
upper collision warning point, yellow light in the tricolor light flashes and buzzer sends
out slow acoustic warning (under normal conditions —— without overloading,
overhoisting and overlowering, etc.).

5. Height display >= upper collision warning point, red light in the tricolor light flashes
and buzzer sends out fast acoustic warning.

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 Figure 2.22 System Configuration

2.3.11 Black box

Under the main menu screen (Figure 2.10), press the icon【BlackBox】to enter the black
box interface (Figure 2.23). This function item displays the OM status of currently recorded
overloading, over speed of anemometer, overhoisting, overlowering, the 5th outrigger
overpressure, boom extension and retraction with a suspended load and historical work OM.
You can also check the OM changing records.

Figure 2.23 Black Box

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 Figure 2.24 Overload Record

Figure 2.25 WorkState Change Record

The prop-up screen is shown in Figure 2.26 after you enter the “Historical work records”.

The user can input the date to be checked and press the button【ENT】for inquiry. When
the date has work records, historical work review screen shown in Figure 2.27 will prop up.
Press the button【ENT】to inquire the detailed work states on that date (Refer to Figure
2.28).

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Figure 2.26 Historical Work Records Inquiry

Figure 2.27 Historical Work Review

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 Figure 2.28 Inquiry of Detailed Historical Work OM

2.3.12 System information

Under the main menu screen (Figure 2.10), press the icon【System Info.】to enter the system
information screen (Figure 2.29). On this interface, you can check vehicle model, software
version and other related information.

Figure 2.29 System Information

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2.3.13 Failure inquiry
Under the main menu screen (Figure 2.10), press the icon【Failure Inquiry】to enter the
failure inquiry screen (Figure 2.30). You can inquire the current failure information in this
screen.

Figure 2.30 Failure Inquiry

You can inquire all the current failures via “Current failure inquiry” (Refer to Figure 2.31).
Press the button【ENT】to enter failure selection mode. Refer to Figure 2.32. The selected
error code will be turned from red to (dark) blue. The default selection is the first failure.
Press the button【ENT】again to inquire cause and remedies of the selected error code.
Refer to Figure 2.33.

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Figure 2.31 Current Failure Inquiry

Figure 2.32 Failure Selection Mode

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 Figure 2.33 Error Code Inquiry

You can inquiry the previous failures and occurrence times. Refer to Figure 2.34.

Figure 2.34 Historical Failure Inquiry

You can inquiry failure description, cause and remedies through “Error Code Inquiry”. Refer
to Figure 2.35. Enter the error code, e.g. “11” in the input box. Press the button【ENT】to
inquire the information of “E11”. Refer to Figure 2.36.

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 Figure 2.35 Error Code Inquiry

Figure 2.36 Inquiry of Entered Error Code

You can inquire current status of the output valve via “Output Valve Status Inquiry”. Refer to
Figure 2.37.

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 Figure 2.37 Output Valve Status Inquiry

You can inquire CAN data received and sent by the load moment limiter via “CAN Data
Inquiry”. Refer to Figure 2.38.

Figure 2.38 Inquiry of Data that Receives ID

You can empty the historical failure records via “Empty Failure Records”. Select “Empty
Failure Records” and press and hold the button【ENT】to empty the historical failure records.
Then, restart the load moment limiter.

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 Figure 2.39 Empty Failure Records

2.3.14 Maintenance reminding

For the “Maintenance Information” screen, refer to Figure 2.40.

Figure 2.40 Enter Maintenance Inquiry

You can inquire maintenance requirements for the maintenance parts via the screen
“Maintenance Requirements Inquiry”. Refer to Figure 2.41.

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 Figure 2.41 Maintenance Requirements Inquiry

You can inquire the parts that is required to be maintained and corresponding maintenance
information via the screen “Maintenance Reminding Inquiry”. Refer to Figure 2.42. Press
the button【ENT】to maintain all the parts that is reminded to be maintained in this screen..

Figure 2.42 Maintenance Reminding Inquiry

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3 Debugging instruction

MCS670 intelligent monitoring device dynamically computes the OM of construction

machinery in real time according to signals from each sensor, providing the timeliest
safeguard for the safe work of construction machinery.

Under the main menu screen (Figure 2.9), press the icon【System Debug】to enter the
system debugging interface (Figure 3.1). Press buttons【▲】and【▼】to select the function
item required to be set. Press buttons【◀】and【▶】to modify the value of selected function
item.

Figure 3.1 System Setting

3.1 Length adjustment

Under the system debugging screen (Figure 3.1), press buttons【▲】and【▼】to select
【Length】for zero adjustment and full adjustment.

【Length 1】adjustment:

Zero ：Confirm that the length detector is properly installed and secured. Adjust the cable
reel potentiometer under the basic arm status. Keep the length AD value remains between
0-1200, then press buttons【▲】and【▼】to select the item of【Length 1】for adjustment.

Full ：Fully extend the boom, press buttons【▲】and【▼】to select the item of 【Length
1】.You can only make full adjustment when AD value of「L1」on the right in Figure 3.2
displays between 1500-4095.

【Length 2】adjustment:

Zero ：Confirm that the length detector is properly installed and secured. Adjust the
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 cable reel potentiometer under the basic arm status. Keep the length AD value remains
between 0-1200, then press buttons【▲】and【▼】to select the item of【Length 2】for
adjustment.

Full ：Fully extend the boom, press buttons【▲】and【▼】to select the item of【Length
2】.You can only make full adjustment when AD value of「L2」on the right in Figure 3.2
displays between 1500-4095.

Figure 3.2 Zero Adjustment and Full Adjustment

Points for attention for length adjustment:

After adjustment, extend and retract the boom to confirm that the boom length is normal.

The boom length display value should change uniformly during the boom extension and
retraction process. Length display may have certain error due to different arrangement
locations of cables inside the cable reel. It is a normal phenomenon.

When the medium-and-long length boom and fully extended boom is lifting a heavy load,
length display may have certain error due to boom deformation. It is also a normal
phenomenon.

3.2 Angle adjustment

Under the system debugging screen (Figure 3.1), press buttons【▲】and【▼】to select
【Angle】for zero adjustment and full adjustment.

Zero : Level the boom. Do not adjust the angle until the angle AD value on the right in Figure
3.2 displays between 0-1200.

Full ：Derrick up the boom to the maximum angle. Do not adjust the angle until the angle
AD value on the right in Figure 3.2 displays between 1500-4095.
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 Caution:

After adjustment, derrick up the boom from the horizontal position to the maximum angle
and derrick down the boom to the original position. Then repeat the process for two to three
times to confirm the angle is normal. The boom angle display value should change uniformly
during the derricking process.

3.3 Radius adjustment

Under the system debugging screen (Figure 3.1), press buttons【▲】and【▼】to select
【Radius Debug】item that is to be set. Press the button【ENT】to enter the screen shown
in Figure 3.3. Press buttons【▲】and【▼】to select the function item that requires to be
set. Press buttons【◀】and【▶】to modify the value of the selected function item.

Figure 3.3 Radius Setting

3.4 Main adjustment (empty hook calibration)

Under the system debugging screen (Figure 3.1), press buttons【▲】and【▼】to select
the【Main Adjust】item that is to be set. Press the button【ENT】to enter the screen shown
in Figure 3.3. Press buttons【▲】and【▼】to select the function item that requires to be

set. Press buttons【◀】and【▶】to modify the value of the selected function item.

1. Weight debugging (Refer to Figure 3.4.): Press buttons【◀】and【▶】to adjust the

empty weight value of main adjustment with an increasing value of ±0.1t. The weight
value after adjustment should be equal to the actual weight of the load lifted by the crane.
After adjustment, press the button【ENT】to enter the screen shown in Figure 3.5 to

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 select the sampling function.
Weight debugging methods: Inspect the parameters of the length (L), angle (A) and
pressure (P1, P2) at first to see whether they are normal before weight debugging. In the
premise of normal operation, derrick up the boom to more than 60 degrees and collect five
data points from basic boom to fully extended boom to conduct the empty hook weight study
to correct the empty hook weight value.
Caution:
Among the five data, the two points of basic boom and fully extended boom must be
collected. In the continuous boom extension process from basic boom, press the button【▼】
once if the displayed weight is heavier than the previous weight for 0.2t-0.3t until the boom
is fully extended.
Weight adjustment rule: L0 – L4 display five groups of boom length value in total. DW1 –
DW5 are the values calculated according to corresponding boom length. After sampling of
one value, press the button【▼】once to select the next group and the like. Points for
attention: Differential value between each group must be ≥1. For example, only if sampling
is taken when L0=10.5, can L1≥11.5 or L1 ≤9.5 conform to the sampling requirements of L1
(the differential value compared with the previous data sampling value is ≥1). For sampling
of L2, the sampling value should be compared with two values of L0 and L1 and the absolute
value of differential value should be ≥1. The sampling requirements are the same for L3 and
L4. After all the five groups are sampled, press the button ENT to calculate and save data
according to the reminder.
2 . Parameter recovery: This function can be adopted for recovering the calculation factor
of main adjustment parameter group into the latest successfully sampled and saved
value.
3. Parameter reset: This function can be adopted for resetting the calculation factor of main
adjustment parameter group to the factory default value.

Figure 3.4 Main Adjust

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Caution:

Inspect whether the pressure sensor has zero drift phenomenon before adjusting the weight.

Methods:

Derrick down the boom to the minimum angle. Drain pressure of P1 and P2. Observe
whether AD value and actual value of P1 and P2 in Figure 3.2 return to the zero position
(AD normal value is 815-825. When it is less than 815 or more than 825, it is abnormal.)

Figure 3.5 Sampling

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3.5 Auxiliary adjustment (weight calibration)
Caution:

Auxiliary adjustment must be done under the guidance of professional.

Under the system debugging interface (Figure 3.1), press buttons【▲】and【▼】to select
two weights of【Weight 1】and【Weight 1】for sampling (operating methods for weight 1
and weight 2 are completely the same). Select the button【ENT】for one of the weights to
enter the following screen shown in Figure 3.6 and Figure 3.8. Press buttons【▲】and【▼】
to select the function item (the same method as the main adjustment). Press the 【Weight
Debug】icon to enter the sampling function (Figure 3.7/3.9). The sampling operation and
rules of auxiliary adjustment is completely same as the main adjustment except that
sampling for auxiliary adjustment adopts the angle value (A1 – A5) and sampling for main
adjustment adopts the length value (L1 – L5). If the weight variation is larger than the weight
of empty hook during sampling when the boom is continuously derricked up and down,
press the button【▼】for collection.

Adjusting methods for auxiliary adjustment weight:

Under the premises that P1 and P2 are normal, select two different weights for the study of
weight calibration (enter Figure 3.6 and select weight via buttons【▲】and【▼】).

Weight 1: For the medium-and-long length boom, select one weight with 30% rated weight
to study derricking up and derricking down, thus to ensure accuracy of small-and-medium
tonnage crane.

Weight 2: For the basic boom, select one weight with 50% rated weight to study derricking
up and derricking down, thus to ensure accuracy of large-tonnage crane.

Figure 3.6 Auxiliary Adjustment 1

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Figure 3.7 Auxiliary Adjustment 2

Figure 3.8 Auxiliary Adjustment 3

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Figure 3.9 Auxiliary Adjustment 4

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4. System Maintenance
Before crane operation, visually inspect each crane component, MCS670 intelligent
monitoring device and each sensor so as to timely find abnormities. Pay attention to the
self-test after the load moment limiter boots up. Inspect whether there is failure tips on the
monitor. Observe whether the displayed value of the length, angle and pressure are normal.
In case of the abnormal phenomenon or the failure tips, it is necessary to timely make a call
to the professional for the proper troubleshooting.

During daily use, keep the intelligent monitoring devices clean. Do not let the rain water, oil,
organic solvent and other harmful liquid pour or splash on the intelligent monitoring devices
and into the sensor interior. Protect the heavy objects or sharp objects from colliding and
scratching the mentor, sensor and various connecting wires.

In the hot summer, do not to let the intelligent monitoring devices expose to the burning sun,
so as to prolong its service life. Because the LCD possesses the inherent characteristic of
the comparatively sensitivity to the temperature, the LCD in the mentor will have the
relatively dark color under the higher air temperature (above 35℃), and have the relatively
light color under the lower air temperature (below -10℃), which are the normal phenomena
and will not influence the using effects.

It is necessary to frequently inspect the working conditions of the battery and generator. If
the battery and generator are defective, the working performance of MCS670 intelligent
monitoring devices will be influenced.

Before finding out the causes, do not blindly dismantle each component and senor of the
intelligent monitoring devices, thus to prevent enlarging of the failure ranges which leads to
other more serious failures.

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5. Basic troubleshooting
When the display of the intelligent monitoring device is abnormal, it is necessary to inspect
whether various components are normal, and whether the cable and cable connections are
perfect. Then consult the following table, and inspect actual situations. If you cannot remove
the failures, please directly consult our company and apply for service. The MCS670
intelligent monitoring device can monitor whether various peripheral sensors have failures
in real time. If failures occur, the warning indicator will illuminate without weight display
(because at this moment the correct lifting weight cannot be displayed).

For troubleshooting methods of various failures, refer to the table below:

Phenomenon Preliminary Analysis Remedies

No power source or Inspect the power interface

open circuit of the power to ensure normal power
There is no display on the
connection supply.
monitor, and the power
The power supply voltage Inspect whether power
lamp does not illuminate.
is too low to start the supply voltage is excessively
mentor. low.
There is no display on the The LCD is damaged or Repair
monitor, but and power the backlight wire
lamp illuminates. connects abnormally.
Mentor
There is normal display on The power lamp is Repair
display
the monitor, but the power damaged.
lamp does not illuminate.
Stripe display, blurred The accidental Restart the mentor
screen, messy code on the phenomena due to
monitor on-site interference, not
influencing the work
Failure of the LCD Repair
LCD connection wiring Repair
connects abnormally.

Phenomenon Preliminary Analysis Remedies

Main boom and jib are not Set correctly.

properly set.
The hydraulic system is Inspect and repair the
The actual weight is unstable. hydraulic system.
Weights inaccurate during The actual weight of the load is Verify the actual weight.
lifting. not verified.
Length and angle are not Re-adjust the length and
correctly adjusted. angle.
The weight adjustment is not Re-adjust the weight.

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 conducted or the adjustment is
improper.
The empty hook has Improper debugging Re-debug in accordance
the with Debugging Instructions.
weight display all the The pressure sensor is Replace the pressure
time. damaged. sensor.
Pressure of hydraulic system is Release the pressure.
The actual weight
locked.
during lifting is not
The pressure sensor is Replace the pressure
changed.
damaged. sensor.
The rated lifting Falls are set incorrectly. Re-adjust the falls.
capacity is incorrect.
The rated lifting The length sensor and angle Inspect the zero value and
capacity changes sensor are abnormal, causing full value of length sensor
suddenly, resulting sudden change in sampling and angle sensor.
in alarming and signal.
cutting-off.

Phenomenon Preliminary Analysis Remedies

Readjustment is not made after Re-debug the length (If
removing the length sensor. the problem is not solved,
inspect whether the
connecting wire is
AD value of length
properly connected.)
displays “4095”, or
The display of “0000—0003” Inspect whether the length
“STOP” indicator on
indicates open circuit of length sensor interface is
the panel illuminates
sensor connection wire or the correctly connected and
and AD value of
short circuit of power source and firmly secured.
length displays
signal.
“0000—0003”.
The display of “4095” indicates Replace the length sensor.
Length
that the sensor is abnormal,
sensors
causing extremely large output
current (more than 20mA).
The length display is
from small to large, Inspect and repair the
The length sensor is defective.
and then turns to be length sensor.
small.
The cable reel cannot The wire is jammed due to Correctly install the cable
be retracted or is incorrect installation location. reel.
retracted slowly after Elastic force of the cable reel is
Replace the cable reel.
being pulled out. insufficient.

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The hoisting limit
(Excluding the hook draw alarm)
switch is activated
When the cable reel is pulled to
when the boom is Replace the cable reel.
certain distance, the internal reed
extended to a certain
is bent with the short circuit.
length.

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 Phenomenon Preliminary Analysis Remedies
Readjustment is not made after Re-debug the angle in
removing the angle sensor. accordance with the
Debugging Instructions.
The angle debugging is incorrect, Re-debug the angle in
making AD value of mentor angle accordance with the
exceed 4095 when the boom does Debugging Instructions.
AD value of angle
not reach the maximum value.
displays “4095”, or
The display of “0000—0003” Inspect whether the angle
“STOP” indicator on the
indicates open circuit of angle sensor interface is
panel illuminates and
sensor connection wire or short correctly connected and
AD value of angle
circuit of power source and signal. firmly secured.
displays “0000—0003”.
Angle The display of “4095” indicates Replace the angle sensor
senso that the sensor is abnormal,
rs causing extremely large output
current (more than 20mA).
The pendulum inside angle sensor
Replace the angle sensor
does not sway flexibly.
The angle does not
change during boom The angle sensor is defective. Replace the angle sensor
derricking.
Angle on the monitor is Debug the angle again in
not displayed to 80° Angle debugging is incorrect. accordance with
after the boom is Debugging Instructions
derricked up to the
The angle sensor is defective. Replace the angle sensor
maximum angle.

Phenomenon Preliminary Analysis Remedies

Pressure P1AD value displays P1 pressure sensor is defective. Replace the pressure
sensors “4095”, or “STOP” sensor
indicator on the panel
illuminates and P1AD
value displays “0010-
800”.
P2AD value displays P2 pressure sensor is defective. Replace the pressure
“4095”, or “STOP” sensor
indicator on the panel
Derrick up and derrick
illuminates and P1AD
Hydraulic leakage down the boom to remove
value displays “0010-
the failure.
800”.
P1 or P2AD value Open circuit of connection wire for Inspect whether the P1 or
displays “0000— P1 or P2 pressure sensor or short P2 pressure sensor
0003”. circuit of power source and signal. interface is correctly
- 49 -
 connected and firmly
secured.
It is not tightened during
Install correctly
installation.
Oil leaks from the Combination washer or O-ring is
Install correctly
pressure sensor. not installed.
Combination washer or O-ring is Replace the combination
defective. washer or O-ring

MCS670 product fault analysis (Special instructions, for sensors only)

Data from various sensors

Zero value Full value Failure analysis

Corresponding
sensor Actual
AD value Actual value AD value
value
Fault diagnosis for big cable reel:
Zero value judgment: fully retract the main
boom to see whether the AD value and the
Confirm
Length actual value are correct.
during
of fully Full value judgment: fully extend the main
Length 1 Length of the
810-1200 extend boom to see whether the actual value is
L1 basic boom full
ed correct.
adjustme
boom If the AD value and actual value displayed in
nt
the process of zero value judgment and full
value judgment differ from the data in the
table, the big cable reel may be defective.
Fault diagnosis for small cable reel:
Length
Zero value judgment: fully retract the
of
telescopic cylinder I to see whether the AD
Confirm boom
value and the actual value are correct.
during with
Full value judgment: fully extend the
Length 2 the telesco
810-1200 0 telescopic cylinder I to see whether the actual
L2 full pic
value is correct.
adjustme cylinder
If the AD value and actual value displayed in
nt I fully
the process of zero value judgment and full
extend
value judgment differ from the data in the table,
ed
the small cable reel may be defective.

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 Fault diagnosis for angle sensor:
Zero value judgment: level the main boom to
see whether the AD value and the actual
Confirm value are correct.
during Full value judgment: derrick up the main
Backpr
Angle the boom to the maximum angle (in the
810-1200 0 essure
A full backpressure status) to see whether the
angle
adjustme actual value is correct.
nt If the AD value and actual value displayed in
the process of zero value judgment and full
value judgment differ from the data in the table,
the angle sensor may be defective.

Pressure 1 Fault diagnosis for pressure 1 and pressure 2:

810-820 0 2844 25MP Zero value judgment: level the main boom,
P1
put the empty hook onto the ground and
disengage the PTO switch to see whether the
AD value and the actual value of P1 and P2
are correct after 5 to 10 minutes.
If the AD value and actual value displayed in
the process of zero value judgment and full
Pressure 2 value judgment differ from the data in the table,
810-820 0 2844 25MP
P2 the pressure sensor may be defective.

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6 Product installation
◼ MCS670 intelligent monitoring device for construction machinery consists of intelligent
monitor, pressure sensors, length sensors, angle sensors, multi-core shield cable and aviation
connectors.

◼ For wring methods of monitor with each sensor and power source control for the MCS670
intelligent monitoring device for construction machinery, refer to Appendix 1.

◼ For installation illustration for MCS670 intelligent monitoring device for construction
machinery, refer to Appendix 2.

7 After-sale service and warranty period

◼ Our company is equipped with the professional after-sale service team. In case of failure,
please contact our company directly.

◼ Warranty of MCS series intelligent monitoring device for construction machinery is twelve
(12) months except human factors and force majeure.

◼ Our company will still provide repair service for the products which are out of warranty.

◼ Our company holds the training class periodically according to the requirements of the
user.For debugging and maintenance personnel who need to be trained on MCS670 intelligent
monitoring device for construction machinery, please directly contact our company.

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Appendix 1 ： Connection method for
signal wire
The system wiring of MCS670 intelligent monitoring device selects the multi-core aviation
connectors, and adopts the multi-core shield cables for the external connection. Application
of connecting wires for aviation plug connecting to the shield cable are determined in
accordance with the following method. The plugging surface of the plug faces to the user
and the locating notch faces down.

MCS670-6201 Illustration of Aviation Interfaces

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Appendix 2: Installation method

- 54 -
- 55 -
Appendix 3 Table – Error Codes
Error Failure Cause
code
E00 Normal, no error ---
E01 Working radius too small Working radius exceeds
or boom angle too large the minimum radius in the
lifting capacity table or
boom angle exceeds the
maximum angle in the
lifting capacity table.
E02 Working radius too large Working radius exceeds
or boom angle too small the maximum radius in the
lifting capacity table or
boom angle is less than the
minimum angle in the lifting
capacity table.
E03 In the prohibited slewing 1. Slew with a load beyond
range (non-permissible the permissible slewing
load bearing area) range.
2. In the incorrect switch
quantity selection OM
status
E04 OM does not exist or not 1. A nonexistent OM code
allowed in the slewing has been selected.
area 2. The main boom is not in
the permissible slewing
range.
E05 Boom length does not 1. The main boom is
within the permissible excessively extended or is
range. not long enough. For
example, the maximum
main boom length is
exceeded or the main
boom does not extended to
the corresponding length
when the jib is installed on
its head.
2. The length sensor is
adjusted. For example, the
length measurement cable
falls off from the cable reel.
E11 Signal value in the main 1. The length sensor is
boom length sensor damaged.
measurement channel is 2. Cable in the
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Suggested remedies
---
Derrick down to the
permissible radius or angle
in the lifting capacity table.
Derrick up to the
permissible radius or angle
in the lifting capacity table.
1. Slew to the permissible
range.
2. Inspect switch quantity
input
1. Set a correct OM.
2. Slew to the permissible
working area.
1. Extend the main boom to
the correct length.
2. Fully retract the main
boom and level the boom.
Inspect whether the length
measurement cable for
sensor falls off. Open the
length sensor and use the
screw driver to rotate it
anticlockwise to the
positioning groove.
1. Replace the length
sensor.
2. Replace the cable or
Error Failure Cause Suggested remedies
code
lower than the minimum measurement channel is plug.
permissible range. damaged or water flows
into the sensor plug.
E12 Signal value in the 1. Oil pressure sensor in 1. Replace the oil pressure
measurement channel of the cylinder piston side is sensor in the cylinder
oil pressure sensor in the damaged. piston side.
cylinder piston side is 2. Cable in the 2. Replace the cable or
lower than the minimum measurement channel is plug.
permissible range. damaged or water flows
into the sensor plug.
E13 Signal value in the Refer to E12 Refer to E12
measurement channel of
oil pressure sensor in the
cylinder piston-rod side is
lower than the minimum
permissible range.
E15 Signal value in the main 1. The main boom angle 1. Replace the angle
boom angle sensor sensor is defective. sensor.
measurement channel is 2. Cable in the 2. Replace the cable or
lower than the minimum measurement channel is plug.
permissible range. damaged or water flows
into the sensor plug.
E21 Signal value in the main Refer to E11 Refer to E11
boom length sensor
measurement channel is
higher than the maximum
permissible range.
E22 Signal value in the Refer to E12 Refer to E12
measurement channel of
oil pressure sensor in the
cylinder piston side is
higher than the maximum
permissible range.
E23 Signal value in the Refer to E12 Refer to E12
measurement channel of
oil pressure sensor in the
cylinder piston-rod side is
higher than the maximum
permissible range.
E25 Signal value in the main Refer to E15 Refer to E15
boom angle sensor
measurement channel is
higher than the maximum

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Error Failure Cause Suggested remedies
code
permissible range.
E60 Engine defects --- ---
E61 CANBUS error CANBUS is turned off. Detect the CANBUS
E62 CANBUS error Error>>96 Detect the CANBUS
E63 CANBUS error Error>>96 Detect the CANBUS.
E64 P port pressure failure Open circuit of sensor Detect the pressure sensor
at P port.
E65 P port pressure failure The input circuit is short to Detect the pressure sensor
the ground. at P port.
E66 P port pressure failure Sensor drifts. Detect the pressure sensor
at P port.
E67 LS port pressure failure Open circuit of sensor Detect the pressure sensor
at LS port.
E68 LS port pressure failure The input circuit is short to Detect the pressure sensor
the ground. at LS port.
E69 LS port pressure failure Sensor drifts. Detect the pressure sensor
at LS port.
E6A Mode switch failure Invalid value Detect the mode switch.
E6B Throttle failure Not in the initial position Detect the throttle.
E6C Throttle failure Signal is undetected. Detect the throttle.
E6D Throttle failure Short circuit Detect the throttle.
E71 Short circuit of The circuit of Detect circuit of the
overloading/overhoisting overloading/overhoisting overloading/overhoisting
solenoid valve solenoid valve is short to solenoid valve when the
ground. load moment limiter is
powered off.
E74 Short circuit of The circuit of overlowering Detect circuit of the
overlowering solenoid solenoid valve is short to overlowering solenoid
valve ground. valve when the load
moment limiter is powered
off.
E76 Short circuit of low speed The circuit of low speed Detect circuit of the low
gear selection solenoid gear selection solenoid speed gear selection
valve valve is short to ground. solenoid valve when the
load moment limiter is
powered off.
EA1 Open circuit of Circuit of the Detect circuit of the
overloading/overhoisting overloading/overhoisting overloading/overhoisting
solenoid valve solenoid valve is open. solenoid valve.
EA4 Open circuit of Circuit of the overlowering Detect circuit of the
overlowering solenoid solenoid valve is open. overlowering solenoid
valve valve.
EA6 Open circuit of low speed Circuit of the low speed Detect circuit of the low
- 58 -
Error Failure Cause Suggested remedies
code
gear selection solenoid gear selection solenoid speed gear selection
valve valve is open. solenoid valve.

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