Troublesshooting Manual 3b6pdf

3B6 LOAD MOMENT INDICATOR (LMI)
FOR MRT TELESCOPIC HANDLERS

TROUBLESHOOTING
MANUAL Su stabilizzatori 360°
0
1
2
0
0
1000
1001
1
5,7
110
2
6,7
100
3
7,9
100
4
9,1
100
5
10,3
100
6
11,5
100
7
12,8
100
8
14
100
9
15,2
100
10
16,6
100
11 29
3 4 5 5 5 4,5 4 3,2 3 2,8 2,8 2,4

4 4,5 5 5 5 4,5 4 3,2 3 2,8 2,8 2,4
5 5 4,5 4,5 4,5 4,5 4 3,2 3 2,8 2,8 2,4
6 5,5 4,2 4,2 4,2 4,2 3,7 3 3 2,8 2,8 2,4
7 6 4 4 4 4 3,5 3 2,8 2,8 2,65 2,3
8 6,5 4 4 4 3,2 2,8 2,8 2,55 2,5 2,3
9 7 3,2 3,2 3,2 3 2,8 2,4 2,4 2,3 2,2
10 7,5 3 3 3 2,8 2,4 2,2 2,2 2,15 2,1
11 8 2,8 2,8 2,8 2,8 2,2 2,2 2,1 2,05 1,95
12 8,5 2,4 2,4 2,4 2,2 2,1 2 1,9 1,8
13 9 2,4 2,4 2,4 2,2 1,9 1,9 1,8 1,7
14 9,5 2,1 2,1 2,1 2,1 1,9 1,8 1,7 1,6
15 10 2 2 2 2 1,8 1,65 1,6 1,55
16 10,5 1,65 1,65 1,65 1,65 1,6 1,5 1,45
17 11 1,6 1,6 1,6 1,5 1,45 1,45
18 11,5 1,4 1,4 1,4 1,4 1,4 1,4
19 12 1,35 1,35 1,35 1,35 1,35 1,35
20 12,5 1,2 1,2 1,2 1,2 1,2 1,2
21 13 1,15 1,15 1,15 1,15 1,15 1,15
22 13,5 1 1 1 1 1
23 14 0,95 0,95 0,95 0,95 0,95
24 14,5 0,85 0,85 0,85 0,85
25 15 0,8 0,8 0,8 0,8
26 15,5 0,8 0,8 0,8 0,8
27
28
29
22-01-02 Up-grade
Complies to the MACHINES DIRECTIVE Standards: EN60204 – 1 , EN954 , EN12077 - 2
EMC according to the “ Heavy Industrial Environment” category: EN50081 - 2 , EN50082 - 2
1
PAGE
ACCESS PROCEDURES TO µMACXxx 2,3,4
DESCRIPTION LMI COMPONENTS POSITIONING ON THE MACHINE 5

INDEX MAIN CONTROL UNIT CODE: UMMST01-2/XX 6
MAIN CONTROL UNIT GENERAL CHARACTERISTICS 7
MAIN CONTROL UNIT CONNECTIONS AND SIGNALS 8
BOOM LENGTH AND ANGLE SENSOR CODE : CIT-1PICW1/xx 9
BOOM LENGTH AND ANGLE SENSOR - DIMENSIONS AND WIRING 10
BOOM LENGTH AND ANGLE SENSOR - EXPLODED VIEW 11
PRESSURE TRANSDUCER CODE : Y11 4740-350 12
PRESSURE TRANSDUCER TECHNICAL SPECIFICATIONS 13
CONTROL PANEL CODE : IDR1-3/xx 14
CONTROL PANEL DIMENSIONS, CHARACTERISTICS, CABLE 15
DETECTION TROUBLESHOOTING 16
ALARM CODES AND ACTIONS TO TAKE 17,18,19
AUTO DIAGNOSTIC- Geometric data and load data 20
AUTO DIAGNOSTIC- Hydraulic pressures data 21
AUTO DIAGNOSTIC- Sensors digital signals 22
AUTO DIAGNOSTIC- Status of digital Inputs 23
AUTO DIAGNOSTIC- Status of digital Outputs 24
ALARM CODE 1 : MEMORY DATA NOT RELIABLE 25
ALARM CODE 2 : ANGLE READING < MINIMUM VALUE 26
ALARM CODE 3 : ANGLE READING > MAXIMUM VALUE 26
ALARM CODE 4 : EXTENSION READING < MINIMUM VALUE 27
ALARM CODE 5 : EXTENSION READING > MAXIMUM VALUE 27
CABLE REEL POWER SUPPLY VERIFYING 28
ANGLE POTENTIOMETER VERIFYING 29
BOOM LENGTH POTENTIOMETER VERIFYING 30
ALARM CODE 8 : MAIN CYLINDER (BOTTOM SIDE ) < MINIMUM VALUE 31
ALARM CODE 9 : MAIN CYLINDER (BOTTOM SIDE ) > MAXIMUM VALUE 32
ALARM CODE10 : MAIN CYLINDER (ROD SIDE ) < MINIMUM VALUE 33
ALARM CODE11 : MAIN CYLINDER (ROD SIDE ) > MAXIMUM VALUE 34
ALARM CODE18 : COMPENSATION CYLINDER (BOTTOM SIDE ) < MINIMUM VALUE 35
ALARM CODE19 : COMPENSATION CYLINDER (BOTTOM SIDE ) > MAXIMUM VALUE 36
ALARM CODE20 : COMPENSATION CYLINDER (ROD SIDE ) < MINIMUM VALUE 37
ALARM CODE21 : COMPENSATION CYLINDER (ROD SIDE ) > MAXIMUM VALUE 38
ACTION EPROM and EEPROM REPLACEMENT 39

POTENTIOMETERS ALIGNMENT 40
ANGLE AND EXTENSION SENSORS CALIBRATION - 1ST PASSWORD INTRODUCTION 41
ANGLE AND EXTENSION SENSORS CALIBRATION - LMI SELF-CALIBRATION 42
DATA DOWNLOADING ON E2PROM -“SAVE” FUNCTION 43
LANGUAGE/MEASURE SYSTEM SELECTION AND 2ND PASSWORD INTRODUCTION 43
DATA DOWNLOAD FROM LAP-TOP TO LMI 44
DATA DOWNLOAD FROM LMI TO PC AND FROM PC TO FLOPPY DISK 45
SYSTEM LAY-OUT AND CONNECTIONS 46
EXTERNAL WIRING 47
RECOMMENDED SPARE PARTS LIST 48
2
ACCESS PROCEDURES TO µMACXxx

LOAD MONITORING SYSTEM (LMI)
This system has been conceived and developed to offer different levels of functionality of access to
internal data, according to the actions to be done; the following description explains these several
levels.
Starting from the basic level (Operator) some access levels are available, identified by three different
PASSWORDS; the first one given to the Technical Service Department and possibly authorized
Dealers (for troubleshooting and sensors replacement), and the second one given to the MANITOU
Technical Service Department only (for refined calibration), and the third one exclusively to
Authorised programming personnel (for Load Table and Machine Parameters programming), due to
the danger of wrong handling.
1°LEVEL:
OPERATOR:
Without needing a PASSWORD (also see OPERATOR MANUAL) all the working information of the machine
is available through system monitoring displayed by the display panel; starting from basic working data: lifted
load, max admitted load, outreach, working conditions, and tilting percentage.
By pressing the ENTER key it is possible to show other machine working data: boom angle and length.
By pressing ENTER again it will be possible to show the hydraulic pressure values at their 4 measuring
points,
(two on the main cylinder, and two on the compensation cylinder); Further pushing of the ENTER key gives
more information about transducers signals digital converted values, and about ON/OFF Inputs and Outputs.
The aim is to give to the Operator the possibility of reviewing these readings, allowing him 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 faults in his OPERATOR MANUAL.
3
2° LEVEL: (1st 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).
For this level a 1st PASSWORD is given, allowing entry into all diagnostic functions and transducer
calibration (Angle and Length) in case of their replacement, without needing any PC or programming tool.
As far as Pressure Transducers are concerned, please note that they do not need any calibration, as they
are totally interchangeable.
5
LMI COMPONENTS POSITIONING ON THE MACHINE
Angle/length
transducers on
left side of the
boom
Display: 4 Pressure
into the cabin
Transducers on
lifting and
compensation
cylinders
Main unit:
into the cabin
SYSTEM LAY-OUT AND CONNECTIONS at page 46

6
MAIN CONTROL UNIT CODE: UMMST01-2/XX
UMMST01-2 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 harsh environments.
UMMST01-2 Main Control Unit is provided with
all EMC necessary components.
7
MAIN CONTROL UNIT
GENERAL CHARACTERISTICS
POWER SUPPLY
• From vehicle battery :10-28 V
• Current consumption, without loads : 0,35A
INPUT / OUTPUT
• 8 Digital Inputs
• 4+1 Digital Outputs
• 6 (+2) Analog Inputs
• Watch Dog Dynamic Output : not used
• Voltage working range : 10-28 VCC
• Output Current : 2A
• Analog Inputs Voltage : 0- 5V
• 2 Serial Links RS232 (panel and PC), CAN BUS (option)
• Clock and Buffer Battery (option)
• Epoxy Resin Coating
• 8 Kb E2prom for Data Recording (32Kb Option)
MECHANICAL CHARACTERISTICS
MECHANICAL DIMENSIONS
• Case Dimension : 253 x 217 x 91 mm
• Fixing holes : 226 x196 mm
VIBRATIONS
• Continuous : 5g’s from 20 to 400Hz Over 3 AXIS
• Shock : 10g’s
ENVIROMENTAL
• Salt spray resistance over 48 Hours
TEMPERATURE
• Working range :-30 -+70°C
• Storage range :-45 - +85°C
8
MAIN CONTROL UNIT NOTE:

CODE DIODE PIN FUNCTION
CONNECTIONS and SIGNALS DI0
DI1
D35
D39
17
18
OUTRIGGERS
FRONT
DI2 D43 19 1/2 OUTRIGGERS
DI3 D47 20 BASKET
EPROM : LOAD TABLES EEPROM: DO0 D68 25 SHUT-DOWN

AND PARAMETERS CALIBRATION DATA DO2 D77 27 WARNING
PC (LAPTOP)
CONNECTIONS
D2 = RED LED
When lit means
that +15V Voltage
is active
D1 = RED LED
When lit means
that +5V Voltage
is active
Note :
D1 and D2 must be
lit when the
system is ON
EXTERNAL WIRING
See page 47
SHUT-DOWN WARNING
D35, D39, D43, D47, D51, D55, D59, D63 =RED LED’s D68, D71, D74, D77 = RED LED’s
They show the INPUT status They show the OUTPUT status
ON = ACTIVE INPUT ON = ACTIVE OUTPUT
9
BOOM LENGTH AND ANGLE SENSOR CODE : CIT-1PICW1/xx
The boom and angle sensor is formed by a cable

reel with pulley on which a cable is wound; the
other end is attached to the boom head (or to the
first telescopic element in case of proportional
extension).
When extending the boom, the cable unwinds (max.
12 mt.) measuring the extension length signal
through a 10-turns servo potentiometer.
While using the machine, it is always necessary to
carefully survey the unwinding cable along the
boom, as it can be accidentally broken if it is
snagged or struck by external forces.
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 thanks to a 1-turn servo-
potentiometer activated by a pendulum.
Analog signals from above potentiometers are used
by the LMI to compute the boom geometrical data.
10
BOOM LENGTH AND ANGLE SENSOR
OVERALL DIMENSION WIRING DIAGRAM

11
BOOM LENGTH AND ANGLE SENSOR

EXPLODED VIEW
Description
7-2 1 Case
2 Base
2 7-1
7 5-1 3 Circuit board
4 Step
5
5 Pinion
11
3 5-1 Shaft
6 Clutch
8-1
6-1 10-turns Potentiometer
7 1-turn Potentiometer
6 7-1 Pendulum
6-1 7-2 Bearing support
8
8 Pulley
12 9 8-1 Cap
10
1 9 Strain relief
10 Breather
4
11 Spring
12 Cable
12
PRESSURE TRANSDUCER CODE : Y11 4740-350

The 4 Pressure transducers detect the pressure into the boom
lifting and compensation cylinders; typically 2 sensors are
required for measuring the differential pressure inside cylinders :
they must be installed on the two cylinder chambers to allow
differential pressure. By these values, weight computing is
achieved by the Main Control Unit.
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 replacement of these elements is very easy because they
are complete compatibility and must be done by Qualified
Personnel.
MECHANICAL DIMENSIONS
13
PRESSURE TRANSDUCER
TECHNICAL SPECIFICATIONS
PIN CONNECTIONS
PIN 3 Wires
1 +VB (15V)
2 Output signal 0,5 .. 5,5 V
3 GND
INPUT DATA
• Measuring ranges 350 bar
• Overload ranges 800 bar
• Max pressure 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
OTHER DATA
• Supply voltage 12 ...30V
• Current consumption ca.15mA
• Life expectancy 106 load cycle
• Weight 145g.
14
CONTROL PANEL CODE : IDR1-3/xx
Operating Mode Identification Symbols ( External automatic selections)
Equipment Identification symbols (Manually selected from the control panel)
Green/Amber/Red Lights showing working conditions( Safety/ Alarm/Shut

down)
Two rows alpha-numeric LCD display

showing working data

2.2 4.0 6.1 11
Symbols and letters related 4 Set-up keys Icon representing the

to the display indications (key “-” and “+” are not machine and letters
used in normal working related to geometric data.
condition)
15
CONTROL PANEL : DIMENSIONS, CHARACTERISTICS, CABLE
TECHNICAL CHARACTERISTICS
• Power supply 8 - 24 V. • Load typical accuracy 3,5%.
• Temperature working range -20°+ 70°. • Outreach computing accuracy 1%.
• Microcontroller structure 16 bit. • Link to Main Control Unit RS-232/C
CONNECTING CABLE TO MAIN CONTROL UNIT
1 Pin plugs 4 6 pins male connector

2 Cable 4x0,5 sch 5 Crimping pins
3 Thermo shrink sheath
16
TROUBLESHOOTING
The first step to check a fault is to identify the problem which occurred with the machine
Operator.
Thanks to the auto-diagnostic procedures, which are able to recognise transducer failures, cable
breaking and internal electronic faults,alarm codes are automatically shown on the display to the
Operator, allowing him a certain capability of repairing, and also to better inform the Technical
Assistance even remotely.
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 upper row.
Depending on the message, the fault can be identified.
Alarm: 18
2.2 4.0 6.1 11
Alarm codes are listed in the following pages.

The list also includes some hints to help solve the problems and return to normal working
conditions.
17
ALARM CODES AND ACTIONS TO TAKE

Alarm
Description What to do
code
• Switch the system off and on.
1 If the alarm persists:
PAGE 25 •Verify that E2prom chip is fitted properly in its socket.
Memory data not reliable
and • Re-enter data and save it again
39,44
• Replace the E2PROM chip and recalibrate the machine
2
PAGE 26 Angle sensor reading •Verify that the wiring and the connectors are not in short circuit.
and lower than the minimum If the alarm persists:
28,29, value • Verify the angle sensor integrity.
40,41
3 Angle sensor reading
•Verify that the cable or the connector wiring is not open
PAGE 26 higher than the
If the alarm persists:
and 28,29, maximum value
40,41 • Verify the angle sensor integrity.
4
PAGE 27 Reading of the boom •Verify that the wiring and the connectors are not in short circuit
and length sensor lower than If the alarm persists:
28,30, the minimum value •Verify the length transducer integrity
40,41
5 Reading of the boom • Verify that the cable or the connector wiring is not broken
PAGE 27 length sensor higher than If the alarm persists:
and28,30,
40,41 the maximum value • Verify the length transducer integrity
Length sensor 1 value
6 lower than the calibration
value
Length sensor 2 value
7 lower than the calibration
value
18
Alarm
codes
Reading pressure of the • Verify that the cable or the connectors wiring is not in short circuit
8 main cylinder (bottom
PAGE 31 side) lower than the
minimum. • Verify the pressure transducer integrity
Reading pressure of the • Verify that the cable or the connector wiring is not open
9 main cylinder (bottom
PAGE 32 side) higher than the
maximum. • Verify the pressure transducer integrity
Reading pressure of the •Verify that the wiring and the connectors is not in short circuit
10
main cylinder (rod side) If the alarm persists:
PAGE 33 lower than the minimum. • Verify the pressure transducer integrity
11 main cylinder (rod side)
PAGE 34 higher than the
maximum. • Verify the pressure transducer integrity
12 N/A
13 N/A
14 N/A
15 N/A
16 Output hasn’t been verify
17 N/A
19
Alarm
codes
Reading pressure of the •Verify that the cable or the connector wiring is not in short circuit
18 compensation cylinder
If the alarm persists, please, contact MANITOU Technical Assistance :
PAGE 35 (bottom side) lower than the
minimum. • Verify the pressure transducer integrity.
19 compensation cylinder
PAGE 36 (bottom side) higher than
the maximum. •. Verify the pressure transducer integrity.
Reading pressure of the • Verify that the cable or the connector wiring is not in short circuit
20 compensation cylinder (rod
PAGE 37 side) lower than the
minimum. •. Verify the pressure transducer integrity.
Reading pressure of the •. Verify that the cable or the connector wiring is not open
21 compensation cylinder (rod
PAGE 38 side) higher than the
maximum. •. Verify the pressure transducer integrity.
12 N/A
13 N/A
14 N/A
15 N/A
19
Alarm
codes
26 N/A
27 N/A
28 N/A
29 N/A
30 “Stabiliser out” fault Check related inputs (all related inputs must have the same status)
Check wiring
Check sensors
31 “Stabiliser touch down” fault Check related inputs (all related inputs must have the same status)
Check wiring
Check sensors
32 Angle fault Check related inputs

Check wiring
Check sensors
33 Check related inputs

Telescope fault
Check wiring
Check sensors
19
Alarm
codes
• Check for short-circuit in the wiring or in wiring connector plugs

Angle sensor 2 reads lower
34 • If the alarm persists, consult Authorised MANITOU Assistance to:
than minimum value.
check for angle sensor default

Angle sensor 2 reads higher
than maximum value.
check for angle sensor default

Elongation sensor 2 reads • If the alarm persists, consult Authorised MANITOU Assistance to:
36
lower than minimum value. check for elongation sensor default

Elongation sensor 2 reads
higher than maximum value.
check for elongation sensor default
20
AUTO DIAGNOSTIC- System internal working conditions monitoring

Geometric data and load data
These readings show on some pages the internal status of the system which is very useful when a fault occurs.
Starting from the main working data page press twice the ENTER button:
The display will show the first control page, giving
geometric data and main cylinder differential pressure summary.
P100 W 5.0 M 5.0

A 60 L20.3 R15.1
This page is displayed for 30 seconds; after which, it returns to the normal working condition page.
The displayed parameters are as follows:
• P : Main cylinder differential pressure in Bar;
• W : Lifted load weight in Tonnes (Pounds/1000 if Imperial Measurement System is used);
• M : Maximum admitted load in present position in Tonnes (Pounds/1000 if Imperial Measurement System is used)
• A : Actual angle in Degrees:
• L : Actual boom length in Meters (in Feet if Imperial Measurement System is used );
• R : Radius from turret rotation centre in Meters (in Feet if Imperial Measurement System is used)
21

Hydraulic pressures data
By pressing the ENTER button again the display will show the second page showing:
individual hydraulic pressures summary :
P100 L: 50 H: 40
p 0 l: 0 h: 0
This page is displayed for 30 seconds; after which , it returns to the normal working condition page.
Upper row:
• P : Main cylinder differential pressure in Bar;
• L : Main cylinder bottom side pressure in Bar;
• H : Main cylinder rod side pressure in Bar;
Lower row:
• p : Compensation cylinder differential pressure in Bar;
• l : Compensation cylinder bottom side pressure in Bar;
• h :Compensation cylinder rod side pressure in Bar;
Remark: hydraulic displayed pressures might have correct values and coherent to the use of the machine.
The effectiveness of these values can be evaluated only on the base of the Technical Engineer experience
and to his knowledge of the actual corresponding pressures into the cylinders
22

Sensors Digital Signals
By pressing once again the ENTER button the display will show the third page giving
pressure transducers and length/angle sensors digital signals corresponding to the actual measurements.
1111 2222 3333

4444 5555 6666
• 1111 : Main cylinder bottom side pressure value in Bits; between 0 and 1023 (*)
• 2222 : Main cylinder rod side pressure value in Bits; between 0 and 1023 (*)
• 3333 : Angle value in Bits; between 0 and 1023 (*)
• 4444 : Boom Length value in Bits; between 0 and 1023 (*)
• 5555 : Compensation cylinder bottom side pressure value in Bits; between 0 and 1023 (*)
• 6666 : Compensation cylinder rod side pressure value in Bits; between 0 and 1023 (*)
REMARK: These numerical readings follow the analog signals variations of the sensors.
Minimum and maximum limits exist and they have not to be exceeded, otherwise the relevant signal
is taken wrong by the system: THE MINIMUM VALUE IS 10, THE MAXIMUM VALUE IS 1010.
(*) = Due to 10bits A/D Converter
23
AUTO DIAGNOSTIC - System internal working conditions monitoring

Status of Digital Inputs
By pressing the ENTER button again, the display will show the fourth page giving
Inputs given by the micro-switches (Operating Mode OM ) status summary.
I 0 1 2 3 4567890123
* * - - ----------
Digital Inputs (I)
The upper row indicates the Input number, while the lower row indicates its status.
The symbol “*” means active Input, the symbol “-” means non active Input .
• 0 : Outriggers : “*” When they are on the ground and completely extended
• 1 : Turret rotation : “*” When in front position.
• 2 : ½ Outriggers : “*” When they are on the ground but half extended.
• 3 : Basket : “*” When a basket is not fitted
• 4…N : N/A
NOTE : The combination of the Inputs status automatically selects the proper Operating Mode (OM ) and the
corresponding load Table, depending on the machine model.
REMARK: This page has the aim to check the proper Inputs status from outside (micro-switches)
in the specific Machine positions.
See also Page 8 : LED’S ON MAIN BOARD
24
AUTO DIAGNOSTIC - System internal working conditions monitoring

Status of Digital Outputs to outside
By pressing the ENTER button again, the display will show the fifth page giving
Outputs of the system status summary ( automatic signals ).
O 0 1 2 3 4567890123
* * - - ----------
This page is displayed for 30 seconds; after which ,it returns to the normal working condition page.
Digital Outputs (O)
The upper row indicates the Output number, while the lower row indicates its status.
The symbol “*” means active Output, the symbol “-” means non active Output .
0 : Shut-off : “*” When the machine is working in safe or alarm conditions.
“-” When the machine gets in to a shut-down condition( 100%)
• 1 : N/A
• 2 : External alarm : “*” In Shut-down and alarm conditions, external buzzer is activated (>90%)
NOTE : The aim of this page is to check the correct Outputs status to the external system components
when an ALARM or SHUT-DOWN occurs.
See also Page 8 : LED’S ON MAIN BOARD

25
ALARM CODE 1 : MEMORY DATA NOT RELIABLE

CAUSE:
All the calibration data is stored in the EEPROM 24C65 .
Through the “Check-sum” equation, software continuously checks the comparison with the original
memorised value. When detecting a difference, the display will show the following message:
ALARM 1 = memory data not reliable.
ACTION TO TAKE: EEPROM

1) Switch the system off and on.
2) Verify that the EEPROM chip is fitted properly in its socket
(see also page 39-EPROM and EEPROM REPLACEMENT).
3) Re-enter data and save again, switch off and on again.
(To load data from the PC, please refer to the
“SAVING DATA TO A PC” section-pages 44-45).
4) If the problem persists, replace the PC board making sure that
software/parameters installed correspond to the
machine characteristics.
26
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 faulty.
NOTE: The Main Unit Processor identifies below and above the signal range a minimum zone and a
maximum zone in order to check the sensor.
ACTION TO TAKE:
Verify the cable reel PC board has the correct power supply ( refer to “CABLE REEL POWER SUPPLY
VERIFYING” section - page 28 ).
Verify angle potentiometer (refer to “ANGLE POTENTIOMETER VERIFYING” section - page 29).
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 faulty.
ACTION TO TAKE:
Verify the cable reel PC board as the correct power supply ( refer to “CABLE REEL POWER SUPPLY
Verify angle potentiometer (refer to “ANGLE POTENTIOMETER VERIFYING” section - page 29).
27
ALARM CODE 4 : 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 length potentiometer (refer to “EXTENSION POTENTIOMETER VERIFYING” section - page 30)
ALARM CODE 5 : BOOM LENGTH TRANSDUCER READING

CAUSE:
The signal from the boom length transducer to the main PC board is higher than the maximum
programmed value.
ACTION TO TAKE:
Verify length potentiometer (refer to “EXTENSION POTENTIOMETER VERIFYING” section - page 30)
28
CABLE REEL POWER SUPPLY VERIFYING
Verify 5Volts between

1(+) and 2(GND)
on cable reel board
TRUE FALSE
Verify the Verify on the Main PC board

Potentiometers 5Volts between
(**) 7(+) and 8(GND)
TRUE FALSE
Disconnect wires
Cable break down.
7 and 8 from the
Check the
Main pc board and + GND
cable-reel cable
Check for 5Vdc
TRUE FALSE
Main pc board
Probably the cable is
Is faulty.
in short circuit.
Replace it with
Check cable
a new one (*)
(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 39
(**) REFER TO pages 29 and 30
29
ANGLE POTENTIOMETER VERIFYING

Put the machine boom at 0° (horizontal).
Verify between
2(GND ) e 3 (+ )
+2,5Vcc +/- 5%
FALSE TRUE
Angle potentiometer
Raise the boom slowly.
broken (**)
Verify with a voltmeter that the

signal increases in a linear
and continous way.
.
The variation is continous
Losses of Signal
and linear
Angle potentiometer
Verify on the Main PC board
broken (**)
the potentiometer signal on
8(GND) and 9(ADC2)
GND ADC2
The signal is The signal
not correct is correct (*) REFER ALSO TO EPROM and EEPROM MEMORIES
REPLACEMENT - page 39
(**) REFER ALSO TO POTENTIOMETERS ALIGNMENT
Problems on the Connection The Main PC board is faulty. - page 40
Cable.Probably short circuited. Proceed with the replacement
Check the cable (*)
30
BOOM LENGTH POTENTIOMETER VERIFYING

The machine boom must be completely retracted.
Verify between
2(GND ) and 5 (+ )
a voltage of roughly +250mV
Voltage higher or
FALSE TRUE at 5V
Boom Length Boom Length

Extend the Boom potentiometer broken
Potentiometer broken
(**) (**)
Verify with a voltmeter that the

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

Losses of Signal
and linear
Boom Length
Verify on the Main PC board
potentiometer broken
the potentiometer signal on
(**)
8(GND) and 12(ADC3)
GND ADC3
The signal is The signal
not correct is correct
(*) REFER ALSO TO EPROM and EEPROM MEMORIES
REPLACEMENT - page 39
(**) REFER ALSO TO POTENTIOMETERS ALIGNMENT
Problems on the Connection The Main PC board is faulty.
- page 40
Cable.Probably short circuited. Proceed with the replacement
Check the cable (*)
31
ALARM CODE 8 : MAIN CYLINDER (BOTTOM SIDE) READING

NOTE:
The Main Unit Processor identifies below and above the signal range a minimum zone and a
Verify on the Main

pc board that between
1(+) e 2(GND) there is a voltage
of +15Vdc
FALSE TRUE + GND
Measure on the Main

Disconnect wires on
PC board the voltage
1(+) and 2(GND) and
on
Verify a voltage of +15Vdc
2(GND) and 3(ADC0)
FALSE TRUE Value <0,5Vdc Value >0,5Vdc
Problems on the Problems on the Broken Pressure

The Main PC board Broken Pressure The Main PC board
Connection Connection Transducer.Proceed
is faulty.Proceed Transducer.Proceed is faulty.Proceed
Cable.Probably Cable.Probably With the
with the With the with the
short circuited. short circuited. Replacement
replacement(*) Replacement replacement(*)
Check the cable Check the cable

32
ALARM CODE 9 : MAIN CYLINDER (BOTTOM SIDE) READING

NOTE:
The Main Unit Processor identifies below and above the signal range a minimum zone and a maximum
zone in order to check the sensor.
Verify on the Main

PC board that between
1(+) e 2(GND) there is a voltage
of +15Vdc
FALSE TRUE + GND
Measure on the Main

Disconnect wires on
1(+) and 2(GND) and
on
2(GND) and 3(ADC0)
FALSE TRUE Value >5Vdc Value <5Vdc
Problems on the Broken Pressure

Connection Transducer.Proceed
Cable.Probably With the
short circuited. Replacement
replacement (*) Replacement replacement (*)
Check the cable

33
ALARM CODE 10: MAIN CYLINDER (ROD SIDE) READING LOWER

THAN THE MINIMUM VALUE
NOTE:
Verify on the Main

1(+) and 2(GND) there is a
voltage of +15Vdc
FALSE TRUE + GND
Measure on the Main

Disconnect wires on
pc board the voltage
1(+) and 2(GND) and
on
2(GND) and 6(ADC1)


34
ALARM CODE 11 : MAIN CYLINDER (ROD SIDE) READING HIGHER

THAN THE MAXIMUM VALUE
NOTE:
Verify on the Main

Voltage of +15Vdc
FALSE TRUE + GND
Measure on the Main

Disconnect wires on
1(+) and 2(GND) and
on
2(GND) and 6(ADC1)

replacement(*) Replacement replacement (*)
Check the cable

35
ALARM CODE 18 : COMPENSATION CYLINDER (BOTTOM SIDE) READING

NOTE:
Verify on the Main

pc board that between
Voltage of +15Vdc
FALSE TRUE + GND
Measure on the Main

Disconnect wires on
1(+) and 2(GND) and
on
2(GND) and 15(ADC4)


36
ALARM CODE 19 : COMPENSATION CYLINDER (BOTTOM SIDE) READING

NOTE:
maximum zone in order to check the sensor
Verify on the Main

Voltage of +15Vdc
FALSE TRUE + GND
Measure on the Main

Disconnect wires on
1(+) and 2(GND) and
on
2(GND) and 15(ADC4)

Check the cable

37
ALARM CODE 20: MAIN CYLINDER (ROD SIDE) READING LOWER

THAN THE MINIMUM VALUE
NOTE:
The Main Unit Processor identifies below and abowe the signal range a minimum zone and a
Verify on the Main

Voltage of +15Vdc
FALSE TRUE + GND
Measure on the Main

Disconnect wires on
1(+) and 2(GND) and
on
2(GND) and 16(ADC5)

replacement (*) Replacement replacement(*)

38
ALARM CODE 21 : COMPENSATION CYLINDER (ROD SIDE) READING HIGHER

THAN THE MAXIMUM VALUE
NOTE:
Verify on the Main

Voltage of +15Vdc
FALSE TRUE + GND
Measure on the Main

Disconnect wires on
1(+) e 2(GND) and
on
2(GND) and 16(ADC5)

replacement (*) Replacement replacement(*)
Check the cable

39
EPROM and EEPROM REPLACEMENT(*)

The picture shows the EPROM storing main program Remove the EPROM and EEPROM carefully
data and Load Tables, and EEPROM storing calibration out of their sockets by means of electronic
data, which has to be removed from the old to the new components tweezers or suitable tools.
PC board.
EEPROM
EPROM
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 referring to their reference mark.
(*) NOTE:
Where replacement of the
memories is required due to
failure of Main Control Unit, this
must be done avoiding .
40
POTENTIOMETERS ALIGNMENT
Mechanical alignment of angle and extension sensors
Following the replacement of a potentiometer, even if this has been done carefully, it is recommended 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 panel monitoring on the display as shown here. 0.0 00.0 6.8 11
After that press the ENTER key a number of times until the page showing XXXX XXXX AAAA
the readings of sensors digital values is displayed. LLLL XXXX XXXX
With regard to the angle setting, it is simply necessary to check that in
horizontal (=°) positioning of the boom the reading of the sensor “AAAA” is
between 500 and 520 by rotating its body before fixing it, and that it
increases as the boom is raised.
For the extension after replacing the sensor adjust its screw to check that
reading on “LLLL” is about 50 and fix it.
Also, in case of cable replacement it is necessary to pre-tension
approximately 1 Mt. of cable-reel cable.
After the replacement of the potentiometer it is recommended to verify the correspondence of values shown on the
display into a couple of known positions of the boom.
I.E.: boom IN and boom OUT, or Boom lower position (Min Angle) and Boom Upper Position (Max Angle) .
These displayed values must correspond to the values given by the Manufacturer for this specific model of the
machine.
41
ANGLE AND EXTENSION SENSORS CALIBRATION-1st PASSWORD INTRODUCTION

To perform the self-calibration of sensors the 1st PASSWORD must be set.
The 2nd PASSWORD, which is reserved for the Manufacturer and to his Personnel authorised to modify the
programming, allows the refined calibration, selection of pre-programmed attachments tables and download of
new attachments tables.
The 1st PASSWORD code can be modified directly during calibration.
Switch machine on and wait for a few seconds until the first starting page shows up UM45_4x dd-mm-yy
on display as indicated here MRT2145
Quickly press once ENTER key.
At this point the page of 1st PASSWORD setting must show up as indicated here *
If different page appears, this means that ENTER Key has been depressed too early Code: 4477
or too late: switch system off and re-start.
Press some times the INDEX key to scroll the asterisk above the desired figure and *
modify its value by means of “+” and “-” keys. Code: XXXX
Confirm it and the following ones (PASSWORD) by ENTER.
The PASSWORD code is memorised into the EPROM together with the machine
data; its number must be known only by Authorised Personnel.
On the display the main data page is shown as indicated here. ****
If the main unit is new, it might indicates the Alarm “1”:before the machine 0.0 00.0 6.8 11
calibration allows normal procedures, but it should disappear at the first “SAVE”
function.
If other alarms occur, it is necessary to clear them before continuing.
42
ANGLE AND EXTENSION SENSORS CALIBRATION (LMI SELF-CALIBRATION)

The second operation consists in the automatic self calibration of angle and extension sensors in boom
in IN/OUT and UP/DOWN conditions.
Sensors self calibration at closed machine conditions

Position the machine with the boom totally retracted and at its lowest position A00 S 6.8 W.0
(min.angle). 12 Transd. Min
By means of “+” and “-” keys look for the page indicated here
Press ENTER and INDEX to confirm the calibration at “Machine closed” condition.
Check that the displayed angle and extension values are correct.
Afterwards, proceed to self calibration of sensors at “Open machine” condition.
Sensors self calibration at open machine conditions
Totally raise and extend the boom making sure that the two cylinders for lifting and A78 S20.3 W .0
extension are at the end of their stroke. In this condition the angle and extension 13 Transd. Max
readings should correspond to the memorised ones. By means of “+” and “-” keys
look for the page indicated here. Press ENTER and, if required INDEX to confirm
the calibration at “Machine open” condition.
Check that the values of angle and extension displayed are correct and retract the A78 S20.3 W .0
boom verifying that the angle and extension readings are correct in all their
positions. Afterwards, if everything is correct, save the self calibration. For the
“save” function see following page 43.
43
DATA DOWNLOADING ON E2PROM -“SAVE” FUNCTION

After performing the self calibration procedure its data must be saved as indicated below.
By means of “+” and “-“ keys, display page "01 Save”. OPTIONS
01 Save
Press ENTER to activate the command. Save In
A message will inform that the saving procedure is in progress. Progress !
After that, the message indicated here will be shown. DONE !
Press INDEX to go back to main working data page.
LANGUAGE/MEASUREMENT SYSTEM SELECTION AND 2nd PASSWORD INTRODUCTION

In this phase it also possible to select the message language, measurement system and to enter the
second password. Act as follows:
By means of “+” and “-” keys look for the page indicated here CONFIGURATION
32 Config.
Press ENTER to activate the command. CONFIGURATION
4 languages are available. For their selections set the proper paramenters Language 0
between 0 and 3.
At the origin the Metric System is set (Parameter = 1); to select Imperial system Eng.Unit 0
set 0.
Set the 2nd password in the place of XXXX PW2 XXXX
44
DATA DOWNLOAD FROM LAP-TOP TO LMI (*)

The following procedure is required when data memorised into the PC must be down-loaded into the LMI
memories.
Connect the cable (supplied by 3 B 6 ) to the RS232 door of the Lap-top, and its other end to the connection
inside the main control unit, fitting it at the place of the MS4 connector (see page 8).
Select prompt MSD on PC.
To start the program digit SAVE on the keyboard, and press ENTER.
The screen will show:
1 : SAVE DATA FROM TRUCK TO COMPUTER
2 : LOAD DATA FROM COMPUTER TO TRUCK
5 : PREPARE DISKETTE
6 : SHOW DATA
0 : EXIT
Scrolling on 2, the list of all the programs contained into the lap-top will show up.
I.E.:
PROGRAMS LIST
00 MRT2145.E14 18/09/2001 11:52 am
01 EM2145.E14 11/09/2001 02:59 pm
----
Select the index corresponding to the model of the required machine (00, 01, 02…) and press ENTER.
The screen will show:
Page xxx of 512
This counter will increase from 0 to 512; after which all data will be down-loaded.
Press any key to continue.
(*) The memorised data detailed here are the ones memorised at the machine start-up
original programming, and stored on a Floppy-Disk that can even be transmitted by E-mail,
by MCI directly to the PC.
45
DATA DOWNLOAD FROM LMI TO PC AND FROM PC TO FLOPPY DISK

Some other loading/down-loading functions from Lap-Top to LMI exist:
SELECTION 1 This function is needed to save data from LMI to PC.

When PC requires it, introduce the name of the File that must be saved (8 figures
maximum). After that press ENTER.
SELECTION 5 This function is needed to down-load data from PC on a Floppy-Disk.

Put a Floppy-Disk into the driver and press ENTER.
Dial the name of the File to be saved and press ENTER.
SELECTION 6 This function is needed to display the memorised file-data directly on the Lap-Top
screen, selecting the proper program.
SELECTION 0 This function is needed to exit the program .

46
SYSTEM LAY-OUT AND CONNECTIONS
OM T
1
2
1
2
1
3
3 4
5
6
6 7 Power supply and

Inputs/Outputs
5
1 Main Unit
2 Pressure Transducers (4)
3 3 Length/Angle Sensor
4 Control Panel
5 Pressure Transducer Cable
6 Control Panel Cable
7 Power Supply and In/Out’s cable
8 Length/Angle Sensor Cable
2
8
47
EXTERNAL WIRING
MAIN CONTROL UNIT BOARD
See also : page 8 MAIN CONTROL UNIT page 9 BOOM ANGLE LENGTH SENSOR
page 13 PRESSURE TRANSDUCERS page 15 CONTROL PANEL
48
RECOMMENDED SPARE PARTS LIST
MAIN COMPONENTS
DESCRIPTION CODE
MAIN UNIT UMMST01-2/xx

CONTROL PANEL IDR1-3/xx
BOOM LENGTH/ANGLE SENSOR CIT-1PICW1/xx
PRESSURE TRANSDUCER Y1 4740-350
CONNECTING CABLE MAIN UNIT/CONTROL PANEL CV2 IDR1-3/xx
CONNECTING CABLE MAIN UNIT /BOOM LENGTH ANGLE CV1MMST1-1/xx
CONNECTING CABLE MAIN UNIT/PRESSURE TRANSDUCER CV2MMST1-1/xx
CABLE IN-OUT MAIN UNIT CV ARM7G1-7M
INTERNAL PARTS
DESCRIPTION CODE
ELECTRONIC BOARD FOR MAIN UNIT S U2MIC-5/xx

ELECTRONIC BOARD FOR CONTROL PANEL S IDR1/xx
ELECTRONIC BOARD FOR BOOM LENGTH/ANGLE SENSOR S CIT1PI/xx
ANGLE POTENTIOMETER Y11 PL310/1K
LENGTH POTENTIOMETER PT 534-2K
DRUM CABLE (17mt) CV 510.726
CABLE REEL MECHANISM WITHOUT INTERNAL
BOARD AND SENSORS GR CITMEC/xx

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3B6 LOAD MOMENT INDICATOR (LMI)

FOR MRT TELESCOPIC HANDLERS

3 4 5 5 5 4,5 4 3,2 3 2,8 2,8 2,4

DESCRIPTION LMI COMPONENTS POSITIONING ON THE MACHINE 5

ACTION EPROM and EEPROM REPLACEMENT 39

ACCESS PROCEDURES TO µMACXxx

2° LEVEL: (1st PASSWORD) SENSORS REPLACEMENTS :

LMI COMPONENTS POSITIONING ON THE MACHINE

SYSTEM LAY-OUT AND CONNECTIONS at page 46

MAIN CONTROL UNIT CODE: UMMST01-2/XX

UMMST01-2 Main Control Unit is equipped with

MAIN CONTROL UNIT NOTE:

EPROM : LOAD TABLES EEPROM: DO0 D68 25 SHUT-DOWN

BOOM LENGTH AND ANGLE SENSOR CODE : CIT-1PICW1/xx

The boom and angle sensor is formed by a cable

BOOM LENGTH AND ANGLE SENSOR

OVERALL DIMENSION WIRING DIAGRAM

BOOM LENGTH AND ANGLE SENSOR

PRESSURE TRANSDUCER CODE : Y11 4740-350

CONTROL PANEL CODE : IDR1-3/xx

Operating Mode Identification Symbols ( External automatic selections)

Equipment Identification symbols (Manually selected from the control panel)

Green/Amber/Red Lights showing working conditions( Safety/ Alarm/Shut

Two rows alpha-numeric LCD display

Symbols and letters related 4 Set-up keys Icon representing the

CONTROL PANEL : DIMENSIONS, CHARACTERISTICS, CABLE

CONNECTING CABLE TO MAIN CONTROL UNIT

1 Pin plugs 4 6 pins male connector

Alarm codes are listed in the following pages.

ALARM CODES AND ACTIONS TO TAKE

32 Angle fault Check related inputs

33 Check related inputs

• Check for short-circuit in the wiring or in wiring connector plugs

• Check for short-circuit in the wiring or in wiring connector plugs

• Check for short-circuit in the wiring or in wiring connector plugs

• Check for short-circuit in the wiring or in wiring connector plugs

AUTO DIAGNOSTIC- System internal working conditions monitoring

P100 W 5.0 M 5.0

AUTO DIAGNOSTIC- System internal working conditions monitoring

AUTO DIAGNOSTIC- System internal working conditions monitoring

1111 2222 3333

AUTO DIAGNOSTIC - System internal working conditions monitoring

AUTO DIAGNOSTIC - System internal working conditions monitoring

See also Page 8 : LED’S ON MAIN BOARD

ALARM CODE 1 : MEMORY DATA NOT RELIABLE

ACTION TO TAKE: EEPROM

ALARM CODE 2 : ANGLE TRANSDUCER READING

ALARM CODE 3 : ANGLE TRANSDUCER READING

ALARM CODE 4 : BOOM LENGTH TRANSDUCER READING

ALARM CODE 5 : BOOM LENGTH TRANSDUCER READING

CABLE REEL POWER SUPPLY VERIFYING

Verify 5Volts between

Verify the Verify on the Main PC board

ANGLE POTENTIOMETER VERIFYING

Verify with a voltmeter that the

BOOM LENGTH POTENTIOMETER VERIFYING

Boom Length Boom Length

Verify with a voltmeter that the