3B6 Mtech Service Manual

Revisione 23/01/2002Complies to the MACHINES DIRECTIVE Standards: EN60204-1, EN954, EN12077-2EMC according to the Heavy Industrial Environment category: EN50081-2, EN50082-2

3B6 LMI

Service Manual

for FRANNA Cranes

INDEXINDEX

2

PAGEACCESS PROCEDURES 3

DESCRIPTION

COMPONENTS LOCATION ON THE MACHINE 4MAIN UNIT AND CONTROL PANEL CODE: U2MIC-2/41 5GENERAL CHARACTERISTICS 6MAIN CONTROL UNIT CONNECTIONS AND SIGNALS 7AC MCP ANGLE/EXTENSION SENSORS CODE : AC MCP236A/2P 8EXTENSION SENSOR CODE : CIT-1PACW/10 9-10-11PRESSURE TRANSDUCERS CODE : Y11 4745-350 12CONTROL PANEL DESCRIPTION 13

DETECTION

TROUBLESHOOTING 14ALARM CODES AND ACTIONS TO TAKE 15-16-17ALARM CODE 1 : MEMORY DATA NOT RELIABLE 18ALARM CODE 2 : ANGLE READING < MINIMUM VALUE 19ALARM CODE 3 : ANGLE READING > MAXIMUM VALUE 19CABLE REEL POWER SUPPLY VERIFYING 20ANGLE POTENTIOMETER VERIFYING 21ALARM CODE 6 : EXTENSION READING < MINIMUM VALUE 22ALARM CODE 7 : EXTENSION READING > MAXIMUM VALUE 22CABLE REEL POWER SUPPLY VERIFYING 23BOOM LENGTH POTENTIOMETER VERIFYING 24ALARM CODE 8 : MAIN CYLINDER (BOTTOM SIDE ) < MINIMUM VALUE 25ALARM CODE 9 : MAIN CYLINDER (BOTTOM SIDE ) > MAXIMUM VALUE 26ALARM CODE 10 : MAIN CYLINDER (ROD SIDE ) < MINIMUM VALUE 27ALARM CODE 11 : MAIN CYLINDER (ROD SIDE ) > MAXIMUM VALUE 28ALARM CODE 14 : EXTENSION READING < MINIMUM VALUE 29ALARM CODE 15 : EXTENSION READING > MAXIMUM VALUE 29CABLE REEL POWER SUPPLY VERIFYING 30BOOM LENGTH POTENTIOMETER VERIFYING 31

ACTION

EPROM and EEPROM REPLACEMENT 32POTENTIOMETERS ALIGNMENT 33SYSTEM LAY-OUT AND CONNECTIONS 34EXTERNAL WIRING 35RECOMMENDED SPARE PARTS LIST 36

3This systems has been conceived and developed to offer two different levels of functionalityof access to internal data, according to the actions to be done.The basic access level (Operator) does not required any password; this one, in fact, isrequired for possible interventions, exclusively by Technical Service Personnel (failuredetecting and repairing).

1 LEVEL:OPERATOR:Without needing PASSWORD (also see OPERATOR MANUAL) all working information ofthe machine are available through several monitoring given by the display panel; startingfrom basic working data: lifted load, max admitted load, outreach, working conditions, tiltingpercentage;Just pressing the GREEN button key, it is possible to show machine working data in agraphic way.The aim to give to the Operator the possibility of entering these readings, allowing tocommunicate them to the Technical Assistance Department, giving relevant data, possiblyavoiding a direct Service on site.The Operator can also find some information to solve easy troubles in his OPERATORMANUAL

2 LEVEL: (PASSWORD) SENSORS REPLACEMENTS :TECHNICAL ASSISTANCE DEPT. AND AUTHORIZED DEALERSThe second level corresponds to the information contained in this TROUBLE SHOOTINGMANUAL, where all details referred to system components are included (Main Unit,Transducers, Display Panel), troubleshooting codes introduction, and the useful informationto remove the problems without specific tools (except a voltmeter).As far as Pressure Transducers are concerned, please note that they do not need anycalibration, as they are totally interchangeable.

FINE CALIBRATION.This means the complete machine calibration, that is done at the first start-up of themachine.To this aim a PASSWORD is given, allowing to enter into the functions of the program, asthe fine calibration of geometrical data and lifted load, and to perform their on-sitecalibration. These calibrations need the use of a PC.

ACCESS PROCEDURESACCESS PROCEDURESLOAD MONITORING SYSTEM (LMI)LOAD MONITORING SYSTEM (LMI)

4COMPONENTS LOCATION ON THE MACHINECOMPONENTS LOCATION ON THE MACHINE

Control Panel :into the cabin

SYSTEM LAY-OUT AND CONNECTIONS at page 34-35

5MAIN CONTROL UNITMAIN CONTROL UNITCODE: U2MIC-2/XXCODE: U2MIC-2/XX

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

and program storage not erasable EPROM type or erasable

EEPROM type for calibration parameters storage.

INPUT/OUTPUT circuits are self-protected against overloads and

short circuits.

Power supply internal circuits are designed to operate at low voltage

and are provided with all protection for hard environment.

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

components.

6GENERAL CHARACTERISTICS o POWER SUPPLY

From vehicle battery :10-28 V Current consumption, without loads : ~0,35A

o INPUT / OUTPUT 14 Digital Inputs 14+1 Digital Outputs 6 (+2) Analog Inputs Watch Dog Dynamic Output Voltage working range : 10-28 VCC Output Current : 2A Analogue Inputs Voltage : 0- 5V Serial Links RS232, CAN BUS Clock and Buffer Battery Epoxy Resin Coating 32 Kb E2prom for Data Recording

MECHANICAL CHARACTERISTICS o MECHANICAL DIMENSIONS

Case Dimension : 260 x 160 x 91 mm Fixing holes : 240 x110 mm

o VIBRATIONS Continuous : 5gs from 20 to 400Hz Over 3 AXIS Shock : 10gs

o ENVIROMENTAL Salt spray resistance over 48 Hours

o TEMPERATURE Working range :-30 -+70C Storage range :-45 - +85C

7"MV 231-346"MORS. 16C. C.S.

CV a FILO 1,5mmq.

"MV

231

-346

"M

OR

S. 1

6C. C

.S.

"MV 231-346"

MORS. 16C. C.S.

MAIN CONTROL UNITMAIN CONTROL UNIT : : CONNECTIONS and SIGNALSCONNECTIONS and SIGNALS

D35, D39, D43, D47, D51, D55, D59, D63 = RED LEDsThey show the INPUT status

ON = ACTIVE INPUT

D68, D71, D74, D77, D80, D83, D86, D89, D101 = RED LEDsThey show the OUTPUT status ON = ACTIVE OUTPUT

D2 = RED LEDWhen lit meansthat +15V Voltageis active

D1 = RED LEDWhen lit meansthat +5V Voltageis active

Note :D1 et D2 always have to belit when the system is ON

NOTE:CODE DIODE PIN FUNCTION DI0 D35 17 Articulation signal (On when +/- 10 deg) DI1 D39 18 Anti two block (On when not 2blocked) DI2 D43 19 Engine Oil Pressure (On when OK) DI3 D47 20 Engine Water Temp (On when OK) DI4 D51 21 Crane/Travel Mode (On in crane mode) DI5 D55 22 Water Level (On when level low) DI6 D59 23 Ignition key signal (On when key on) DI7 D63 24 Optional Seat Switch (Off= empty seat)

EEPROM:CALIBRATION DATA,BLACK BOX

EEPROM:PROGRAM ANDLOAD TABLES

NOTE:CODE DIODE PIN FUNCTIONDO0 D68 25 Not usedDO1 D71 26 Not usedDO2 D74 27 Not usedDO3 D77 28 Not usedDO4 D80 29 Alarm BuzzerDO5 D83 30 Stop FunctionDO6 D86 31 Not usedDO7 D89 32 Not used

8AC MCP cable reel is used where the A2Bfunction is required (i.e.: MAC25).The length transducer (or transducers) isformed by drum cable servo-winders on whicha cable is wound that is attached to the boomhead (or to intermediate elements).When the boom is telescoped, the wireunwinds measuring the boom length through apotentiometer sensing device.During crane operations, it is alwaysnecessary to carefully check the cableunwinding along the boom, as it can besubjected to accidental break if collided.The replacement of this element is to be doneby qualified personnel only.

The angle transducer (inside to cable reel) detects the absolute angle of the crane boomthrough an accelerometer sensing device.The signal is used by the limiter to compute the geometry.The replacement of this element is delicate and for this reason it must be done by qualifiedpersonnel.

180

Mmm

11

Fmm

495

Gmm

0

Hmm

AC MCP214I/3P

MODEL

420460603231003,8320003x0,22shields.

3

Emm

Dmm

Cmm

Bmm

Amm

Diam

mmLength

mmType

SlipRings

AC MCP ANGLE / EXTENSION SENSORAC MCP ANGLE / EXTENSION SENSOR Code : AC Code : AC MCP236A/2PMCP236A/2P

9EXTENSION SENSOREXTENSION SENSORCODE : CIT-CODE : CIT-1PACW/101PACW/10

The boom and angle sensor is formed by a cable reel having a pulleyon which a cable is wound; the other side is attached to the boom head(or to the first telescopic element in case of proportional extension).Extending the boom, the cable unwinds (max. 12 mt.) measuring theextension length signal through 10-turns servo potentiometer.While using the machine, it is always necessary to carefully check thelength cable along the boom, because it can be subject to accidentalbreak if collided.The replacement of this element has to be done by Qualified Personnelonly.The angle sensor (inside the cable reel) detects the absolute angle ofthe boom referred to the vertical gravity reference through anaccelerometer sensing device.Analogue signals from above potentiometers are used by the LMI tocompute the boom geometric data.

10

OVERALL DIMENSION

WIRING DIAGRAM

8-1

6

6-1

2

7-2

77-1

8

12

1

4

109

5

5-1

113

7 Angle accelerometer7-1 Not Used7-2 Not Used8 Pulley8-1 Cap9 Strain relief10 Breather11 Spring12 Cable

DESCRIPTION

11

1 Case2 Base 3 Circuit board4 Step5 Pinion5-1 Shaft 6 Clutch6-1 10-turns Potentiometer

EXTENSION SENSOR EXTENSION SENSOR EXPLODED VIEW

12

Pressure transducers detect the pressureinto boom lifting cylinders; typically 2sensors are required for measuring thedifferential pressure on lifting cylinders :they must be installed on the two cylinderchambers.By these values, weight computing is taken.These sensing devices detect the pressureby means of a sensor, which transforms themeasured pressure into a direct voltageproportional to the pressure itself.An on-board amplifier is included in thetransducer itself.Any possible replacement of these elementsis very easy because of their completecompatibility.

PRESSURE TRANSDUCERS CODE : Y11 4745-350PRESSURE TRANSDUCERS CODE : Y11 4745-350

TECHNICAL SPECIFICATIONS

PIN CONNECTIONSPIN 3 Wires1 +VB2 output signal 0,5 .. 5,5 V3 GND

INPUT DATA Measuring ranges 350 bar Overload ranges 800 bar Max pressures 2000 bar Parts in contact with oil Stainless steel ; Viton seal

OUTPUT DATA Output Signal 0,5 ... 5,5V Temperature compensation Max 0,15%/10K Typ.0,08%/10K Accuracy Max 0,3%FS Typ.0,1%FS Hysteresis Max 0,1%FS Typ.0,05%FS Repeatability 0,05%FS

ENVIRONMENTAL CONDITIONS Nominal temperature range -25 ...+85C Operating temperature range -40 ...+85C Storage temperature range -40 ... +100C Fluid temperature range -40 ... +100C Protection class IP65

OTHER DATA Supply voltage 12 ...30V Current consumption ca.15mA Life expectancy 106 load cycle Weight 145g.

13

CONTROL PANEL DESCRIPTIONCONTROL PANEL DESCRIPTION

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

4) JIB OFFSET ANGLE Displaying Degrees, with a decimal point.

5) TIP HEIGHT FROM GROUND Displaying Meters, with a decimal point.

6) BOOM LENGTH Displaying Meters, with a decimal point.7) WORKING RADIUS Displaying Metres, with a decimal point8) MAIN BOOM ANGLE Displaying Degrees, with a decimal point.

9) PARTS OF LINE Manually selectable with F1 & F2 buttons.10) OPERATING MODE Corresponds to the Duty of the load charts table.

11) REAR AXLE LOAD Weight on the rear axle (Refer Notes)

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

1 2 3 4

5 6 7 8

9 10

14

The first step to seek a fault is to identify the problem that has occurred, andto advise the crane Operator.

The auto-diagnostic procedures are able to identify transducers failures,cable breakages and internal electronic faults; alarm codes are automaticallyshown on the display to the Operator, providing him with a certain ability tolocate the fault, and also to better inform the Technical Assistance even froma remote location.

When an alarm occurs, the LMI puts itself in a safe condition (shut down)blocking the dangerous movements and, at the same time, the display showsthe alarm corresponding message on the display lower row.

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

Alarm codes are listed in the following pages.The list also includes some hints able to solve the problems and get back tonormal working conditions.

TROUBLESHOOTINGTROUBLESHOOTING

15

Not Used4

Not Used5

Verify that the cable or the connector wiring is notopenIf the alarm persists, please, contact TechnicalAssistance : Verify the length transducer integrity

Reading of theboom lengthsensor 1 higherthan the maximumvalue

7Page

22, 23,24, 32

Verify that the wiring and the connectors are not inshort circuitIf the alarm persists, please, contact TechnicalAssistance:Verify the length transducer integrity

Reading of theboom lengthsensor 1 lower thanthe minimum value

6Page

22, 23,24, 32

Verify that the cable or the connector wiring is notopenIf the alarm persists, please, contact TechnicalAssistance : Verify the angle sensor integrity.

Angle sensorreading higher thanthe maximum value

3Page

19, 20,21, 32

Verify that the wiring and the connectors are not inshort circuit.If the alarm persists, please, contact TechnicalAssistance : Verify the angle sensor integrity.

Angle sensorreading lower thanthe minimum value

2Page

19, 20,21,32

Switch the system off and on.If the alarm persists, please, contact TechnicalAssistance to:Verify that E2prom chip is fitted properly in its socket. Re-enter data and save them again Replace the E2PROM chip and recalibrate themachine

Memory data notreliable

1Page18,32

What to doDescriptionAlarmcode

ALARM CODES AND ACTIONS TO TAKEALARM CODES AND ACTIONS TO TAKE

16

Not used12

Not Used13

Verify that the cable or the connectors wiring arenot in short circuitIf the alarm persists, please, contact TechnicalAssistance : Verify the pressure transducer integrity

Reading pressure ofthe main cylinder(bottom side) lowerthan the minimum.

8Page

25

Verify that the cable or the connector wiring arenot openIf the alarm persists, please, contact TechnicalAssistance :Verify the pressure transducer integrity

Reading pressure ofthe main cylinder(bottom side) higherthan the maximum.

9Page

26

Verify that the cable or the connector wiring is notopenIf the alarm persists, please, contact TechnicalAssistance : Verify the length transducer integrity

Reading of the boomlength sensor totalhigher than themaximum value

15Page

29, 30,31

Verify that the wiring and the connectors are not inshort circuitIf the alarm persists, please, contact TechnicalAssistance:Verify the length transducer integrity

Reading of the boomlength sensor totallower than theminimum value

14Page

29, 30,31

Verify that the cable or the connector wiring arenot openIf the alarm persists, please, contact TechnicalAssistance :Verify the pressure transducer integrity

Reading pressure ofthe main cylinder (rodside) higher than themaximum.

11Page

28

Verify that the wiring and the connectors are not inshort circuitIf the alarm persists, please, contact TechnicalAssistance :Verify the pressure transducer integrity

Reading pressure ofthe main cylinder (rodside) lower than theminimum.

10Page

27


17

Apply parking brake prior to opening door orturning the ignition key off.Reset with F9.

Parking Brake Not Set35

Engine will stop ten seconds after vacating seat,engine will not start if driver not seated.Reset with F9.

Driver Not Seated34

Stop engine and check cooling system whensafe to do so, reset with F9.Low Water Level33

Stop the crane as soon as safely possible andshift to N (Neutral). Accelerate the engine to1200 rpm and allow the temperature to return tonormal(2 or 3 minutes),reset with F9 and resumeoperation.

High Transmission OilTemperature

32

Stop engine and determine cause, reset with F9High Water Temp.31

Stop engine and check oil level, reset with F9Low Engine Oil Press.30

Not used12

Not Used13

Please, select the operating mode in use andconfirm it.

Table charts notavailable..The operating conditionselection is missing

18

Engine Monitoring System (reset alarms withF9)

Optional


18

EEPROM

ALARM CODE 1 : MEMORY DATA NOT RELIABLE

CAUSE:All the calibration data are stored in four EEPROM 24C65.Through the Check-sum equation, software checks continuously the result to theoriginal memorised value. When detecting a difference, the display will show thefollowing message : ALARM 1 = memory data not reliable.

ACTION TO TAKE:

1) Switch the system off and on.

2) Verify that the EEPROM chip is fitted properly in its socket.3) Re-enter data and save again, switch off and on again.

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

software/parameters installed are corresponding to the

machine characteristics.

19

ALARM CODE 2 :ANGLE TRANSDUCER READING

LOWER THAN THE MINIMUM VALUE(*)CAUSE:The signal from the angle transducer to the main PC board is lower than theminimum programmed value.This can be produced by a short-circuit in the electrical wiring, between theMain Unit and Sensor or the sensor itself is in interdiction.

ACTION TO TAKE: Verify the wiring

Verify cable reel PC board proper power supply

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

Verify angle potentiometer

(refer to ANGLE POTENTIOMETER VERIFYING section page 21).

ALARM CODE 3:ANGLE TRANSDUCER READING

HIGHER THAN THE MAXIMUM VALUE (*)CAUSE:The signal from the angle transducer to the main PC board is higher than themaximum programmed value.This can be produced by a break in the electrical wiring, between the MainUnit and Sensor or the sensor itself is in saturation.

ACTION TO TAKE: Verify the wiring

Verify cable reel PC board proper power supply (refer to CABLE REEL POWER SUPPLY VERIFYING section page 20). Verify angle potentiometer (refer to ANGLE POTENTIOMETER VERIFYING section page 21).

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

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

20

1 (+)

3 (GND)

+ GND

CABLE REEL POWER SUPPLY VERIFYINGCABLE REEL POWER SUPPLY VERIFYING

FALSETRUE

FALSETRUE

Verify 5Volts between1(+) and 3(GND)

on cable reel board

FALSETRUE

Verify the Potentiometers

(**)

Cable break down.Check the

cable-reel cable

Probably the cable is in short circuit.

Check cable

Main pc board Is faulty.

Replace it with a new one (*)

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

Verify on the Main PC board5Volts between

10(+) and 11(GND)

Disconnect wires 10 and 11 from theMain pc board and

Check for 5Vdc

21

2 (CA2) 3 (GND)

CA2 GND

The Main pc board is faulty.Proceed with the replacement

(*)

The signal is not correct

Problems on the Connection Cable. Probably short circuited.

Check the cable

The signalis correct

ANGLE POTENTIOMETER VERIFYINGANGLE POTENTIOMETER VERIFYING

Put the machine boom at 0 (horizontal).

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

Is +2,5Vdc +/- 5%

Angle potentiometer broken (**) Raise the boom slowly.

TRUE

Loss of Signal The variation is continuous and linear

FALSE

Verify with a voltmeter that thesignal increases in a linear

and continuous way.

Angle potentiometerbroken (**)

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

Verify on the Main pc boardthe potentiometer signal on

9(CA2) and 11(GND)

22

ALARM CODE 6 :BOOM LENGTH TRANSDUCER READINGLOWER THAN THE MINIMUM VALUE(*)

CAUSE:The signal from the boom length transducer to the main PC board is lowerthan the minimum programmed value.This can be produced by a short-circuit in the electrical wiring, between theMain Unit and Sensor or the sensor itself is in interdiction.

ACTION TO TAKE:

Verify the cabling. Verify cable reel PC board proper power supply (refer to CABLE REEL POWER SUPPLY VERIFYING section page 23). Verify length potentiometer (refer to EXTENSION POTENTIOMETER VERIFYING section - page 24).

ALARM CODE 7 :BOOM LENGTH TRANSDUCER READINGHIGHER THAN THE MAXIMUM VALUE (*)

CAUSE:

The signal from the boom length transducer to the main PC board is higherthan the maximum programmed value.This can be produced by a short-circuit in the electrical wiring, between theMain Unit and Sensor or the sensor itself is in saturation..

ACTION TO TAKE: Verify the cabling. Verify cable reel PC board proper power supply (refer to CABLE REEL POWER SUPPLY VERIFYING section page 23). Verify length potentiometer (refer to EXTENSION POTENTIOMETER VERIFYING section - page 24).

(*) NOTE: Main Unit Processor identifies below and over the signal range aminimum zone and a maximum zone in order to check the sensor.

+ GND

23


on cable reel board

FALSETRUE


(**)


7(+) and 8(GND)


cable-reel cable

Disconnect wires 7 and 8 from the

Main pc board and Check for 5Vdc

TRUE

FALSETRUE

FALSE


Check cable

Main pc board Is faulty.


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

VERIFYING CABLEVERIFYING CABLE REEL POWER REEL POWER SUPPLYSUPPLY

GND CA3

24

VERIFYING BOOMVERIFYING BOOM LENGTH LENGTH POTENTIOMETERPOTENTIOMETER

The boom must be completely retracted.

Voltage higher or at 5V

Boom Length potentiometer broken

(**)

Verify voltage between 2(GND ) and 5 (+ )

of app. +250mV

Boom Length Potentiometer broken

(**)

Extend the Boom.

TRUE


Verify on the Main pc boardthe potentiometer signal on

8(GND) e 12(CA3)

The Main pc board is faulty.Proceed with the replacement

(*)

FALSE


and continuous way.


Problems on the Connection Cable.Probably short circuited.

Check the cable

The signal is correct


(**)


25

TRUEFALSE FALSE

Value 0,5Vdc

+ GND GND CA0

ALARM CODE 8 :MAIN CYLINDER (PISTON SIDE) READING

LOWER THAN THE MINIMUM VALUENOTE:Main Unit Processor identifies below and over the signal range a minimum zone and amaximum zone in order to check the sensor.

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

is +15Vdc

TRUE

Measure the voltage between2(GND) and 3(CA0)

on the Main PC board

The Main PC board is faulty. Proceed

with the replacement(*)

Problems on the Connection

Cable. Probably short circuited.

Check the cable

Broken Pressure Transducer. Proceed

With the Replacement

FALSE

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

Verify a voltage of +15Vdc





Check the cable



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

26

+ GND GND CA0

ALARM CODE 9 :MAIN CYLINDER (PISTON SIDE) READING

HIGHER THAN THE MAXIMUM VALUENOTE:Main Unit Processor identifies below and over the signal range a minimum zone and amaximum zone in order to check the sensor.


is +15Vdc

TRUE



Value >5Vdc Value

27

+ GND GND CA1

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

THAN THE MINIMUM VALUENOTE:Main Unit Processor identifies below and over the signal range a minimum zone and amaximum zone in order to check the sensor.

TRUEFALSE FALSE

Value 0,5Vdc


is +15Vdc

TRUE







Check the cable



FALSE

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

Verify a voltage of +15Vdc





Check the cable



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

28

+ GND GND CA1

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

THAN THE MAXIMUM VALUENOTE:Main Unit Processor identifies below and over the signal range a minimum zone and amaximum zone in order to check the sensor.


is +15Vdc

TRUE



Value >5Vdc Value

29

ALARM CODE 14 :BOOM LENGTH TRANSDUCER READINGLOWER THAN THE MINIMUM VALUE(*)

CAUSE:The signal from the boom length transducer to the main PC board is lowerthan the minimum programmed value.This can be produced by a short-circuit in the electrical wiring, between theMain Unit and Sensor or the sensor itself is in interdiction.

ACTION TO TAKE:

Verify the cabling. Verify cable reel PC board proper power supply (refer to CABLE REEL POWER SUPPLY VERIFYING section page 30). Verify length potentiometer (refer to EXTENSION POTENTIOMETER VERIFYING section - page 31).

ALARM CODE 15 :BOOM LENGTH TRANSDUCER READINGHIGHER THAN THE MAXIMUM VALUE (*)

CAUSE:

The signal from the boom length transducer to the main PC board is higherthan the maximum programmed value.This can be produced by a short-circuit in the electrical wiring, between theMain Unit and Sensor or the sensor itself is in saturation..

ACTION TO TAKE: Verify the wiring. Verify cable reel PC board proper power supply (refer to CABLE REEL POWER SUPPLY VERIFYING section page 30). Verify length potentiometer (refer to EXTENSION POTENTIOMETER VERIFYING section - page 31).

(*) NOTE: Main Unit Processor identifies below and over the signal range aminimum zone and a maximum zone in order to check the sensor.

30

1 (+)

3 (GND)

+ GND

CABLE REEL POWER SUPPLY VERIFYINGCABLE REEL POWER SUPPLY VERIFYING

FALSETRUE

FALSETRUE


on cable reel board

FALSETRUE


(**)


cable-reel cable


Check cable

Main PC board Is faulty.


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


10(+) and 11(GND)

Disconnect wires 10 and 11 from theMain PC board and

Check for 5Vdc

31

2 (CA3)3 (GND)

GND CA4

BOOM LENGTH POTENTIOMETER VERIFYINGBOOM LENGTH POTENTIOMETER VERIFYINGRetract the boom completely.

Voltage higher or at 5V


(**)

Verify between 3(GND ) e 5 (CA3 )

a voltage of roughly +250mV

Boom Length Potentiometer broken

(**)

Extend the Boom.

TRUE


The Main PC board is faulty.Proceed with the replacement

(*)

FALSE


and continuous way.


Problems on the Connection Cable. Probably short circuited.

Check the cable

The signal is correct


(**)


Verify on the Main PC boardthe potentiometer signal on

11(GND) e 15(CA4)

32

EEPROM

EPROM

EPROM and EEPROM REPLACEMENT(*)EPROM and EEPROM REPLACEMENT(*)

The picture shows the EPROM storing main program data and Load Tables,and EEPROM storing calibration data, that have to be removed from old tothe new PC board.

Remove the EPROM and EEPROM carefully out of their sockets by meansof electronic components tweezers or adequate tools.

Insert the EPROM and EEPROM in their sockets on the new PC Board inthe correct way, taking care not to damage their pins, and looking to theirreference mark.

(*) REMARK: Replacementof memories is required incase of failure of MainControl Unit that must bereplaced, avoiding anyre-programming andre-calibration of the system .

33

After the replacement of the potentiometer, it is advisable to verify the comparisonbetween the values shown on the display to a couple of known boom position.I.E: Boom completely closed / Boom extended and 0 / maximum angle

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

Referring to the angle, simply check that, with the boom in horizontal position ( o ) theangles reading on the display ( zone 1-5 ) is 0 acting on the potentiometers body.Before fitting the potentiometer, make sure that, the value will increase by lifting the boom.After the length potentiometer has been replaced, its necessary proceed with its alignment.With the machines boom completely retracted,rotate the potentiometers body until thelength indication on the display (zone 1-6) will be the same at the minimum length value( please,refer to the load charts table ).In case of cable reel wire replacement, refer to applicable procedure.

POTENTIOMETERS ALIGNMENTPOTENTIOMETERS ALIGNMENT

Mechanical alignment of angle and extension sensorsFollowing the replacement of a potentiometer, even if this has been done carefully, it issuggested to check its alignment.The following procedure, if properly done, allows the total restoring of the machinebehaviour without any calibration operation.

Switch on the machine without load and wait for a few seconds for the main working datapage to be shown.Select the operating mode used as described into the User Manual.

34

SYSTEM LAY-OUT AND CONNECTIONSSYSTEM LAY-OUT AND CONNECTIONS

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

CENTRAL UNIT: U2MIC-2/41

PRESSURE TRANSDUCERS

INPUT OUTPUT SIGNALSAND EXTERNAL SUPPLY

(Y11 4745-350)

A

B

J1 PG1 PG2 PG3 PG4 PG5 PG6

ANGLE/LENGTH SENSOR

CONTROL PANELCMC100/10

CV ATG12/21

CIT- 1PI/13(USED IN CASE OF BOOM INDIPENDENT SECTIONS)

CV 6X0.35+SCH

F.C.

AC MCP214I/2A

LENGTH SENSOR

SHLD

SHLD

+15V

AGND CA0 +15V AGND CA1 +5V

AGND CA2 +5V AGND CA3 +5V AGND CA4 CA5

MS1BROWNWHITEGREEN

BROWNWHITE

GREENBROWN

WHITE

PINK

SHIELD

12

33

21

SHIELD

BROWNGREENWHITE

12

+

PINK

WHITEBROWN

SHIELD

1615

1213

109

117

56

42

38

114

43

65

-A

1S

2A

2S

1

+VB

OUT6

31

INP1

18

INP0

17

OUT5

OUT2OUT3OUT4

INP6

INP7OUT0

INP3INP4INP5

OUT1

INP2

2120

1923

2224

2826

2527

2930

OUT7

32

-VB

3533

3436

-VB+VBWDO

-+

GR

EY

12

CA

2

+5V

WH

ITE

AG

ND

SH

LD

68 7 5 4 3 2

BR

OW

N

PINK

BLUERED

BROWNWHITEGREY

+5V

A2B

3 1

SCH

SCH MS2

MS3

TX2

43

RX2+VOUT

TX1RX1

+VOUT

GND

3740

3839

4142

+15V

+5VD-D+GND

GND

CA7CA6-15V

5047

4544

4648

4951

52

53689 7 5 4 712 98 4

PENDULUM BOARD

6

RE

DP

INK

BLU

E

YELLOW

GREEN

EXT.ALL

+V

TX1

RX1

GND

+VOUT

GREY

WHITE

BROWN A B

SH

LD

YELLOW

GREEN

PINK EC

DF

BROWNPINK

GR

EE

N

YE

LLOW

GREYYELLOWWHITE

GR

EE

N

MS4

BROWN

WHITEGREEN

CIT- 1PI/13(USED IN CASE OF BOOM

LENGTH SENSOR

PRESSURE TRANSDUCERS(Y11 4745-350)

ANGLE/LENGTH SENSORAC MCP214I/2A

CM

C100/10

CO

NT

RO

L PA

NE

L

INDIPENDENT SECTIONS)

35

EXTERNAL EXTERNAL WIRINGWIRINGRefer to applicable schematicsRefer to applicable schematics

36

RECOMMENDED SPARE PARTS LISTRECOMMENDED SPARE PARTS LIST

MAIN COMPONENTS DESCRIPTION CODE MAIN UNIT U2MIC-2/41CONTROL PANEL (in dash) HTD65-01I2/11CONTROL PANEL (out of dash) HTD65-01O2/11

LENGTH/ANGLE SENSOR (MAC25) AC MCP236A/2PLENGTH/ANGLE SENSOR (AT15/20 & UC15) CIT-1PACW/10PRESSURE TRANSDUCERS Y11 4745-350

CONNECTING CABLE MAIN UNIT/CONTROL PANEL CV ATG12/21CONNECTING CABLE MAIN UNIT/CONTROL PANEL P/SUPPLY CV ATG77-1/10GENERAL WIRING CV 4x0,5+SCH

INTERNAL PARTS DESCRIPTION CODE MAIN BOARD WITH BLACK BOX S U2MIC-6/42ELECTRONIC BOARD FOR BOOM LENGTH/ANGLE SENSOR S CIT1PACW/10ANGLE ACCELEROMETER ASA*23/180/10

LENGTH POTENTIOMETER PT 534-2KLENGTHCABLE (18.5mt)(MAC25) CV C0102/18.5LENGTHCABLE (8.5mt)(AT15/20, UC15) CV CIT-8.5

CABLE REEL MECHANICS WITHOUT INTERNAL BOARD AND SENSORS GR CITMEC/10

3B6 Mtech Service Manual

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Transcript of 3B6 Mtech Service Manual