Troublesshooting manual 3b6.pdf

Complies to the MACHINES DIRECTIVE Standards: EN60204 – 1 , EN954 , EN12077 - 2EMC according to the “ Heavy Industrial Environment” category: EN50081 - 2 , EN50082 - 2

TROUBLESHOOTING TROUBLESHOOTING MANUALMANUAL

3B6 LOAD MOMENT INDICATOR (LMI)3B6 LOAD MOMENT INDICATOR (LMI)FOR FOR MRTMRT TELESCOPIC HANDLERSTELESCOPIC HANDLERS

Su stabilizzatori 360°

0 1 2 3 4 5 6 7 8 9 10 11 290 0 5,7 6,7 7,9 9,1 10,3 11,5 12,8 14 15,2 16,61 1000 110 100 100 100 100 100 100 100 100 1002 10013 4 5 5 5 4,5 4 3,2 3 2,8 2,8 2,44 4,5 5 5 5 4,5 4 3,2 3 2,8 2,8 2,45 5 4,5 4,5 4,5 4,5 4 3,2 3 2,8 2,8 2,46 5,5 4,2 4,2 4,2 4,2 3,7 3 3 2,8 2,8 2,47 6 4 4 4 4 3,5 3 2,8 2,8 2,65 2,38 6,5 4 4 4 3,2 2,8 2,8 2,55 2,5 2,39 7 3,2 3,2 3,2 3 2,8 2,4 2,4 2,3 2,210 7,5 3 3 3 2,8 2,4 2,2 2,2 2,15 2,111 8 2,8 2,8 2,8 2,8 2,2 2,2 2,1 2,05 1,9512 8,5 2,4 2,4 2,4 2,2 2,1 2 1,9 1,813 9 2,4 2,4 2,4 2,2 1,9 1,9 1,8 1,714 9,5 2,1 2,1 2,1 2,1 1,9 1,8 1,7 1,615 10 2 2 2 2 1,8 1,65 1,6 1,5516 10,5 1,65 1,65 1,65 1,65 1,6 1,5 1,4517 11 1,6 1,6 1,6 1,5 1,45 1,4518 11,5 1,4 1,4 1,4 1,4 1,4 1,419 12 1,35 1,35 1,35 1,35 1,35 1,3520 12,5 1,2 1,2 1,2 1,2 1,2 1,221 13 1,15 1,15 1,15 1,15 1,15 1,1522 13,5 1 1 1 1 123 14 0,95 0,95 0,95 0,95 0,9524 14,5 0,85 0,85 0,85 0,8525 15 0,8 0,8 0,8 0,826 15,5 0,8 0,8 0,8 0,8272829

22-0

1-02

Up-

grad

e

PAGEACCESS PROCEDURES TO µMACXxx 2,3,4

DESCRIPTION LMI COMPONENTS POSITIONING ON THE MACHINE 5MAIN CONTROL UNIT CODE: UMMST01-2/XX 6MAIN CONTROL UNIT GENERAL CHARACTERISTICS 7MAIN CONTROL UNIT CONNECTIONS AND SIGNALS 8BOOM LENGTH AND ANGLE SENSOR CODE : CIT-1PICW1/xx 9BOOM LENGTH AND ANGLE SENSOR - DIMENSIONS AND WIRING 10BOOM LENGTH AND ANGLE SENSOR - EXPLODED VIEW 11PRESSURE TRANSDUCER CODE : Y11 4740-350 12PRESSURE TRANSDUCER TECHNICAL SPECIFICATIONS 13CONTROL PANEL CODE : IDR1-3/xx 14CONTROL PANEL DIMENSIONS, CHARACTERISTICS, CABLE 15

DETECTION TROUBLESHOOTING 16ALARM CODES AND ACTIONS TO TAKE 17,18,19AUTO DIAGNOSTIC- Geometric data and load data 20AUTO DIAGNOSTIC- Hydraulic pressures data 21AUTO DIAGNOSTIC- Sensors digital signals 22AUTO DIAGNOSTIC- Status of digital Inputs 23AUTO DIAGNOSTIC- Status of digital Outputs 24ALARM CODE 1 : MEMORY DATA NOT RELIABLE 25ALARM CODE 2 : ANGLE READING < MINIMUM VALUE 26ALARM CODE 3 : ANGLE READING > MAXIMUM VALUE 26 ALARM CODE 4 : EXTENSION READING < MINIMUM VALUE 27ALARM CODE 5 : EXTENSION READING > MAXIMUM VALUE 27CABLE REEL POWER SUPPLY VERIFYING 28ANGLE POTENTIOMETER VERIFYING 29BOOM LENGTH POTENTIOMETER VERIFYING 30ALARM CODE 8 : MAIN CYLINDER (BOTTOM SIDE ) < MINIMUM VALUE 31ALARM CODE 9 : MAIN CYLINDER (BOTTOM SIDE ) > MAXIMUM VALUE 32ALARM CODE10 : MAIN CYLINDER (ROD SIDE ) < MINIMUM VALUE 33ALARM CODE11 : MAIN CYLINDER (ROD SIDE ) > MAXIMUM VALUE 34ALARM CODE18 : COMPENSATION CYLINDER (BOTTOM SIDE ) < MINIMUM VALUE 35ALARM CODE19 : COMPENSATION CYLINDER (BOTTOM SIDE ) > MAXIMUM VALUE 36ALARM CODE20 : COMPENSATION CYLINDER (ROD SIDE ) < MINIMUM VALUE 37

ALARM CODE21 : COMPENSATION CYLINDER (ROD SIDE ) > MAXIMUM VALUE 38

ACTION EPROM and EEPROM REPLACEMENT 39POTENTIOMETERS ALIGNMENT 40ANGLE AND EXTENSION SENSORS CALIBRATION - 1ST PASSWORD INTRODUCTION 41ANGLE AND EXTENSION SENSORS CALIBRATION - LMI SELF-CALIBRATION 42DATA DOWNLOADING ON E2PROM -“SAVE” FUNCTION 43LANGUAGE/MEASURE SYSTEM SELECTION AND 2ND PASSWORD INTRODUCTION 43DATA DOWNLOAD FROM LAP-TOP TO LMI 44DATA DOWNLOAD FROM LMI TO PC AND FROM PC TO FLOPPY DISK 45SYSTEM LAY-OUT AND CONNECTIONS 46EXTERNAL WIRING 47RECOMMENDED SPARE PARTS LIST 48

IND

EX

IND

EX

1

This system has been conceived and developed to off er 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 acces s levels are available, identified by three differe nt PASSWORDS; the first one given to the Technical Ser vice Department and possibly authorized Dealers (for troubleshooting and sensors replacemen t), and the second one given to the MANITOU Technical Service Department only (for refined cali bration), and the third one exclusively to Authorised programming personnel (for Load Table an d 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.

ACCESS PROCEDURES TO ACCESS PROCEDURES TO µµMACXxx MACXxx LOAD MONITORING SYSTEM (LMI)LOAD MONITORING SYSTEM (LMI)

2

2° LEVEL: (1 st PASSWORD) SENSORS REPLACEMENTS :TECHNICAL ASSISTANCE DEPT. AND AUTHORIZED DEALERSThe 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.

3

5

Angle/length transducers on left side of the boom

4 Pressure Transducers on lifting and compensation cylinders

Display:into the cabin

Main unit:into the cabin

LMI COMPONENTS POSITIONING ON THE MACHINELMI COMPONENTS POSITIONING ON THE MACHINE

SYSTEM LAY-OUT AND CONNECTIONS at page 46

MAIN CONTROL UNITMAIN CONTROL UNIT CODE: UMMST01CODE: UMMST01--2/XX2/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.

6

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

7

MAIN CONTROL UNITMAIN CONTROL UNIT

PC (LAPTOP) CONNECTIONS

NOTE:CODE DIODE PIN FUNCTIONDI0 D35 17 OUTRIGGERSDI1 D39 18 FRONTDI2 D43 19 1/2 OUTRIGGERSDI3 D47 20 BASKET

DO0 D68 25 SHUT-DOWNDO2 D77 27 WARNING

SHUT-DOWN WARNING

D35, D39, D43, D47, D51, D55, D59, D63 =RED LED’sThey show the INPUT statusON = ACTIVE INPUT

CONNECTIONS CONNECTIONS andand SIGNALSSIGNALS

MAIN CONTROL UNITMAIN CONTROL UNIT

8

EXTERNAL WIRINGSee page 47

D2 = RED LED When lit means that +15V Voltageis active

D1 = RED LEDWhen lit means that +5V Voltageis active

Note :D1 and D2 must belit when thesystem is ON

D68, D71, D74, D77 = RED LED’sThey show the OUTPUT statusON = ACTIVE OUTPUT

EPROM : LOAD TABLESAND PARAMETERS

EEPROM:CALIBRATION DATA

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

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.

9

OVERALL DIMENSION WIRING DIAGRAM

BOOM LENGTH AND ANGLE SENSORBOOM LENGTH AND ANGLE SENSOR

10

8-1

6

6-1

2

7-2

77-1

8

12

1

4

109

5

5-1

113

BOOM LENGTH AND ANGLE SENSOR BOOM LENGTH AND ANGLE SENSOR EXPLODED VIEW

11

Description1 Case2 Base 3 Circuit board 4 Step

5 Pinion

5-1 Shaft

6 Clutch

6-1 10-turns Potentiometer 7 1-turn Potentiometer

7-1 Pendulum

7-2 Bearing support

8 Pulley

8-1 Cap9 Strain relief

10 Breather

11 Spring

12 Cable

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

PRESSURE TRANSDUCERPRESSURE TRANSDUCER CODE : Y11 4740CODE : Y11 4740--350350

12

PIN CONNECTIONS

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.

TECHNICAL SPECIFICATIONS

PIN 3 Wires1 +VB (15V)2 Output signal 0,5 .. 5,5 V3 GND

PRESSURE TRANSDUCERPRESSURE TRANSDUCER13

CONTROL PANEL CODE : IDR1CONTROL PANEL CODE : IDR1 --3/3/xxxx

��

2.2 4.0 6.1 11

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/Shutdown)

Two rows alpha-numeric LCD display showing working data

Symbols and letters relatedto the display indications

4 Set-up keys(key “-” and “+” are notused in normal working condition)

Icon representing the machine and lettersrelated to geometric data.

14

CONTROL PANEL : DIMENSIONS, CHARACTERISTICS, CABLECONTROL PANEL : DIMENSIONS, CHARACTERISTICS, CABLE

• Power supply 8 - 24 V.• Temperature working range -20°+ 70°.• Microcontroller structure 16 bit.

• Load typical accuracy 3,5%.

• Outreach computing accuracy 1%.

• Link to Main Control Unit RS-232/C

TECHNICAL CHARACTERISTICS

CONNECTING CABLE TO MAIN CONTROL UNIT

1 Pin plugs2 Cable 4x0,5 sch3 Thermo shrink sheath

4 6 pins male connector5 Crimping pins

15

TROUBLESHOOTINGTROUBLESHOOTINGThe 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: 182.2 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.

16

ALARM CODES AND ACTIONS TO TAKEALARM CODES AND ACTIONS TO TAKE

Length sensor 1 value lower than the calibration value

6

• Verify that the cable or the connector wiring is not brokenIf the alarm persists:• Verify the length transducer integrity

Reading of the boom length sensor higher than the maximum value

5PAGE 27 and28,30,

40,41

7

•Verify that the wiring and the connectors are not in short circuit If the alarm persists:•Verify the length transducer integrity

Reading of the boom length sensor lower than the minimum value

4PAGE 27

and 28,30, 40,41

•Verify that the cable or the connector wiring is not open If the alarm persists:• Verify the angle sensor integrity.

Angle sensor reading higher than the maximum value

3PAGE 26 and 28,29,

40,41

•Verify that the wiring and the connectors are not in short circuit. If the alarm persists:• Verify the angle sensor integrity.

Angle sensor reading lower than the minimum value

2PAGE 26

and 28,29, 40,41

• Switch the system off and on. If the alarm persists:•Verify that E2prom chip is fitted properly in its socket.• Re-enter data and save it again• Replace the E2PROM chip and recalibrate the machine

Memory data not reliable

1PAGE 25

and 39,44

What to doDescriptionAlarmcode

17

Length sensor 2 value lower than the calibration value

N/A15

N/A14

N/A13

N/A12

Output hasn’t been verify16

• Verify that the cable or the connector wiring is not open If the alarm persists:• Verify the pressure transducer integrity

Reading pressure of the main cylinder (rod side) higher than the maximum.

11PAGE 34

N/A17

•Verify that the wiring and the connectors is not in short circuit If the alarm persists:• Verify the pressure transducer integrity

Reading pressure of the main cylinder (rod side) lower than the minimum.

10PAGE 33

• Verify that the cable or the connector wiring is not open If the alarm persists:• Verify the pressure transducer integrity

Reading pressure of the main cylinder (bottom side) higher than the maximum.

9PAGE 32

• Verify that the cable or the connectors wiring is not in short circuit If the alarm persists:• Verify the pressure transducer integrity

Reading pressure of the main cylinder (bottom side) lower than the minimum.

8PAGE 31

What to do DescriptionAlarm codes

18

•. Verify that the cable or the connector wiring is not open If the alarm persists, please, contact MANITOU Technical Assistance :•. Verify the pressure transducer integrity.

Reading pressure of the compensation cylinder (rod side) higher than the maximum.

21PAGE 38

• Verify that the cable or the connector wiring is not in short circuitIf the alarm persists, please, contact MANITOU Technical Assistance :•. Verify the pressure transducer integrity.

Reading pressure of the compensation cylinder (rod side) lower than the minimum.

20PAGE 37

• Verify that the cable or the connector wiring is not open If the alarm persists, please, contact MANITOU Technical Assistance :•. Verify the pressure transducer integrity.

Reading pressure of the compensation cylinder (bottom side) higher than the maximum.

19PAGE 36

•Verify that the cable or the connector wiring is not in short circuit If the alarm persists, please, contact MANITOU Technical Assistance :• Verify the pressure transducer integrity.

Reading pressure of the compensation cylinder (bottom side) lower than the minimum.

18PAGE 35

What to doDescriptionAlarm codes

19

N/A15

N/A14

N/A13

N/A12

29

28

27

26


19

N/A

32

N/A

N/A

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

33

Angle fault

Check related inputsCheck wiring Check sensors

Check related inputs Check wiring Check sensors

Telescope fault

19

Elongation sensor 2 reads higher than maximum value.

37

Elongation sensor 2 reads lower than minimum value.

36

Angle sensor 2 reads higher than maximum value.

35

• Check for short-circuit in the wiring or in wiring connector plugs• If the alarm persists, consult Authorised MANITOU Assistance to:

check for angle sensor default

Angle sensor 2 reads lower than minimum value.

34



check for angle sensor default


check for elongation sensor default


check for elongation sensor default

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, givinggeometric data and main cylinder differential press ure summary.

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)

AUTO DIAGNOSTICAUTO DIAGNOSTIC -- System internal working conditions monitoringSystem internal working conditions monitoringGeometric data and load data

P100 W 5.0 M 5.0A 60 L20.3 R15.1

20

By pressing the ENTER button again the display will show the second page showing:individual hydraulic pressures summary :

This page is displayed for 30 seconds; after which , it returns to the normal working condition page. The displayed parameters are as follows: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;

P100 L: 50 H: 40p 0 l: 0 h: 0

AUTO DIAGNOSTICAUTO DIAGNOSTIC -- System internal working conditions monitoringSystem internal working conditions monitoringHydraulic pressures data

21

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

This page is displayed for 30 seconds; after which, it returns to the normal working condition page. The displayed parameters are as follows:• 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 (*)

By pressing once again the ENTER button the display will show the third page givingpressure transducers and length/angle sensors digit al signals corresponding to the actual measurements .

1111 2222 33334444 5555 6666

AUTO DIAGNOSTICAUTO DIAGNOSTIC -- System internal working conditions monitoringSystem internal working conditions monitoringSensors Digital Signals

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 signalis taken wrong by the system: THE MINIMUM VALUE IS 10, THE MAXIMUM VALUE IS 1010.

(*) = Due to 10bits A/D Converter

22

This page is displayed for 30 seconds; after which, it returns to the normal working condition page. The displayed parameters are as follows: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/ANOTE : The combination of the Inputs status automat ically 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

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* * - - ----------

AUTO DIAGNOSTIC AUTO DIAGNOSTIC -- System internal working conditions monitoringSystem internal working conditions monitoringStatus of Digital Inputs

23

This page is displayed for 30 seconds; after which ,it returns to the normal working condition page. The displayed parameters are as follows:

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

By pressing the ENTER button again, the display will show the fifth page giving Outputs of the system status summary ( automatic si gnals ).

O 0 1 2 3 4567890123* * - - ----------

AUTO DIAGNOSTIC AUTO DIAGNOSTIC -- System internal working conditions monitoringSystem internal working conditions monitoringStatus of Digital Outputs to outside

24

ALARM CODE 1 : MEMORY DATA NOT RELIABLECAUSE: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:

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.

EEPROM

25

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. 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 as 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).

26

ALARM CODE 4 : BOOM LENGTH TRANSDUCER READINGLOWER THAN THE MINIMUM VALUE

CAUSE:The signal from the boom length transducer to the main PC board is lower than the minimum programmed value.This can be produced by a short-circuit in the electrical wiring, between the Main Unit and Sensor or the sensor itself is 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 length potentiometer (refer to “EXTENSION POTENTIOMETER VERIFYING” section - page 30)

ALARM CODE 5 : BOOM LENGTH TRANSDUCER READING HIGHER THAN THE MAXIMUM VALUE

CAUSE:The signal from the boom length transducer to the main PC board is higher than the maximum programmed value.This can be produced by a short-circuit in the electrical wiring, between the Main Unit and Sensor or the sensor itself is 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 length potentiometer (refer to “EXTENSION POTENTIOMETER VERIFYING” section - page 30)

27

Verify 5Volts between1(+) and 2(GND)

on cable reel board

Verify the Potentiometers

(**)

Verify on the Main PC board5Volts between7(+) and 8(GND)

FALSE

Cable break down.Check the

cable-reel cable

Disconnect wires7 and 8 from the

Main pc board and Check for 5Vdc

Probably the cable isin short circuit.Check cable

Main pc board Is faulty.

Replace it witha new one (*)

TRUE

TRUE

FALSETRUE

FALSE

+ GND

28

(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 39(**) REFER TO pages 29 and 30

CABLE REEL POWER SUPPLY VERIFYINGCABLE REEL POWER SUPPLY VERIFYING

ANGLE POTENTIOMETER VERIFYINGANGLE POTENTIOMETER VERIFYING

Verify between2(GND ) e 3 (+ )+2,5Vcc +/- 5%

Angle potentiometerbroken (**)

Raise the boom slowly.

TRUE

Losses of SignalThe variation is continous

and linear

Verify on the Main PC boardthe potentiometer signal on

8(GND) and 9(ADC2)

The Main PC board is faulty.Proceed with the replacement

(*)

FALSE

Verify with a voltmeter that thesignal increases in a linear

and continous way.

.

The signal isnot correct

Problems on the Connection Cable.Probably short circuited.

Check the cable

The signalis correct

Put the machine boom at 0° (horizontal).

Angle potentiometerbroken (**)

GND ADC2

29

(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 39(**) REFER ALSO TO POTENTIOMETERS ALIGNMENT - page 40

BOOM LENGTH POTENTIOMETER VERIFYINGBOOM LENGTH POTENTIOMETER VERIFYINGThe machine boom must be completely retracted.

Voltage higher or at 5V

Boom Lengthpotentiometer broken

(**)

Verify between2(GND ) and 5 (+ )

a voltage of roughly +250mV

Boom LengthPotentiometer broken

(**)

Extend the Boom

TRUE

Losses of SignalThe variation is continous

and linear

Verify on the Main PC boardthe potentiometer signal on

8(GND) and 12(ADC3)

The Main PC board is faulty.Proceed with the replacement

(*)

FALSE

Verify with a voltmeter that thesignal increases in a linear

and continous way.

The signal isnot correct

Problems on the Connection Cable.Probably short circuited.

Check the cable

The signalis correct

Boom Lengthpotentiometer broken

(**)

GND ADC3

30

(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 39(**) REFER ALSO TO POTENTIOMETERS ALIGNMENT - page 40

ALARM CODE 8 : MAIN CYLINDER (BOTTOM SIDE) READINGLOWER THAN THE MINIMUM VALUE

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 Mainpc board that between

1(+) e 2(GND) there is a voltageof +15Vdc

TRUEFALSE

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

Verify a voltage of +15Vdc

TRUEFALSE

The Main PC boardis faulty.Proceed

with thereplacement(*)

Problems on the Connection

Cable.Probably short circuited.

Check the cable

Broken PressureTransducer.Proceed

With the Replacement

Measure on the MainPC board the voltage

on 2(GND) and 3(ADC0)

Value <0,5Vdc Value >0,5Vdc





Check the cable



+ GND

31

(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 39

ALARM CODE 9 : MAIN CYLINDER (BOTTOM SIDE) READINGHIGHER THAN THE MAXIMUM VALUE


Verify on the MainPC board that between

1(+) e 2(GND) there is a voltageof +15Vdc

TRUEFALSE



TRUEFALSE


with thereplacement (*)



Check the cable





Value >5Vdc Value <5Vdc





+ GND


32

ALARM CODE 10 : MAIN CYLINDER (ROD SIDE) READING LOWER THAN THE MINIMUM VALUE



1(+) and 2(GND) there is a voltage of +15Vdc

TRUEFALSE



TRUEFALSE





Check the cable



Measure on the Mainpc board the voltage







Check the cable



+ GND


33

ALARM CODE 11 : MAIN CYLINDER (ROD SIDE) READING HIGHER THAN THE MAXIMUM VALUE



1(+) and 2(GND) there is a Voltage of +15Vdc

TRUEFALSE



TRUEFALSE





Check the cable










+ GND


34

ALARM CODE 18 : COMPENSATION CYLINDER (BOTTOM SIDE) READINGLOWER THAN THE MINIMUM VALUE


Verify on the Mainpc board that between


TRUEFALSE



TRUEFALSE





Check the cable










Check the cable



+ GND


35

ALARM CODE 19 : COMPENSATION CYLINDER (BOTTOM SIDE) READINGHIGHER THAN THE MAXIMUM VALUE

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



TRUEFALSE



TRUEFALSE





Check the cable










+ GND


36

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 maximum zone in order to check the sensor



TRUEFALSE



TRUEFALSE





Check the cable










Check the cable



+ GND


37

ALARM CODE 21 : COMPENSATION CYLINDER (ROD SIDE) READING HIGHER THAN THE MAXIMUM VALUE

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



TRUEFALSE

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


TRUEFALSE





Check the cable










+ GND


38

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, which has to be removed from the old to the new PC board.

Remove the EPROM and EEPROM carefullyout of their sockets by means of electronic components tweezers or suitable tools.

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

39

(*) NOTE:Where replacement of the

memories is required due to failure of Main Control Unit, this must be done avoiding .

EPROMEEPROM

POTENTIOMETERS ALIGNMENTPOTENTIOMETERS ALIGNMENTMechanical alignment of angle and extension sensorsFollowing 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.

XXXX XXXX AAAALLLL XXXX XXXX

After that press the ENTER key a number of times until the page showing the readings of sensors digital values is displayed.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.

****

0.0 00.0 6.8 11

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.

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.

40

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.

ANGLE AND EXTENSION SENSORS CALIBRATIONANGLE AND EXTENSION SENSORS CALIBRATION --1st PASSWORD INTRODUCTION

****0.0 00.0 6.8 11

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 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.

*Code: XXXX

Press some times the INDEX key to scroll the asterisk above the desired figure and modify its value by means of “+” and “-” keys.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.

*Code: 4477

At this point the page of 1st PASSWORD setting must show up as indicated hereIf different page appears, this means that ENTER Key has been depressed too early or too late: switch system off and re-start.

UM45_4x dd-mm-yyMRT2145

Switch machine on and wait for a few seconds until the first starting page shows up on display as indicated hereQuickly press once ENTER key.

41

ANGLE AND EXTENSION SENSORS CALIBRATION (LMI SELFANGLE AND EXTENSION SENSORS CALIBRATION (LMI SELF --CALIBRATION)CALIBRATION)

Sensors self calibration at closed machine conditions

A78 S20.3 W .0Check that the values of angle and extension displayed are correct and retract the 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.

A78 S20.3 W .013 Transd. Max

Totally raise and extend the boom making sure that the two cylinders for lifting and extension are at the end of their stroke. In this condition the angle and extension 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.

Sensors self calibration at open machine conditions

A00 S 6.8 W.012 Transd. Min

Position the machine with the boom totally retracted and at its lowest position (min.angle).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.

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

42

DATA DOWNLOADING ON E2PROM DATA DOWNLOADING ON E2PROM --““ SAVESAVE”” FUNCTIONFUNCTION

Save In Progress !

Press ENTER to activate the command. A message will inform that the saving procedure is in progress.

DONE ! After that, the message indicated here will be shown.Press INDEX to go back to main working data page.

OPTIONS01 Save

By means of “+” and “-“ keys, display page "01 Save”.

After performing the self calibration procedure its data must be saved as indicated below.

43

LANGUAGE/MEASUREMENT SYSTEM SELECTION AND 2nd PASSW ORD INTRODUCTLANGUAGE/MEASUREMENT SYSTEM SELECTION AND 2nd PASSW ORD INTRODUCTIONION

CONFIGURATIONEng.Unit 0

Press ENTER to activate the command. At the origin the Metric System is set (Parameter = 1); to select Imperial system set 0.

CONFIGURATIONLanguage 0

Press ENTER to activate the command. 4 languages are available. For their selections set the proper paramentersbetween 0 and 3.

CONFIGURATIONPW2 XXXX

Press ENTER to activate the command. Set the 2nd password in the place of XXXX

CONFIGURATION32 Config.

By means of “+” and “-” keys look for the page indicated here

In this phase it also possible to select the message language, measurement system and to enter the second password. Act as follows:

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 COMPUTER2 : LOAD DATA FROM COMPUTER TO TRUCK5 : PREPARE DISKETTE 6 : SHOW DATA0 : EXIT

Scrolling on 2, the list of all the programs contained into the lap-top will show up.I.E.:

PROGRAMS LIST00 MRT2145.E14 18/09/2001 11:52 am01 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.

DATA DOWNLOAD FROM LAPDATA DOWNLOAD FROM LAP --TOP TO LMI (*)TOP TO LMI (*)

44

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 .

45

DATA DOWNLOAD FROM LMI TO PC AND FROM PC TO FLOPPY DISK DATA DOWNLOAD FROM LMI TO PC AND FROM PC TO FLOPPY DISK

2

3

33

654

OM1

2

1

2

T

4

6

5

7

1

8

SYSTEM LAYSYSTEM LAY --OUT AND CONNECTIONSOUT AND CONNECTIONS

1 Main Unit2 Pressure Transducers (4)3 Length/Angle Sensor4 Control Panel5 Pressure Transducer Cable6 Control Panel Cable7 Power Supply and In/Out’s cable8 Length/Angle Sensor Cable

Power supply and Inputs/Outputs

46

EXTERNAL WIRINGEXTERNAL WIRING

47

MAIN CONTROL UNIT BOARD

See also : page 8 MAIN CONTROL UNIT page 9 BOOM ANGLE LENGTH SENSORpage 13 PRESSURE TRANSDUCERS page 15 CONTROL PANEL

48

MAIN COMPONENTS

DESCRIPTION CODE

MAIN UNIT UMMST01-2/xxCONTROL PANEL IDR1-3/xxBOOM LENGTH/ANGLE SENSOR CIT-1PICW1/xxPRESSURE TRANSDUCER Y1 4740-350CONNECTING CABLE MAIN UNIT/CONTROL PANEL CV2 IDR1-3/xxCONNECTING CABLE MAIN UNIT /BOOM LENGTH ANGLE CV1MMST1-1/xxCONNECTING CABLE MAIN UNIT/PRESSURE TRANSDUCER CV2MMST1-1/xxCABLE IN-OUT MAIN UNIT CV ARM7G1-7M

INTERNAL PARTS

DESCRIPTION CODE

ELECTRONIC BOARD FOR MAIN UNIT S U2MIC-5/xxELECTRONIC BOARD FOR CONTROL PANEL S IDR1/xxELECTRONIC BOARD FOR BOOM LENGTH/ANGLE SENSOR S CIT1PI/xxANGLE POTENTIOMETER Y11 PL310/1KLENGTH POTENTIOMETER PT 534-2KDRUM CABLE (17mt) CV 510.726CABLE REEL MECHANISM WITHOUT INTERNAL BOARD AND SENSORS GR CITMEC/xx

RECOMMENDED SPARE PARTS LISTRECOMMENDED SPARE PARTS LIST

Troublesshooting manual 3b6.pdf

Documents

Transcript of Troublesshooting manual 3b6.pdf