3 B6 LM I

Se r vice M a n u a l
for FRAN N A Cr a n e s

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

INDEX

PAGE
ACCESS PROCEDURES 3

DESCRIPTION

COMPONENTS LOCATION ON THE MACHINE 4

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

DETECTION

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

ACTION

EPROM and EEPROM REPLACEMENT 32

POTENTIOMETERS ALIGNMENT 33
SYSTEM LAY-OUT AND CONNECTIONS 34
EXTERNAL WIRING 35
RECOMMENDED SPARE PARTS LIST 36
3

ACCESS PROCEDURES
LOAD MONITORING SYSTEM (LMI)
This systems has been conceived and developed to offer two different levels of functionality
of access to internal data, according to the actions to be done.
The basic access level (Operator) does not required any password; this one, in fact, is
required for possible interventions, exclusively by Technical Service Personnel (failure
detecting and repairing).
1° LEVEL:
OPERATOR:
Without needing PASSWORD (also see OPERATOR MANUAL) all working information of
the machine are available through several monitoring given by the display panel; starting
from basic working data: lifted load, max admitted load, outreach, working conditions, tilting
percentage;
Just pressing the GREEN button key, it is possible to show machine working data in a
graphic way.
The aim to give to the Operator the possibility of entering these readings, allowing to
communicate them to the Technical Assistance Department, giving relevant data, possibly
avoiding a direct Service on site.
The Operator can also find some information to solve easy troubles in his OPERATOR
MANUAL
2° LEVEL: (PASSWORD) SENSORS REPLACEMENTS :
TECHNICAL ASSISTANCE DEPT. AND AUTHORIZED DEALERS
The second level corresponds to the information contained in this TROUBLE SHOOTING
MANUAL, where all details referred to system components are included (Main Unit,
Transducers, Display Panel), troubleshooting codes introduction, and the useful information
to remove the problems without specific tools (except a voltmeter).
As far as Pressure Transducers are concerned, please note that they do not need any
calibration, as they are totally interchangeable.
FINE CALIBRATION.
This means the complete machine calibration, that is done at the first start-up of the
machine.
To this aim a PASSWORD is given, allowing to enter into the functions of the program, as
the fine calibration of geometrical data and lifted load, and to perform their on-site
calibration. These calibrations need the use of a PC.
4

COMPONENTS LOCATION ON THE MACHINE

Control Panel :
into the cabin
SYSTEM LAY-OUT AND CONNECTIONS at page 34-35
5

MAIN CONTROL UNIT

CODE: U2MIC-2/XX

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

and program storage not erasable EPROM type or erasable
EEPROM type for calibration parameters storage.
INPUT/OUTPUT circuits are self-protected against overloads and
short circuits.
Power supply internal circuits are designed to operate at low voltage
and are provided with all protection for hard environment.
U2MIC-2/41 Main Control Unit is provided with all EMC necessary
components.
6

GENERAL 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 : 5g’s from 20 to 400Hz Over 3 AXIS
• Shock : 10g’s
o ENVIROMENTAL
• Salt spray resistance over 48 Hours
o TEMPERATURE
• Working range :-30 -+70°C
• Storage range :-45 - +85°C
7

MAIN CONTROL UNIT : CONNECTIONS and SIGNALS

EEPROM: EEPROM:
PROGRAM AND CALIBRATION DATA,
LOAD TABLES BLACK BOX

MORS. 16C. C.S.

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

CV a FILO 1,5mmq.

D2 = RED LED
When lit means
that +15V Voltage D35, D39, D43, D47, D51, D55, D59, D63 = RED LED’s
is active They show the INPUT status
ON = ACTIVE INPUT
D1 = RED LED
When lit means
that +5V Voltage
is active D68, D71, D74, D77, D80, D83, D86, D89, D101 = RED LED’s
They show the OUTPUT status ON = ACTIVE OUTPUT
Note :
D1 et D2 always have to be
lit when the system is ON
NOTE:
CODE DIODE PIN FUNCTION
NOTE: DO0 D68 25 Not used
CODE DIODE PIN FUNCTION DO1 D71 26 Not used
DI0 D35 17 Articulation signal (On when +/- 10 deg) DO2 D74 27 Not used
DI1 D39 18 Anti two block (On when not 2blocked) DO3 D77 28 Not used
DI2 D43 19 Engine Oil Pressure (On when OK) DO4 D80 29 Alarm Buzzer
DI3 D47 20 Engine Water Temp (On when OK) DO5 D83 30 Stop Function
DI4 D51 21 Crane/Travel Mode (On in crane mode) DO6 D86 31 Not used
DI5 D55 22 Water Level (On when level low) DO7 D89 32 Not used
DI6 D59 23 Ignition key signal (On when key on)
DI7 D63 24 Optional Seat Switch (Off= empty seat)
8

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

AC MCP cable reel is used where the A2B
function is required (i.e.: MAC25).
The length transducer (or transducers) is
formed by drum cable servo-winders on which
a cable is wound that is attached to the boom
head (or to intermediate elements).
When the boom is telescoped, the wire
unwinds measuring the boom length through a
potentiometer sensing device.
During crane operations, it is always
necessary to carefully check the cable
unwinding along the boom, as it can be
subjected to accidental break if collided.
The replacement of this element is to be done
by qualified personnel only.

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

Slip Length Diam A B C D E F G H M

Type mm
MODEL
Rings mm mm mm mm mm mm mm mm mm mm

3 3x0,22 32000 3,8 100 323 60 460 420 11 495 0 180 AC MCP214I/3P
shields.
9

EXTENSION SENSOR
CODE : CIT-1PACW/10

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

OVERALL DIMENSION

WIRING DIAGRAM
11

EXTENSION SENSOR
EXPLODED VIEW

7-2

2 7-1
7 5-1

11
3

8-1

6-1
8

12 9
10
1

DESCRIPTION

1 Case 7 Angle accelerometer

2 Base 7-1 Not Used
3 Circuit board 7-2 Not Used
4 Step 8 Pulley
8-1 Cap
5 Pinion
9 Strain relief
5-1 Shaft 10 Breather
6 Clutch 11 Spring
6-1 10-turns Potentiometer 12 Cable
12

PRESSURE TRANSDUCERS CODE : Y11 4745-350

Pressure transducers detect the pressure

into boom lifting cylinders; typically 2
sensors are required for measuring the
differential pressure on lifting cylinders :
they must be installed on the two cylinder
chambers.
By these values, weight computing is taken.
These sensing devices detect the pressure
by means of a sensor, which transforms the
measured pressure into a direct voltage
proportional to the pressure itself.
An on-board amplifier is included in the
transducer itself.
Any possible replacement of these elements
is very easy because of their complete
compatibility.

TECHNICAL SPECIFICATIONS
PIN CONNECTIONS
PIN 3 Wires
1 +VB
2 output signal 0,5 .. 5,5 V
3 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 ...+85°C
• Operating temperature range -40 ...+85°C
• Storage temperature range -40 ... +100°C
• Fluid temperature range -40 ... +100°C
• Protection class IP65
OTHER DATA
• Supply voltage 12 ...30V
• Current consumption ca.15mA
• Life expectancy 106 load cycle
• Weight 145g.
13

CONTROL PANEL DESCRIPTION

9 1 2 3 4 10

5 6 7 8

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 point
8) 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)
14

TROUBLESHOOTING
The first step to seek a fault is to identify the problem that has occurred, and
to advise the crane Operator.
The auto-diagnostic procedures are able to identify transducers failures,
cable breakages and internal electronic faults; alarm codes are automatically
shown on the display to the Operator, providing him with a certain ability to
locate the fault, and also to better inform the Technical Assistance even from
a remote location.
When an alarm occurs, the LMI puts itself in a safe condition (shut down)
blocking the dangerous movements and, at the same time, the display shows
the alarm corresponding message on the display lower row.
Depending on the message, the fault can then be identified.

Alarm codes are listed in the following pages.

The list also includes some hints able to solve the problems and get back to
normal working conditions.
15

ALARM CODES AND ACTIONS TO TAKE

Alarm
Description What to do
code
• Switch the system off and on.
If the alarm persists, please, contact Technical
1 Assistance to:
Memory data not
Page •Verify that E2prom chip is fitted properly in its socket.
reliable
18,32 • Re-enter data and save them again
• Replace the E2PROM chip and recalibrate the
machine
• Verify that the wiring and the connectors are not in
2
Angle sensor short circuit.
Page reading lower than If the alarm persists, please, contact Technical
19, 20, Assistance :
the minimum value
21,32
• Verify the angle sensor integrity.
•Verify that the cable or the connector wiring is not
3
Angle sensor open
Page reading higher than If the alarm persists, please, contact Technical
19, 20, Assistance :
the maximum value
21, 32
• Verify the angle sensor integrity.
4 Not Used
5 Not Used

6 Reading of the • Verify that the wiring and the connectors are not in
boom length short circuit
Page
If the alarm persists, please, contact Technical
22, 23, sensor 1 lower than Assistance:
24, 32 the minimum value Verify the length transducer integrity

7 Reading of the • Verify that the cable or the connector wiring is not
Page boom length open
22, 23, sensor 1 higher If the alarm persists, please, contact Technical
24, 32 than the maximum Assistance :
value • Verify the length transducer integrity
16

Alarm
Description What to do
code
• Verify that the cable or the connectors wiring are
Reading pressure of
8 not in short circuit
the main cylinder
Page If the alarm persists, please, contact Technical
(bottom side) lower Assistance :
25
than the minimum.
• Verify the pressure transducer integrity

9 • Verify that the cable or the connector wiring are

Reading pressure of
not open
Page the main cylinder
26 If the alarm persists, please, contact Technical
(bottom side) higher Assistance :
than the maximum.
•Verify the pressure transducer integrity
•Verify that the wiring and the connectors are not in
Reading pressure of
10 short circuit
the main cylinder (rod
Page If the alarm persists, please, contact Technical
side) lower than the Assistance :
27
minimum.
•Verify the pressure transducer integrity
• Verify that the cable or the connector wiring are
11 Reading pressure of
not open
the main cylinder (rod
Page If the alarm persists, please, contact Technical
side) higher than the Assistance :
28 maximum.
•Verify the pressure transducer integrity
12 Not used

13 Not Used

14 Reading of the boom • Verify that the wiring and the connectors are not in
length sensor total short circuit
Page
lower than the If the alarm persists, please, contact Technical
29, 30, Assistance:
31 minimum value
Verify the length transducer integrity

15 • Verify that the cable or the connector wiring is not

Reading of the boom
open
Page length sensor total
If the alarm persists, please, contact Technical
29, 30, higher than the Assistance :
31 maximum value
• Verify the length transducer integrity
17

Alarm
Description What to do
code
12 Not used
13 Not Used
Table charts not
available.. •Please, select the operating mode in use and
18 The operating condition confirm it.
selection is missing

Engine Monitoring System (reset alarms with

Optional
F9)
30
Low Engine Oil Press. •Stop engine and check oil level, reset with F9

31 High Water Temp. •Stop engine and determine cause, reset with F9

•Stop the crane as soon as safely possible and

shift to N (Neutral). Accelerate the engine to
32 High Transmission Oil 1200 rpm and allow the temperature to return to
Temperature normal
(2 or 3 minutes),reset with F9 and resume
operation.

•Stop engine and check cooling system when

33 Low Water Level
safe to do so, reset with F9.

•Engine will stop ten seconds after vacating seat,

34 Driver Not Seated engine will not start if driver not seated.
•Reset with F9.

•Apply parking brake prior to opening door or

35 Parking Brake Not Set turning the ignition key off.
•Reset with F9.
18

ALARM CODE 1 : MEMORY DATA NOT RELIABLE

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

EEPROM

ACTION TO TAKE:
1) Switch the system off and on.
2) Verify that the EEPROM chip is fitted properly in its socket.
3) Re-enter data and save again, switch off and on again.
4) If the problem persists, replace the PC board making sure that
software/parameters installed are corresponding to the
machine characteristics.
19

ALARM CODE 2 :
ANGLE TRANSDUCER READING
LOWER THAN THE MINIMUM VALUE(*)
CAUSE:
The signal from the angle transducer to the main PC board is lower than the
minimum programmed value.
This can be produced by a short-circuit in the electrical wiring, between the
Main Unit and Sensor or the sensor itself is in interdiction.

ACTION TO TAKE:
• Verify the wiring
• Verify cable reel PC board proper power supply
(refer to “CABLE REEL POWER SUPPLY VERIFYING” section – page 20).
• Verify angle potentiometer
(refer to “ANGLE POTENTIOMETER VERIFYING” section – page 21).

ALARM CODE 3:
ANGLE TRANSDUCER READING
HIGHER THAN THE MAXIMUM VALUE (*)
CAUSE:
The signal from the angle transducer to the main PC board is higher than the
maximum programmed value.
This can be produced by a break in the electrical wiring, between the Main
Unit and Sensor or the sensor itself is in saturation.

ACTION TO TAKE:
• Verify the wiring
• Verify 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

CABLE REEL POWER SUPPLY VERIFYING

3 (GND)
1 (+)

Verify 5Volts between

1(+) and 3(GND)
on cable reel board

TRUE FALSE

Verify the Verify on the Main PC board

Potentiometers 5Volts between
(**) 10(+) and 11(GND)

TRUE FALSE

+ GND
Disconnect wires
Cable break down.
10 and 11 from the
Check the
Main pc board and
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 32

(**) REFER TO page 21
21

ANGLE POTENTIOMETER VERIFYING

Put the machine boom at 0° (horizontal).

2 (CA2) 3 (GND)

Verify voltage between

2(CA2 ) and 3 (GND)
Is +2,5Vdc +/- 5%

FALSE TRUE

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

Verify with a voltmeter that the

signal increases in a linear
and continuous way.

The variation is continuous

Loss of Signal
and linear

Angle potentiometer Verify on the Main pc board

broken (**) the potentiometer signal on
9(CA2) and 11(GND)

CA2 GND
The signal is The signal
not correct is correct

Problems on the Connection The Main pc board is faulty.

Cable. Probably short circuited. Proceed with the replacement
Check the cable (*)

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

(**) REFER ALSO TO POTENTIOMETERS ALIGNMENT - page 33
22

ALARM CODE 6 :
BOOM LENGTH TRANSDUCER READING
LOWER 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 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 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 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 a
minimum zone and a maximum zone in order to check the sensor.
23

VERIFYING CABLE REEL POWER SUPPLY

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 + GND

Cable break down. Disconnect wires

Check the 7 and 8 from the
cable-reel cable Main pc board and
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 32

(**) REFER TO pages 24
24

VERIFYING BOOM LENGTH POTENTIOMETER

The boom must be completely retracted.

Verify voltage between

2(GND ) and 5 (+ )
of app. +250mV

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 continuous way.

The variation is continuous

Loss of Signal
and linear

Boom Length
Verify on the Main pc board
potentiometer broken
the potentiometer signal on
(**)
8(GND) e 12(CA3)

GND CA3
The signal is The signal
not correct is correct

Problems on the Connection The Main pc board is faulty.

Cable.Probably short circuited. Proceed with the replacement
Check the cable (*)

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

(**) REFER ALSO TO POTENTIOMETERS ALIGNMENT - page 33
25

ALARM CODE 8 :
MAIN CYLINDER (PISTON SIDE) READING
LOWER THAN THE MINIMUM VALUE
NOTE:
Main Unit Processor identifies below and over the signal range a minimum zone and a
maximum zone in order to check the sensor.

+ GND GND CA0

Verify voltage between 1(+) and TRUE

2(GND) on the Main PC board
is +15Vdc
Measure the voltage between
2(GND) and 3(CA0)
on the Main PC board

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

Problems on the Broken Pressure

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

FALSE

Disconnect wires on
1(+) and 2(GND) and
Verify a voltage of +15Vdc

FALSE TRUE FALSE

Problems on the
The Main PC board Broken Pressure
Connection
is faulty. Proceed Transducer. Proceed
Cable. Probably
with the With the
short circuited.
replacement(*) Replacement
Check the cable
(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 32
26

ALARM CODE 9 :
MAIN CYLINDER (PISTON SIDE) READING
HIGHER THAN THE MAXIMUM VALUE
NOTE:
Main Unit Processor identifies below and over the signal range a minimum zone and a
maximum zone in order to check the sensor.

+ GND GND CA0

Verify voltage between 1(+) and TRUE

2(GND) on the Main PC board
is +15Vdc
Measure the voltage between
2(GND) and 3(CA0)
on the Main PC board

Value >5Vdc Value <5Vdc

Broken Pressure
The Main PC board
Transducer.Proceed
is faulty.Proceed
With the
with the
Replacement
replacement (*)

FALSE

Disconnect wires on
1(+) and 2(GND) and
Verify a voltage of +15Vdc

FALSE TRUE TRUE

Problems on the
The Main pc board Broken Pressure
Connection
is faulty.Proceed Transducer.Proceed
Cable.Probably
with the With the
short circuited.
replacement (*) Replacement
Check the cable
(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 32
27

ALARM CODE 10:

MAIN CYLINDER (ROD SIDE) READING LOWER
THAN THE MINIMUM VALUE
NOTE:
Main Unit Processor identifies below and over the signal range a minimum zone and a
maximum zone in order to check the sensor.

+ GND GND CA1

Verify voltage between 1(+) and TRUE

2(GND) on the Main PC board
is +15Vdc
Measure the voltage between
2(GND) and 6(CA1)
on the Main PC board

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

Problems on the Broken Pressure

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

FALSE

Disconnect wires on
1(+) and 2(GND) and
Verify a voltage of +15Vdc

FALSE TRUE FALSE

Problems on the
The Main PC board Broken Pressure
Connection
is faulty. Proceed Transducer. Proceed
Cable. Probably
with the With the
short circuited.
replacement(*) Replacement
Check the cable
(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 32
28

ALARM CODE 11 :
MAIN CYLINDER (ROD SIDE) READING HIGHER
THAN THE MAXIMUM VALUE
NOTE:
Main Unit Processor identifies below and over the signal range a minimum zone and a
maximum zone in order to check the sensor.

+ GND GND CA1

Verify voltage between 1(+) and TRUE

2(GND) on the Main PC board
is +15Vdc
Measure the voltage between
2(GND) and 6(CA1)
on the Main PC board

Value >5Vdc Value <5Vdc

Broken Pressure
The Main PC board
Transducer.Proceed
is faulty.Proceed
With the
with the
Replacement
replacement (*)

FALSE

Disconnect wires on
1(+) and 2(GND) and
Verify a voltage of +15Vdc

FALSE TRUE TRUE

Problems on the
The Main PC board Broken Pressure
Connection
is faulty.Proceed Transducer.Proceed
Cable.Probably
with the With the
short circuited.
replacement (*) Replacement
Check the cable
(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 32
29

ALARM CODE 14 :
BOOM LENGTH TRANSDUCER READING
LOWER 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 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 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 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 a
minimum zone and a maximum zone in order to check the sensor.
30

CABLE REEL POWER SUPPLY VERIFYING

3 (GND)
1 (+)

Verify 5Volts between

1(+) and 3(GND)
on cable reel board

TRUE FALSE

Verify the Verify on the Main PC board

Potentiometers 5Volts between
(**) 10(+) and 11(GND)

TRUE FALSE

+ GND
Disconnect wires
Cable break down.
10 and 11 from the
Check the
Main PC board and
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 32

(**) REFER TO page 31
31

BOOM LENGTH POTENTIOMETER VERIFYING

Retract the boom completely.

3 (GND)
2 (CA3)

Verify between
3(GND ) e 5 (CA3 )
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 continuous way.

The variation is continuous

Loss of Signal
and linear

Boom Length
Verify on the Main PC board
potentiometer broken
the potentiometer signal on
(**)
11(GND) e 15(CA4)

GND CA4
The signal is The signal
not correct is correct

Problems on the Connection The Main PC board is faulty.

Cable. Probably short circuited. Proceed with the replacement
Check the cable (*)

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

(**) REFER ALSO TO POTENTIOMETERS ALIGNMENT - page 33
32

EPROM and EEPROM REPLACEMENT(*)

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

EEPROM

EPROM

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

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

(*) REMARK: Replacement

of memories is required in
case of failure of Main
Control Unit that must be
replaced, avoiding any
re-programming and
re-calibration of the system .
33

POTENTIOMETERS ALIGNMENT
Mechanical alignment of angle and extension sensors
Following the replacement of a potentiometer, even if this has been done carefully, it is
suggested to check its alignment.
The following procedure, if properly done, allows the total restoring of the machine
behaviour without any calibration operation.

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

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

After the replacement of the potentiometer, it is advisable to verify the comparison

between the values shown on the display to a couple of known boom position.
I.E: Boom completely closed / Boom extended and 0° / maximum angle
These displayed values must correspond to the values given by the Manufacturer for this
specific machine model.
34

SYSTEM LAY-OUT AND CONNECTIONS

Refer to layout applicable to each model

CONTROL PANEL
CMC100/10
CENTRAL UNIT: U2MIC-2/41

F.C.

ANGLE/LENGTH SENSOR
AC MCP214I/2A

J1 PG1 PG2 PG3 PG4 PG5 PG6

CV ATG12/21
PRESSURE TRANSDUCERS
(Y11 4745-350)

A INPUT OUTPUT SIGNALS

AND EXTERNAL SUPPLY

CV 6X0.35+SCH

LENGTH SENSOR
CIT- 1PI/13
(USED IN CASE OF BOOM INDIPENDENT SECTIONS)
35

EXTERNAL WIRING
Refer to applicable schematics

SHLD

SHLD

BROWN
MS1
BROWN

123
+15V

1 2 3 4 5 6 7 8 9 10 11 1213 14 15 16
GREEN WHITE
WHITE AGND
GREEN
PRESSURE TRANSDUCERS SHIELD
BROWN CA0
(Y11 4745-350) BROWN

1 23
GREEN WHITE +15V
WHITE AGND
GREEN
SHIELD CA1
BROWN
+5V
WHITE
AGND
PINK
CA2
RED
+5V
BLUE
AGND
PINK
CA3
BROWN
+5V
WHITE
AGND
GREY
CA4
LENGTH SENSOR CA5
CIT- 1PI/13
(USED IN CASE OF BOOM YELLOW
+5V
INDIPENDENT SECTIONS)
SCH

+VB
SCH
MS2

17 18 19 20 21 22 23 24 25 26 27 28 2930 31 32
INP0
GREEN
INP1
INP2
INP3
INP4
INP5
INP6
INP7
OUT0
GREEN

OUT1
BROWN OUT2
+ - A1 A2 S1 S2
1 2 3 4 5 6

WHITE OUT3
OUT4
OUT5
PINK OUT6
SHIELD
OUT7

MS3
3334 35 36
WDO
-VB

+VB
+

-VB

ANGLE/LENGTH SENSOR
-

AC MCP214I/2A
PINK MS4
BROWN
37 3839 40 4142 43 44 45 46 47 4849 50 5152

+VOUT
GREY
RX1
SHLD

YELLOW
GREEN
BLUE
PINK

YELLOW
RED
WHITE
GREY
BROWN

TX1
WHITE
GND
+VOUT
RX2
TX2
8
7
6
5
4
3
2
1

GND
D+
2

D-
AGND

+5V
1
3
+5V
CA2

GND
+15V
2

6
9
8

1
7
6
5
4
3

7
8
9
4
5

-15V
CA6
CA7
PENDULUM
BOARD
A2B

BROWN
+VOUT
A B C D E F

CONTROL PANEL

WHITE
GND
CMC100/10

GREY
RX1
YELLOW
TX1
PINK
+V
SHLD

GREEN
EXT.ALL
36

RECOMMENDED SPARE PARTS LIST

MAIN COMPONENTS

DESCRIPTION CODE

MAIN UNIT U2MIC-2/41

CONTROL PANEL (in dash) HTD65-01I2/11
CONTROL PANEL (out of dash) HTD65-01O2/11

LENGTH/ANGLE SENSOR (MAC25) AC MCP236A/2P

LENGTH/ANGLE SENSOR (AT15/20 & UC15) CIT-1PACW/10
PRESSURE TRANSDUCERS Y11 4745-350
CONNECTING CABLE MAIN UNIT/CONTROL PANEL CV ATG12/21
CONNECTING CABLE MAIN UNIT/CONTROL PANEL P/SUPPLY CV ATG77-1/10
GENERAL WIRING CV 4x0,5+SCH

INTERNAL PARTS

DESCRIPTION CODE

MAIN BOARD WITH BLACK BOX S U2MIC-6/42

ELECTRONIC BOARD FOR BOOM LENGTH/ANGLE SENSOR S CIT1PACW/10
ANGLE ACCELEROMETER ASA*23/180/10

LENGTH POTENTIOMETER PT 534-2K

LENGTHCABLE (18.5mt)(MAC25) CV C0102/18.5
LENGTHCABLE (8.5mt)(AT15/20, UC15) CV CIT-8.5

CABLE REEL MECHANICS WITHOUT INTERNAL

BOARD AND SENSORS GR CITMEC/10