3B6 LOAD MOMENT INDICATOR (LMI)

TELESCOPIC CRANES Series ATT

TROUBLESHOOTING
MANUAL
LTB1 Name Code Ballast Outrigger Jib Angle Jib Length Zone
C71_1: BOOM ON OUTRIGGERS 300 2,5 6,3 0

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 Length 9,4 14,4 19,5 24,7 28,9 30,4
2 I 0 24 48 73 93 100
3 II 0 24 48 73 93 100
4 III 0 24 48 73 93 100
5 IV
6
7
8 Amax 79 32 79 19 79 17 79 14 79 10 79 9
9 Amin 0 8 0 4,3 0 2 0 1,05 0 0,5 18 0,8
10 2 2 2 2 2 2 2
11 3 62,4 32 71,9 20
12 3,5 58,4 27,45 69,8 20,35 75,9 18
13 4 54,1 24,4 67,4 20,75 74,5 18,45 76 14
14 4,5 49,5 21,8 65,2 21,2 73,1 18,7 75,2 14,5
15 5 45 19,4 62,8 19,3 71,7 17,3 74,6 14,3
16 6 33,4 15,5 58 14,75 68,6 13,45 72,9 12,35 77,2 10 78,2 9
17 7 19,1 11,5 53 11,7 65,2 10,9 71,2 10,1 75,2 9,55 76,4 8,85
18 8 47,7 9,4 61,7 9,05 69,2 8,5 73,2 8,05 74,5 7,9
19 9 41,8 7,65 57,8 7,7 67,9 7,25 71,2 6,9 72,5 6,8
20 10 35 6,4 53,7 6,45 64,4 6,25 69 6 70,4 5,9
21 11 24,7 5,4 49,4 5,4 61,8 5,4 66,8 5,25 68,2 5,15
22 12 11 4,65 43 4,7 59 4,75 64,4 4,6 65,8 4,55
23 13 40,4 4,05 55,8 4,1 62 4,1 63,4 4,05
24 14 35,6 3,55 52,6 3,6 59,4 3,6 61 3,6
25 15 30,6 3,05 48,9 3,1 57 3,1 59,5 3,1
26 16 23,7 2,75 45 2,75 54,2 2,8 55,6 2,8
27 17 12,9 2,35 40,8 2,4 51,4 2,4 53 2,4
28 18 36,2 2,15 48,6 2,2 50,1 2,2
29 19 31,4 1,95 45,8 1,95 47,2 1,95
30 20 26,4 1,7 42,8 1,7 44,2 1,7
31 21 22,6 1,5 40 1,5 43,3 1,5
32 22 12,4 1,35 36 1,35 37,8 1,35
33 23 31,2 1,2 33,8 1,2
34 24 26 1,05 29,2 1,05
35 25 19,2 0,9 24 0,9
36 26 11 0,8 18 0,8
37 27 0,5
38 28
39 29
40

07/01/2002 Up-Grade

Complies to the MACHINES DIRECTIVE Standards: EN60204-1, EN954, EN12077-2

EMC according to the “ Heavy Industrial Environment” category: EN50081-2, EN50082-2
 2

INDEX

PAGE
ACCESS PROCEDURES 3

DESCRIPTION

COMPONENTS LOCATION ON THE MACHINE 4

MAIN UNIT AND CONTROL PANEL CODE: UMC1-1/XX 5
GENERAL CHARACTERISTICS 6
MAIN CONTROL UNIT CONNECTIONS AND SIGNALS 7
AC MCP ANGLE/EXTENSION SENSORS CODE : AC MCP214I/3P 8
PRESSURE TRANSDUCER CODE : Y11 4745-450 9
CONTROL PANEL DESCRIPTION 10

DETECTION

TROUBLESHOOTING 11
ALARM CODES AND ACTIONS TO TAKE 12,13
AUTO DIAGNOSTIC- Geometric data and load data 14
AUTO DIAGNOSTIC- Hydraulic pressures data 14
AUTO DIAGNOSTIC- Sensors digital signals 15
AUTO DIAGNOSTIC- Status of digital Inputs from outside 16
AUTO DIAGNOSTIC- Status of digital Outputs to outside 16
ALARM CODE 56 : MEMORY DATA NOT RELIABLE 17
ALARM CODE 15 : ANGLE READING < MINIMUM VALUE 18
ALARM CODE 25 : ANGLE READING > MAXIMUM VALUE 18
ALARM CODE 11 : EXTENSION READING < MINIMUM VALUE 19
ALARM CODE 21 : EXTENSION READING > MAXIMUM VALUE 19
CABLE REEL POWER SUPPLY VERIFYING 20
ANGLE POTENTIOMETER VERIFYING 21
BOOM LENGTH POTENTIOMETER VERIFYING 22
ALARM CODE 12 : MAIN CYLINDER (BOTTOM SIDE ) < MINIMUM VALUE 23
ALARM CODE 22 : MAIN CYLINDER (BOTTOM SIDE ) > MAXIMUM VALUE 24
ALARM CODE 13 : MAIN CYLINDER (ROD SIDE ) < MINIMUM VALUE 25
ALARM CODE 23 : MAIN CYLINDER (ROD SIDE ) > MAXIMUM VALUE 26

ACTION

EPROM and EEPROM REPLACEMENT 27

POTENTIOMETERS ALIGNMENT 28
SYSTEM LAY-OUT AND CONNECTIONS 29
EXTERNAL WIRING 30
RECOMMENDED SPARE PARTS LIST 31
 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.
Pressing the GREEN button again, it will be possible to show the hydraulic pressure values
at their 2 measuring points;
Pressing the RED button key, the system gives more information about transducers signals
digital converted values, and about ON/OFF Inputs and Outputs
from/towards outside status.
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).
At this aim a PASSWORD is given, allowing to enter 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.
FINE CALIBRATION. -SELECTION OF PREMEMORIZED ATTACHMENTS, DOWNLOAD
OF NEW ATTACHMENT TABLES, RECEIVED BY E-MAIL FROM MANUFACTURING
PLANT:
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 do not need the use of a PC.
 4

COMPONENTS LOCATION ON THE MACHINE

Length/Angle
sensor:
On the left side of
the boom

Nr.2 Pressure
Transducers:
On the lifting
cylinder. Rod
and bottom
side

Main Unit and

Control Panel :
into the cabin

SYSTEM LAY-OUT AND CONNECTIONS at page 29-30

 5

MAIN UNIT AND CONTROL PANEL

CODE: UMC1-1/XX

UMC1-1/XX Main Unit and Control Panel 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.
UMC1-1/XX 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
• 14 Digital Inputs
• 14+1 Digital Outputs
• 6 (+2) Analog Inputs
• Watch Dog Dynamic Output
• Voltage working range : 10-28 VCC
• Output Current : 2A
• Analog Inputs Voltage : 0- 5V
• Serial Links RS232, CAN BUS
• Clock and Buffer Battery
• Epoxy Resin Coating
• 32 Kb E2prom for Data Recording

MECHANICAL CHARACTERISTICS

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

MECHANICAL DIMENSIONS
179
180

225 265

40

TEREX CRANES 140

 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 actiive 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 4(n.a.), 8(com) Movement’s shut off
CODE DIODE PIN FUNCTION DO1 D71 12(n.a.), 16(com) Anti two block shut off
DI0 D35 17 Not used DO2 D74 Not used
DI1 D39 18 Not used DO3 D77 Not used
DI2 D43 19 Not used DO4 D80 13(com), 14(n.a.) Max.angle shut off
DI3 D47 20 Turrett sensor position 15(n.c.)
DI4 D51 21 Not used DO5 D83 Not used
DI5 D55 22 Anti two block switch by pass key DO6 D86 Not used
DI6 D59 23 Boom syncronizing Key DO7 D89 Not used
DI7 D63 24 Main by pass key DO8 D101 Not used
 8

AC MCP ANGLE / EXTENSION SENSOR Code : AC MCP214I/3P

AC MCP servocable-reels are used where
telescopic boom extensions over 12 meters
are needs.
The unwinding transducer (or transducers) is
formed by drum cable servo-winders on which
a cable is wound that is attached to the arm
head (or to intermediate elements).
With the unwinding extension, the wire
unwinds measuring the unwinding length
thanks to a potentiometric sensing device.
In the use of the crane, it is always necessary
to carefully survey the cable unwinding along
the arm, because 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 arm
thanks to a potentiometric 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 MODEL
Rings mm 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

PRESSURE TRANSDUCERS CODE : Y11 4745-450

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 are 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 450 bar
• Overload ranges 900 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.
 10

CONTROL PANEL DESCRIPTION

5 7

10
8
9
11
12
13

1 Working data display;

5 GREEN Button/lamp : if pressed, it allows the operator to scroll the pages lit = safety
6 AMBER Button/lamp :The lamp lit indicates that the load has reached the pre-alarm
condition. Pressing the button, the buzzer will stop.
7 RED Button/lamp : The lamp lit indicates that the load has reached the maximum load
allowed and the shut off has been performed;
The flashing light indicates that the machine is in shut down
procedures and the by pass key is activated.
The button can also used to confirm a selection.
8 Operating mode selection key press to increase operating mode value;
9 Operating mode selection key press to decrease operating mode value;
10 Rope number ( tackle ) selection key: press as many times as necessary to obtain the required
value in order to achieve a correct load reading;
11 Dimmer
12 Serial link connector for external Pc;
13 Buzzer ( positioned on the rear panel ) :
Intermittent beeping = prealarm condition;
Continuous beeping = alarm condition ( shut off movements).
 11

TROUBLESHOOTING
The first step to seek a fault is to identify the problem which occurred to the
machine Operator.
Thanks to the auto-diagnostic procedures, which are able to recognise
transducers failures, cable breaking and internal electronic faults, alarm
codes are automatically shown on the display to the Operator, allowing him
to 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 zone 1-8.
Depending on the message, the fault can be identified.

.2 t
max
13.4
m
24° 12.3
m 9.2 RUN
0°

m
%
ALARM :……………
1-8
101 1 .0 0 5.5
m

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.
 12

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
56 Assistance to:
Memory data not
Page17, •Verify that E2prom chip is fitted properly in its socket.
reliable
27, 32 • Re-enter data and save them again
• Replace the E2PROM chip and recalibrate the
machine
15 • Verify that the wiring and the connectors are not in
Page18, Angle sensor short circuit.
20, 21, reading lower than If the alarm persists, please, contact Technical
28, 29, the minimum value Assistance :
30 • Verify the angle sensor integrity.
25
•Verify that the cable or the connector wiring is not
Page18, Angle sensor
open
20, 21, reading higher
28, 29, If the alarm persists, please, contact Technical
than the maximum Assistance :
30 value
• Verify the angle sensor integrity.

• Verify that the cable or the connectors wiring are not

Reading pressure
in short circuit
12 of the main cylinder
If the alarm persists, please, contact Technical
Page23 (bottom side) lower Assistance :
than the minimum.
• Verify the pressure transducer integrity

Reading pressure • Verify that the cable or the connector wiring are not
22 of the main cylinder open
(bottom side) If the alarm persists, please, contact Technical
Page24 higher than the Assistance :
maximum. •Verify the pressure transducer integrity
 13

Alarm
Description What to do
code
•Verify that the wiring and the connectors are not in
Reading pressure of
13 short circuit
the main cylinder (rod
If the alarm persists, please, contact Technical
Pag.25 side) lower than the Assistance :
minimum.
•Verify the pressure transducer integrity
• Verify that the cable or the connector wiring are
Reading pressure of
23 not open
the main cylinder (rod
If the alarm persists, please, contact Technical
Pag.26 side) higher than the Assistance :
maximum.
•Verify the pressure transducer integrity
11 Reading of the boom • Verify that the wiring and the connectors are not in
Pag.19, length sensor lower short circuit
20, 22, than the minimum If the alarm persists, please, contact Technical
28, 29, Assistance:
value
30 Verify the length transducer integrity
21 • Verify that the cable or the connector wiring is not
Reading of the boom
Pag.19, open
length sensor higher
20, 22, If the alarm persists, please, contact Technical
than the maximum Assistance :
28, 29, value
30 • Verify the length transducer integrity

E01 The boom’s angle has

MINIMUM overtaken the • Lower the boom
RADIUS maximum value
This message appears
when the boom is
E02 positioned in a way •Lift or close the crane boom until a load chart table
MAXIMUM that, referring to the
RADIUS load charts, there isn’t can be applied.
any load charts table
applicable

And more, to make things easier, the internal operating conditions can be displayed
directly on the display as follows.
 14

AUTO DIAGNOSTIC
System internal working conditions monitoring
Geometric data and load data
These readings show on some pages the internal status of the system which become very
useful when a fault occurs.
Starting from the main working data page press twice the GREEN button:
The display will show the control page, giving
geometric data and main cylinder differential pressure summary.

The displayed parameters are as follows:

• P : Main cylinder differential pressure

in Bar;

• W : Lifted load weight in Tonnes; .2 t

max
13.4
m
24° 12.3
• M : Maximum admitted load in present m 9.2 RUN
0°

position in Tonnes;
%
% 0/ 0/ 0 S:
P49 W 0.2 M13.4
A24 L12.3 R 9.2
• A : Actual angle in Degrees; m

• L : Actual boom length in Meters;

• R : Radius from turret rotation centre

in Meters;

Hydraulic pressures data

By pressing the RED BUTTON the display shows the individual hydraulic pressures
summary :

The displayed parameters are as follows:

• P : Main cylinder differential pressure
in Bar;

• PL : Main cylinder bottom side pressure

.2 t
max
13.4
m
in Bar; 24° 12.3
m 9.2 RUN
0°

m
%
% 0/ 0/ 0 S:
• PH : Main cylinder rod side pressure P49 PL 54 PH 17
in Bar; A24 L12.3 W 0.2
m

• A : Actual angle in Degrees;

• L : Actual boom length in Meters;

• W : Lifted load weight in Tonnes;

To return to the main page, press the Green button.

 15

AUTO DIAGNOSTIC
System internal working conditions monitoring
Sensors Digital Signals
Pressing once again the RED button the display will show the first page giving pressure
transducers and length/angle sensors digital signals corresponding to the actual
measurements.

The displayed parameters are as follows:

0 xxx : Main cylinder bottom side pressure

value in Bits; between 0 and 1023 (*)
.2 t
max
13.4
1 xxx : Main cylinder rod side pressure value m
12.3
24°
in Bits; between 0 and 1023 (*) m 9.2 RUN
0°

m
%
% 0/ 0/ 0 S:
0 XXX 1 XXX
2 xxx : Angle value in Bits; 2 XXX 3 XXX
between 0 and 1023 (*) m

3 xxx : Boom Length value in Bits;

between 0 and 1023 (*)

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

Pressing once again the RED button the display will show the second page giving digital
signals corresponding to the measurements of the other analogic inputs:

The displayed parameters are as follows:

4 xxx : not used;

5 xxx : not used;

.2 t
max
13.4
6 xxx : Anti two block status: in safety 24°
m
12.3
condition, the value must be around m 9.2 RUN
0°

530(*); %
% 0/ 0/ 0 S:
4 XXX 5 XXX
6 XXX 7 XXX
7 xxx : not used; m

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

To return to the main page, press the Green button.

 16

AUTO DIAGNOSTIC
System internal working conditions monitoring
Status of Digital Inputs from outside
Pressing once more the RED button, the display shows the summary of the ON/OFF
selections given by external micro-switches:
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 : Not used
• 1 : Not used .2 t 13.4
max
• 2 : Not used m
24° 12.3
• 3 : Turret position sensor :“*” micro switch active m 9.2 RUN
0°

m
%

• 4 : Not used % 0/ 0/ 0 S:
I 01234567890123
• 5 : Anti two block by pass key : -------------*
“*” when the anti two block by pass button is pressed m

• 6 : Boom synchronizing key:

“*” When the Boom synchronizing key is activated
• 7 : Main by pass key :
“*”When the main by pass key is activated.
• 8-N.: Not used
Status of Digital Outputs to outside
Pressing once more the RED button, the display shows the Outputs of the system status
summary ( automatic signals):
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 Movements :
“*” when the machine works in safety condition.
“-” when the machine is entered in shut off
procedures (100%) .2 t 13.4
max
1 : Anti two block shut off : m
24° 12.3
“*” when the anti two block is not activated m 9.2 RUN
0°

“-” when the anti two block is activated. %

% 0/ 0/ 0 S:
2 : Not used O 01234567890123
**--*---*----*
3 : Non used m

4 : Maximum angle shut off :

“*” when the maximum angle shut off is not activated
“-” when the maximum angle shut off is activated
5-N.:Not used

To return to the main page, press the Green button.

 17

ALARM CODE 56 : 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 56 = 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.
( To load data from the PC, please refer to the
“SAVING DATA TO A PC” in the calibration manual ).
4) If the problem persists, replace the PC board making sure that
software/parameters installed are corresponding to the
machine characteristics.
 18

ALARM CODE 15 :
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 25:

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
 19

ALARM CODE 11 :
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 20).
• Verify length potentiometer
(refer to “EXTENSION POTENTIOMETER VERIFYING” section - page 22).

ALARM CODE 21 :
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 20).
• Verify length potentiometer
(refer to “EXTENSION POTENTIOMETER VERIFYING” section - page 22).
(*) 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
21 22 23 24
X1 X2
20
Verify on connector X2
Verify the 16
(connected to MECACOMP unit)
Potentiometers 12
between plinth 19(+) and 7(GND).
(**) 8
a voltage of 5Vdc

1 2 3 4

TRUE FALSE

Disconnect connector X2. 20

Cable brake down. Verify on the pc board 16
Check the between plinth 12
cable-reel cable 19(+) and 7 (GND). 8
a voltage of 5Vdc
1 2 3 4

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 27

(**) REFER TO pages 21 and 22
 21

ANGLE POTENTIOMETER VERIFYING

Put the machine boom at 0° (horizontal).

2 (CA2) 3 (GND)

Verify between
2(CA2 ) e 3 (GND)
+2,5Vcc +/- 5%

FALSE TRUE

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

Verify with a voltmeter that the

signal increases in a linear X1 X2
and continous way.

The variation is continous

Losses of Signal
and linear

Angle potentiometer Verify on connector X2 21 22 23 24

broken (**) (connected to MEGACOMP unit)
the potentiometer signal 20
between plinth 7(GND) e 11(CA2) 16
12
8
The signal is The signal
not correct is correct 1 2 3 4

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 27

(**) REFER ALSO TO POTENTIOMETERS ALIGNMENT - page 28
 22

BOOM LENGTH POTENTIOMETER VERIFYING

The machine boom must be completely retracted.

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

Perform a Boom extension. potentiometer broken
Potentiometer broken
(**) (**)

Verify with a voltmeter that the

signal increases in a linear
and continous way.
X1 X2

The variation is continous

Losses of Signal
and linear

Boom Length Verify on connector X2

21 22 23 24
potentiometer broken (connected to MEGACOMP unit)
(**) the potentiometer signal
20
between plinth 7(GND) e 15(CA3)
16
12
8
The signal is The signal
not correct is correct
1 2 3 4

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 27

(**) REFER ALSO TO POTENTIOMETERS ALIGNMENT - page 28
 23

ALARM CODE 12 :
MAIN CYLINDER (BOTTOM SIDE) READING
LOWER THAN THE MINIMUM VALUE
CAUSE:
Main Unit Processor identifies below and over the signal range a minimum zone and a
maximum zone in order to check the sensor.
ACTION TO TAKE :

21 22 23 24 21 22 23 24
X1 X2 X1 X2
20 20
16 16
12 12
8 8

1 2 3 4 1 2 3 4

Verify on connector X2 TRUE

(connected to MEGACOMP unit )
between plinth 5(+) and 9(GND)
A voltage of 15Vdc Check on connector X2
(MEGACOMP unit) the voltage
between plinth 9(GND)
And 17(CA 0)

Value <0,5Vcc Value >0,5Vcc

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
20
16
Disconnect connector X2. 12
Verify again on the pc board 8
between plinth 5(+) and 9 (GND).
a voltage of 15Vdc
1 2 3 4

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 27

 24

ALARM CODE 22 :
MAIN CYLINDER (BOTTOM SIDE) READING
HIGHER THAN THE MAXIMUM VALUE
CAUSE:
Main Unit Processor identifies below and over the signal range a minimum zone and a
maximum zone in order to check the sensor.
ACTION TO TAKE:
21 22 23 24 21 22 23 24
X1 X2 X1 X2
20 20
16 16
12 12
8 8

1 2 3 4 1 2 3 4

Verify on connector X2 TRUE

( connected to MEGACOMP unit )
between plinth 5(+) and 9(GND)
A voltage of 15Vdc Check on connector X2
(connected to MEGACOMP unit)
the voltage between
plinth 9(GND) and 17(CA0)

Value >5Vcc Value <5Vcc

Broken Pressure The Main pc board

Transducer.Proceed is faulty.Proceed
With the with the
Replacement replacement (*)

FALSE
20
16
Disconnect connector X2. 12
Verify again on the pc board 8
Between plinth 5 (+) and 9 (GND).
a voltage of 15Vdc
1 2 3 4

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 27
 25

ALARM CODE 13:

MAIN CYLINDER (ROD SIDE) READING LOWER
CAUSE:
THAN THE MINIMUM VALUE
Main Unit Processor identifies below and over the signal range a minimum zone and a
maximum zone in order to check the sensor.
ACTION TO TAKE:
21 22 23 24 21 22 23 24
X1 X2 X1 X2
20 20
16 16
12 12
8 8

1 2 3 4 1 2 3 4

Verify on connector X2 TRUE

( connected to MEGACOMP unit )
between plinth 6(+) and 10 (GND)
a voltage of 15Vdc Check on connector X2
(connected to MEGACOMP unit)
the voltage between
plinth 10(GND) and 18 (CA1)

Value <0,5Vcc Value >0,5Vcc

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
20
16
Disconnect connector X2.
12
Verify again on the pc board
8
between plinth 6 (+) and 10 (GND).
a voltage of 15Vdc
1 2 3 4

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 27

 26

ALARM CODE 23 :
MAIN CYLINDER (ROD SIDE) READING HIGHER
THAN THE MAXIMUM VALUE
CAUSE:
Main Unit Processor identifies below and over the signal range a minimum zone and a maximum
zone in order to check the sensor.
ACTION TO TAKE:
21 22 23 24 21 22 23 24
X1 X2 X1 X2
20 20
16 16
12 12
8 8

1 2 3 4 1 2 3 4

Verify on connector X2 TRUE

( connected to MEGACOMP unit )
between plinth 6(+) and 10 (GND)
a voltage of 15Vdc Check on connector X2
(connected to MEGACOMP unit)
the voltage between
plinth 10(GND) and 18 (CA1)

Value >5Vcc Value <5Vcc

Broken Pressure The Main pc board

Transducer.Proceed is faulty.Proceed
With the with the
Replacement replacement (*)

FALSE
20
16
Disconnect connector X2.
12
Verify again on the pc board
8
between plinth 6 (+) and 10 (GND).
a voltage of 15Vdc
1 2 3 4

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 27

 27

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 adeguate 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 .
 28

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.

Press twice the green button in order to visualize the %

% 0/ 0/ 0 S:
geometrical and load page summary. P49 W 0.2 M13.4
A24 L12.3 R 9.2
m

Press the red button until the transducers reading page will
be displayed

%
% 0/ 0/ 0 S:
0 XXX 1 XXX
2 XXX 3 XXX
m

Regarding the angle reading, simply verify that, with the boom horizontal (0°), the “2XXX
sensor is reading between 500 and 520. Check that, the value will increase by raising the
boom.
Proceed with the sensor assembly.
After the length potentiomer has been replaced, it’s necessary proceed with its alignment.
With the machine’s boom completely closed, rotate the potentiometer body until the “3
XXX” reading is around 50. Proceed with the sensor assembly.
In case of cable reel wire replacement, put it around 1 mt. pre-tension, fixing the other
side to the boom end.
Rotate the potentiometer body until the “3 XXX” reading is around 50, check that, the value
will increase by extending the boom.
After the replacement of the potentiometer, it is advisable to verify the correspondence
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.
 29

SYSTEM LAY-OUT AND CONNECTIONS

MAIN UNIT AND

CONTROL PANEL : UMC1-1/10

Anti Two Block

TEREX CRANES
X1 X2

INPUT/OUTPUT
SIGNALS AND
EXTERNAL SUPPLY LENGTH/ANGLE SENSOR L=32 mt
AC MCP214I/3P

PRESSURE TRANSDUCERS
Y11 4745-450
 30

EXTERNAL WIRING

X1
+VB
1 +VB
-VB
2 -VB
3 -VB
4 K0 No
5 K2 Com
6 K2 No
7 K2 Nc
8 K0 Com
9 K3 Com
10 K3 No
11 K3 Nc
LOW CHAMBER 12 K1 No
LOW CHAMBER
PIN WIRE SIGNAL 13 K4 Com
1 BROWN +15V 14 K4 No
1 23

2 WHITE AGND 15 K4 Nc
3 GREEN CA0 16 K1 Com
INP0
SHIELD SHLD
17 INP0
INP1
18 INP1
INP2
19 INP2
INP3
1 23

20 INP3
INP4
21 INP4
INP5
22 INP5
INP6
HIGH CHAMBER 23 INP6
INP7
24 INP7
HIGH CHAMBER
PIN WIRE SIGNAL
1 BROWN +15V
2 WHITE AGND SHLD

1 5 9 13 17 21 2 6 1014 18 3 7 1115 19 4 8 12 16 20 22 2324

3 GREEN CA1 SHLD
BROWN
SHIELD +15V
SHLD WHITE
AGND

GREEN
CA0

SHLD
SHLD
BROWN
+15V
WHITE
SERVO CABLE-REEL + INCLINOMETER AGND

GREEN
CA1
SHLD
SHLD
WHITE
AGND
WHITE (GND) YELLOW
CA2
GREEN
YELLOW(CA2) CA3
BROWN
BROWN (+5V) +5V

AGND
CA4
CA5
YELLOW
+5V
1 +5V BROWN GREY
+15V
2 CA3 GREEN PINK
CA6
3 GND WHITE
GREY
PINK X2

PTS-10

A2B
 31

RECOMMENDED SPARE PARTS LIST

MAIN COMPONENTS

DESCRIPTION CODE

MAIN UNIT AND CONTROL PANEL UMC1-1/xx

LENGTH/ANGLE SENSOR AC MCP214I/3P
PRESSURE TRANSDUCER Y11 4745-450

INTERNAL PARTS

DESCRIPTION CODE

MAIN PC BOARD S U2MIC-6/42

CONNECTOR’S INTERFACE PC BOARD S I.UMC1-1/10
KEY BOARD PC BOARD S DT-CMC1/20
DISPLAY PC BOARD S DM-CMC1/30

LENGTH AND ANGLE TRANSDUCER INTERNAL PARTS

DESCRIPTION CODE

ANGLE POTENTIOMETER PC BOARD GR TIHP300/10

ANGLE POTENTIOMETER Y11 PL310/1K
LENGTH POTENTIOMETER PT 534-2K
CABLE REEL WIRE 32 + 5 mt CV 102/00
CABLE REEL WIRING KIT KIT CBL/10