MotoCrane ULTRA User manual

ULTRA Troubleshooting Guide v2.0
July 2020
This guide helps users diagnose and repair issues in the field.
It should be used in conjunction with the ULTRA Operation Manual.
If a quick fix is available, one is prescribed. If a quick fix is not possible, we give a service
procedure for repair using the spare parts in the Deadlock Service Kit (available for purchase
online). Without a Deadlock Service Kit, spare parts can be purchased individually or the
affected modules can be returned to MotoCrane for repair.
Via MotoCrane Academy, Certified Technicians and Operators are trained on how to perform
these more common service procedures. Find more information at
www.motocrane.com/academy.
1

Contents
Understanding System Feedback 3
COM and Power LEDs 3
GUI Warning and Error Messages 4
Diagnosing Common Issues 5
“I have anodizing/finish problems” 5
“Grease is Leaking from the Base” 5
“Swing is not working” 6
“Lift is not working” 7
“The system is not turning on” 8
Appendix 1: Diagnosis Procedures 9
External Deactivation of Lift Drive Brake 9
“Remove PSU Top” 10
“Remove 24V Power Fuse” 10
“Check Power Fuse for Continuity” 10
“Unplug CAN-TRVL, Check Pins 3 and 4 for Continuity” 11
“Check continuity across Pins H and J on the BDU Main Power Input Socket” 11
“Open Base Pedestal Plate, Remove CAN IN Connector” 11
“Remove Lift Encoder Cover, Unplug CAN IN from Lift Encoder Board” 12
“Check continuity between pins H and J on the LDU Main Power Input Socket” 12
“Emergency Bypass Procedure” (for PSU Circuit Board failure) 12
Appendix 2: Error Codes Lookup Table 15
Revision History 29
2

Understanding System Feedback
ULTRA provides system feedback using two primary methods: LEDs and GUI Messages.
COM and Power LEDs

The Base Driver Unit, Base Pedestal, PSU, and Turret all contain LEDs to help quickly
identify problems with electrical connections.

The COM LED will turn on when the electronics at that location are successfully
communicating on the CAN-bus with the other parts of the system. If this LED turns off,
this indicates that either the electronics at that location have stopped functioning
properly, a wiring issue has developed that prevents normal communication to occur,
or in an extremely rare case that the COM LED has burned out.

The COM LEDs can help to diagnose cabling vs. electronics issues. If all COM LEDs are
off, this could be an issue with the Main Power Cable from the PSU to the Base. If only
the Base Driver Unit COM LED is on, this could indicate internal wiring problems in the
Base. If both the Base Driver Unit and Base Pedestal COM LEDs are on, but the Turret
COM LED is off, this could indicate a bad cable between the Base Pedestal and Turret,
or an LDU electronics failure.

Similarly, the Power LEDs indicate the presence of the 48V system power in their
respective locations. Power LEDs are also present in the PSU, to provide a visual
confirmation that the system power is connected and switched on.


** Please note: Due to inherent properties of the power management system, the
Power LEDs may remain dimly lit for a short while after the system power is turned off.


3

GUI Warning and Error Messages

ULTRA has multiple internal sensors and an error reporting system built into the GUI.

If an active error or warning is present, the respective red or yellow icon will be
displayed. A yellow icon indicates a warning, and the controller will beep once to alert
the user. A red icon indicates an error, and the controller will beep repeatedly until the
icon is touched or the DISARM physical switch is pressed by the user.
Touching the error or warning icon will bring you to the Status page, where you can
see a list of active errors and warnings. If you are experiencing an intermittent issue,
and the warning or error is not currently active, you can review events by navigating to
the System Log, which is accessible through the Diagnostics page. The System Log will
also provide a list of errors and warnings that have occurred, along with the time since
the event occurred (in 2 minute increments). Note that the System Log will only hold
the most recent 10 events, and is cleared upon power cycling the system.

From either the Status or System Log page, you can access the Code Lookup Table,
which will provide you with a short description of the error or warning and a
recommended first step for troubleshooting and clearing the issue. For reference, the
‘Controller - GUI’ section of the Operation Manual shows the location of the System
Log and Code Lookup buttons within their respective pages.

More detail is given below about each error message along with a description of what
to try if the first step does not work.

**When debugging any error or warning, first ensure that all cables are properly
connected and check the status of the COM and Power LEDs on all modules.
4

Diagnosing Common Issues
Please see the list of common symptoms below, and the procedure for fixing solving.
“I have anodizing/finish problems”
● Anodizing/finish problems in non-wear areas.
○ Cause: Some anodizing batches are more susceptible to fade/ color change
under UV exposure.
○ Operation Manual reference: N/A
○ Repair Procedure: Replace or re-finish problematic parts.
○ Warranty: Covered, manufacturing defect in fit/finish. The customer pays all
shipping costs, as outlined in Terms of Sale.
● Cracking Anodizing around boom fasteners.
○ Cause: Washers are needed to minimize surface abrasion.
○ Operation Manual: See ULTRA Boom + Isolator Setup on p. 21 to ensure
customers are using washers appropriately.
○ Repair Procedure: N/A
○ Warranty: Not covered. Normal wear and tear.
“Grease is Leaking from the Base”
● Some grease has become liquid and escaped through the grease ports.
○ Cause: As the swing axis moves, the grease is continually circulated within the
chamber and undergoes a transition from thick to thin, depending on its location
and temperature. Some thin grease may escape at times, but this is not a cause
for concern. Simply wipe it away and it should diminish over time.
○ Operation Manual: N/A
○ Repair Procedure: N/A
○ Warranty: N/A
5

YES
NO
NO YES
Is Swing Axis
MOTOR CMD moving
when the joystick is
moved?
Controller Giving Error Codes?
Go to DIAGNOSTICS
page on Controller
GUI
Go to STATUS page
on Controller GUI
(touch Error/Warning
notice)
NO YES Is BDU MAIN
POWER STATUS
LED on? (green)
NO YES
Is Swing SPEED set
to 99 and SMOOTH
set to 0?
NO YES
Does Lift Joystick
function
normally?
SUCCESSFUL ADJUSTMENT
CANNOT
ADJUST
Adjust Swing
SPEED to 99 and
SMOOTH to 0
NO YES
Is E-STOP (DISARM)
released? (twisted
and pulled out)
Swing Joystick is
Faulty - replace it
Controller Circuit
Board is likely
damaged - needs
replacement
Release E-Stop
YES
NO
Is Base Pedestal
MAIN POWER
STATUS LED on?
(green)
NO YES
Is Turret MAIN
POWER STATUS
LED on? (green)
Electrical Problems
Exist Within the Base
- Contact MotoCrane
Customer Support
Base Driver Circuit
Board has failed -
BDU needs to be
replaced
Base Driver Circuit
Board has failed -
BDU needs to be
replaced
Main Power pathway may
be faulty - or PSU has
internal damage
Try replacement PSU and
cables if available
Otherwise, Contact
MotoCrane Customer
Support
Code 075 Code 130 Code 125
Base Driver Circuit
Board has failed -
BDU needs to be
replaced
Swing Joystick is
Faulty - replace it
Swing Joystick is
Faulty - replace it
3
2
1
1
1 2 2
4
5
"SWING IS NOT WORKING"
ISSUE 1)BDU failure
Solution: Replace BDU or contact MotoCrane Support
ISSUE 2)Swing joystick failure
Solution: Replace joystick or contact MotoCrane Support
ISSUE 3)Controller Board failure
Solution: Replace Controller board or contact MotoCrane Support
ISSUE 4)PSU/Cable failure
Solution: Replace PSU, Cables or contact MotoCrane Support
ISSUE 5)ULTRA Base failure
Solution: Contact MotoCrane Support
POSSIBLE ISSUES
After completing the flowchart, use the
key below to determine next steps.

YES
NO
NO YES
Is Lift Axis MOTOR
CMD moving when
the joystick is moved?
Controller Giving Error Codes?
Go to DIAGNOSTICS
page on Controller
GUI
Go to STATUS page
on Controller GUI
(touch Error/Warning
notice)
NO YES
Is LDU MAIN
POWER STATUS
LED on? (green)
NO YES
Is Lift SPEED set to
99 and SMOOTH set
to 0?
NO YES
Does Swing
Joystick function
normally?
SUCCESSFUL ADJUSTMENT
CANNOT
ADJUST
Adjust Lift SPEED
to 99 and SMOOTH
to 0
NO YES
Is E-STOP (DISARM)
released? (twisted
and pulled out)
Lift Joystick is
Faulty - replace it
Controller Circuit
Board is likely
damaged - needs
replacement
Release E-Stop
YESNO Is Base Pedestal
MAIN POWER
STATUS LED on?
(green)
NO YES
Is BDU MAIN
POWER STATUS
LED on? (green)
Electrical Problems
Exist Within the Unit -
Contact MotoCrane
Customer Support
Lift Driver Circuit
Board has failed -
LDU needs to be
replaced
Lift Driver Circuit
Board has failed -
LDU needs to be
replaced
Main Power pathway may
be faulty - or PSU has
internal damage
Try replacement PSU and
cables if available
Otherwise, Contact
MotoCrane Customer
Support
Code 035 Code 129 Code 125
Lift Driver Circuit
Board has failed -
LDU needs to be
replaced
Lift Joystick is Faulty
- replace it
Lift Joystick is Faulty
- replace it
3
2
1
1
122
4
5
"LIFT IS NOT WORKING"
YESNO Code 109 Also?
Check cables and
replace Base
Pedestal to Turret
cable if possible
Contact MotoCrane
Customer Support if
this is not an option
ISSUE 1)LDU failure
Solution: Replace LDU or contact MotoCrane Support
ISSUE 2)Lift joystick failure
Solution: Replace joystick or contact MotoCrane Support
ISSUE 3)Controller Board failure
Solution: Replace Controller board or contact MotoCrane Support
ISSUE 4)PSU/Cable failure
Solution: Replace PSU, Cables or contact MotoCrane Support
ISSUE 5)ULTRA Base or Turret failure
Solution: Contact MotoCrane Support
POSSIBLE ISSUES
After completing the flowchart, use the
key below to determine next steps.

NO YES
PSU Main Power Input Voltage
Meter On?
YES
NO Is power source >
42V?
YESNO PSU MAIN POWER
STATUS LED on?
(green)
"THE SYSTEM WON'T TURN ON"
Turn off PSU Main
Power Switch
Disconnect Controller
Cable from COM port
Provide Adequate
Power Source
Disconnect Main
Power Output Cable
from PSU
Turn on PSU Main
Power Switch
Turn off PSU Main
Power Switch
NO YESPSU MAIN POWER
STATUS LED on?
(green)
PSU is Damaged -
Replace PSU
*Assumes PSU Main Power ON/OFF Switch is already "ON"
and the Controller does not boot up and turn on
* Try different or new cables, if possible, before moving to
troubleshooting steps
Disconnect Main
Power Output Cable
from PSU
Turn on PSU Main
Power Switch
NO YES
Does Controller boot-
up and turn on?
There is likely a
problem with the 24V
line in the Base or
Turret
Turn off PSU Main
Power Switch Make sure the Base
Pedestal to Turret
Main Power Cable is
not connected
Use a multimeter to
check continuity
across pins H and J
on the BDU Main
Power Input Socket
NO YESIs there continuity
across pins H and J?
(short-circuit)
Use a multimeter to
check continuity
across pins H and J
on the LDU Main
Power Input Socket
Open Base Pedestal
Cover (using 2.5mm
hex key)
Turn off PSU Main
Power Switch
Unplug the 4-pin
"CAN-IN" connector
from the Swing
Encoder Circuit Board
NO YES Is there continuity
across pins H and J?
(short-circuit)
Use a multimeter to
check continuity
across pins H and J
on the BDU Main
Power Input Socket
YES
NO Is there continuity
across pins H and J?
(short-circuit)
Replace BDU
Replace Swing
Encoder Circuit
Board
Contact MotoCrane
Customer Support -
this issue cannot be
isolated in the field
Try using a different
PSU to Base Main
Power Cable if
possible
Open Turret Fulcrum
Encoder Cover (using
3mm hex key)
Unplug the 4-pin
"CAN-IN" connector
from the Lift Encoder
Circuit Board
Use a multimeter to
check continuity
across pins H and J
on the LDU Main
Power Input Socket
NO YES
Is there continuity
across pins H and J?
(short-circuit)
Replace Lift
Encoder Circuit
Board
Replace LDU
Contact MotoCrane
Customer Support -
this issue cannot be
isolated in the field
Reconnect Main
Power Output Cable
to PSU
Disconnect Controller
COM Cable from
PSU
Turn on PSU Main
Power Switch
PSU MAIN POWER
STATUS LED is
probably burned out
NO YES
Do COM Lights
appear (blue) on the
Base and Turret?
Turn off PSU Main
Power Switch
Disconnect all cables
from PSU
Remove PSU top
cover
Remove 24V Power
Fuse
Use a multimeter to
check continuity of
fuse
YES NO
Is there continuity
across the fuse?
Replace PSU - 24V
DC/DC converter
has likely failed
* SOMETHING HAS BLOWN THE FUSE
FUSE OR PSU WILL NEED TO BE REPLACED
ONCE THE ROOT CAUSE IS ADDRESSED
Unplug the 4-pin
"CAN-TRVL"
connector from the
PSU Circuit Board
Use a multimeter to
check continuity
across pins 3 and 4
on the circuit board
YES
NO
Is there continuity
across the pins?
Try new Controller
cable if possible
Replace Controller if
this does not solve
the problem
Replace PSU -
Circuit board is
likely damaged
OR
Emergency Bypass
Procedure
(Appendix 1)
Plug Back in the
CAN-TRVL connector
ISSUE 1)PSU failure
Solution: Replace PSU or contact MotoCrane Support
** EMERGENGY BYPASS OPTION - see Appendix A
ISSUE 2)Controller failure
Solution: Replace Controller or contact MotoCrane Support
ISSUE 3)Lift Encoder Board failure
Solution: Replace Lift Encoder Board or contact MotoCrane
Support
ISSUE 4)LDU failure
Solution: Replace LDU or contact MotoCrane Support
ISSUE 5)Swing Encoder Board failure
Solution: Replace Swing Encoder Board or Contact
MotoCrane Support
ISSUE 6)BDU failure
Solution: Replace BDU or Contact MotoCrane Support
ISSUE 7)Multiple issues - requires further debugging
Solution: Contact MotoCrane Support
POSSIBLE ISSUES
After completing the flowchart, use the
key below to determine next steps.
1
1
7
1
2
34
56
7
SEE APPENDIX 1

Appendix 1: Diagnosis Procedures
External Deactivation of Lift Drive Brake
In a rare situation, it is possible that the lift motor driver electronics could fail due to
extreme overuse, disregard for system warnings, faulty cables, improper system power
supply, among others. Because the nature of the lift drive brake is ‘fail-safe’, this means
that when the system is unpowered (more specifically, the lift motor driver electronics
are not receiving power), the brake is activated and the lift axis will not move, except in
the case of extreme imbalance between payload and counterweight. In the event that
the lift motor driver electronics stop working, and the lift axis is stuck in an undesirable
position, the following steps can be taken to manually unlock the lift axis:

1. Turn off power from the system and remove the short cable connecting the Base
Pedestal to the Turret
2. Plug the main power input cable directly into the socket on the Turret (this cable
normally connects directly to the Base Driver Unit)
3. Ensure the other side of the main power input cable is connected to the PSU
4. Remove the small rectangular cover on the Turret, immediately adjacent to the
main power input socket (there are two small flat-head cap screws to remove)
5. Turn on the main power switch on the PSU
6. Depress and latch the button that was exposed by removing the rectangular
cover on the Turret
7. An audible click should be heard when this button is pressed, and the brake
should be deactivated
8. Manually position the boom to the desired location
9. Press the button again to un-latch it
10.Turn off the main power switch on the PSU
11.Replace the rectangular cover back on the Turret
Note that this feature is an immediate solution for re-positioning the fulcrum and
boom, in the event that the system cannot otherwise be transported or disassembled
normally. Service will still be required to repair the electronics and return the system to
normal operating conditions.

9

“Remove PSU Top”



“Remove 24V Power Fuse”



“Check Power Fuse for Continuity”

NO Continuity YES Continuity




 
10


“Unplug CAN-TRVL, Check Pins 3 and 4 for Continuity”

“Check continuity across Pins H and J on the BDU Main Power Input
Socket”

NO Continuity YES Continuity
“Open Base Pedestal Plate, Remove CAN IN Connector”



11

“Remove Lift Encoder Cover, Unplug CAN IN from Lift Encoder Board”


“Check continuity between pins H and J on the LDU Main Power Input
Socket”

NO Continuity YES Continuity

“Emergency Bypass Procedure” (for PSU Circuit Board failure)
NOTE: This procedure is only recommended for emergency and time-critical situations. For
everything else, the best course of action is to wait for a replacement PSU or PSU Circuit Board
in order to restore the system to its original state. Operating the PSU without the capacitors and
without a proper fuse may present risks to the rest of the system, and lacks protection for
potential (but unlikely) failures in other modules, such as the Base, Turret, or Controller.
Additional information about this procedure:
We have seen isolated failures of two capacitors in particular (C10 and C11 on the PSU Circuit
Board), which results in a short circuit of the low power 24V communication power line in the
system, blowing the fuse in the PSU and preventing the system from powering up. Although
these capacitors are on the board for a reason, they are not absolutely essential to the short
term operation of the circuit. Therefore, the emergency bypass procedure involves physically
removing these capacitors from the board in order to remove the short circuit condition and
allow for operation of the unit until a new PSU circuit board can be installed. In addition to
12

removing the capacitors, the fuse will need to be replaced or bypassed with a conductor, since
the fuse fails in an open-circuit configuration. Please refer to the following images and
descriptions for information about removing these capacitors and bridging the fuse connection.
FUSE BYPASS
A common multi-strand wire can be used to bypass (bridge) the fuse.
Start by stripping the insulation, and separating out 4-6 individual copper wires.
Wrap the copper strands around the fuse legs, and re-install into the Fuse Holder.
**NOTE: For this procedure, it is also possible to remove the fuse completely and replace
it with a paper clip or solid wire, provided that it fits snugly in the fuse-holder terminals.
The objective is to create continuity between the two terminals of the fuse-holder.
13

REMOVE C10 and C11 CAPACITORS
While it is preferable to use a hot air/soldering station, a small jeweler’s/precision screwdriver
can be used to “pop” or “pry” the damaged C10 and C11 capacitors off of the PSU circuit,
making the circuit functional again.
14

Appendix 2: Error Codes Lookup Table

Code
Description
Service
Details
002
Lift Motor Temp
Warning
●Use caution and watch
motor temp
●Make sure payload and
counterweight are
properly balanced
●Make sure there are no
obstructions preventing
the boom from raising
or lowering
●Keep system
‘DISARMED’ during
periods of inactivity
The lift motor temperature has risen to a
level that is higher than expected, under
normal use. This can be caused by
excessive load and higher than normal
current passing through the motor.

Under very high ambient temperatures
and with the Turret Fulcrum in direct
sunlight, this warning can appear from
time to time and is not a concern.
Keeping the system ‘DISARMED’ during
periods of inactivity, and keeping the
system covered or in shade will help
prevent this warning from happening
003
Lift Motor Temp
Error
●Discontinue use until
temp is reduced
●Make sure payload and
counterweight are
properly balanced
●Make sure there are no
obstructions preventing
the boom from raising
or lowering
The lift motor temperature has risen to a
level that is potentially dangerous to the
system. This could be caused by extreme
overuse, high ambient temperatures,
imbalanced load, obstruction of lift
movement, or some combination of
these events. Allow the system to cool
down below the error threshold before
continuing major lift-axis movements.
004
Lift Motor Temp
Sensor Failure
●Use caution and
contact MotoCrane
Support
●Avoid heavy use of lift
moves in high ambient
temperatures
The lift motor temperature sensor
reading has been lost by the system. The
most likely cause of this failure is damage
to the Turret internal wiring or
electronics. Service on the Turret by
MotoCrane is required to resolve this
issue. The unit can still be used with
caution, but should be serviced at the
earliest convenience.
007
Lift Motor Driver
Temp Warning
●Use caution and watch
driver temp
●Make sure payload and
The temperature of the lift motor driver
electronics has risen to a level that is
higher than expected, under normal use.
15

counterweight are
properly balanced
●Make sure there are no
obstructions preventing
the boom from raising
or lowering
This is generally caused by excessive
load and higher than normal current
being used by the motor. If the problem
is persistent, contact MotoCrane
Support.
008
Lift Motor Driver
Temp Error
●Discontinue use until
temp is reduced
●Make sure payload and
counterweight are
properly balanced
●Make sure there are no
obstructions preventing
the boom from raising
or lowering
The temperature of the lift motor driver
electronics has risen to a level that is
potentially dangerous to the system. This
could be caused by extreme overuse,
high ambient temperatures, imbalanced
load, obstruction of lift movement, or
some combination of these events. If the
problem is persistent, contact MotoCrane
Support.
009
Lift Motor Driver
Temp Sensor
Failure
●Use caution and
contact MotoCrane
Support
●Avoid heavy use of lift
moves in high ambient
temperatures
The lift motor driver temperature sensor
reading has been lost by the system. The
most likely cause of this failure is damage
to the Turret electronics. Service on the
Turret by MotoCrane is required to
resolve this issue. The unit can still be
used with caution, but should be serviced
at the earliest convenience.
012
Lift
Over-Current
Warning
●Use caution and
observe current and
temps
●Make sure payload and
counterweight are
properly balanced
●Make sure there are no
obstructions preventing
the boom from raising
or lowering
The lift motor current has risen to a level
that is higher than expected, under
normal use. This is generally caused by
excessive load and higher than normal
current passing through the motor.
013
Lift
Over-Current
Error
●Discontinue use while
error is active
●Make sure payload and
counterweight are
properly balanced
●Make sure there are no
obstructions preventing
the boom from raising
The lift motor current has risen to a level
that is potentially dangerous to the
system. This could be caused by extreme
movements, imbalanced load,
obstruction of lift movement, or some
combination of these events.
16

or lowering
014
Lift Current
Sensor Failure
●Use caution and
contact MotoCrane
Support
●Avoid extreme
movements of lift axis
and make sure payload
and counterweight are
balanced
The lift motor current sensor reading has
been lost by the system. The most likely
cause of this failure is damage to the
Turret electronics. Service on the Turret
by MotoCrane is required to resolve this
issue. The unit can still be used with
caution, but should be serviced at the
earliest convenience.
018
Lift Motor Stall
●Disarm, power cycle,
and check functionality
●Make sure there are no
obstructions preventing
the boom from raising
or lowering
Stall conditions are detected to prevent
excessive current and temperature from
damaging the motor. If the motor current
is above a certain threshold for a period
of time, without any movement of the
motor, a stall is detected and the power
to the motor is shut off. In order to
attempt movement again, the joystick
has to be returned to a neutral position
first. If there are no obstructions
preventing the boom from moving up
and down, and this error continues to
occur, this likely means there is an issue
with the lift drive mechanism and the
Turret needs to be serviced by
MotoCrane. If the problem is persistent,
contact MotoCrane Support.
020
Lift IMU
Warning
●Do not subject the
system to higher forces
This warning indicates that the G-forces
experienced by the unit are slightly
higher than normal. Do not attempt to
subject the system to more extreme
conditions than those that triggered the
warning.
021
Lift IMU Error
●Reduce intensity of use
to acceptable level
This error indicates that the G-forces
experienced by the unit are much higher
than normal. Do not continue operating
the unit in these extreme conditions.
022
Lift IMU Sensor
Failure
●Use caution and
contact MotoCrane
Support
The lift IMU reading has been lost by the
system. The most likely cause of this
failure is damage to the Turret
electronics. Service on the Turret by
17

MotoCrane is required to resolve this
issue. The unit can still be used with
caution, but should be serviced at the
earliest convenience.
029
Lift Motor
Command
Timeout
●Power cycle system to
reset
●Double check all cable
connections
●With system Disarmed,
enter the Diagnostics
page of the GUI and
move the lift joystick to
check for motor
commands
This error indicates that the lift driver
board is not receiving commands from
the Controller. The most likely cause of
this error is an issue with the Controller,
which may be solved with a simple power
cycle. If this does not resolve the issue,
the Controller may have sustained
damage and has stopped generating the
appropriate motor commands. If the
problem is persistent, contact MotoCrane
Support.
031
Boom
Imbalance -
Front Heavy
●Ensure Payload and CW
are properly balanced,
in accordance with the
Operation Manual
instructions
While lift limits are turned on, an option
is available (within the Settings+ page of
the GUI) to enable ULTRA to auto-detect
Payload/CW imbalances. The system can
generally detect situations where the
Payload is more than +/- 5 lbs
heavy/light.
032
Lift Limits
Disabled From
Error
●Power cycle and
calibrate lift angle
This error occurs if limits are enabled,
and an encoder error or failure is
triggered. Because lack of reliable
encoder data prevents limits from being
trusted, limits are disabled and cannot be
enabled again while the error persists. If
power cycling the system does not
eliminate the encoder error, limits will not
be available until the encoder can be
repaired.
033
Boom
Imbalance -
Back Heavy
●Ensure Payload and CW
are properly balanced,
in accordance with the
Operation Manual
instructions
While lift limits are turned on, an option
is available (within the Settings+ page of
the GUI) to enable ULTRA to auto-detect
Payload/CW imbalances. The system can
generally detect situations where the
Payload is more than +/- 5 lbs
heavy/light.
035
Central
●Power cycle system to
This error occurs if the lift motor driver
18

Heartbeat
Timeout
reset
●Double check all cable
connections
electronics are not detected in the
system. This error will be triggered if the
Turret is not connected to the system, or
if the cable between the Base Pedestal
and the Turret has failed. COM LEDs on
the Turret may also help to isolate the
issue. If changing the cable does not
solve the issue, the electronics may have
been damaged and the Turret will need
to be serviced. If the COM LED on the
Turret is the only one that is not on,
check the Diagnostics page in the GUI. If
good values are present for the lift
position, there is likely a problem with
the Turret electronics, which will require
service. If Code 109 is also seen, there is
likely a cable problem, either between
the Base Pedestal and the Turret, or
internal to the turret. If this issue cannot
be solved by power cycling or replacing
cables, a field repair can be achieved by
replacing the LDU.
042
Swing Motor
Temp Warning
●Use caution and watch
motor temp
●Make sure there are no
obstructions preventing
the boom from
swinging
The swing motor temperature has risen
to a level that is higher than expected,
under normal use. This is generally
caused by excessive load and higher
than normal current passing through the
motor. If the swing motor is
experiencing low to moderate use, but
high ambient temperatures and direct
sunlight are a factor, there is no need for
concern. Do not push the system past
the swing motor temp error threshold.
043
Swing Motor
Temp Error
●Discontinue use until
temp is reduced
●Make sure there are no
obstructions preventing
the boom from
swinging
The swing motor temperature has risen
to a level that is potentially dangerous to
the system. This could be caused by
extreme overuse, high ambient
temperatures, obstruction of swing
movement, or some combination of
these events. Wait until the temperature
has dropped below the error threshold to
attempt movement again.
19

044
Swing Motor
Temp Sensor
Failure
●Use caution and
contact MotoCrane
Support
●Avoid heavy use of
swing moves in high
ambient temperatures
The swing motor temperature sensor
reading has been lost by the system. The
most likely cause of this failure is damage
to the Base internal wiring or electronics.
Service on the Base by MotoCrane is
required to resolve this issue. The unit
can still be used with caution, but should
be serviced at the earliest convenience.
047
Swing Motor
Driver Temp
Warning
●Use caution and watch
driver temp
●Make sure there are no
obstructions preventing
the boom from
swinging
The temperature of the swing motor
driver electronics has risen to a level that
is higher than expected, under normal
use. This is generally caused by
excessive load and higher than normal
current being used by the motor.
048
Swing Motor
Driver Temp
Error
●Discontinue use until
temp is reduced
●Make sure there are no
obstructions preventing
the boom from
swinging
The temperature of the swing motor
driver electronics has risen to a level that
is potentially dangerous to the system.
This could be caused by extreme
overuse, high ambient temperatures,
obstruction of swing movement, or some
combination of these events.
049
Swing Motor
Driver Temp
Sensor Failure
●Use caution and
contact MotoCrane
Support
●Avoid heavy use of
swing moves in high
ambient temperatures
The swing motor driver temperature
sensor reading has been lost by the
system. The most likely cause of this
failure is damage to the Base electronics.
Service on the Base by MotoCrane is
required to resolve this issue. The unit
can still be used with caution, but should
be serviced at the earliest convenience.
052
Swing
Over-Current
Warning
●Use caution and
observe current and
temps
●Make sure there are no
obstructions preventing
the boom from
swinging
The swing motor current has risen to a
level that is higher than expected, under
normal use. This is generally caused by
excessive load and higher than normal
current passing through the motor.
053
Swing
Over-Current
Error
●Discontinue use while
error is active
●Make sure there are no
obstructions preventing
The swing motor current has risen to a
level that is potentially dangerous to the
system. This could be caused by extreme
movements, obstruction of swing
20