Terex 3B6 Programming manual

LTB1 Name Code Ballast Outrigger Jib Angle Jib Length Zone
300 0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 Length
2I
3II
4 III
5IV
6
7
8Amax7932791979177914791079 9
9 Amin 0 8 0 4,3 0 2 0 1,05 0 0,5 18 0,8
102222222
11 3 62,43271,920
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
9,4 14,4 19,5 24,7 28,9 30,4
C71_1: BOOM ON OUTRIGGERS 2,5 6,3
0 24487393100
0 24487393100
0 24487393100
Rev. 01/08/05
TROUBLESHOOTING
TROUBLESHOOTING
MANUAL
MANUAL
Complies to the MACHINES DIRECTIVE Standards: EN60204-1, EN954, EN12077-2
EMC according to the “ Heavy Industrial Environment” category: EN50081-2, EN50082-2
3B6
3B6
LOAD MOMENT INDICATOR (LMI)
LOAD MOMENT INDICATOR (LMI)
TELESCOPIC CRANES
TELESCOPIC CRANES

INDEX
INDEX
2
PAGE
ACCESS PROCEDURES 3
DESCRIPTION
COMPONENTS LOCATION ON THE MACHINE 4
MAIN UNIT AND CONTROL PANEL CODE: U2MIC-2/XX 5
GENERAL CHARACTERISTICS 6
MAIN CONTROL UNIT CONNECTIONS AND SIGNALS 7
AC MCP ANGLE/EXTENSION SENSORS CODE : AC MCP214A/3P 8
EXTENSION SENSOR CODE : ACT 9-10-11
PRESSURE TRANSDUCERS CODE : Y11 4745-450 12
CONTROL PANEL DESCRIPTION 13
DETECTION
TROUBLESHOOTING 14
ALARM CODES AND ACTIONS TO TAKE 15-16-17
ALARM CODE 56 : MEMORY DATA NOT RELIABLE 18
ALARM CODE 15 : ANGLE READING < MINIMUM VALUE 19
ALARM CODE 25 : ANGLE READING > MAXIMUM VALUE 19
CABLE REEL POWER SUPPLY VERIFYING 20
ANGLE POTENTIOMETER VERIFYING 21
ALARM CODE 6 : BOOM L. READING < MINIMUM VALUE 22
ALARM CODE 7 : BOOM L. READING > MAXIMUM VALUE 22
CABLE REEL POWER SUPPLY VERIFYING 23
BOOM LENGTH POTENTIOMETER VERIFYING 24
ALARM CODE 12 : MAIN CYLINDER (BOTTOM SIDE ) < MINIMUM VALUE 25
ALARM CODE 22 : MAIN CYLINDER (BOTTOM SIDE ) > MAXIMUM VALUE 26
ALARM CODE 13 : MAIN CYLINDER (ROD SIDE ) < MINIMUM VALUE 27
ALARM CODE 23 : MAIN CYLINDER (ROD SIDE ) > MAXIMUM VALUE 28
ALARM CODE 11 : BOOM L. READING < MINIMUM VALUE 29
ALARM CODE 21 : BOOM L. 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 34-37
RECOMMENDED SPARE PARTS LIST 38

3
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 need any password; this one, in fact, is
required for possible assistances, only 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.
ACCESS PROCEDURES
ACCESS PROCEDURES
LOAD MONITORING SYSTEM (LMI)
LOAD MONITORING SYSTEM (LMI)

4
COMPONENTS LOCATION ON THE MACHINE
COMPONENTS LOCATION ON THE MACHINE
Control Panel :
into the cabin
Main Unit
Nr.2 Pressure
Transducers:
On the lifting cylinder.
Rod and bottom side
Length sensor
Used in case of boom
indipendent sections
Length/Angle sensor

5
MAIN CONTROL UNIT
MAIN CONTROL UNIT
CODE: U2MIC
CODE: U2MIC- -2/XX 2/XX
U2MIC-2/XX 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/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
MECHANICAL DIMENSIONS
•Case Dimension : 260 x 160 x 91 mm
•Fixing holes : 240 x110 mm
VIBRATIONS
•Continuous : 5g’s from 20 to 400Hz Over 3 AXIS
•Shock : 10g’s
ENVIROMENTAL
•Salt spray resistance over 48 Hours
TEMPERATURE
•Working range :-30 -+70°C
•Storage range :-45 - +85°C

7
"MV 231-346"
MORS. 16C. C.S.
CV a FILO 1,5mmq.
"MV 231-346" MORS. 16C. C.S.
"MV 231-346"
MORS. 16C. C.S.
MAIN CONTROL UNIT
MAIN CONTROL UNIT : : CONNECTIONS
CONNECTIONS and and SIGNALS SIGNALS
D35, D39, D43, D47, D51, D55, D59, D63 = RED LED’s
They show the INPUT status
ON = ACTIVE INPUT
D68, D71, D74, D77, D80, D83, D86, D89, D101 = RED LED’s
They show the OUTPUT status ON = ACTIVE OUTPUT
D2 = RED LED
When lit means
that +15V Voltage
is active
D1 = RED LED
When lit means
that +5V Voltage
is actiive
Note :
D1 et D2 always have to be
lit when the system is ON
NOTE:
CODE DIODE PIN FUNCTION
DI0 D35 17 (Turret position sensor ) Length type
DI1 D39 18 Anti two block
DI2 D43 19 Turret micro switch stop
DI3 D47 20 Not used
DI4 D51 21 Not used
DI5 D55 22 Not used
DI6 D59 23 Not used
DI7 D63 24 Main by pass key
EEPROM:
CALIBRATION DATA,
BLACK BOX
EEPROM:
PROGRAM AND
LOAD TABLES
NOTE:
CODE DIODE PIN FUNCTION
DO0 D68 25 Movement’s shut off
DO1 D71 Not used
DO2 D74 Not used
DO3 D77 Not used
DO4 D80 Not used
DO5 D83 Not used
DO6 D86 Not used
DO7 D89 Not used
DO8 D101 Not used

8
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
Rings Type Length
mm Diam
mm A
mm B mm C mm D mm E mm F mm G mm H mm M mm MODEL
3 3x0,22
shields. 32000 3,8 100 323 60 460 420 11 180495 0 AC MCP214I/3P
AC MCP ANGLE / EXTENSION SENSOR
AC MCP ANGLE / EXTENSION SENSOR Code : AC MCP214A/3P Code : AC MCP214A/3P

9
EXTENSION SENSOR CODE : ACT
EXTENSION SENSOR CODE : ACT
The boom and angle sensor is formed by a cable reel having pulley on
which a cable is wounded; 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 survey the
unwinding 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.
Analog signals from above potentiometers are used by the LMI to
compute the boom geometrical data.

10
OVERALL DIMENSION
B-B ( 1 : 2 )
150
?
180
?
35,5
70,5
114,6
185
?
145
?
20,8
18
Ingranaggio Z=60 M=0.75
Ingranaggio Z=20 M=0.75
B
B
246 269
?
191
103
120
32
12,5

11
WIRING DIAGRAM
MS2 DESCRIPTION
6
3
5
4
2
1
LENGTH2
ANGLE2
ANGLE1
LENGTH1
-V (0V)
+V (+5V)
3123124654231
MS2MS1 MS3
SHIELD
CONNECTION

12
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.
PRESSURE TRANSDUCERS CODE : Y11 4745
PRESSURE TRANSDUCERS CODE : Y11 4745- -350 350
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.

m
m
13
CONTROL PANEL DESCRIPTION
CONTROL PANEL DESCRIPTION
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 button: press to increase operating mode value;
9 Operating mode selection button: 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 Key to exclude the manoeuvre block
Note : The function of the unstable key with return spring consists on disable the
automatic alarm function of the safety system.
Only the authorised staff can use the key to by-pass the safety system. In case of
improper use, the safety equipment and the crane manufacturer are relieved of any
responsibility.
11 Buzzer ( positioned on the rear panel ) :
Intermittent beeping = pre alarm condition;
Continuous beeping = alarm condition ( shut off movements).
1
7
10
6
9
5
8
11
12

m
m
ma x
RUN
0°
12.3
13.4
.2
9.2
24°
m
m
t
ALARM ..........
01 4 .0 0 5.7
14
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, allowing the operator 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 upper row.
Depending on the message, the fault can 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.
1.8
TROUBLESHOOTING
TROUBLESHOOTING

15
Alarm
code Description What to do
56
Page
18,32
Memory data not
reliable
• Switch the system off and on.
If the alarm persists, please, contact Technical
Assistance to:
•Verify that E2prom chip is fitted properly in its socket.
• Re-enter data and save them again
• Replace the E2PROM chip and recalibrate the
machine
15
Page
19, 20,
21,32
Angle sensor
reading lower than
the minimum value
• Verify that the wiring and the connectors are not in
short circuit.
If the alarm persists, please, contact Technical
Assistance :
• Verify the angle sensor integrity.
25
Page
19, 20,
21, 32
Angle sensor
reading higher than
the maximum value
•Verify that the cable or the connector wiring is not
open
If the alarm persists, please, contact Technical
Assistance :
• Verify the angle sensor integrity.
12
Page
25
Pressure reading of
the main cylinder
(bottom side) lower
than the minimum.
• Verify that the cable or the connectors wiring are not
in short circuit
If the alarm persists, please, contact Technical
Assistance :
• Verify the pressure transducer integrity
22
Page
26
Pressure reading of
the main cylinder
(bottom side) higher
than the maximum.
• Verify that the cable or the connector wiring are not
open
If the alarm persists, please, contact Technical
Assistance :
•Verify the pressure transducer integrity
ALARM CODES AND ACTIONS TO TAKE
ALARM CODES AND ACTIONS TO TAKE

16
Alarm
code Description What to do
13
Page
27
Pressure reading of
the main cylinder (rod
side) lower than the
minimum.
•Verify that the wiring and the connectors are not in
short circuit
If the alarm persists, please, contact Technical
Assistance :
•Verify the pressure transducer integrity
23
Page
28
Pressure reading
pressure of the main
cylinder (rod side)
higher than the
maximum.
• Verify that the cable or the connector wiring are
not open
If the alarm persists, please, contact Technical
Assistance :
•Verify the pressure transducer integrity
E01
RADIUS
MIN
The boom’s angle has
overtaken the
maximum value • Lower the boom
E02
RADIUS
MAX
This message appears
when the boom is
positioned in a way
that, referring to the
load charts, there isn’t
any load charts table
applicable
•Lift or close the crane boom until a load chart table
can be applied.
11
Page
29, 30,
31
Boom length sensor
total reading lower
than the minimum
value
• Verify that the wiring and the connectors are not in
short circuit
If the alarm persists, please, contact Technical
Assistance:
Verify the length transducer integrity
21
Page
29, 30,
31
Boom length sensor
total reading higher
than the maximum
value
• Verify that the cable or the connector wiring is not
open
If the alarm persists, please, contact Technical
Assistance :
• Verify the length transducer integrity

17
Alarm
code Description What to do
18
Table charts not
available..
The operating
condition selection is
missing
•Please, select the operating mode in use and
confirm it.
20 Group
Alarm.Configuration
errore
•Please, select the operating mode in use and
confirm it.
6
Page
22, 23,
24, 32
Boom length sensor 1
reading lower than the
minimum value
• Verify that the wiring and the connectors are not in
short circuit
If the alarm persists, please, contact Technical
Assistance:
Verify the length transducer integrity
7
Page
22, 23,
24, 32
Boom length sensor 1
reading higher than
the maximum value
• Verify that the cable or the connector wiring is not
open
If the alarm persists, please, contact Technical
Assistance :
• Verify the length transducer integrity
NOTE: The code of the alarms can change in case of particular functions or client
needs

18
EEPROM
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 1 = memory data not reliable.
ACTION TO TAKE:
1) Switch the system off and on.
2) Verify that the EEPROM chip is fitted properly in its socket.
3) Re-enter data and save again, switch off and on again.
4) If the problem persists, replace the PC board making sure that
software/parameters installed are corresponding to the
machine characteristics.

19
ALARM CODE 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

20
+ GND
CABLE REEL POWER SUPPLY VERIFYING
CABLE REEL POWER SUPPLY VERIFYING
FALSETRUE
FALSETRUE
Verify 5Volts between
+ and GND
on cable reel board
FALSETRUE
Verify the
Potentiometers
(**)
Cable brake down.
Check the
cable-reel cable
Probably the cable is
in short circuit.
Check cable
Main pc board
Is faulty.
Replace it with
a new one (*)
(*) REFER ALSO TO EPROM and EEPROM MEMORIES REPLACEMENT - page 32
(**) REFER TO page 21
Verify on the Main PC board
5Volts between
10(+) and 11(GND)
Disconnect wires
10 and 11 from the
Main pc board and
Check for 5Vdc
+
GND