Alarm Trouble Shooting - Eng - 01

ALARM TROUBLE
SHOOTING
DATA: 02/09/2007
File: COMPLETE ALARM TROUBLE SHOOTING .ppt

TO: CUSTOMER
FROM: GianLuca Pez
OBJ. :TROUBLESHOOTING INSTRUCTION
MULTIMETER SETTING
CONTINUITY TEST
SET THE MULTIMETER IN
OHM AND BUZZER
CONFIGURATION
POWER SUPPLY TEST

SET THE MULTIMETER IN
VOLT CONFIGURATION
DEPENDING BY THE
MULTIMENTER YOU
CAN HAVE TWO
VOLTAGE SECTOR
PLEASE SELECT THE
SECTCOR WITH THIS
SIMBOL
or DC
ALARM n° 4
Power supply not present in to the pin 43:

Due to:
1.Main fuse burn:
2. Power supply connection fault.
3. Internal wire broke.
1. The fuse burn is due to a short circuit.
The fuse 10 A is dedicated to power supply the radio remote
control and all the sensors in to the crane less than pressure
sensor. After the replacement, if the fuse burning again, please
disconnect the radio and all the sensor and reconnect first the
radio remote control and than one by one all the other sensor
until find the device in fault.
1. Please control that all the power supply cable are not
disconnected from the power connector (The power supply
connection depending by the crane installer, we produce the
crane and the electrical system of this part)..
3. By Digital Multimeter set in ohm and buzzer configuration please
check the cable continuity between the power connection wire to
pin 43 of the 56 pin plug (see the sketch).
If there is not continuity in this line the internal wire of
the harness is broke.
Replace the main wiring of the crane and contact the after sales department
ALARM n°
5 - Faulty block output on
6 - Faulty block output off
Due to:
1. Diode in to the connector broke in short circuit

2. Emergency solenoid valve in short circuit.
3. Wiring connection in short circuit
4. Load limiting device fault
1. In to the valve bank of the crane there is the Emergency valve

The name of the cable is YVH1
.
Disconnect the 90° degrees connector from the valve.
Take off the screw from the connector
Take off the base of the connector where the wires are connect.
Between the two pin there is:
diode
+ -
Resistor LED
Remove the Diode from the connector and reconnect the electrical
part in to the solenoid.
Press RESET button in to the Load Limiting Device do delay the
alarm and verify if the alarm disappear.
Replace the diode.
Please contact the after services department
2. Unscrew and remove the 90° Connector from the Emergency valve.
By the multimeter in ohm setting, check if the solenoid is not in short
circuit.
The value of impedance depending by the voltage of the system.
Voltage Ohm
12V 7,3Ω
24V 28,8Ω
7,3
Emergency valve
If the value of electro valve solenoid impedance is zero the

solenoid must be replace with a new one.
3. Disconnect the 90° degrees connector from the valve.
Take off the base of the connector where the wires are connect.
Disconnect the wire from the cable YVH1.
Take off the 56 pin plug from load limiting device.
By the multimeter in ohm setting check the wires in to the
emergency valve cable there is a short circuit. (see the
sketch).
The result must be a open circuit between the two wires.
OL
1
YVH1
2
If the multimeter show the short circuit valve the reason is in to the
cable that could be damage somewhere.
4. If the test above have a positive result the problem is related
to the Load limiting device.
Press enter button (long time, three seconds) in to the load limiting
device. The display will show
CHECK MENU
INPUTS MENU
Inputs
KEY - KEY + ENTER

KEY
CHECK MENU SHORT
OUTPUTS MENU
Outputs
KEY - KEY + ENTER

KEY
CHECK MENU SHORT
INDEX SENSORS MENU
Sensors
KEY
LONG
KEY - KEY + ENTER
KEY
CHECK MENU SHORT
ALARMS MENU
Alarms
KEY - KEY + ENTER

KEY
CHECK MENU SHORT
SERVICE MENU
Service
KEY - KEY + ENTER

KEY
CHECK MENU SHORT
SETTING MENU
Setting
By winch button move to the page CHECK MENU output

Press ENTER button (short time)
Outputs
DUMP VALVE: OFF
KEY - KEY +
Outputs
OUT1: ON/OFF
KEY - KEY +
Outputs
YELLOW LAMP:ON/OFF
KEY - KEY +
Outputs
INDEX
KEY RED LAMP: ON/OFF
LONG
KEY - KEY +
Outputs
RADIO S1: ON/OFF
KEY - KEY +
Outputs
RADIO S2: ON/OFF
KEY - KEY +
Outputs
BUZZER: ON/OFF
KEY - KEY +
Outputs KEY +
MX POWER: ON/OFF
DUMP VALVE output must be OFF when no movement is require

from the operator.
When one movement is require (radio or manual crane work
condition make no difference) the DUMP VALVE output
must be change in ON staus.
If any Load Limiting Device internal fault the out put status doesn’t
change .
Please contact the after services department.
ALARM n°10
TP1 reading too low (open circuit)
Due to:
1. Cable cut or damage
3. Pressure transducer broken in open circuit
WIRING STRUCTURE
Main
part
Wiring
extension
Step 1 wiring test
The wiring related with the pressure transducer line is
XS2 see sketch above could it be damage or interrupt
somewhere.
Trouble shooting material necessary to solve the
problem:
- Digital multimeter
1.Disconnect (unscrew the silver crown) the pressure

transducer TP1 located in the bottom of the main
cylinder.
Disconnect the load limiting device 56 pin plug connector.
The connector are numbered like as sketch following:
29 42 43 56
1 14 15 28
Test the wire continuity between the 56 pin connector and

pressure transducer connector like as following:
Pin 40 and pin 1than pin 31 and pin 2.
In the both wiring test the multimeter must show in to
the display 0000 and the buzzer ring on, that means
wiring line OK than move to step 2.
Otherwise disconnect XS2 connection and move to test
like following sketch:
Main wiring continuity test
Pin 40 and pin 1

Than
Pin 31 and pin2
XS2 is located between the

column to valve bank support
under the black cover
protection
Extension wiring continuity test
Pin 1 and pin 1

Than
Pin 2 and pin2
If continuity is not present in one of this two test you must
replace the wire in trouble. After cable replacement start the
crane operation.
Step 2 Load limiting device test
Trouble shooting material necessary to solve the problem:
- Bypass pressure transducer part number 5160026
XS2 connection is located between the column to valve bank.

Remove the black cover protection to find the connection.
Disconnect the cable XS2 from the column and connect the
bypass pressure transducer in to the main part.
Press RESET button in to the load limiting device.
If the alarm disappear and the percentage value of TP1 (second
row left part display) is showing 50% value the load limiting
device is working OK and
go to the step n 3
Step 3 transducer pressure
If the two step 1 and step 2 resulting OK the component that

make the alarm on is the pressure transducer and must be
replaced.
The pressure transducer TP1 located in the bottom of the
main cylinder.
The top of the crane must be positioning in to the ground.
Switch off the PTO and whit power ON
Discharge the pressure in to the crane system by the hand
lever of the bank valve.
Unscrew the component from the cylinder and replace it.
Reconnect the electrical connection and start the crane
operation.
No load limiting device calibration is require after the sensor
replacement.
P.S. wire bridge without the resistor in the

connection can causes the damages in the
internal board of the load limiting device.
ALARM n°11
TP1 reading too high (short circuit)
Due to:
1. Cable damage in short circuit
3. Pressure transducer broken in short circuit
See the wiring structure in to the alarm 10

description
Step 1 wiring test
XS2 see sketch above could it be damage and in short
circuit somewhere.
problem:

transducer TP1 located in the bottom of the main
cylinder.
The connector are numbered like as sketch in to alarm 10
chapter:
Do test the wire short circuit test in to XS2 pressure transducer
line like as following:
Pin 1 and pin 2

Of the pressure trans.
connector
The multimeter must show the vale O.L that means no short
circuit in to the wiring line, than move to step number two.
Otherwise disconnect XS2 connection and move to test like
following sketch:
Main wiring short circuit test
Pin 1 and pin 2

protection
Extension wiring short circuit test
Pin 1 and pin 2

If short is present in one of this two test you must replace
the wire in trouble with a new one.
Please contact after sales department to have a spare part
information.
After cable replacement start the crane operation.

row left part display) is showing 50% value the load limiting
device is working OK and
go to the step n 3.

make the alarm on is the pressure transducer and must be
replaced.
The pressure transducer TP1 located in the bottom of the
main cylinder.
The top of the crane must be positioning in to the ground.
Switch off the PTO and with power ON
Discharge the pressure in to the crane system by the hand
lever of the bank valve.
Reconnect the electrical connection and start the crane
operation.
replacement.

connection can causes the damages in the
internal board of the load limiting device.
ALARM n°30
TP3 reading too low (open circuit)
Due to:
1. Cable cut or damage
3. Pressure transducer broken in open circuit
WIRING STRUCTURE
Main
part
Wiring
extension
Wiring
extension
Step 1 wiring test
somewhere.
problem:

transducer TP3 located in the bottom of the main JIB
cylinder.
29 42 43 56
1 14 15 28

pressure transducer connector like as following:
Pin 40 and Pin 1
than
Pin 32 and Pin 2.
wiring line OK than move to step number two.
Pin 40 and pin 1

Than
Pin 32 and pin2
protection
Pin 1 and pin 1

Than
Pin 2 and pin2
Extension wiring continuity test
Pin 1 and pin 1

Than
Pin 2 and pin2
If continuity is not present in one of this three tests you must
replace the wire in trouble.
information.


row middle display part) is showing 50% value the load
limiting device is working OK and
go to the step n 3
If the two step 1 and step 2 resulting OK the component that make
the alarm on is the pressure transducer and must be replaced.
The pressure transducer TP3 located in the bottom of the main JIB
cylinder.
Positioning the crane like a sketch following

Discharge the pressure in to the crane system by the hand lever of
the bank valve.
Reconnect the electrical connection and start the crane operation.
replacement.

connection can causes the damages in the internal
board of the load limiting device.
ALARM n°31
TP 3 reading too high (short circuit)
Due to:
3. Pressure transducer broken in short circuit

description
Step 1 wiring test
XS10 see sketch above could it be damage and in short
circuit some where.
problem:

transducer TP3 located in the bottom of the main JIB
cylinder.
The connector are numbered like as sketch in to alarm 30
chapter:
Do test the wire short circuit test in to XS10 pressure transducer
line like as following:
Pin 1 and pin 2

Of the pressure transducer
connector
following sketch:
Pin 1 and pin 2

protection
Pin 1 and pin 2

If short circuit is present in one of this two test you must
replace the wire in trouble with a new one.
information.

If the alarm disappear and the percentage value of TP3(second
row middle display part) is showing 50% value the load
limiting device is working OK and
Go to the step n 3
If the two step 1 and step 2 resulting OK the component that make
the alarm on is the pressure transducer and must be replaced.
The pressure transducer TP3 located in the bottom of the main JIB
cylinder.
Positioning the crane like a sketch following

Discharge the pressure in to the crane system by the hand lever of
the bank valve.
Reconnect the electrical connection and start the crane operation.
replacement.

connection can causes the damages in the internal
board of the load limiting device.
ALARM n°40
Reading from extensometer amplifier too low
(open circuit)
Due to:
1. Cable damage in open circuit
2. No power supply
4. Extensometer broken in open circuit
Wiring structure
Step 1 wiring test
The wiring related with the WINCH line is XS7 see sketch
above could it be damage or interrupt somewhere.

problem:
Disconnect the 5 pin connector XS7 located in next to the

WINCH. See the wiring structure.
29 42 43 56
1 14 15 28

WINCH connector like as following:
In the wiring test the multimeter must show in to the
display 0000 and the buzzer ring on, that means wiring
line OK than move to step number two.
Pin 35 and Pin 2
Pin 2 and Pin 2

information
Power supply winch line test

12 or 24V
Power on the system

Disconnect the winch
connection close to it
(5 pin connector)
Check by multimeter in Volt
configuration between
1 and 5 pin.
The value must be the same
as the power supply of
the system.
If power supply is present in
to the winch line please
move to the step 2
- Bypass winch part number 5160013

If the alarm disappear and the percentage value of winch
(second row right part) is showing a fixed value (independent by
the weight of the charge) the load limiting device is working
OK and
Go to the step n 3
Step 3 extensometer
sensor and board Test.
• If the two step 1 and step 2 resulting OK the component hat
make the alarm ON is the extensometer sensor or the board
Extensometer ROTZLER sensor test

Trouble shooting material necessary
- Multimeter
Extensometer DINAMIC OIL sensor test
Trouble shooting material necessary
- Multimeter
TEST PROCEDURE
Power on the system.
Open the aluminum box close to the winch.
Step 1: No load on the winch
By the multimeter check the voltage between the
extensometer wires YELLOW and WHITE
Step 2: Max winch capacity (depend by the model)
By the multimeter check the voltage between the
extensometer wires YELLOW and WHITE
The voltage different between step 1 and step 2 must
be included from 2mV to 7mV.
Please pay attention at the voltage range that the
display show ( normally the mV range is on the
right top of display)
If the test result is different from the above value the
extensometer is in fault.
Please contact after sales department to have a spare
part information.
If the extensometer is not in fault

the part in trouble is the electronic board contain in to the winch
aluminum box.
Please contact the after sales service to spare part information.

ALARM n°41
Reading from extensometer amplifier too high
(short circuit)
Due to:
3. Extensometer broken in short circuit
Wiring structure See the alarm n°40
Step 1 wiring test

The wiring related with the WINCH line is XS7 see
sketch above could it be damage or interrupt
somewhere.

problem:
Disconnect the 5 pin connector XS7 located in next to the

WINCH. See the wiring structure alarm 40.
Disconnect 56 pin connector from load limiting device
Test the wire between the 5 pin connector like as following:
Step test
Multimeter in ohm configuration
1 TEST PIN 1 e PIN 2
IN ALL OF THIS TEST THE

DISPLAY RESULT MUST
BE O.L otherwise
following the next sketch:
Step test
Step test
TEST
PIN 1 and PIN 2
THE VALUE MUST BE CLOSE TO MEGA ohm
PIN 2 and PIN 5
THE VALUE MUST BE CLOSE TO KILO ohm
PIN 2 and PIN 3
PIN 2 and PIN 4
TEST
PIN 1 and PIN 2
THE VALUE MUST BE CLOSE TO MEGA ohm
PIN 2 and PIN 5
PIN 2 and PIN 3
PIN 2 and PIN 4
If short circuit is present in one of this test you must replace
the wire in trouble with a new one.
information.
Otherwise move to the step 2

- Bypass winch part number 5160013

If the alarm disappear and the percentage value of winch
(second row right part) is showing a fixed value (independent by
the weight of the charge) the load limiting device is working
OK and
Go to the step n 3
Step 3 extesometer sensor
and board Test.
PLESE REFER TO ALARM

40 STEP 3 TO SENSOR
TEST PROCEDURE
If the extensometer is not in fault

the part in trouble is the electronic board contain in to the winch
aluminum box.
Please contact the after sales service to spare part information.

ALARM n°50
B2 bubble inputs both OFF
Due to:

2. No power supply
4. Sensor broken in open circuit
Wiring structure
Step 1 wiring test
The wiring related with the bubble sensor line is XS 3
see sketch above could it be damage or interrupt
somewhere.
problem:
1.Disconnect bubble sensor connector XS3 located in the

second boom of the crane.
29 42 43 56
1 14 15 28

bubble sensor connector like as following:
Pin 5 and Pin 2
than
Pin 33 and Pin 3.

Otherwise disconnect XS3 connection between main
part and extension and move to test like following
sketch:
Pin 5 and pin 2
Than
Pin 33 and pin3

protection
Pin 1 and pin 1

Extension wiring
Than
continuity test
Pin 2 and pin2
Pin3 and pin 3
Pin 4 and pin 4
information.

- Bypass bubble sensor
1 2

bypass sensor connector in to the main part.
If the alarm disappear the load limiting device is working OK.
Repeat the same operation with the bypass connector 2 and if
also this test will be OK
go to the step n 3
Power supply bubble sensor line test
Power on the system

Disconnect the sensor second
crane boom
configuration between 1 and
4 pin.
The value must be the same as
the power supply of the
system.
If power supply is present in to
the winch line please repeat
the test middle connection of
the line.
Power supply fault from wiring
the main part causes other
sensor fault in to the system
and alarm 4 will be on in to
the display. See the
dedicated chapter
Step 3 bubble sensor

make the alarm on is the bubble sensor and must be replaced.
The bubble sensor located in the second boom of the crane .
Replace the sensor and repositioning the new one in the same
position of the old one to avoid any safety problem during the
overload situation.
ALARM n°51
B2 bubble inputs both ON
Due to:
3. Bubble sensor broken in short circuit
description
Step 1 wiring test
The wiring related with the bubble sensor line is XS3
see sketch above could it be damage and in short circuit
some where.
problem:
1.Disconnect the bubble sensor located in the crane second

boom.
Do test the wire short circuit test in to XS3bubble sensor line
like as following:
Pin 2 and pin 3

Of the bubble sensor
connector
following sketch:
Pin 2 and pin 3

protection
Pin 2 and pin 3

information.

go to the step n 3

overload situation.
ALARM n°52
JIB bubble inputs both OFF
Due to:
2. No power supply
Wiring structure
Step 1 wiring test
The wiring related with the bubble JIB sensor line is
somewhere.
problem:
1.Disconnect bubble sensor connector XS11 located in the JIB

boom
29 42 43 56
1 14 15 28

Pin 8 and Pin 2
than
Pin 34 and Pin 3.

sketch:
Pin 8 and pin 2
Than
Pin 34 and pin3

protection
Extension wiring
continuity test Pin 1 and pin 1
Than
Pin 2 and pin2
Pin3 and pin 3
Pin 4 and pin 4
information.

1 2

go to the step n 3
Power on the system

crane boom
4 pin.
system.
the Jib bubble sensor line
please repeat the test middle
connection of the line.
Power supply fault from the main
wiring part causes other
dedicated chapter.

The bubble sensor located in the Jib main boom .
overload situation.
ALARM n°53
Jib bubble inputs both ON
Due to:
chapter
Step 1 wiring test
some where.
problem:

boom.
Do test the wire short circuit test in to XS11 bubble sensor line
like as following:
Pin 2 and pin 3

connector
following sketch:
Pin 2 and pin 3

protection
Pin 2 and pin 3

information.

go to the step n 3

The bubble sensor located in Jib main boom .
overload situation.
ALARM n°54
AN2 reading too LOW
Due to:
2. No power supply
Wiring structure
Step 1 wiring test
The wiring related with the bubble sensor line is XS 3
see sketch above could it be damage or interrupt
somewhere.
problem:
1.Disconnect bubble analog sensor connector XS3 located in

the second boom of the crane.
29 42 43 56
1 14 15 28

bubble analog sensor connector like as following:
Pin 33 and Pin 3
.When analog sensor is using
pin 5 is not USED
In the wiring test the multimeter must show in to the

display 0000 and the buzzer ring on, that means wiring
line OK than move to step number two.
sketch:
Pin 33 and pin 3

When analog sensor is
using pin 5 is not USED

protection
Pin 1 and pin 1

Extension wiring
Than
continuity test
Pin 3 and pin 3
Pin 4 and pin 4
information.


Go to the step n 3
Power on the system

crane boom
4 pin.
system.
the winch line please repeat
the test middle connection of
the line.
Power supply fault from wiring
the main part causes other
dedicated capter
If the two step 1 and step 2 resulting OK the component that make the
alarm on is the bubble sensor and must be replaced.
Replace the sensor and repositioning the new one in the same position of
the old one to avoid any safety problem during the overload
situation.
Please contact the after service department to order the part

ALARM n°55
AN2 reading too high
Due to:
chapter
Step 1 wiring test
some where.
problem:

boom.
2.Disconnect the load limiting device 56 pin plug connector.
Do test the wire short circuit test in to XS3bubble sensor line
like as following:
Pin 3 and pin 1

connector
The multimeter must show the vale O.L that means NO short
Otherwise disconnect XS 3 connection and move to test like
following sketch:
Pin 1 and pin 3

protection
Pin 1 and pin 3

information.

Go to the step n 3

overload situation.
ALARM n°56
ANJ reading to LOW
Due to:
2. No power supply
Wiring structure
Step 1 wiring test
The wiring related with the bubble JIB sensor line is
somewhere.
problem:
1.Disconnect bubble sensor connector XS11 located in the JIB

boom
29 42 43 56
1 14 15 28

Pin 34 and Pin 3.
With analog sensor pin 8

is not used

sketch:
Pin 34 and pin3
With analog sensor pin 8
is not USED

protection
Pin 1 and pin 1

Than
Extension wiring
continuity test
Pin3 and pin 3
Pin 4 and pin 4
information.


Go to the step n 3
Power on the system

crane boom
4 pin.
system.
the Jib bubble sensor line
please repeat the test middle
connection of the line.
Power supply fault from the main
wiring part causes other
dedicated chapter.

overload situation.
ALARM n°57
ANJ reading too high
Due to:
chapter
Step 1 wiring test
some where.
problem:

boom.
2.Disconnect the load limiting device 56 pin plug connector.
Do test the wire short circuit test in to XS11 bubble sensor line
like as following:
Pin 3 and pin 1

connector
The multimeter must show the vale O.L that means NO short
Otherwise disconnect XS 11 connection and move to test like
following sketch:
Pin 1 and pin 3

protection
Pin 1 and pin 3

information.

Go to the step n 3

overload situation.
ELECTRO HYDRAULIC ACTUATOR
FOR ANY MOVEMENT THERE IS ONE ELECTRO
HYDRAULIC ACTUATOR
DANFOSS COMPONENT
Electro-Hydraulic
actuator
ELECTRICAL CONNECTION
HAWE COMPONENT
Electro-Hydraulic
actuator
ELECTRICAL CONNECTION
RADIO REMOTE CONNECTOR LOAD LIMITING DEVICE

CONNECTOR
SET UP NEUTRAL POSITION
Hawe bank valve only
Is possible by a “set up keyboard tool” reset the
neutral position of the electro hydraulic
actuator
The part number of the “set up keyboard tool”is
3310936
Keyboard
Feeder
Amp super seal connector
DIN 43650 connector

To be connect to electro
hydraulic actuator
Set up procedure
1. In to the control valve disconnect the load limiting device
connector (DIN 43650) of the main wiring.
2. Connect the DIN 43650 connector of the set up keyboard
device.
3. Connect the 2 pin AMP connector in to the feeder and
connect the feeder in to the 220V plug.
4. Press the power supply button (left) and keep pressed.
5. Press the OUT B button (right) and keep pressed.
6. Release the power supply (left).
7. Release the OUT B (right).
8. Press the OUT B (right).
The calibration is done, the led out A and B must be light on.
Depending by the direction lever ,led corresponding it
should power off and the buzzer ring up.
If any problem occurring during the set up or the electro
hydraulic actuator is in fault the led out A and B are not
powered when the lever is in neutral.
Retry the set up or replace the actuator.
For any other information please contact the a
fter sales department.
Alarm Description
number
60 both rotation micro switches OFF
61 both primary boom micro switches OFF
62 both secondary boom micro switches OFF
63 both crane extension boom micro switches OFF
64 both jib boom micro switches OFF
65 both jib extension boom micro switches OFF
66 both winch micro switches OFF
67 both bucket micro switches OFF
68 both rotor micro switches OFF
Due to:
2. No power supply
4 .Electro Hydraulic actuator broken
1. TAKE OFF FROM THE BLACK PROTECTION FROM THE LOAD
LIMITING DEVICE SIDE
ELECTRICAL CONNECTION IN TO
THE CONTROL VALVE
Load limiting
device
Radio remote control

BETWEEN THE COLON TO EBB SUPPORT THERE IS THE
DISTRIBUTOR WHIT THE ELECTRO HYDRAULIC ACTUATOR
TWO CONNECTOR FOR EACH ACTUATOR.

GREY CONNECTOR :From radio remote control
(PWM valve control)
Three wires connected
BLACK CONNECTOR: From load limiting device
(Direction lever micro switch control)
Four wires connected
ALARM 60 IS RELATED TO ACTUATOR M01
THE FOLLOWING ROUBLE SHOOTING DESCRIPTION
REGARDING THE ALARM 60 AND IS THE SAME FOR ALL THE
OTHER ALARM (60-68)
TO KNOW THE WIRING CONNECTION PLEASE REFER TO THE
ELECTRICAL DIAGRAM
Alarm n. : 60
% 0
DISCONNECT THE BLACK CONNECTOR FROM M01
M01
1
M02
USING A SREWDRIVER AS THE PICTURE LIFT UP THE PURPLE
LOCKING2 AND PULL OUT THE CONNECTOR
DO THE SAME FOR BLACK CONNECTOR FROM M02
CONNECT THE CONNECTOR 1 IN M02 ACTUATOR AND CONNECTOR 2

IN M01 ACTUATOR
AT THE END OF THE OPERATION WILL HAVE
THIS CONFIGURATION
M01
2
M02
1
NOW PRESS THE RESET BOTTON IN TO THE EBB.

THE ALARM 60 DISAPPEAR FOR THREE SECOND AND
THAN:
1. THE ALARM BECAME 61 SO IT MEANS THAT THE PROBLEM IS
IN TO THE ELECTRHYDRAULIC ACTUATOR M01
REPLACE THE COMPONENT.
SEE THE REPLACEMENT CHAPTER.
2. IF THE ALARM STILL 60 THE PROBLEM COULD BE IN TO THE
WIRING CONNECTION
ELECTRICAL WIRING STRUCTURE
WIRIRNG TEST
THE ALARM 60 CAMES ON AGAIN SO IT MEANS THAT THE
PROBLEM IS IN TO THE CABLE 1
-CHECK THE CONNECTION BETWEEN THE CONNECTOR 1 TO EBB PLUG
POWER SUPPLY TEST CONTINUITY TEST
PIN4
CHASSIS
-CHECK THE POWER SUPPLY IN TO THE CONNECTOR PIN4
KEPP PRESSED THE LOAD LIMITING DEVICE RESET BUTTON (DUE
TO THE ALARM LOAD LIMITING DEVICE CUT OFF THE POWER
SUPPLY TO THE ELECTRO HYDRAULIC ACTUATOR) SEE THE
SHETCH ABOWE PART 1 THE MULTIMETER MUS SHOW THE VALUE
LIKE A BATTERY VOTAGE IF POWER IS PRESENT
-CHECK THE NEGATIVE IN TO THE CONNECTOR PIN3
CONNECT THE MULTIMETER IN VOLT CONFIGURATION RED TEST PIN IN TO
PIN 4 AND BLACK TEST PIN IN TO THE PIN 3.
KEPP PRESSED THE RESET BUTTON IN TO THE LOAD LIMITING DEVICE
THE MULTIMETER SHOW THE VALUE LIKE A BATTERY VOTAGE IF
NEGATIVE IS PRESENT
-CHECK THE CONTINUITY LINE IN TO THE WIRING
SEE THE SHETCH ABOVE PART 2 AND FOLLOWING THE STEP
4 PIN 56 PIN 4 PIN 56 PIN

CONNECTOR CONNECTOR CONNECTOR CONNECTOR
1 16 4 27
4 PIN 56 PIN 4 PIN

CONNECTOR CONNECTOR CONNECTOR
2 44 3 CHASSIS
IN ALL OF THIS CASE THE MULTIMETER MUST RINGING UP AND THE

DISPLAY MUST SHOW 0.000
IF ANY DIFFERENT RESULT THE CONNECTION MUST BE REPLACED.
PLEASE CONTACT THE AFTER SALES DEPARTMENT TO RECEIVE ALL THE
INFO
3.EBB IN FAULT
AT THE MOMENT WE DON’T HAVE ANY FEEDBACK FROM AFTHER
SALES SERVICE ABOUT LOAD LIMITING DEVICE INPUT IN FAULT
FOR ALL THE OTHER ALARM THE PROCEDURE IS THE

SAME BUT IT IS DIFFERENT THE NUMBER AND THE
POSITION OF THE CONNECTOR THAT YOU HAVE TO
CHECK SEE THE REFERENCE CHART ABOVE.
SIMPLE CRANE
Alarm Description ELECTROHYDRAULIC

number ACTUATOR
60 both rotation micro switches OFF M01
61 both primary boom micro switches OFF M02
62 both secondary boom micro switches OFF M03
63 both crane extension boom micro switches OFF M04
CRANE WHIT JIB AND WHINC AND BUCKET

number ACTUATOR
64 both jib boom micro switches OFF M06
65 both jib extension boom micro switches OFF M07
66 both winch micro switches OFF M05
68 both bucket micro switches OFF M08
CRANE WHIT JIB AND WHINC AND ROTOR
number ACTUATOR

66 both winch micro switches OFF M05
68 both rotor micro switches OFF M08
CRANE WHIT JIB AND BUCKED AND ROTOR

number ACTUATOR

CRANE WHIT BUCKED AND ROTOR

number ACTUATOR
ALARM ->0<-
MEANS
THIS ALARM IS DETECTED ONLY WHEN THE RADIO REMOTE

CONTROL FUNCTION IS ACTIVATED.
THREE SECOND LATER AT THE END OF THE RADIO CRANE
OPERATION, THE LOAD LIMITING DEVICE DETECT ONE, OR MORE
THAN ONE INPUT RELATED WITH THE ELECTRO HYDRAUIC
ACTUATOR MOUNTED IN TO THE CONTROL VALVE NOT IN
NEUTRAL POSITION.( SEE THE CHAPTER BEFORE TO
ELECTROHYDRAULIC ACTUATOR)
BEFORE MOVING A HEAD PLEASE CHECK IF ALL

THE LEVER ARE FISICALLY IN NEUTRAL POSITION
DUE TO
1. MECHANICAL LEVERIRSM PROBLEM

2. DIRT IN TO THE SPOOL
3. ELECTRCAL HARNES FAULT
4. ELECTRO HYDRAULICAL ACTUATOR FAULT
FOLLOW THIS ISTRUCTION ONLY
WHEN THE ALLARM ->0<- IS ACTIVE
->0<-
25%
ENTER KEY
LONG
CHECK MENU
INPUT
ENTER KEY
SHORT
• CHECK MENU INPUT
• IN THIS AREA ALL THE INPUT ARE
MONITORIZED IN REAL TIME
• M = MOVEMENT
• 1 = MOVEMENT NUMBER
• A = DIRECTION LEVER
• B = DIRECTION LEVER
DIR B
DIR A
PRESS THE LOAD LIMITING DEVICE RESET KEY BUTTON
AND KEEP PRESSED DURING FOLLOWING OPERATION.
USE KEY + AND – TO SCROLL DOWN ALL THE INPUT AND
CHECK WHICH ONE IS NOT IN ON STATUS.
KEY - KEY +
Inputs Inputs
M1 A: ON M5 A: ON
KEY - KEY + KEY - KEY +
Inputs Inputs
M1 B: ON M5 B: ON
KEY - KEY +
Inputs Inputs
M2 A: ON M6 A: ON
KEY - KEY +
KEY - KEY +
Inputs Inputs
M2 B: ON M6 B: ON
Inputs Inputs
M3 A: ON M7 A: ON
Inputs Inputs
M3 B: ON M7 B: ON
Inputs Inputs
M4 A: ON M8 A: ON
Inputs Inputs
M4 B: ON M8 B: ON
KEY - KEY +
REFERT TO THE FOLLOWING CHART CONTROLL IN
TO THE CHECK INPUT MENU THE STATUS OF THE
INPUT.
INPUT STATUS ON OK
INPUT STATUS OFF FAULT
DEPENDING BY THE CRANE CONFIGURATION YOU
WILL FIND ONE OR MORE OF THE INPUT IN OFF
STATUS
1. TAKE OFF FROM THE BLACK PROTECTION FROM THE LOAD
LIMITING DEVICE SIDE
ELECTRICAL CONNECTION IN TO
THE CONTROL VALVE
Load limiting
device
Radio remote control

BETWEEN THE COLON TO LOAD LIMITIN DEVICE SUPPORT
THERE IS THE DISTRIBUTOR WHIT THE ELECTRO
HYDRAULIC ACTUATOR
ELECTRO HYDRAULIC ACTUATOR POSITION
TWO CONNECTOR FOR EACH ACTUATOR.

-GREY CONNECTOR FOR RADIO ELECTRICAL HARNESS
FOR PWM CONTROL
Three wires connected
-BLACK CONNECTOR FOR EBB ELECTRICAL HARNESS
FOR LEVER DIRECTION POSITION
Four wires connected
THIS PROBLEM IS DUE TO:
1.ELECTRICAL CONNECTION
2.ELECTRO HYDRAULIC ACTUATOR FAULT
THE FASTER WAY TO UNDERSTAND WHICH PART IS

IN FAULT FOLLOW THIS PROCEDURE
DISCONNECT THE BLACK CONNECTOR FROM THE ELECTRO
HYDRAULIC COMPONENT WITH INPUT OFF AND CROSS WITH
THE NEXT ONE OR PREVIOUSE ONE
M01
USING A SREWDRIVER
1 AS THE PICTURE LIFT UP THE PURPLE
LOCKING AND PULL OUT THE CONNECTOR
M02
2
PRESS RESET BUTTON AND MOVE THE CRANE BY RADIO
REMOTE CONTROL UNTILL THE ALARM COME ON AGAIN
THAN REPEAT THE CHECK INPUT CONTROLL OPERATION
AS BEFORE AND VERIFY :
1.IF INPUT IN OFF IS THE SAME THAN BEFORE THE
PROBLEM IS IN TO THE CABLE:
BROKEN CABLE BEETWEN THE CONNECTOR TO LOAD
LIMITING DEVICE PIN (SEE THE DIAGAM AND CHEK THE
CONTINUITY BY MULTIMETER SEE CHAPTER ALARM 60)
POSITIVE AND NEGATIVE JUNCTION ARE LOCATED IN TO THE
INTERNAL WIRING POSITION, AND TO REPARE IT MEANS OPEN
ALL THE WIRING COVER (TERMO HETERING) AND IS NOT
POSSIBLE REPLACE WITH A NEW ONE.
REPLACE THE WIRING IS THE FASTER AND SAFETY SOLUTION.
2.IF THE INPUT IN OFF IS MOVING FROM THE CONNECTOR

CROSSED THE PROBEM IS THE ELCTRIC ACTUATOR:
ELECTRO HYDAULIC ACTUATOR DAMAGE

M03 M02 M01
PLEASE CONTACT THE AFTERSALES DEPARTMENT TO

HAVE ALL THE INFORMATION.
IN THE NEW SOFTWARE VERSION
AV_02_12 08/10/2007
WHEN ANY ELECTRO HYDRAULIC

ACTUATOR FAULT IS OCCURING THE
LOAD LIMITING DEVICE DISPLAY
WILL SHOW TO THE OPERATOR THE
ELCTRO HYDRAULIC ACTUATOR IN
FAULT.
WARNING >0< M1
% 25
THE WARNING WILL BE VISUALIZED IN

TO THE DISPLAY UNTILL THE
WARNING REMAIN ACTIVE
THE ALARM WILL BE STORE IN TO THE
ELECTRONIC BLACK BOX

Alarm Trouble Shooting - Eng - 01

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Alarm Trouble Shooting - Eng - 01

Uploaded by

Copyright:

Available Formats

ALARM TROUBLE

File: COMPLETE ALARM TROUBLE SHOOTING .ppt

POWER SUPPLY TEST

Power supply not present in to the pin 43:

1. Diode in to the connector broke in short circuit

1. In to the valve bank of the crane there is the Emergency valve

If the value of electro valve solenoid impedance is zero the

KEY - KEY + ENTER

KEY - KEY + ENTER

KEY - KEY + ENTER

KEY - KEY + ENTER

By winch button move to the page CHECK MENU output

DUMP VALVE output must be OFF when no movement is require

1.Disconnect (unscrew the silver crown) the pressure

Test the wire continuity between the 56 pin connector and

Pin 40 and pin 1

XS2 is located between the

Extension wiring continuity test

Pin 1 and pin 1

Step 2 Load limiting device test

Trouble shooting material necessary to solve the problem:

- Bypass pressure transducer part number 5160026

XS2 connection is located between the column to valve bank.

If the two step 1 and step 2 resulting OK the component that

P.S. wire bridge without the resistor in the

See the wiring structure in to the alarm 10

1.Disconnect (unscrew the silver crown) the pressure

Pin 1 and pin 2

Pin 1 and pin 2

XS2 is located between the

Extension wiring short circuit test

Pin 1 and pin 2

Trouble shooting material necessary to solve the problem:

- Bypass pressure transducer part number 5160026

XS2 connection is located between the column to valve bank.

If the two step 1 and step 2 resulting OK the component that

P.S. wire bridge without the resistor in the

1.Disconnect (unscrew the silver crown) the pressure

Test the wire continuity between the 56 pin connector and

Pin 40 and pin 1

Pin 1 and pin 1

Extension wiring continuity test

Pin 1 and pin 1

Step 2 Load limiting device test

- Bypass pressure transducer part number 5160026

XS10 connection is located between the column to valve bank.

Positioning the crane like a sketch following

Switch off the PTO and with power ON

P.S. wire bridge without the resistor in the

See the wiring structure in to the alarm 30

1.Disconnect (unscrew the silver crown) the pressure

Pin 1 and pin 2

Pin 1 and pin 2

XS10 is located between the

Extension wiring short circuit test

Pin 1 and pin 2

Trouble shooting material necessary to solve the problem:

- Bypass pressure transducer part number 5160026

XS10 connection is located between the column to valve bank.

Positioning the crane like a sketch following

Switch off the PTO and with power ON

P.S. wire bridge without the resistor in the

Trouble shooting material necessary to solve the