Calibration Procedure UK

LOAD CELL REPLACEMENT
The following technical information is referred to Faresin Inudstries SpA products listed
below
Model 6.25 X Model 7.42 X Model 14.35 X

Model 7.30 C X Model 9.30 X Model 17.40 X
Model 7.30 X Model 10.50 X Model 18.45
Model 7.33 X Model 10.70 X Model 22.45
Model 7.35 X Model 11.30 X
Model 7.38 X Model 11.35 X
First of all you need to know the alarm code that is generated by the SAR system. These alarms are
to be read as described in the manual, by recognizing the sequence of flashing LEDs.
At the end of the procedure (page 12) you will find the sequence of alarms that may occur in the
controller with the corresponding description.
SEQUNCE ALLARM CODE
 Channel Number:
CHANNEL 1 = 3 brief flashes
 Alarm Number: 1st DIGIT

1,…,9 long flashes
PAUSE
 Alarm number 2nd DIGIT

In case we encounter an alarm 38,51 or 52 and the load cell is an old model it’s required to change
the load cell whit a new model. In case we are working on a machine with the new load cell
(38.0056.00A0 Rev B-1.01 side tag EC green dot.) and we have an error 51 or 52 we suggest to
perform a Calibration Test.
For any other alarm please follow the instruction write on the manual.

Pag. 1
SAFETY REGULATIONS
All maneuvering must be done by authorized personnel.
Is required to be equipped with all the adequate Protective equipment. gloves, goggles, safety shoes,
work overalls.
Materials needed for cell replacement:
Wrench 8mm hex

Torque wrench
Sandpaper various measures
Scissors
Ties different (from 10 cm to 30 cm)
Staple pull straps
Loctite 638
# 1 load cell kit mod: 38.0056.00A0 Rev B-1.01 side tag
EC and green dot.

Pag. 2
BEGINNING OF WORKS FOR CELL REPLACEMENT

First we will go to disconnect the connector of
the cell, during this operation we can check if
the plastic seal are installed correctly on the
connector if are ok proceed on freed any cable
ties that may bound the cable on the body of the
machine, if the seal are broken or miss please
provide for replacement.

We can remove the old load cell and start to
clean the surface of the axle with sandpaper and
dust cleaner.

The surface of the axle where it will be set the
sensor must be cleaned as shown in the photo
Pag. 3
At this point we proceed to Replace the load cell
by following this step:
1. Tight the screw completely on the two

thread to be sure that no residual of loctite
are present. When the screw is free remove
it and proceed on the next step.

2. Put loctite on the thread and the surface of
the load cell

3. Install the load cell on the axle and tighten
the screws by hand be sure that the machine
have the tyres on the leveled ground and the
boom fully close and fully down, then
proceed on the tightening with the torque
wrench set on 65 Nm (+5, -0) Nm , the
screws must be tighten alternate to don’t
have false force accumulated, at the end put
the plastic cap come with the kit.

The installation is complete now we must wait at list one hour before proceed with the calibration
to let the loctite dry.

Pag. 4
CALIBRATION PROCEDURE OF ANTI-TIPPING CONTROL UNIT
We must be sure that the Loctite has dried (wait at least one hour) before proceeding with the
calibration. Remove any tool installed on the machine, find a flat surface and make sure you have
enough operating space in order to extend the arm along its entire length and height. Calibration
deletion is accessed by entering an access code during the second phase of the ignition panel.
NOTE: After entering the key sequence to wait 5 seconds before proceeding with the
otherwise the cancellation of the calibration unit does not perform the test.
DELETE CALIBRATION
CALIBRATION STEPS SAR PANEL

To enter in the system procede with the
following step:
1. Start the system.

2. Wait that the system start make the self
checking. T3
3. Make the following sequenze of buttons
before that the self checkin leds switch off. T2
Push 2 times the button T3. T1
Push 3 times the button T2.
Wait for 5 seconds.
Red led L5 flashes (Fig. S5).
· Press key “T3” to delete calibration from the

memory. T3
Fig. S5
Led L6 flashes (fig. S6).
· Press key “T1” to delete calibration.
Led L6 lights up steady for 2 sec, confirming

calibration is deleted.
The device then switches to Operating Mode.
T1
Fig. S6
Pag. 5
CALIBRATION WITHOUT OUTRIGGERS
SYSTEM
CONFIGURATION
To enter in the system procede
with the following step:

2. Wait that the system start T3
make the self checking.
3. Make the following T2
sequenze of buttons before
that the self checkin leds T1
switch off.

Led green L1 flashes (fig. S1). P1
· Set the system up in

configuration P1.
· Press key “T1” to

memorise the data.
Move the machine with the
Led L1 lights up steady. T1 boom completely retracted and
horizontal, with the fork
Fig. S1 installed.
Green led L2 flashes (Fig. S2). P2

configuration P2.
· Press key ”T1” to
memorise the data.
Led L2 lights up steady.

T1
Fig. S2
boom completely retracted and
completely lifted, with the fork
installed.
Pag. 6
Yellow led L3 flashes P3
(Fig. S3).

configuration P3.
· Press key ”T1” to memorise
the data.
Led L3 lights up steady. T1
Fig S3
boom completely extended and
totally lifted, with the fork
installed.

(Fig. S4).

configuration P4.
the data.
T1 boom completely extended and
horizontal, with the fork
installed.
Fig. S4
WARNING: pay P5
attention to this
operation it’s really dangerous.

configuration P5.
· Press key ”T1” to memorise T1
the data.
boom completely lowered, the
Fig. S5 maximum weight and extend
the boom till the tires touch a
little the round (limit of
tipping).
Pag. 7
· Press key “T1” to save the

calibration.
The device switches to

operating mode and is ready
for use.
T1
Fig. S6
Turn on the bypass key retract the boom till you reach the stable condition of the
machine.
Unload the weight from the fork.

Switch off the machine.
When you restart the machine the setting was done.
Two tests of performance to make sure that the system is stable. These tests must be performed on
and off-road for a time of 15 minutes and at the end of the operation let the shaft to cool and retest
the system.

Pag. 8
CALIBRATION WITH OUTRIGGERS
SYSTEM
CONFIGURATION
To enter in the system procede
with the following step:

2. Wait that the system start
T3
make the self checking.
3. Make the following sequenze T2
of buttons before that the self
checkin leds switch off. T1
Led green L1 flashes (fig. S1). P1

configuration P1.
· Press key “T1” to

memorise the data.
Led L1 lights up steady. T1 boom completely retracted
and horizontal, with the fork
Fig.S1 installed.
Green led L2 flashes (Fig. S2). P2

configuration P2.
· Press key ”T1” to
memorise the data.

T1
Fig.S2
boom completely retracted
and completely lifted, with the
fork installed.
Pag. 9
(Fig. S3).

configuration P3.
the data.
Led L3 lights up steady. T1
Fig.S3

boom completely extended
and totally lifted, with the
fork installed.

(Fig. S4).

configuration P4.
the data.
T1 Move the machine with the
Led L4 lights up steady. boom completely extended
and horizontal, with the fork
Fig.S4 installed.
WARNING:pay attention P5
to this operation it’s
really dangerous.

configuration P5.
T1 Move the machine with the
· Press key ”T1” to memorise boom completely lowered, the
the data. maximum weight and extend
Fig.S5 the boom till the tires touch a
Led L5 lights up steady. little the round (limit of
tipping).
Pag. 10
Yellow led L7 flashes P5+S
(Fig. S5a).

configuration P5+S. L7
The led L7 will light constant
when the outriggers are down.
T1 Please retract completely the
· Press key ”T1” to memorise boom , lower completely the
the data. Fig.S5a stabilizers and extend the
boom until the calibration
Led L7 switch off . point according to the loading
Led L5 lights up steady. diagram of the machine.
(remember that the central
unit will calculate
automatically 30% less that
the maximum calibration).
· Press key “T1” to save the

calibration.
The device switches to

operating mode and is ready for
use.
T1
Fig.S6
Turn on the bypass key retract the boom till you reach the stable condition of the
machine.
Unload the weight from the fork.

Switch off the machine.
When you restart the machine the setting was done.
Two tests of performance to make sure that the system is stable. These tests must be performed on
and off-road for a time of 15 minutes and at the end of the operation let the shaft to cool and retest
the system.

Pag. 11
VIEW ALARMS ON SAR PANEL

Note: Led L6 on the LED bar signals the alarms, the buzzer is not used to signal alarms.
Description of operation
When the system registers an alarm/anomaly, led L6 will flash on the panel, while leds L1,..,L5 stay
off. Led L6 will emit a sequence of flashes according to a code below on to identify the faulty
channel and the alarm number. The system detects the alarms for each single channel (maximum
total of 10 alarms at the same time) and displays the first of the recorded alarms on the screen. The
alarm appears on the display until the condition is restored.
Note: When a system alarm occurs, all of the outputs switch off (including WDO).
Alarm code sequence

 First sequence of flashes Channel Number
 Second sequence of flashes Alarm Number: 1st DIGIT
 Third sequence of flashes Alarm Number: 2nd DIGIT
HOW TO READ THE ALARM
 Channel Number:
 Alarm Number: 1st DIGIT

PAUSE
 Alarm number 2nd DIGIT

Pag. 12
ALARM CODE LIST
CODE DESCRIPTION WHAT TO DO

CRC error in the memory area that Replace the SAR
11
contains the software If the error persists, contact assistance
Replace the SAR
CRC error in the memory area that
12 Delete and re-run calibration.
contains the parameters
If the error persists, contact assistance
Replace the SAR
13 Programme flow control error
Data exchange error between two Replace the SAR
14
microcontrollers If the error persists, contact assistance
When the machine is off and on, make sure
Supply voltage out of range error
15 that the battery voltage is within the stated
(+7 Vdc ÷ +18 Vdc)
range
Supply voltage out of range inside 1st Replace the SAR
16
channel error (+ 4.8 Vdc ÷ 5.2 Vdc) If the error persists, contact assistance
Supply voltage out of range 2nd channel Replace the SAR
17
error (+ 4.8 Vdc ÷ 5.2 Vdc) If the error persists, contact assistance
Make sure the cables are not damaged
21 Cut Off 1 output status congruency error Replace the SAR
22 Cut Off 2 output status congruency error Replace the SAR
23 WDO 1 output status congruency error Replace the SAR
24 Output 1 status congruency error Replace the SAR
25 Output 2 status congruency error Replace the SAR
26 WDO 2 output status congruency error Replace the SAR
Load cell A: Replace the load cell
31
Load sensor internal parameters CRC error If the error persists, contact assistance
Run the calibration test
Load cell A Run calibration again
32 Signal reading out of range error Make sure the cell is clamped on
(10 – 990) Replace the load cell
Load cell A
Replace the load cell
33 Internal offset reading out of range error
(466 – 526)
Load cell A Replace the load cell
34
Internal 5 Vdc supply voltage error If the error persists, contact assistance
35
No thermal calibration error If the error persists, contact assistance
Pag. 13
36
Bus LIN message check sum error If the error persists, contact assistance
37 Load cell A Sent data CRC error
Check cable integrity
Load cell A
38 Replace the load cell
Bus LIN message reception error
39
Bus LIN message control meter error If the error persists, contact assistance
Load cell B Replace the load cell
41
Load sensor internal parameters CRC error If the error persists, contact assistance
Run the calibration test
Load cell B Run calibration again
42 Signal reading out of range error Make sure the cell is clamped on
(10 – 990) Replace the load cell
Load cell B
43 Internal offset reading out of range error
(526 – 586)
44
Internal 5Vdc supply voltage error If the error persists, contact assistance
45
No thermal calibration error If the error persists, contact assistance
46
Bus LIN message check sum error If the error persists, contact assistance
47
Sent data CRC error If the error persists, contact assistance
Check cable integrity
Load cell B
48 Replace the load cell
Bus LIN message reception error
49
Bus LIN message control meter error If the error persists, contact assistance
Difference between load cell A and B
51 Run Calibration Test
readings too great
Difference between the load percentage
52 Run Calibration Test
readings for channels 1 and 2 too great
Make sure the micro switches or
proximities installed on the machine are
Double safety input reading for outriggers
61 working correctly
on the ground congruency error
Check the cables
Make sure the micro switches or
proximities installed on the machine are
Double safety input reading of retracted
62 working correctly
boom congruency error
Check the cables
Make sure the selector installed on the
machine is working correctly
Inputs from mode selector congruency
63 Check the cables
error
Pag. 14
Do not turn the SAR on when the bypass
key is active
Make sure the key-operated selector
Exclusion key input active upon ignition
64 installed on the machine is working
error
correctly
Check the cables
Do not turn the SAR on when you re-arm
movement
Re-arm movements input when lock is Make sure the switch installed on the
65
enabled upon ignition error machine is working correctly
Check the cables
Check the cables
Make sure the internal control unit is
66 Feedback signal reading in frequency error
working correctly
Make sure the external drive is working
External drive 1 feedback signal reading (relay or solenoid)
67
error Check the cables
Make sure the external drive is working
External drive 2 feedback signal reading (relay or solenoid)
68
error Check the cables
Make sure the joystick is operating
Analogue signal from joystick reading correctly
71
error, out of range Check the cables
Make sure the pressure transducer is
Pressure transducer reading error, to check operating correctly
72
joystick re-arming Check the cables
CAN BUS message reception error, in the Check the cables
73
optional external unit If the error persists, contact assistance
Note: Not all the alarms force you to exit the calibration phase.
The alarm error codes that force you to exit the calibration phase are:
- from 11 to 17;
- from 31 to 39;
- from 41 to 49;
- 61.
Release the keys. Turn the system off and
81 Keys pressed upon ignition error then back on again.
Note: The system displays an anomaly, but it is not working (deactivated outputs):
- other alarms may have occurred that block the outputs.
Pag. 15

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LOAD CELL REPLACEMENT

Model 6.25 X Model 7.42 X Model 14.35 X

SEQUNCE ALLARM CODE

 Alarm Number: 1st DIGIT

 Alarm number 2nd DIGIT

Materials needed for cell replacement:

Wrench 8mm hex

1. Tight the screw completely on the two

CALIBRATION STEPS SAR PANEL

1. Start the system.

Wait for 5 seconds.

Red led L5 flashes (Fig. S5).

· Press key “T3” to delete calibration from the

Led L6 flashes (fig. S6).

· Press key “T1” to delete calibration.

Led L6 lights up steady for 2 sec, confirming

1. Start the system.

Push 2 times the button T3.

Led green L1 flashes (fig. S1). P1

· Set the system up in

· Press key “T1” to

Green led L2 flashes (Fig. S2). P2

· Set the system up in

Led L2 lights up steady.

· Set the system up in

Led L3 lights up steady. T1

Yellow led L4 flashes P4

· Set the system up in

Red led L5 flashes (Fig. S5).

· Set the system up in

· Press key “T1” to save the

The device switches to

Unload the weight from the fork.

1. Start the system.

· Set the system up in

· Press key “T1” to

Green led L2 flashes (Fig. S2). P2

· Set the system up in

Led L2 lights up steady.

· Set the system up in

Led L3 lights up steady. T1

Move the machine with the

Yellow led L4 flashes P4

· Set the system up in

Red led L5 flashes (Fig. S5).

· Set the system up in

· Set the system up in

Red led L6 flashes (Fig. S6).

· Press key “T1” to save the

The device switches to

Unload the weight from the fork.

Alarm code sequence

HOW TO READ THE ALARM

 Alarm Number: 1st DIGIT

 Alarm number 2nd DIGIT

CODE DESCRIPTION WHAT TO DO

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