Supplementary

Installer Manual

Stability Control
L System
(ORIGINAL INSTRUCTIONS)

7845048-01
04/14
Amco Veba s.r.l., Via Einstein, 4 42028 Poviglio (RE) Italy
Tel. ++39 0522 408011 Fax. ++39 0522 408080
E-mail: info@amcoveba.it http://www.amcoveba.com
INDEX

1.  SYMBOLS AND UNITS OF MEASUREMENT ...............................................................................................................1 

2.  DESCRIPTION OF SYSTEM COMPONENTS................................................................................................................2 

2.1  Digital sensors.....................................................................................................................................................................................................2 
2.1.1  Schematic of the cabling for sensors .............................................................................................................................................................. 2 
2.1.2  Sensors to monitor beams open, stabilizer feet on the ground and crane rotation......................................................................................... 3 
2.1.3  Sensor to indicate closed crane ...................................................................................................................................................................... 4 
2.1.4  Inclination sensor of the crane boom .............................................................................................................................................................. 5 
2.1.5  Rotation sensors of the crane ......................................................................................................................................................................... 5 
2.2  Analog sensors ...................................................................................................................................................................................................6 
2.2.1  Pressure transducer ........................................................................................................................................................................................ 6 
2.2.2  Planarity transducer ........................................................................................................................................................................................ 7 

3.  FUNCTIONS OF THE CONTROL PANELS ...................................................................................................................8 

4.  HOW THE L SYSTEM FUNCTIONS...............................................................................................................................9 

4.1  Functions of L system in fully stabilized mode ...............................................................................................................................................9 
4.2  Functions of L system in planarity mode .......................................................................................................................................................12 

5.  CALIBRATION OF L SYSTEM.....................................................................................................................................17 

5.1  Stability test and calibration of the moment limiter.......................................................................................................................................17 
5.2  Procedure to recalibrate the moment limiter..................................................................................................................................................19 
5.3  Stability test and calibration of the planarity transducer..............................................................................................................................20 

APPENDICES
Appendix 1: Registration form to record limiting pressures .........................................................................................................................................25 
Appendix 2: Visual and audible warning signals ............................................................................................................................................................26 
Appendix 3: Alarm signals.................................................................................................................................................................................................27 
Appendix 4: Programming menu ......................................................................................................................................................................................28 
Appendix 5: Vehicle instability during calibration of moment limiter ...........................................................................................................................29 
Appendix 6: Vehicle instability during calibration of planarity transducer ..................................................................................................................30 
Appendix 7: Electrical Schematics ...................................................................................................................................................................................31 
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L System

1. SYMBOLS AND UNITS OF MEASUREMENT

Symbols
Unit of
Symbol Description
measure
CW Clockwise -
CCW Counterclockwise -
CVS Control valve side -
DOWN Configuration of stabilizer feet on the ground -
k Derating factor of maximum inclination -
M Pressure gauge connection -
MAUM Use, maintenance, and warning manual -
MAX Configuration of maximum stabilizer beam opening -
MID Configuration of intermediate stabilizer beam opening -
MIN Configuration of minimum stabilizer opening -
MI Installer manual -
NC Normally closed -
NO Normally open -
OCVS Opposite control valve side -
P1LIM Crane limiter pressure (P1LIM=P1TIP/n) bar
P1TIP Overturning pressure limit bar
TL Load for the stability test (Test Load) kg
UP Configuration of stabilizer feet not on the ground -
Vbatt Battery voltage V
X Limit angle determinated by the planarity test on the positive semiaxis x °
-X Limit angle determinated by the planarity test on the negative semiaxis x °
Y Limit angle determinated by the planarity test on the positive semiaxis y °
-Y Limit angle determinated by the planarity test on the negative semiaxis y °
 Inclination angle °

Subscripts
Unit of
Symbols Description
measure
max maximum -
min minimum -
X x axis: axis perpendicular to the axis of the vehicle frame -
Y y axis : axis parallel to the axis of the vehicle frame -
Read instantaneous value -
Stab stabilization -
Threshold preset threshold -

Legend of warning lights and audible alarms

Unit of
Symbol Description
measure

Warning lights off -

Warning lights turned on -

Flashing warning lights -

Audible alarm deactivated -

Continuous audible alarm -

Intermittent audible alarm -

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L System

2. DESCRIPTION OF SYSTEM COMPONENTS

To gather enough information for monitoring stability, the system uses digital proximity sensors and analog sensors on the crane:

 Digital sensors (stabilizer beam extension, stabilizer feet on the ground, crane in closed position, crane rotation,
inclination sensor on boom)
 Analog sensors (pressure transducers, planarity sensor)

2.1 Digital sensors

The digital proximity sensors are positioned to sense objects in the immediate vicinity of the “sensitive side” of the sensor without
requiring physical contact. The distance within which these sensors can detect objects is termed the “nominal range” (or sensing field).

The proximity sensors offer two modes of operation:

 Normally closed (NC): the output is +Vbatt when the sensor doesn’t detect the presence of the stabilizer beam
 Normally open (NO): the output is -Vbatt when the sensor doesn’t detect the presence of the stabilizer beam

The absence of a mechanical actuation mechanism and of physical contact between sensor and object allows the
sensor to have a higher level of reliability.

2.1.1 Schematic of the cabling for sensors

FRONT

Legend
P1: Proximity sensor for stabilizer on the ground P11 P10
P2: Proximity sensor for stabilizer on the ground P1 P2
P3: Proximity sensor for stabilizer on the ground P5
P4: Proximity sensor for stabilizer on the ground P6 P7 SECOND
BOOM
L
P5: Proximity sensor for closed crane System
P12
P6: Proximity sensor for stabilizer beam completely open
P7: Proximity sensor for stabilizer beam completely open
P8: Proximity sensor for stabilizer beam completely open CVS OCVS
P9: Proximity sensor for stabilizer beam completely open
P10: Proximity sensor for crane rotation
P11: Proximity sensor for crane rotation RB
P12: Inclination sensor
RB: Rear Box P4 P3

P9 P8

REAR

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L System

2.1.2 Sensors to monitor beams open, stabilizer feet on the ground and crane rotation

Monitoring of beam opening, of stabilizer feet on the ground and of crane rotation is carried out by proximity sensors with NC outputs
connected in series, positioned under the stabilizer beams (stabilizer feet on the ground) and on the beam flange (beams open)

The system, given the series connection of the sensors, receives a +Vbatt signal only when the stabilization is completely correct
(beams completely open and stabilizer feet on the ground).

PROXIMITY SENSOR FUNCTIONING FOR STABILIZER FEET ON THE GROUND

In the event that a stabilizer foot is not on the ground, the sensor will detect the presence of metal and supply a signal equal to 0 V
(Vbatt). When a foot is correctly placed on the ground and lifts the stabilizer beam, the sensor no longer detects the presence of the
beam and switches to an output state of +Vbatt, providing power to the next sensor in series.

The functioning of the sensor is indicated by a light mounted on the sensor itself: when the stabilizer foot is not on the ground the light is
off, and when the stabilizer foot is properly in position the light is on.

PROXIMITY SENSOR FUNCTIONING FOR STABILIZER BEAMS OPEN

In the event that a beam is not at full extension, the sensor detects the presence of the metal beam and supplies a signal equal to 0 V
(Vbatt). Once the beam is completely extended, the sensor aligns with a hole and no longer detects the presence of the beam, causing
it to supply an output of +Vbatt which powers the next sensor in series.

The functioning of the sensor is indicated by a light mounted on the sensor itself: when the stabilizer beam is not fully opened the light is
off, and when the stabilizer beam is fully opened the light is on.

PROXIMITY ROTATION FUNCTIONING

Depending on its position, the crane's column changes the status of the two proximity switches and consequently changes the
movements allowed to return the crane to safety.

Electrical connections
- power connected to main crane power
- output connected to the system’s digital input
- negative connected to system negative

Collegamenti su M12
PIN FUNCTION
1 Positive
2 Sensor output
3 Negative
4 Not connected

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L System

2.1.3 Sensor to indicate closed crane

Sensing of the crane in closed position is perfomed by a proximity sensor with NO contacts positioned on the base near the support for
crane in closed position.

FUNCTIONING
The sensor signals closure of the boom assembly when the metal of the crane boom comes into proximity: in this configuration the
output is equal to +Vbatt. When the crane is not in the closed position the sensor output switches to -Vbatt, signaling to the system the
opening of the crane.

The functioning of the sensor is indicated by a light mounted on the sensor itself (see figure): when the crane boom is closed the light is
on.

For the manufacturer, the closed position for a standard crane is with the extension group supported on the crane
base.

Electrical connections:
- power connected to main crane power
- output connected to the system’s digital input
- negative connected to system negative

Connections on M12
PIN FUNCTION
1 Positive
2 Not connected
3 Negative
4 Sensor Output

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L System

2.1.4 Inclination sensor of the crane boom

The inclination of the boom system to the horizontal is determined by a sensor capable of converting the inclination above / below the
horizontal to a digital value of current.

No recalibration is required when the inclination sensor is reassembled in the same position.

Electrical connections:
- power connected to main crane power
- output connected to the system’s digital input
- negative connected to system negative

Connections on the 4-pole AMP connectors

PIN FUNCTION COLOR
1 Positive WH/RD
2 Opposite signals detecting boom GY
3 inclination (above/below horizontal line) GN
4 Negative BK/VL

2.1.5 Rotation sensors of the crane

The sector where the crane works is monitored by two proximity sensors installed on the base.

No recalibration is required when only replacing the rotation sensor.

Electrical connections:
- power connected to main crane power
- output connected to the system’s digital input
- negative connected to system negative

Connections on M12
PIN FUNCTION
1 Positive
2 Output
3 Negative

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L System

2.2 Analog sensors

The term “analog sensors” describes devices for converting a physical dimension that we wish to measure (pressure, angle of
inclination, etc) into an electrical signal, making it more easily measurable or recordable.

Analog sensors integrate several internal components such as voltage regulators, signal amplifiers, communication circuits, etc. We end
this section by defining transducers.

2.2.1 Pressure transducer

Sensing of the pressure in the lifting cylinder, in order to monitor the load, is performed by a pressure transducer. We make use of a
component that modulates the output current in response to the detected pressure.

The transducer is designed to output a current from 4mA to 20mA: 0 bar of pressure corresponds to a current value of 4mA, and 400 bar
(maximum pressure for the transducer) corresponds to an output of 20mA. The output current changes in a linear response to the
pressure.

mA

20

0 400 bar

The system is capable of detecting anomalous readings from the pressure transducer for current values under 4mA (open circuit) or over
20mA (short circuit).

The installer, prior to the performing the calibration procedure, must verify correct operation of the pressure
transducer by operating the connected cylinder to full extension and then holding the lever depressed until the moment limiter
intervenes, blocking the movement. In the time between reaching full cylinder extension and the moment limiter’s activation,
the load registered on the display must reach 100%.

After replacing the pressure transducer, the installer must carry out the above indicated functioning proof. No
recalibration is required.

Electrical connections:
- positive connected to the system
- output connected directly to the system, which converts the value in electrical current to pressure.
- the pressure transducer does not require a negative electrical connection

PIN FUNCTION
1 Positive
2 Current signal

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L System

2.2.2 Planarity transducer

Detection of the angle of crane inclination with respect to the horizon is performed by an angle transducer to convert the inclination angle
to a current value.
The transducer is designed to output a current from 4mA to 20mA: -10° corresponds to a current value of 4mA, and 10° corresponds to
an output of 20mA. The output current changes in a linear response to the detected angle Read, with 10° ≤ Read ≤ 10°.

The system is capable of detecting anomalous readings from the pressure transducer for current values under 4mA (open circuit) or over
20mA (short circuit).

No recalibration is required when only replacing the planarity transducer.

Electrical connections:
- positive: the system operates with a supply voltage (between 10V and 30V).
- outputs 2 and 4, directly connected to the system that converts the current values in degrees.
- negative connected to -Vbatt.

Connections on the 4-pole AMP connectors

PIN FUNCTION COLOR
1 Positive RD
2 Current signal for y axis BU
3 Negative BK - YL - WH
4 Current signal for x axis GN

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L System

3. FUNCTIONS OF THE CONTROL PANELS

In this paragraph we illustrate the main functions of the two control panels.

EMERGENCY

STOP

Power light, green

The light is on when the control panel has power (emergency valve and moment limiter active). Pressing the
emergency stop button turns off electrical power to the crane. Reactivation of the emergency stop button provides
power to the crane’s control box.

Load and planarity lights, orange and red

The orange light turns on when the crane's loading surpasses 90% of the maximum capacity. The red light turns on
when the crane's loading reaches 100% of the maximum capacity. The red light flashes when the crane's inclination
reaches the limit angle (planarity limit). Other dangerous work conditions signalled by the warning lights are indicated
in Appendix 2.

Reset Button
In case of overload, pressing the Reset button allows beginning emergency crane movement for 3s, after which it
blocks all movements for 30s. This emergency operation is permitted for 5 times in succession.
If the system is started when it is already correctly stabilized, the button is used to confirm stabilization.
In programming mode, the button is used to confirm inserted data.

Key switch in "emergency mode"

Turning the key to "emergency" disables the radio receiver and then the radio control is inactive: in this condition the
crane can be moved with the emergency controls only, after manually disabling the solenoid emergency valve YVH1.
The emergency controls can be used only when the radio remote control is unusable and only to return the
crane to the transport position, without lifting any load.

Key switch in "fully stabilized mode"

Turning the key on this position, it's possible to control the crane only from the radio control. The system works in fully
extended beam and feet on the ground mode (see §4.1) because the planarity transducer is disabled. The crane
operates at rated speed. In this condition, if the operator does not fully extend the stabilizer beams, the crane can not
be moved and the display shows:

BOOM IN ONLY
PLANAR. KEY OFF

Key switch in "partially stabilized mode" - planarity mode

Turning the key on this position, it's possible to control the crane only from the radio control. The system works in
partially extended beam and feet on the ground mode (see §4.2) because planarity transducer is enabled. The crane
operates at derated speed. In this condition, if the operator fully extends the stabilizer beams, the crane works in "fully
stabilized mode", but with derated speed.

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L System

4. HOW THE L SYSTEM FUNCTIONS

The system allows use of the crane with fully extended stabilizer beams and feet on the ground: in this case the crane is blocked by the
pressure transducer.
The system allows use of the crane also with partially extended stabilizer beams, feet on the ground and planarity: in this case the crane
is blocked by pressure transducer and planarity transducer.

4.1 Functions of L system in fully stabilized mode

The system allows use of the crane at rated speed only after the machine is correctly stabilized, which is after:

 100% extension of all stabilizer beams (and supplementary beams, if present)

 Lowering of all stabilizer feet to the ground
 key switch on fully stabilized mode

FRONT
ANTERIORE

100%
o area non permessa
or non-permitted area

CABINA

LS RS

100% 0% 0% 100%

100% 100%
LSS RSS

100% 0% 0% 100%

100%
REAR
POSTERIORE

Placement of the stabilizers is only allowed when the crane is in the rest position. During opening and positioning of the stabilizers, the
system posts the following message on the display:

STAB NON PIAZ. GRU CHIUSA

STAB UNDEPLOYED CRANE FOLDED

Once stabilizion is complete, the system allows to move the crane: the system displays

STAB PIAZZATI GRU CHIUSA

STAB DEPLOYED CRANE FOLDED

After opening the crane, the system blocks all stabilizer controls: stabilizer legs and stabilizer beams (if present).
The normal operation screen appears:

RADIO
XX% XXX bar

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L System

MOMENT LIMITER
When the max working pressure is reached, the system disables
all crane movements, except retraction of hydraulic extensions.
The display will show:

BLOCCO - BLOCK
XX% XXX bar
Permitted movements

Warning signals: load between 90% and 100% Warnings signals: 100% load
90% 100% Light tower Audible alarm 90% 100% Light tower Audible alarm

WINCH PULL LIMITER (OPTION)

When the max winch pull is reached, the system disables all
crane movements, except descent of the rope. The display does
not show any alarm.

Permitted movements

Warning signals: winch pull between 90% and 100% Warnings signals: 100% winch pull
90% 100% Light tower Audible alarm 90% 100% Light tower Audible alarm

LOSS OF CONTACT BETWEEN STABILIZER AND GROUND DURING WORKING OPERATIONS

It can happen that during working operations one or more stabilizers momentarily lift off the ground: in this case, despite detecting the
momentary loss of contact between stabilizer and ground, the system will allow continued operation of the crane while alternately
flashing the following screens:

RADIO STAB NON PIAZ.

XX% XXX bar STAB UNDEPLOYED

Warnings signals: stabilizer lifted off the ground

90% 100% Light tower Audible alarm

This signal continues until correct stability returns

If the crane reaches 100% load while in this condition, the system activates the warning signals of 100% load.

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L System

CRANE POWER TURNED ON WITH CRANE ALREADY STABILIZED

If crane power is turned while the crane has already been stabilized, the operator must press the Reset button to confirm to the system
that stabilization is complete; this will in turn enable all crane functions.

STAB PIAZZATI? STAB PIAZZATI

STAB DEPLOYED? STAB DEPLOYED

SENSOR FOR CLOSED CRANE BYPASSED

If the sensor for closed crane has somehow been bypassed, that is, the sensor indicates closed crane and the pressure transducer on
1st boom cylinder detects a pressure more than 10% (approximately) of the max. allowed pressure, the display shows:

P1>Pmax (GRU CH.)

P1>Pmax (CRN FLD)

Warnings signals: sensor for closed crane bypassed

90% 100% Light tower Audible alarm

The system activates a protection logic: it permits all crane movements, except control of stabilizers, for a duration of 5s and then
deactivates them for 30s. This cycle of functions disabled for 5s and enabled for 30s continues until the detected pressure is below 10%
(approximately) of the set maximum.

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L System

4.2 Functions of L system in planarity mode

The allows use of the crane at derated speed only after the machine is correctly stabilized, which is after:

 partially or fully extension of all stabilizer beams (and supplementary beams, if present)
 Lowering of all stabilizer feet to the ground
 key switch on planarity mode
 the first planarity check with positive result, that is, the inclination angle measured after stabilization, Stab, must be lower than the
limit angle Threshold,max (see max inclination angle of crane in Technical Sheet)

horizontal line
Stab Ground

Ground
inclination of the ground

where:
Stab = Inclination of crane base with respect to the horizontal line detected by the planarity transducer after stabilization
Ground = Inclination of the ground with respect to the horizontal line

PLANARITY CHECK DURING STABILIZATION

The movement of the stabilizers is permitted only when the crane is in rest position. During crane stabilization the display shows:

STAB NON PIAZZ. GRU CHIUSA

STAB UNDEPLOYED CRANE FOLDED

Once stabilizion is complete, the system allows crane movement: the system displays

PIEDI PIAZZATI GRU CHIUSA

FEET DEPLOYED CRANE FOLDED

The sensor carries out a first inclination measure after the stabilization: if the detected angle exceeds the maximum threshold angle
(Stab > Threshold,max), all crane controls are disabled, except control of stabilizers. The display shows:

Angle Stab: X= XX ; Y= YY

Stab > Threshold,max Stab > Threshold,max

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L System

In order to enable the crane controls, it is necessary to stabilize the crane so that the stabilization angle does not exceed the maximum
thresholdangle (Stab < Threshold,max).
If Stab < Threshold,max, then confirm with the Reset button or with Clacson button on radio transmitter.

Angle Stab: OK? PLANARITA’ OK

XX < YY PLANARITY OK

Then the normal operation screen appears:

RADIO Read GRU CHIUSA

XX% XXX bar CRANE FOLDED

Once the Reset button has been pushed, the system blocks all stabilizer movements.

PLANARITY CHECK DURING WORK OPERATIONS

During work operations the planarity transducer continously detects the inclination angle Read: all crane control are enabled only if the
following condition is met:

Read < k·max

horizontal line
stabilization line
Read
working line

where:
Read = angle between the working line and the stabilization line, continously detected during work operations.
k = derating factor, linked to the inclination of the stabilization line (≤1): it depends on the tresholds set by the installer (Threshold1,2,3) and
by the stabilization angle, Stab.
max = maximum inclination angle, that changes with the rotation of the column: it varies with angles X, -X, Y, -Y detected during stability
test with test load, retracted beams, feet on the ground and vehicle in horizontal position.

The angle Read is calculated as a module of the angular risultant identified by angles XRead e YRead detected by the transducer:

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L System

If the inclination angle exceeds the maximum allowed angle (Read > k·max ), the system blocks the crane. The display shows

MANCANZA DI PLAN RADIO Read

LACK OF PLAN XX% XXX bar

Warning signals: loss of planarity

90% 100% Light tower Audible alarm

In order to return to normal work condition, it's necessary to decrease the crane's inclination until the angle is less than the maximum
allowed angle (Read < k·max), using the permitted controls (see figures below).

Permitted movements

2nd boom over the horizontal line 2nd boom under the horizontal line

FRONT FRONT
X X

Y
REAR
REAR
Rear-cab crane Rear-body crane

When Read < k·max le warning lights turn off, the audible alarm deactivates and the display shows

RADIO Read
XX% XXX bar

The warning of loss of planarity has priority over the warning of foot lifted off the ground.

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L System

MOMENT LIMITER
When the max working pressure is reached, the system disables
all crane movements, except retraction of hydraulic extensions.
The display will show:

BLOCCO - BLOCK
XX% XXX bar

Permitted movements

Warning signals: load between 90% and 100% Warning signals: 100% load
90% 100% Light tower Audible alarm 90% 100% Light tower Audible alarm

WINCH PULL LIMITER (OPTION)

When the max winch pull is reached, the system disables all
crane movements, except descent of the rope. The display does
not show any alarm.

Permitted movements

Warning signals: winch pull between 90% and 100% Warnings signals: 100% winch pull
90% 100% Light tower Audible alarm 90% 100% Light tower Audible alarm

LOSS OF CONTACT BETWEEN STABILIZER AND GROUND DURING WORKING OPERATIONS

It can happen that during working operations one or more stabilizers momentarily lift off the ground: in this case, despite detecting the
momentary loss of contact between stabilizer and ground, the system will allow continued operation of the crane while alternately
flashing the following screens:

RADIO Read PIEDI NON PIAZ.

XX% XXX bar FEET UNDEPLOYED

Warning signals: stabilizer lifted off the ground

90% 100% Light tower Audible alarm

This signal continues until correct stability returns

The warning of loss of planarity has priority over the warning of foot lifted off the ground.

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L System

CRANE POWER TURNED ON WITH CRANE ALREADY STABILIZED

If crane power is turned on while the crane has already been stabilized, the operator must press the Reset button to confirm to the
system that stabilization is complete (feet on the ground and stabilization angle OK); this will in turn enable all crane functions.

PIEDI A TERRA?
STAB ON THE GROUND?

SENSOR FOR CLOSED CRANE BYPASSED

If the sensor for closed crane has somehow been bypassed, that is, the sensor indicates closed crane and the pressure transducer on
1st boom cylinder detects a pressure more than 10% (approximately) of the max. allowed pressure, the display shows:

P1>Pmax (GRU CH.)

P1>Pmax (CRN FLD)

Warning signals: sensor for closed crane bypassed

90% 100% Light tower Audible alarm

The system activates a protection logic: it permits all crane movements, except control of stabilizers, for a duration of 5s and then
deactivates them for 30s. This cycle of functions disabled for 5s and enabled for 30s continues until the detected pressure is below 10%
(approximately) of the set maximum.

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L System

5. CALIBRATION OF L SYSTEM

5.1 Stability test and calibration of the moment limiter

During the calibration phase it’s necessary to work in a space large enough to allow full opening of the stabilizers (crane and auxiliary
stabilizers) and with a surface that can withstand the pressure exerted by the stabilizers (see MAUM). The following list of materials is
required for performing the stability test:

Tools
 Pressure gauge
 Test load for the crane, equal to TL (see MAUM). The installer must use a weighing device with sufficient precision to reach the
accuracy requested (see MI).
 Chain for lifting the load. The chain must allow the load to be lifted several centimeters off the ground with the crane in a horizontal
position, in order to protect against vehicle overturning during calibration.
 System programming tool

Procedure of calibration
In the case of derating of the crane’s lifting capacity due to inadequate stability, the limiter must be recalibrated according to the following
procedure:

 Connect the pressure gauge to the test port (M)

 Turn off the control box by pressing the emergency STOP button.
 Connect the USB-serial adapter (code 3.31.1387) to connector X20 (with programmer cable disconnected it’s not possible to
access the programming menu).
Pmax
Pmin

 Turn the potentiometer to Pmin (complete turning counterclockwise) and turn the key switch to "fully stabilized mode".

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L System

 Power on the system by releasing the emergency STOP button. Keep the Reset button pressed until the display shows the first
screen of the calibration menu. The red 100% light turns on (see programming menu, Appendix 4).

PROGRAMMAZIONE CALIBRAZ. P1 MAX

SETTING UNIT SETTING P1 MAX
(3 s)

At this point the emergency valve loses the function of blocking the crane and therefore the moment limiter is
inactive. During the programming phase it’s therefore critical to avoid any crane movement which could cause overturning of
the vehicle or structural overloads.

 Press the Reset button until the display shows the P1 pressure setting screen (at this point the display doesn’t show the current
pressure)

CALIBRAZ. P1 MAX PRESS.

SETTING P1 MAX P1
(3 s)

 Stabilize the machine as described in the MAUM, extending all stabilizer beams completely.
 Retract the extensions, lift load TL, and position the crane booms in the position of maximum lift capacity (see load diagram in
MAUM).
 Extend the hydraulic extensions toward full reach. Stop extending if you reach an unstable condition (see Appendix 5).
 In case you reach an unstable condition, retract the extensions until a stable condition is reached.
 Rotate the crane through it’s complete working arc. Stop rotating if you reach a condition of instability.
 In case you reach an unstable condition, retract the extensions until a stable condition is reached.
 Continue with this operation until you have completed the entire rotation arc of the crane. With this procedure we obtain pressure
P1TIP, which ensures stability through the crane’s entire working arc.
 Note pressure P1TIP from the pressure gauge.
 Retract the extensions to a safe position and return the load to the ground.
 Calculate P1LIM = P1TIP x 0.88. Record this in the form from Appendix 1.
 Turn the potentiometer on the programming cable until the display shows the calculated pressure.
 Press and hold the Reset button until the display shows:

100% P1 TARATO
100% P1 SETTED

 The display returns to the main programming menu (see Appendix 4)

 Turn the system off and then on again (by pressing and releasing the emergency button)
 Create a new load diagram to add to the MAUM and apply on the crane.

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L System

5.2 Procedure to recalibrate the moment limiter

If you have the setting pressures for the moment limiter (see Appendix 1 completed during the stability test), you are in a position to
perform a moment limiter recalibration with the following procedure.

Procedure of recalibration
 Turn off the control box by pressing the emergency STOP button.
 Connect the USB-serial adapter (code 3.31.1387) to connector X20 (with programmer cable disconnected it’s not possible to
access the programming menu).

Pmax
Pmin
 Turn the potentiometer to Pmin (complete turning counterclockwise) and turn the key switch to "fully stabilized mode".

 Power on the system by releasing the emergency STOP button. Keep the Reset button pressed until the display shows the first
screen of the calibration menu. The red 100% light turns on (see programming menu, Appendix 4).

PROGRAMMAZIONE CALIBRAZ. P1 MAX

SETTING UNIT SETTING P1 MAX
(3 s)

At this point the emergency valve loses the function of blocking the crane and therefore the moment limiter is
inactive. During the programming phase it’s therefore critical to avoid any crane movement which could cause overturning of
the vehicle or structural overloads.

 Press the Reset button until the display shows the P1 pressure setting screen (at this point the display doesn’t show the current
pressure)

CALIBRAZ. P1 MAX PRESS.

SETTING P1 MAX P1
(3 s)

 Turn the potentiometer on the programming cable until the display shows the calculated pressure recorded in Appendix 1.
 Press and hold the Reset button until the display shows:

100% P1 TARATO
100% P1 SETTED

 The display returns to the main programming menu (see Appendix 4)

 Turn the system off and then on again (by pressing and releasing the emergency button)
 If it’s necessary, create a new load diagram to add to the MAUM and apply on the crane.

19
 
L System

5.3 Stability test and calibration of the planarity transducer

During the calibration phase it’s necessary to work in a space large enough to allow full opening of the stabilizers (crane and auxiliary
stabilizers) and with a surface that can withstand the pressure exerted by the stabilizers (see MAUM). The following list of materials is
required for performing the test:

Tools
- Computer
- RS232-USB-serial adapter (Cod. 3.31.1409)
- Software “Tool Labview”, version 4.13 or later

Procedure part A
 Position the vehicle on a flat and horizontal square, secure the wheels using chocks: check that the parking brake is ON.
 Connect the RS232 adapter to plug "X16" (see electrical schematic) and to a computer's USB port.
 Turn on the crane power supply.
 Run the software "Tool Labview”.
 Set the Com port (automatically the software requires this setting): the Com port is indicated on the device manager.

 Enter username and password: the codes are the same as Pin1 and Pin2 normally used for the other systems) and click on "Log In"

 Select on the tools bar "Setup Stability"

20
 
L System

 Compurer screen will show the form with the calibration of the planarity transducer. The manufacturer has preset this values so that
the crane can not be used before a calibration by the installer.

 Substitute the angular values -X,X,-Y,Y and the “Planarity Histeresys” with the recommended values shown in the following figure.

 After entering the values, click “Send Data”

From this moment until the end of the procedure, the control system does not ensure stability of the machine.

21
 
L System

 After sending the data, reset the crane system pressing and releasing the emergency stop button. The display shows:

STAB NON PIAZZ. GRU CHIUSA

STAB UNDEPLOYED CRANE FOLDED

 Stabilize the crane with fully retracted beams: lower the stabilizer feet and lift the vehicle slightly without however fully releasing its
suspensions. Keep the vehicle in a horizontal position so that

max(X, Y ) < 0.2°

The display shows the angles Stab < Threshold,max

GRU CHIUSA Angle Stab: OK? X= XX ; Y= YY

CRANE FOLDED Stab < Threshold,max Stab < Threshold,max

 Press the Reset button (or Clacson button on radio transmitter): the system saves Stab, calculates k (in this case equal to 1) and
blocks all stabilizer movements. The display shows:

RADIO Read GRU CHIUSA

P1 XX% XXX bar CRANE FOLDED

 Now it is possible to move the crane and the display shows

RADIO Read
P1 XX% XXX bar

 Prepare a load of TL/2 (TL is indicated in MAUM) and position its near the the crane along the Y axis (see load diagram in MAUM,
in horizontal position).

22
 
L System

Procedure part B
 Rotate the unloaded crane in Y direction (perpendicular to the axis of the vehicle frame, in OCVS direction).
 Switch OFF the crane power supply and switch back ON (the system saves the Ground value).
 Wait the testing procedure of the moment limiter, then the system indicates on the display:

PIEDI A TERRA?
STAB ON THE GROUND?

 Confirm the request by Reset button.

Angle Stab: OK? X= XX ; Y= YY

Stab < Treshold,max Stab < Threshold,max

 Confirm the request by Reset button.

 Lift the load placing the boom to the horizontal position.

 Extend the hydraulic extensions toward full reach. Stop extending if you reach an unstable condition (see Appendix 6). If an
unstable condition is not reached, carry out the same procedure lifting the load TL.

23
 
L System

 Click “Real Time Status”. The following screen appears:

 Read and record the Y value. Retract completely the hydraulic extensions.
 Rotate the crane on the next detection point (in direction -X, -Y, X).
 Repeat the same operations starting from Procedure part B and record the corresponding tilting angles -X -Y, X.
 After ending the planarity test, click “Setup Stability" and enter the recorded values. Enter the value of “Planarity Histeresys” equal
to 0.1 (recommended value).

In the example above the recorded values are:

X = 1.80°
Y = 1.50°
-X = -1.00°
-Y = -1.50°

 Click “Send Data” to save the entered data.

The installer can save the data to a file (see manual "Tool Labview").

24
 
L System

Appendix 1: Registration form to record limiting pressures

RECORDING FORM P1LIM

Crane model / Serial Nr.

Vehicle model / Chassis serial Nr.

Crane Installation □ BEHIND CAB □ BEHIND BODY

Position of dead point □ STANDARD □ REVERSED

TL = ....... kg

P1LIM = 0.88 x P1TIP

.......... = 0.88 x ..........

Record the pressure values in bar

(*) All stabilizer beams must be completely open during calibration

Date and signature of installer

25
 
L System

Appendix 2: Visual and audible warning signals

MOMENT LIMITER

Event Power 90% 100% Light tower Audible alarm

Normal work operations

Load less than 90% of maximum
capacity

Load between 90% and 100% of

maximum capacity

Load at 100% of maximum

capacity

Stabilizer foot lifted off the ground

Sensor for closed crane

bypassed

Loss of planarity
(Read > k·max)

WINCH PULL LIMITER (OPTION)

Event Power 90% 100% Light tower Audible alarm

Load between 90% and 100% of

max winch pull

Load at 100% of maximum wich

pull

Legend

Warning lights off

Warning lights turned on

Flashing warning lights

Audible alarm deactivated

Continuous audible alarm

Intermittent audible alarm

26
 
L System

Appendix 3: Alarm signals

ALARM 01 Control box not programmed or damaged.

BLOCKED SYSTEM

ALARM 02 During manual setting procedure of moment limiter, the box current value is
BLOCKED SYSTEM lower than 4mA or higher than 20mA.

ALARM 05 The YVH1 digital output and the feedback value are not equal.
BLOCKED SYSTEM

ALARM 06 Open circuit on YVH1 emergency valve.

BLOCKED SYSTEM

ALARM 10 The current value of pressure transducer is lower than 4mA.

BLOCKED SYSTEM

ALARM 11 The current value of pressure transducer is higher than 20mA.

BLOCKED SYSTEM

ALARM 12 The x current value of planarity transducer is lower than 4mA.

BLOCKED SYSTEM

ALARM 13 The x current value of planarity transducer is higher than 20mA.

BLOCKED SYSTEM

ALARM 14 The y current value of planarity transducer is lower than 4mA.

BLOCKED SYSTEM

ALARM 15 The y current value of planarity transducer is higher than 20mA.

BLOCKED SYSTEM

ALARM 16 The signal "STAB OK" is high and the signal "FEET ON GROUND" is low.
BLOCKED SYSTEM

27
 
L System

Appendix 4: Programming menu

The following illustrates the functions contained in the menu, accessed by pressing the Reset button for 3s.
After having connected the programming tool, the operator can access the programming menu by pressing the Reset button during
system startup. The displayed menu changes every 10s.

Connect the box

for manual setting

Keep the Reset pressed

button during startup

The first setup menu shows: PROGRAMMAZIONE

SETTING UNIT

From now the display shows the

following screens at regular
intervals:
Select the maximum pressure
turning the trimmer's wheel.
Then press Reset to save.

CALIBRAZ. P1 MAX PRESS. 100% P1 TARATO

SETTING P1 MAX _ _ _ P1 100% P1 SETTED

10s Change the operating mode

pressing the Reset button.

CONTROL. STABIL. ON CONTROL. STABIL. ON CONTROL. STABIL. OFF

STAB. CONTROL. ON STAB .CONTROL. ON STAB .CONTROL. OFF

10s Change the operating mode

pressing the Reset button.

STOP MOV. TEMP. ON/OFF STOP MOV. TEMP. ON STOP MOV. TEMP. OFF
STOP MOV. TIM ON/OFF STOP MOV. TIM ON STOP MOV. TIM OFF

10 s Change the operating mode

pressing the Reset button.

CONTR. PLAN ON/OFF CONTR. PLAN ON CONTR. PLAN OFF

PLAN CONTR. ON/OFF PLAN CONTR. ON PLAN CONTR. OFF

10 s In order to end the setup program

and to save the data.

FINE PROGRAMMAZIONE? FINE PROG.

EXIT TO SET UP? PROG. ENDED

28
 
L System

Appendix 5: Vehicle instability during calibration of moment limiter

In the following table we briefly demonstrate the criteria for considering a load condition unstable.

INSTABILITY
CRITERIA Crane behind cab Crane behind cab Crane behind body Crane behind body
without auxiliary with auxiliary without auxiliary with auxiliary
stabilizers stabilizers stabilizers stabilizers

   
Load in a lateral
zone of the vehicle

 
Load in the rear   V V
zone of the vehicle
 

Load in the front    V
zone of the vehicle


Legend

 1 vehicle wheel lifted from the ground

 2 vehicle wheels lifted from the ground

 1 stabilizer foot lifted from the ground

 2 stabilizer feet lifted from the ground

V Or

29
 
L System

Appendix 6: Vehicle instability during calibration of planarity transducer

In the following table we briefly demonstrate the criteria for considering a load condition unstable.

INSTABILITY
CRITERIA Crane behind cab Crane behind cab Crane behind body Crane behind body
without auxiliary with auxiliary without auxiliary with auxiliary
stabilizers stabilizers stabilizers stabilizers

   
Load in a lateral
zone of the vehicle

 
Load in the rear   V V
zone of the vehicle
 

Load in the front    V
zone of the vehicle


Legend

 1 vehicle wheel lifted from the ground

 2 vehicle wheels lifted from the ground

 1 stabilizer foot lifted from the ground

 2 stabilizer feet lifted from the ground

V Or

30
 D01, X1 CONNETTORE AD INNESTO MASCHIO SICMA, 211 PL249S0005. CODICE AMCOVEBA 3311225.
7C 8B 7B 4B 3C 6C 2A 1A 1C 2C 4A 4C 7A 8C 8A 5A 5B 6A 1B 2B 3A
+
0000 BU 1,5
1Q01 RD 1,5
2Q02 GY 0,5
3000 RD 1,5

1Q02 BR 1,5
F01
10A
L System


2ADC01 WH 0,5 (2)

3CD01 WH 0,5 (2)

3CD01 WH 0,5 (3)

3CD01 WH 0,5 (4)

1CD01 WH 0,5 (1)

1CD01 WH 0,5 (2)

4CD01 WH 0,5 (2)

8CDO1 WH 0,5 (1)

2BD01 WH 0,5 (3)

4BD01 WH 0,5 (2)

4BD01 WH 0,5 (1)

4BD01 WH 0,5 (1)

4BD01 WH 0,5 (2)

1AD01 WH 0,5 (1)

2CD01 WH 0,5 (1)

4AD01 WH 0,5 (2)

7AD01 WH 0.5 (4)

4AD01 WH 0,5 (2)

4AD01 WH 0,5 (2)

1AD01 WH 0,5 (2)

7AD01 WH 0,5 (1)

6CD01 BK 0,5 (1)

6AD01 BK 0,5 (6)

2BD01 BK 0,5 (2)

3AD01 BK 0,5 (3)

31
1S07 WH 0,5 (2)

1S07 WH 0,5 (1)

2Q02 GY 0,5 (4)

1S06 WH 0,5 (2)

1S06 WH 0,5 (1)

1Q01 RD 0,5 (4)

1Q02 BR 1.5 (3)

2Q02 GY 0,5 (1)

1Q01 RD 0,5 (1)

1Q01 RD 0,5 (1)

2Q02 GY 0,5 (1)

1F 01 RD 1,5 (1)

1Q01 RD 1,5 (2)

1Q01 RD 0,5 (1)

1Q01 RD 0,5 (2)

8AD01 WH 1 (2)

5AD01 WH 1 (3)

5BD01 WH 1 (5)

1Q01 RD 0,5 (1)

1Q02 BR 1,5 (5)

0000 BU 0,5 (3)

0000 BU 0,5 (3)

0000 BU 0,5 (3)

0000 BU 0,5 (3)

0000 BU 1.5 (5)

0000 BU 0.5 (3)

0000 BU 0,5 (3)

0000 BU 0,5 (3)

0000 BU 0,5 (3)

0000 BU 0,5 (3)

0000 BU 0,5 (5)

1BD01 BK 1 (4)

0000 BU 0,5 (2)

1BD01 BK 1 (3)

1BD01 BK 1 (4)

0000 BU 0,5 (4)

1Q01 RD 1 (4)
+ + SRPSPR + O- + O- + O- + O- S08 FHS09 SP - + O RDOR ORRD - GN PL CR + + - + Iy GND Ix SU + - + O- + O- B1RSMSYVH1 BDRE 3 + - YVH1 YVH1 TXRX -
1 2 3 4 5 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 4 5 1 2 1 2 1 2 3 4 1 2 3 4 5 1 2 3 4 1 2 3 1 2 3 1 2 3 1 2 3 4 5 6 1 2 1 2 3 4 1 2 3 4
X2 X6 X8 X7 X9 X15 X3 X19 X5 X14 X28 X20 X4 X25 X13 X27 X10 X16 PROG
AMP superseal AMP superseal AMP superseal AMP superseal AMP superseal AMP AMP AMP superseal AMP superseal AMP superseal AMP superseal AMP superseal AMP AMP superseal AMP superseal
superseal superseal AMP superseal 282108-1 superseal
AMP superseal 282089-1 AMP superseal 282089-1
282087-1 282087-1 282087-1 282087-1 282089-1 282088-1 282088-1 282087-1 282087-1 282087-1 282088-1 282088-1
Appendix 7: Electrical Schematics

282080-1 282104-1 282104-1

Complete electrical schematic: moment limiter

Stab CV Stab OCV AstaCV Asta OCV TP1 90%-100% Gru

X2 X15 Colonnina Power RDC Radio connect X27 X10
side side side side chiusa AMP
AMP superseal 282107-1
AMP superseal
282107-1
Luminosa AMP superseal
282106-1
AMP superseal
282105-1
AMP superseal
282105-1
superseal
AMP superseal
282106-1
AMP superseal
282106-1
282104-1
1 2 3 4 5 1 2 3 4 5 1 2 3 4 1 2 3 1 2 3 1 2 1 2 3 4 1 2 3 4
+ + PSPR S08 FHS09 SP YVH1 YVH1
0000 BU 1.5

CAPOCORDA AOCCHIELLO ISOLATO Ø 6 mm Aux gru Speed

Planarity sensor Taratura LINK
STESSA COSA PER IL POLO POSITIVO Pres.Man. Chiusa reduction
Traversa RLC/LIS
posteriore
1Q01 RD 1,5 (2)

2Q02 GY 0,5 (4)

1F 01 RD 1,5 (1)

1Q02 BR 1,5 (5)

-
Q01 Q02
Cod. 3.31.1632 KEYFUNCTION MODE POSIZIONE0
 DO2, X49 CONNETTORE COMPLETO 30 POLI HETRONIC. CODICE AMCOVEBA 3311488
7 2 3 6 10 31 8 9 12 19 22 21 25 28 17 18 20 30 27 26 14 13 16 15 11 23 24 5 4

24D02 WH 1,5 (1)

0000 BU 1,5 (5)
L System

V17 V21


V18

32
21DO2 WH 1 (3)
19D02 WH 1 (1)

17D02 WH 1 (1)

17D02 WH 1 (2)
25D02 WH 1 (2)

11D02 WH 0,5 (6)

1Q01 RD 1 (1)

11D02 WH 0,5 (1)

0000 BU 0,5 (2)

12DO2 WH 0,5 (1)
2D02 WH 0,5 (1)

3D02 WH 0,5 (1)

1Q01 RD 1 (4)

1BD01 BK 1 (4)
7DO2 WH 0,5 (2)

8D02 WH 0,5 (2)

9D02 WH 0,5 (3)

5D02 WH 0,5 (1)

4D02 WH 0,5 (2)

1Q02 BR 0,5 (1)

1Q02 BR 0,5 (2)

1Q02 BR 0,5 (2)

1Q02 BR 0,5 (1)

22D02 WH 1 (1)

21D02 WH 1 (1)

25D02 WH 1 (1)

28D02 WH 1 (1)

18D02 WH 1 (1)

17D02 WH 1 (1)

18D02 WH 1 (3)

18D02 WH 1 (4)

20D02 WH 1 (1)

30D02 WH 1 (1)

27D02 WH 1 (1)

26D02 WH 1 (1)

14D02 WH 1 (1)

13D02 WH 1 (3)

16D02 WH 1 (1)

15D02 WH 1 (3)
0000 BU 0.5 (3)

0000 BU 0.5 (3)

6D02 WH 0,5 (1)

1Q02 BR 1.5 (3)

1BD01 BK 1 (1)

19D02 WH 1 (5)
0000 BU 1,5 (5)

1BD01 BK 1 (3)

1BD01 BK 1 (4)

0000 BU 1 (2)

0000 BU 1 (2)

0000 BU 1 (2)

0000 BU 1 (2)

0000 BU 1 (2)

0000 BU 1 (2)

0000 BU 1 (2)

0000 BU 1 (2)

0000 BU 1 (2)

0000 BU 1 (2)

0000 BU 1 (2)

0000 BU 1 (2)

0000 BU 1 (2)

0000 BU 1 (4)

0000 BU 1 (2)

0000 BU 1 (4)
0000 BU 1 (4)

0000 BU 1 (2)
Complete electrical schematic: radio control

+ 2 - + 2 - 3 + PL + + - + 8 9 - + - YVH1 YVH1 YVH1 - 19 - B1 RS MS YVH1 BDRE 22 - 21 - 25 - 28 - 18 - 17 - 17 17 18 18 20 - 30 - 27 - 26 - 14 - 13 - 16 - 15 - 11 - 100% 90%

1 2 3 1 2 3 1 2 1 2 3 4 5 1 2 3 4 1 2 3 4 1 2 1 2 1 2 3 4 5 6 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 4 1 2 1 2 1 2 1 2 1 2 3 4 1 2 3 4 1 2 1 2
X29 X26 X27 X24 X18 Y01 Y05
X13 Y16 Y15 Y09 Y02 Y04 Y03 X22 Y06 Y07 Y08 Y10 X17 X23 X21 X19
AMP AMP AMP X14 AMP superseal AMP superseal AMP superseal AMP superseal AMP AMP
superseal superseal superseal DIN 43650 DIN 43650 DIN 43650 DIN 43650 DIN 43650 DIN 43650 DIN 43650 DIN 43650 AMP superseal DIN 43650 DIN 43650 DIN 43650 DIN 43650 superseal superseal
AMP superseal 282107-1 AMP superseal 282090-1 Capocordaø25
282087-1 282087-1 282080-1 282088-1 282088-1 282088-1 282088-1 282088-1 282080-1 282080-1
Power RDC YVH1 1° Boom Radio connect Stabilizer Stabilizer Boom Valve Rotation Rotation 1° Boom 2° Boom 2° Boom Boom GND ON 100%
DOWN DOWN PROP CCW CW DOWN OUT CHASSIS 90%
X29 X26 X27 X24 X18
UP IN
X22
UP UP
X17 X23 X21
AMP AMP AMP AMP
superseal superseal superseal AMP superseal AMP superseal AMP superseal AMP superseal AMP superseal superseal
282105-1 282105-1 282104-1 282106-1 282106-1 282106-1 282106-1 282106-1 282104-1
1 2 3 1 2 3 1 2 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2
YVH1 YVH1 17 17 18 18
Proximity 2 Proximity 1 Speed reduction
Horizontal Winch 1° Aux 2° Aux CLAXON
Function Function
Sensor
Rotation
Cod. 3.31.1633

STOP
 ADDITIONAL STABILIZERS
3311471 PART OF 5120154
3311311 3310723
3311159
TEKNE TEKNE
RESET
EMERGENCY
POWER 90% 100%
TEKNE TEKN E
www.te k n e .i t
STOP
3311332
YVH1 YO1 YO1
PROPORTIONAL
YO2 YO2
X5
X22 X21
X27
X20
X25

X16 PROG

X1
X2
X10
X24
X18 X27
3311545 5160002
L System


3311634

33
X17
X15
X23
Y10 Y10 Y09 Y09
YO7 YO7 YO8 YO8
3311332
YO5 YO5 YO6 YO6
Complete electrical schematic: radio control

X14

X13
X28

X19

X8

X7

X6

X4
X9

PWR
X3
YO4 YO4 YO3 YO3
3311311
Y15 Y15 Y16 Y16 3311332

10 A
X29
3311311

+
-
X13

3311636

3311372

5160001
X26
X14 X19
Cod. 1.01.0222 3311561 3311311 3310612
3311312