Version 14/02/06

INDEX

INTRODUCTION PAGE 3
WARNINGS PAGE 3
IMPORTANT NOTES PAGE 4
SYSTEM OPERATING DESCRIPTION PAGE 5
MAIN FEATURES PAGE 6
SYSTEM DESCRIPTION PAGE 7
COMPONENT LOCATION ON THE MACHINE PAGE 8
SYSTEM START UP PAGE 9
PANEL DESCRIPTION PAGE 10 , 11
KEY FUNCTION PAGE 12
STARTING UP PAGE 13
HOW TO SELECT THE OPERATING MODE PAGE 13
CONFIGURATION LIST PAGE 14 - 16
HOW TO SELECT THE NUMBER OF ROPE : PAGE 16
ABLE VIBRATE JOYSTICK PAGE 17
PANEL VISUALIZATION PAGE 18 - 21
ISAAC PAGE 22
HOW TO SELECT A LIMIT PAGE 23 , 24
ENGINE VISUALIZATION PAGE 25
DIAGNOSTIC PAGE 26
TROUBLE SHOOTING PAGE 26 , 27
AUTO DIAGNOSTIC – Geometric data and load data PAGE 28
AUTO DIGNOSTIC – Hydraulic pressure data PAGE 29
AUTO DIGNOSTIC – Sensor digital inputs PAGE 30
AUTO DIGNOSTIC – Sensor digital outputs PAGE 30
AUTO DIGNOSTIC – Diagnostic external unit PAGE 30
WARNINGS PAGE 31 , 32
 3

INTRODUCTION

The information on this document could be subject to change without notice.

The constructor is not responsible for possible content mistakes or misprints that could
be present in this manual.
Any reproduction, translation or copy of parts of this manual is forbidden without prior
written authorization by The constructor.

WARNINGS

The load limiting device, is an electronic control device, designed to help the operator in
the safe use of the machine, warning him by means of visual and audible alarms when
approaching a dangerous condition.
However, this device won’t replace the good experience of the operator in the proper
use of the crane.
The responsibility of the operations in safety conditions of the machine is on operator
care, as well as the fulfilment of all safety rules prescribed.
The operator must be able to recognize if the data transmitted by the system is correct
and coherent with the real conditions.
He also must be able to utilize the data in order to operate in safe conditions.
The limiter is an electronic device with several components and could be subject to
failures or defects.
The operator must recognize these events and must act consequently (to proceed to
repair, if possible, or to call the constructor assistance).
Before starting the operations with the machine, user must fully read and understand this
manual and follow the instructions written in it.
 4

IMPORTANT NOTES

• The limiter is supplied with a key for automatic shut-off over-ride.

• In the normal working condition this key must be positioned properly not to operate the
override functions.
• It is prohibited to use this key to lift loads exceeding the load table limits provided by the
manufacturer of the crane.
• The key must be used only in extreme cases: malfunctioning or situations justifying its use.
• The use of the key is allowed only by authorized personal, who are responsible of its use.
• The limiter has a powerful FAIL-SAFE self-diagnostics program suitable to verify the good
operation of its circuits and measuring transducers. In case of a failure is detected, the
limiter puts itself in emergency status by blocking the manoeuvres.
• Nevertheless, the operator, before starting the operation of the machine, must secure
that the limiter functions correctly. To do this, he must verify the accuracy of the displayed
values by performing some tests. He must also verify that there are not messages or alarm
indications, and verify the correct operation of shut down function
• Generally, the limiter does not automatically change the operating conditions of the
machine (tables). The operator is responsible for the proper setting of the operating
conditions of the machine and the correct use of the device
About this, follow the indications given forwards in the manual and concerning the
operating modes. An incorrect setting of the tables can cause an incorrect operation of the
limiter , will create a dangerous situation in the crane operating.
For this reason it is essential to set the correct operating mode.
These operating conditions generally vary when:
a) outriggers are extended or retracted
b) switching, the operation from outrigger mode to on tires mode
c) telescopic mechanical extensions are extended or not
d) further equipment (jib, ext, etc.) are installed or not
e) the number of parts of line is properly selected.
In general, it is mandatory to follow the instructions given by the crane manufacturer.
 5

SYSTEM OPERATION DESCRIPTION

The Load Limiting Device is designed to aid the operator in safe functions of the crane.
The limiter compares automatically the lifted load to the maximum one supplied by load
table providing the necessary information to the user in order to work in safety
condition.
The main readings are: - actual lifted load
- maximum admitted load
- tilting percentage
- operating radius
- boom angle
- boom extension (length)
- working mode ( Operating mode)
- warning lights (green, yellow, red) and audible alarm

The system determines the lifted load by computing it from the relevant sensing devices
signals (pressure or load cell), and by means of the measures of boom angle and
extension operating radius is computed too.
The lifted load is continuously compared with the maximum allowable load obtained from
the load tables.
Consequently three possible situations can occur:

Safety : green lamp is on, no presence of acoustic signal :

lifted load is lower than 90% of the maximum load.

Warning: yellow lamp is on and audible alarm intermittently sounds; this is the warning

situation.The signal occurs when the lifted load is more than 90% and less
than 100% of maximum load.

Alarm: red lamp is on and audible alarm sound continuously: lifted load exceeds the
allowable load so that the control functions shut down is activated. In the
alarm situation, only control function operations to allow the machine in a
safe working condition are enabled.
 6

MAIN FEATURES

Working condition Memorization of the load charts/table Visualization data

measuring and data computing and setting

CONTROL PANEL

Pressure Transducers
(lifted weight data )

Readings :
- % tilting
- Lifted Weight
- Load allowed
- Working Radius
- Boom Extension
- Boom Slope
- Operating Mode
- Attachment used
- Diagnostic

ALARM:
Lights Green,Amber,Red
LENGTH/ANGLE MANUAL SELECTION:
SENSOR - Main Boom
(Boom’s geometrical Activation of the emergency - Jib
data) functions - Counterweight
- Number of Lines
External Alarm / Automatic shut off
AUTOMATIC - Tires
SELECTIONS
External
Micro-switches:
- Rotation
- A2B
 7
SYSTEM DESCRIPTION

1 Main Unit Cod.: HEAD-CS/22

2 Color Display Cod.: VIEW-V01CI/01
3 Connecting Cable Length 10 mt Cod.: CV ATG77-2/10
4 Connecting Cable 56 poles Length 1 mt Cod.: CV1 C56/10
5 RS 232 and Can Bus Cable L= 5 mt Cod.: CV ATG96-1/10
6 Pressure Transducers Cod.: Y11 4745-450
7 Cable Reel 32 Length 32 mt Cod.: AC MCP214A/3P
8 Cable Reel Length 11 mt Cod.: ACT10AE100/12
9 Smart-Winch Cod.: SMARTWINCH.02
10 Optical encoder Cod.: Y11 BMMH42S1N
 8
MACHINE COMPONENT LOCATION

Length/Angle
sensor:
On the left side of
the boom Nr.2 Pressure
Transducers:
On the lifting cylinder.
Rod and piston side
End of rope
transducer

A2B

Main Unit and

Control Panel :
in the cab
 9

SYSTEM START UP

Switch On

Internal
Data Integrity check and warning Lamps check
checking

PPM TEREX Logo Displayed and Software version

Logo

Working Indication of the Settings, geometrical data and

page operating mode of the machine

Confirm or
Selection and confirm of the operative mode and setting
Change Data

Operation Now the system is ready to operate

 10
PANEL DESCRIPTION

1 13 11 14

10
4
12
3
15

2 16

17

18

5 6 7 8 9 20 19
 11

Rif. Icon Description

1 Working data display

2 Two lights showing the safe work condition

3 Light showing the pre alarm condition

4 Light showing the shut off condition has occurred

5 Function key button depending of the page displayed

6 Function key button depending of the page displayed

7 Function key button depending of the page displayed

8 Function key button depending of the page displayed

9 Function key button depending of the page displayed

10 Confirm an action ( operating mode, procedure, limit )

11 Scroll up inside the menu

12 Scroll down inside the menu

13 Increase menu / list ( operating mode, number of lines, etc )

14 Decrease menu/list (operating mode, number of lines, etc )

15 Enable/Disable joystick vibration

16 Disabling buzzer

17 Performs zeroing of the hook height from the ground

18 Changing of the pages

Back to the main page. It also has a function of deleting the alarms
19 once acknowledged
Key button in order to let the operator to enter in the calibration’s
menu. In order to have access and configure the system, the user
20 must scroll up to the operating page. The function is available only if
provided with the password ( to digit when the Logo is displaying )
 12

KEY FUNCTION

How to disable the buzzer:

Disable: when the audible alarm is active on, by key you can disable the audible
alarm until the new alarm is detected.
Enable: after few seconds that the alarm is switch off the audible alarm will enable
automatically.

How to change viewing page:

By pressing, the view page can be changed to indicate the LMI page , Winch page,
Engine page, ISAAC page
 13
STARTING UP

When the system get started, the last operating conditions is screened on the display, the
latest setting before the machine was turned off. During this procedure, the system performs
an auto test and it put itself in shut off condition.

HOW TO SELECT THE OPERATING MODE

Before starting the lifting operation, the user must check that the operating mode set
corresponds to the real machine’s configuration ( boom, outriggers, counterweight,
jib’s length and angle, etc ) and the number of lines and confirming it pressing
In order to change the operating mode, please proceed as follows

HOW TO SELECT THE OPERATING MODE :

- By key you must change the outrigger geometry;

- By key you must change the counterweight;

- By key you must change the configuration of the boom or the attachment;

- By key you must change the configuration of the attachment or the angle

of the jib
- By key confirm the operative mode

When you confirm the code line it indicates the number of the operative mode
 14

CONFIGURATION LIST:
Press the button for change the outrigger configuration, like below

Outrigger full extended

Outrigger half extended

Outrigger fully retracted

On wheels

Press the button for change the counterweight, like below

Counterweight 5,15 Ton

Counterweight 7,75 Ton

Counterweight 9,1 Ton

Counterweight 11,6 Ton

 15

CONFIGURATION LIST:
Press the button for change the of the boom or the attachment, like below

Main Boom 1

Jib 8 m

Jib 15 m
2

Jib 7 m + 8 m stored

Press the button for change the configuration of attachment or angle Jib is install
at the moment, like below

Any Jib stored

Selection is possible only if

Two Jibs stored 1 “Main Boom” has been
previously selected

One Jib stored

Selection is possible only if

0 degree inclination Jib 2 “Jib” has been previously
selected
 16

CONFIGURATION LIST:

20 degree inclination Jib

Selection is possible only if
2 “Jib” has been previously
selected

40 degree inclination Jib

Press to confirm the configuration

HOW TO SELECT THE PARTS OF LINE :

Press the button for change the number of rope, like below

0 Parts of Line

1 Parts of Line

2 Parts of Line

N Parts of Line

By key to confirm the parts of line

 17
ABLE VIBRATION JOYSTICK

Press to enable or disable the vibrating joystick

When the joystick is disabled the icon shows a line across it

When the joystick is enabled the icon has no line across it.
 18

PANEL VISUALIZATIONS 1/2

21 22 23 24 25 26

27 30

28 29

31 32

33 34

35

36

37

38 39 40 41 42
 19

PANEL VISUALIZATIONS 2/2

43

44

45

46
 20

Rif. Icon Description

21 It indicates the LMI by pass key ( Red Icon = Activated )

22 It indicates the winch limit switch status (Red Icon = Activated )

23 This icon indicates the Shut Off from Isaac

24 It indicates the machine is in the normal working condition

25 It indicates the machine is in the pre-alarm working condition (90%)

26 It indicates the machine is in the Shut off working condition (100%)

27 Indication of the Load percentage bar

28 Indication of the actual load. Value in Ton

29 Indication of the maximum load in that machine condition.

It indicates the Boom’s extension MOD 1 or MOD 2 status

30 (M1 = Red Icon ; M2 = Yellow Icon)

31 Indication of the main boom’s radius. Value in meters or feet

32 Indication of the main boom’s angle. Value in degrees

33 Indication of the main boom’s length. Value in meters or feet

Indication of the height from the ground. Refer to the “head of the
34 boom”. Value in meters or feet

35 0 It indicates the element extension of the main boom. Value in %

36 Alarm: Indication of the Alarm code that its present at the moment

37 Code: Indication of the number of operative mode

38 Configuration of the outrigger geometry

39 Configuration of the counter weight

40 Indication of Parts of Line

41 Configuration of the boom or the attachments

42 Configuration about the attachment that is install

 21

Rif. Icon Description

It indicates the joystick vibrating function status
43
( When is crossed = Deactivated)

44 By the key is possible disable the joystick vibration

It concerns the right button . performs zeroing of height from the
45 ground

46 Indicates the value of the height to the ground

 22

ISAAC

By pressing the key button in the previous page, the operator will enter into the
ISAAC Menu.
ISAAC is the system allowing to select and limit a working area which the user will set
through the help of the panel, using text and icons.

Icons and indication in

order to set the maximum
angles and reading of the
actual of the turret.

Status indication of the

right and left limit

Icon indicating the left angle setting limit and the related
value set ( in this case not activated )

Icon indicating the right angle setting limit and the related
value set ( in this case activated )

Icon indicating the turret position read by the encoder and the
actual value

Icon which represent the left angle limit

( in this case neutral because is NOT activated )

To set the left angle limit, rotate the turret to the position then press the key button
To delete the set value, press the key button

Icon which represents the right angle limit

( in this case red because is activated )
To set the right angle limit, rotate the turret to the position then press the key button

To delete the set value, press the key button.

 23
HOW TO SELECT THE LIMIT

To enter in this page, press the key button , until this one appears

Icons and indication in

order to set the limits

ANGLE

Block Value: REAL VALUE:

Indication of the Indication of the actual
maximum value set value

HEIGHT

Block Value: REAL VALUE:

Indication of the Indication of the actual
maximum value set value

RADIUS

Block Value: REAL VALUE:

Indication of the Indication of the actual
maximum value set value
 24
HOW TO SELECT LIMIT

Indication of the limits status Indication of the limits status

Neutral icons = not activated Red icons = activated

How to set the maximum angle.

In order to set the maximum angle, boom up to the position and then press the key
button.
To delete the set value, press the key button.

How to set the maximum height.

In order to set the maximum height, boom to the position and then press the key
button.
To delete the set value, press and hold the key button

How to set the maximum radius

In order to set the maximum radius, set the main boom to the position and then press
the key button.
To delete the set value, press and hold the key button
 25
ENGINE VISUALIZATION

To enter in this page, press the key button until this one appears

Indication and
engine’s alarm codes

It indicates the engine’s revolution per minute.

Analog representation of the parameter. Value in RPM

It indicates the water temperature.

Analog representation of the parameter. Value in degrees.

It indicates the oil pressure.

Analog representation of the parameter. Value in BAR

It indicates the code related to the engine’s alarm. In this specific case
K FAULT CODE

Icon which represent the engine’s alarms.

High temperature alarm.

When the alarm occurs, the icon is red

Low oil pressure alarm.

When the alarm occurs, the icon is red
 26

DIAGNOSTIC
An overall self test diagnostic is provided. When each of the following alarm occurs cut-off
relay is de-energized and proper alarm message appears on alphanumeric display

TROUBLE SHOOTING

MESSAGE CAUSE SOLUTION

 ALARM 6 potentiometer inside broken .  Check integrity of winder
Boom Length 1 Possible lack of continuity in  Check wire continuity
Low wires carrying the unwinding  Replace it if broken.
Fault in main unit.  Call assistance
 ALARM 7  potentiometer inside broken. Check integrity of winder
Boom Length 1 Possible lack of continuity in  Check wire continuity
High wires carrying the unwinding  Replace it if broken.
Fault in main unit.  Call assistance
 ALARM 11 potentiometer inside broken .  Check integrity of winder
Boom Length 2 Possible lack of continuity in  Check wire continuity
Low wires carrying the unwinding  Replace it if broken.
Fault in main unit.  Call assistance
ALARM 12 Lower chamber pressure Replace pressure transducer
PRESSL Low transducer broken Check connection wires.
Possible lack of continuity Check insertion of connector
in connection wires on transducer
Fault in main unit  Call assistance
ALARM 13 Lower chamber pressure Replace pressure transducer
PRESSH Low transducer broken Check connection wires.
Possible lack of continuity Check insertion of connector
in connection wires on transducer
Fault in main unit  Call assistance
 ALARM 14 Angle sensing device broken. Check inclinometer
Angle Low Check the inclinometer. Replace it if broken.
Possible lack of continuity in Check connection wires
wires carrying the angle signal Call assistance
Fault in main unit.
 27

MESSAGE CAUSE SOLUTION

 Simultaneously Input M1 and M2  Check the input status
ALARM 20
ON  Deactivate the undesired one
Fault M1 / M2
Fault in main unit.  Call assistance
 ALARM 21 potentiometer inside broken .  Check integrity of winder
Boom Length 2 Possible lack of continuity in wires  Check wire continuity
High carrying the unwinding  Replace it if broken.
Fault in main unit.  Call assistance
ALARM 22 Upper chamber pressure Replace pressure transducer
PRESSL High transducer broken Check connection wires.
Possible lack of continuity Check insertion of connector
in connection wires on transducer
Fault in main unit  Call assistance
ALARM 23  Upper chamber pressure  Replace pressure transducer
PRESSH High transducer broken  Check connection wires.
Possible lack of continuity in  Check insertion of connector
connection wires on transducer
Fault in main unit  Call assistance
 ALARM 25 Angle sensing device broken. Check inclinometer
Angle High Possible shot circuit of Replace it if broken.
connection wires. Check connection wires
Fault in main unit. Call assistance
 ALARM 56 Error in EEPROM memory Call assistance
E2PROM KO •The contained data are
damaged or altered
• ALLARM 190 • CAN BUS cable broken; • Check of the CAN BUS cable
CANBUS • internal problem • Replace unit
HEAD KO
• ALLARM 192 • CAN BUS cable broken; • Check of the CAN BUS cable
CANBUS • internal problem • Replace Encoder
ENCODER
TURRET
ROTATION KO
 28

AUTO DIAGNOSTIC
SYSTEM INTERNAL WORKING CONDITIONS MONITORING
GEOMETRIC DATA AND LOAD DATA
These readings indicate the internal status of the system when troubleshooting a fault
condition.
Starting from the main working data page press button:
The display will indicate the control page, giving geometric data and main cylinder
pressure summary.

A 1 a d c A 1 a c t

7 0 0 7 8 0
The displayed parameters are as follows:

• A1adc : Value (bit) reads directly from the angle sensor

• A1act: Value (degree x 10) of the angle

To return to the main page, press the button.

S 1 a d c S 1 a c t

4 0 0 1 8 7 0

The displayed parameters are as follows:

• S1adc : Value (bit) reads directly from the potentiometer of the Length 1

• S1act: Value (meter x 100) of the length

To return to the main page, press the button.

S 2 a d c S 2 a c t

4 0 0 1 9 0 0
The displayed parameters are as follows:

• S2adc : Value (bit) reads directly from the potentiometer of the Length 2

• S2act: Value (meter x 100) of the length

To return to the main page, press the button.

 29

AUTO DIAGNOSTIC
SYSTEM INTERNAL WORKING CONDITIONS MONITORING
HYDRAULIC PRESSURE DATA

By pressing the the display shows the individual hydraulic pressures summary
:

P L a d c P L a c t

3 0 0 5 5 0

The displayed parameters are as follows:

• PLadc : Value (bit) reads directly from the pressure sensor

• PLact: Value of the pressure on the bottom side

P H a d c P H a c t

1 0 0 2 0 0

The displayed parameters are as follows:

• PHadc : Value (bit) reads directly from the pressure sensor

• PHact: Value of the pressure on the rod side

 30
AUTO DIAGNOSTIC
SYSTEM INTERNAL WORKING CONDITIONS MONITORING
SENSOR DIGITAL INPUTS

Pressing once again the button the display will indicates the digital input page;
Where the asterisk is present means, that digital input is activated otherwise if is not
present the asterisk the digital input is off

I 0 1 2 3 4 5 6 7 8 9 0 1 2 3

* * _ _ _ _ _ _ _ _ _ _ _ _

AUTO DIAGNOSTIC
SYSTEM INTERNAL WORKING CONDITIONS MONITORING
SENSOR DIGITAL OUTPUTS

Pressing once again the button the display will indicate the digital output page;
Where the asterisk is present means, that digital output is activated otherwise if is not
present the asterisk the digital output is off

O 0 1 2 3 4 5 6 7 8 9 0 1 2 3

_ _ _ _ _ _ _ _ _ _ * _ _ _

AUTO DIAGNOSTIC
SYSTEM INTERNAL WORKING CONDITIONS MONITORING
DIAGNOSTIC EXTERNAL UNIT
By pressing the the display indicates the summary of the remote units

H E A D E N C O D E R

1 0 0 8 1
The displayed parameters are as follows:
• HEAD: counter control about Head unit: if this counter moves means that
the unit is activate

 ENCODER: counter control about Encoder: if this counter moves means

that the encoder is activate
 31

WARNINGS

• The LMI is an electronic device with the aim to aid the operator in the
current use of the machine, warning him by means of visual and audible
alarms when approaching dangerous conditions.
• However this device can’t replace the operator’s good experience in the
safe use of the machine.
• The responsibility of the operations in safe conditions of the machine is
the operator concern as well as the accomplishment of all prescribed
safety rules
• The Operator must be able to detect if the data given by the LMI is
correct and correspond to actual working conditions.
• He must be able to utilize the data given by the LMI in order to operate in
safe conditions in any time.
• The LMI is an electronic device including several sensing components,
therefore it can be subject to failures or defects.
• The operator must recognize these events and he must take action ( to
proceed to repair if possible or to call Assistance).
• Before starting the operation with the machine, the user must fully read
and understand this manual and follow the instructions at any time.
 32

• The LMI is supplied with a key for shut-down function by-passing.

• In normal working operations, this key must be positioned not to by-pass shut-down..
• It’s prohibited to use the key to lift loads exceeding the loads values allowed by the
Manufacturer.

• The key can be used only when an emergency/malfunctioning occurs or a situation

justifying its use.

• Only Authorized Personnel is allowed to the use of the key; they are also responsible for it.

• The LMI has a powerful FAIL-SAFE auto diagnosis program suitable to verify its good
operations and the one of its transducers.
In case a trouble has been detected, the LMI puts itself in a safe state by stopping the
manoeuvres (please see the AUTODIAGNOSTIC chapter).

• In spite of this, the Operator, before starting the operation with the machine, must take
care that the LMI is working correctly.
To do this, he must verify the validity of the displayed values by doing some tests.
He must verify that there are not messages or alarm indications; he must verify the correct
operation of the manoeuvre stopping functions.

• The operator is responsible for the correct setting of the machine load table and therefore
for the right LMI set.
When switching-on the machine the last selected Table is kept valid, to allow Operator
check.

• About this, please follow the instructions given in the OPERATING MODE SELECTION
chapter. An incorrect setting of the tables, can cause an incorrect LMI operation and
therefore can provoke a dangerous situation for the machine.

• Operating conditions usually change when:

Further attachment are fitted or removed ( jib counterweight) and relevant Table
selecting mode is set on the control panel.
Outriggers Extension / Withdrawn, Turret Front/360° rotation , On Wheels/Outriggers,
operating Modes are set in automatic way by micro-switches.

Generally, it’s compulsory to follow the Manufacturer instructions and

procedures at any time.
 33

Have a good day !