contents-auction-QFPIRA000HBW-QFPIRA00T4ST-!QFPIRA00T526DMU Technical Assistance Manual PDF

THE POWER OF PERFORMANCE
DATA MONITOR UNIT

DMU 3000 PLUS
DMU 3000
DMU 2000
TECHNICAL
ASSISTANCE MANUAL
DMU Suite 1.3
Cod.: MI00002GB_4 - 14/02/09
essebi - bo -
Electronic device DMU2000 - DMU3000 - DMU3000 PLUS
The purpose of this manual is to provide all the workshops that are part of the assistance network
of EFFER cranes with instructions for the use of the new software to run DMU2000, DMU3000
and DMU3000PLUS.
NOTE: The first version of load electronic control system fitted to EFFER cranes is called DMU
2000. Subsequently, all the electrical wiring was redesigned, different electrical components
were used and the logic to check crane boom uplifting was introduced. The system was named
DMU 3000.
At the end of the year 2007 the DMU 3000 PLUS was designed and installed as a standard fea-
ture on some crane models. This electronic system, unlike the previous ones, also runs the crane
maximum operating speed allowed according to load applied to the hook and the geometric
configurations which the crane has when working.
Please note that with the interface software DMU Suite 1.3 you can connect all types of DMU de-
vices mentioned above, to edit the preset parameters or diagnostic operations.
To use the program “DMU Suite 1.3” you need a computer with the following minimum system
requirements:
- PC with Pentium 100 MHz processor

- CD-ROM drive
- Microsoft Windows operating system 98 or a more recent version
- Ram 32 MB (64 MB recommended)
- 100 MB of free space on hard disk
- Video card that supports a 800x600 monitor resolution or higher
- Monitor (laptops) 13’’ or higher
- n. 1 Standard free serial port (see p. 8 for more information)
In addition, it requires:
- n. 1 electrical cable for PC connection to DMU (code 9395261 l=10 M)
The following optional items may be supplied:

- n. 1 USB serial port adapter (code 9395668)
The software must be installed on your PC hard disk (portable computer recommended); it is not pos-
sible to start the programme directly from the CD-ROM.
Sol.Ge S.p.A. - 40013 Castel Maggiore (Bologna) - Italy

Via Bonazzi, 12/14 - Ph. + 39_(0)51_4181211 - Fax + 39_(0)51_701492
www.effer.it - e-mail: info@effer.it

INDEX
1. Introduction
2. Glossary of terms used in the manual
3. Installing the software in the computer
4. Connecting the computer to crane
5. Using the software
6. Instructions for communication port setting
7. Explanation of various changeable parameters
8. Displaying/changing available data in the software
9. Printing DMU setting data
10. Instructions for diagnostics
11. Adjusting angle sensors fitted to booms
12. Instructions to change “anti-bridge height” intervention point -optional
13. Entering new parameters
14. Overload test
15. Quick Turning Off the “Pin” code
16. DMU diagnostics - Trouble shooting
DMU
3000
PLUS
SPEED DYNAMIC CONTROL

1. Introduction
The software DMU Suite 1.3 is a software that should be preferably installed on a portable computer.
The software DMU Suite 1.3 allows managing/changing some of the parameters of the device. These
parameters are defined by LEVEL 1, that is available only to Sol.Ge S.p.A. autorized workshops, by enter-
ing the correct password.
A special electrical cable is required to connect the crane to the computer. This cable is supplied by Sol.
Ge with the software to install on your computer.
It is possible to run the software only after typing a password. In this way it is always possible to find the
operator that has carried out changes/variation in standard setting parameters.
The password has a deadline: before the date of expiry the new password is communicated only to
workshops with which cooperation is established.
N.B.: If an expired password is typed in even by mistake to have access to the software, the soft-
ware is automatically stopped. In order to use the software again it is necessary to perform a
new complete installation of the software on your computer.
NOTE: the DMU 3000 PLUS, unlike the other two types, also runs the radio control speed.
Please note that when the crane is fitted with DMU 3000 PLUS the operating speeds are not
editable with the software, but it requires an authorization called LEVEL 2 which is reserved for
EFFER technicians.
2. Glossary of terms used in the manual

- DESKTOP : Screen that appears after starting the computer
- ICON : When selecting this image an action follows.
- MOUSE : Tool to move the cursor and to start an action.
- CURSOR: This indicator is on the display and is moved using the mouse.
- LAYOUT : Drawing showing the project.
- TO CLICK : Place the cursor on the required icon and press the left-hand button on the
mouse.
- DOUBLE CLICK: Press the left-hand button on the mouse quickly twice.
- DMU: Equipment fitted to cranes; electronic load limiting device

3. Installing the software in the computer

Please find below the various steps required for software installation:
A- Insert the CD in the computer.

B- Click: “DMU INSTALL......”
C- Installation on the PC is automatically run by clicking “Next” every time it is requested, and
finally click “End”.
D- To start the program, just double-click the icon that automatically appears on computer
desktop.
Software startup requires 5-10 sec. according to the features of your computer.
E- On a dialog box, select a language with which you wish to dialogue with the software
(see section 5.)
F- After setting the language, an identical dialog box will ask for the password to access the
software.
NOTE: After installing the software on your computer, you can edit the setting parameters, or pro-
ceed to troubleshooting steps.
In order to complete software installation, we recommend you create a folder on your hard disk C of
your computer, inside the software folder, called - necessarily - “DMU2000Library” and dedicated to
the archive of the setting files that can be sent to you if you need to carry out updates to the crane:
in this specific case, the crane DMU will automatically connect to that folder, and from there you can
select the correct file to be sent to DMU.

4. Connecting the computer to crane

N.B.: Cable connection between the DMU and
the PC must be done when DMU is off, and
when software is not running.
u Connect the programming cable between

DMU equipment installed on the crane and the
PC.
u Arrange the remote control- when fitted

– next to the crane.
5. Using the software

a) Software startup
After connecting the computer to cranes as described in section 4, you can proceed to the activities
permitted by the software, following the instructions below:
u Turn on the DMU and enable the remote control (if fitted)
u Double-click the icon “DMU Suite 1.3” on the computer desktop to run the software.
- The software is ready to be used.
Note: When using the software for the first time, a window “Select Language” appears.
u Select the dialogue language and CLICK OK
Then the software will always display

the last language selection.

- A window “Enter the password to access” appears.
u Enter the password in CAPITAL LETTERS.
Note: This password is provided by Sol.Ge with the software, and the operator’s code linked to the
password will be stored in memory by DMU on which you will work. The password has a time limit: the
date of expiry shall be communicated with the password, and the operator has to request a new pass-
word at least 4 months before the deadline.
u CLICK OK
- The shown screen appears from which you can access the allowed functions explained in Chapter 7.

b) Changing the dialogue language

If you want to change the dialogue language, with the software already running:
u Click on the icon “Options”
u Click on the icon “User Level Settings and Language”
- The window “DMU settings” appears

u Click on the icon “Language Selection”
A list of the different languages present in the

software appears; select the language
u CLICK OK
u CLICK OK again

c) Quitting the software

u Click on the icon “File” with the cursor. You see a window, click on the icon “Quit” to exit the soft-
ware.

6. Instructions for communication port setting

If your laptop has a Serial Port compatible with the original cable provided, you need an USB adapter, and
you have to install the adapter drivers present in the setup CD.
u Insert the CD in the computer.
u Click the icon related to the USB

adapter software installation.
u CLICK “NEXT” :
NOTE: Sol.ge can supply an USB adapter,

see page 2.
NOTE:
In case there is no communication between the DMU and the computer, the words “ERROR 2” ap-
pear on the screen.
In this case, you have to match the communication port (COM 1 or COM 2) selectable in the software
from “Options”-” Communication port “, with the Port (COM 1 or COM 2) that is pre-set in the oper-
ating system.
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Operating instructions
Through the path “Start”,“Settings”,“Control Panel”, you must reach the system properties, filed un-
der the icon “system”
N.B.: According to the type of display set on the computer, you may need to go through “Perfor-
mances and Maintenance”.
u In the “Hardware” menu click “Device Manager”.
u Select “COM ports and LPT” that you can find in the drop-down menu. After you open the sub-
menu the code related to the USB cable connected to the PC appears. After selecting it, click Properties.
In the window that appears select “Set COM ports”.
Our software is designed to use both COM1 and COM2 ports:
u Select without distinction the free port on your personal computer.
11
7. Explanation of changeable parameters

To access the management part concerning change in certain performance parameters, follow the
path:
u CURRENT CRANE
u DISPLAY/CHANGE DMU DATA SHEET
In the opening screen some setting values appear.

Using the vertical scroll bar, you can access the 17 avail-
able and changeable setting values.
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1 Serial number inside the DMU

The serial number inserted inside the DMU should be the same as the crane one. If the DMU fitted to
the crane is to be replaced, a new one taken from stock shall be fitted. This new device will therefore
not include the setting files, then you will have to enter not only these files which are provided by Sol.
Ge S.p.A. for the specific crane, but also the crane serial number in the box provided.
2 Pressure 100% basic crane 1st boom cylinder
The first boom cylinder can have two different maximum pressures permitted for the use as basic crane
and for the use with additional jib: the setting value shown on the first line concerns the operation of a
basic crane, i.e. a crane equipped with additional jib or that is working without the jib fitted. When this
pressure value inside the first boom cylinder is achieved, the load limiting device comes into operation.
If a performance downgrading of the basic crane is necessary, due to a problem of stability, (value to be
decreased according to practical tests) the load limiting device should be operated first, by decreasing
the value on this line.
3 Pressure 100% basic crane 1st boom cylinder with Jib fitted
The setting value shown on the second line concerns the operation of the load limiting device when
the max. allowed pressure value inside the first boom cylinder is achieved, operating with a crane, that
is working with the additional jib fitted. If a performance downgrading of the basic crane is necessary,
following a problem of stability, (value to be decreased according to practical tests) the load limiting
device should be operated first, by decreasing the value on this line.
Reductions of more than 50% of the original values are not recommended: should this necessity arise
please contact Sol.Ge S.p.A. technical office.
NOTE: If a performance downgrading is required in the area of maximum performance for a problem
of stability, you can decrease the maximum pressure values inside the DMU, but it is not necessary to
reduce also the working pressure in the hydraulic circuit of the crane. When the operating lockout re-
sulting from DMU setting comes into operation, the boom rise movements are still possible, but these
movements are automatically interrupted when performance is increased approximately by 10% com-
pared to the set value.
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4 Pressure 100% 2nd boom cylinder

When this pressure value inside the second boom cylinder is achieved, the load limiting device is oper-
ated.
5 Pressure 100% additional jib cylinder
When this pressure value inside the jib cylinder is achieved, the load limiting device is operated.
6 % Downgrading 1st boom cylinder to work in B area
By changing this value, you change the crane performance relating to the front work area. Performance
is expressed as a percentage of the crane maximum lifting capacity .
NOTE: On crane models fitted with an encoder to determine the position of the crane booms with
respect to the truck longitudinal axis, zero is displayed instead of the value originally set, and to make
a change in performance in B Area, you should use the appropriate software interface called “SERVICE
MANUAL, edit stability parameters.
7 Cancel performance downgrading in B area
If the installation of the crane does not require any identification of the area “B”, related to performance
downgrading, if you select “OFF” you cancel this function.
NOTE: We recommend not setting the front working area by 100%, as the load limiting device opera-
tion would lead to functional restrictions relating to the manoeuvrability of the crane upper booms
owing to the off selection (e.g. when it comes into operation no rise manoeuvre with the crane booms
is allowed). If you must reverse the position of working area “A” with the position of the work area “B”,
you must operate mechanically cranes by moving the proximity switches or the cam: this change in
position is not possible using the DMU.
NOTE: Crane models fitted with an encoder to determine the position of the crane booms with respect
to the truck longitudinal axis, OFF appears and you cannot change it. In order to cancel performance
downgrading in B Area, you should use the appropriate software interface called “SERVICE MANUAL,
edit stability parameters“.
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8 % Downgrading 1st boom cylinder for bucket

A control to operate a bucket is fitted to the crane hydraulic control bank: we remind you that this con-
trol is hydraulically operated after the sequence of two manoeuvres to simulate closing, plus a manoeu-
vre to simulate opening are carried out. To return to the standard crane operation you must perform a
new start-up procedure of the device.
This implies a performance downgrading of the crane, already set at 12%.
By changing this value you have a consequent intervention of the load limiting device when the per-
centage of the performance set is achieved.
9 % Downgrading 1st boom cylinder for CS exchange solenoid valve

An exchange solenoid valve is fitted to crane additional jib. This valve has the function to divert oil in-
tended for a function of a crane jib to a bucket. This solenoid valve is operated by means of an electric
switch. Each time you turn this switch, a performance downgrading of the crane is operated, already
set at 12%.
By changing this value you have a consequent intervention of the load limiting device when the per-
centage of the performance set is achieved.
10 % Downgrading 1st boom cylinder for basket/PLE

If the use of the crane in the PLE function requires a limitation in horizontal outreach for stability prob-
lems you can change the load limiting device setting value. This downgrading does not affect the per-
formance of the crane during normal work for lifting loads.
11 % Downgrading jib cylinder for basket/PLE

If the use of the crane in the PLE function requires a limitation in horizontal outreach only of the addi-
tional extensions for problems of additional jib load stability, you can change the setting value of the
load limiting device connected to jib: this downgrading does not affect the jib performance during
normal work for lifting loads.
10
11
15
12 Jib stroke final value (Change in end-of-stroke point while additional jib is opening)
A proper setting of electronic angle sensor placed on additional jib makes crane lock not operational
when you run a manoeuvre of maximum opening, after the maximum pressure value inside the jib
cylinder is achieved.
In this case, use the RESET button to retrieve the crane movements. The movement of jib opening
should be discontinued by the angle sensor setting by preventing the jib cylinder from achieving its
maximum extension, even 0. 5 mm. only.
By editing this parameter the electronic end-of-stroke point related to jib opening is moved , thus
avoiding stopping crane operation without reason.
Note: Please see page 33 for further information.
13 Disabling stand-by function

On all the DMUs the stand-by function is turned on: after 30 minutes during which the DMU is elec-
trically operated but no movement with the crane is carried out, the electronic part with the highest
power input automatically switches off, thus limiting the electric consumption by truck batteries. (To
restore full crane operation it is necessary to press the stop emergency button, and after it is released
operate the RESET button). Certain operators may find this procedure complicated, therefore the ne-
cessity to cancel the stand-by function may arise.
If ON is set in the computer screen, the stand-by function is disabled.
If OFF is set in the computer screen, the stand-by function is enabled.
13
12
16
14 2nd boom safe opening device (ON=2; OFF=100)

You can operate an automatic device which stops the crane opening manoeuvre when the crane is
folded behind cab - if the second boom cylinder, on the rod side, has not sufficient pressure inside to
prevent the second boom from falling down as soon as it releases from the support fitted to the col-
umn.
The crane shall be delivered with the device off (the number 100 appears on the box).
15 Enabling angular sensor to detect 1st boom position

As the anti-bridge function is installed, an angle sensor is fitted to the first boom, and the function must
be enabled otherwise the DMU reports an error.
Enable is on when the box is selected (tick).
NOTE: the DMU emits an output electric signal, according to the position of the crane boom. This
signal controls the operation of an alarm, or better, prevents crane stabilizers from rising , when crane
boom is in wrong position.
The authorization above is only possible on cranes where the DMU 2000 or DMU 3000 are fitted . On
cranes where the DMU 3000 PLUS is fitted, OFF appears next to this indication and you cannot use
this function.
14
15
17
16 Winch maximum capacity ( maximum weight )

A value expressed in kg appears next to this indication: this is an indication of the weight on the
hook which should not be exceeded when using the winch. Otherwise all crane boom lifting move-
ments and winch lifting movements are automatically stopped.
In order to use this function the optional “radio pin” or “winch proportional load cell” must be fitted to
the crane. Please note that the value of weight which appears next to this indication is relating to the
use of the winch in one-cable lifting configuration (direct pull).
17 Detecting winch load with load cell ( enverr )

Depending on the type of crane, and the type of winch fitted, it may happen that instead of the
traditional “torque limit”, a proportional load cell is fitted to the same winch to limit the maximum ca-
pacity of the load applied to the hook. In these specific cases, you get crane good operation if ON ap-
pears next to such indication.
If off appears the crane is inoperative.
18 Detecting pin load on winch (enperno)

Depending on the type of crane, and the type of winch fitted, it may happen that instead of the tradi-
tional “torque limit” a proportional load cell is fitted to the hook connecting pin to limit the maximum
capacity of the load applied to the hook . In these specific cases, you have the good operation of the
crane if ON appears next to the indication.
If off appears the crane is inoperative.
19 Enabling load reading with radio pin on winch or hook ( enpeso )

The cranes which are not provided with the function described in paragraph 17 or 18 a pin for the
junction of the hook to the crane can be installed - always as an option - with a proportional load cell
at its interior, with which it is possible to have an indication of the value of the load applied to the hook.
This value can be read on the display of the radio pushbutton panel. To use this function, ON should
appear next to the indication.
Off disables the function.
18
Other available data:
A Crane serial number (it must correspond to the serial numer marked on the crane)
B This code identifies the last operator who made a change in a parameter in the DMU device
C The date that appears is the last change made in a parameter in the DMU device
D Sets out the crane model
E This code identifies the type of programming entered for the configuration of the particular
version of cranes
F This optional code identifies a customised remote control
G This code identifies the type of programming entered for the configuration of the jib
H This code identifies the type of programming entered for the configuration of the jib, if the jib
is made of two part, or is customised.
I This code identifies the type of programming entered for the configuration of the
supplementary controls (ex. bucket and rotor)
L This code identifies the type of programming entered for the configuration of the winch
M This code identifies the type of programming entered for special configurations
N This code identifies the type of programming entered for special configurations
O This code identifies the type of programming entered for special configurations
P This code identifies the type of programming entered for special configurations
A
D
I
E
L P
F M N G C H
O
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8. Displaying/changing available data in the software

a) DISPLAYING
To display and change the data in the

DMU fitted to the crane it is necessary
to:
u Click on the icon “Current Crane”
u Click on the icon “Display/Change

DMU Data Sheet”
- The software runs the data uploading inside the DMU on the computer.
You must wait a few seconds to run the operation.
- “DMU Data Sheet” window appears
In column A on the
left, the maximum A B
setting values al-
lowed for this proj-
ect are shown, while
in the column B the
set setting values
are shown.
Why are the maximum pressure values higher than setting values???
The setting values ensure that the crane is able to handle the loads indicated in the load diagrams with
an “ideal” hydraulic system, i.e. with values of back-pressure on oil exhaust pipes almost close to zero:
If this is not found on a specific installation, you can raise the values in last column up to the maximum
values allowed. Thus the DMU device delays its operation, and the crane increases its performance.
As to the setting value for the work in front of the cab, (first boom downgrading in B area) the setting
value that appears is the value resulting from the application of the crane to the truck, which is the
minimum possible in respect of the weights on the axes only: in case the specific truck allows operating
in conditions of stability with higher performance, you can change this value, i.e. increase it.
20
b) CHANGING
The data that can be changed are those in the right column, called B in the previous paragraph.
u Click twice on the line that you want to change: only the selected line is still highlighted.
u Type the desired value in the box..
N.B.: The value does not exceed the maximum value allowed as stated on the previous screen, other-
wise the system does not accept it, i.e. even if a higher value is typed, the maximum allowed value is
recorded inside the DMU.
u CLICK OK
u Exit the screen by CLICKING OK
The changed data shall be conveyed to DMU.
u Click on the icon “Send Data Sheet to DMU”
21
A dialog box appears and asks if you really want to change the data inside the DMU.
u CLICK YES
- Wait for a few seconds.
- To confirm the varia-

tion, the DMU emits a
sound.
Further confirmation of your change in the data is given by the dialog box that appears after the
comparison of data sent and those stored.
u CLICK OK
While carrying out a

change in the values of
the data inserted inside
the DMU, the DMU must
not be in stand-by.
22
It comes out from the content above that the electronic system automatically locks certain DMU move-
ments of the crane when the value set as the maximum performance is reached.
On the cranes with the manual FPI device (which can be turned on / off by operating an electric switch
on the radio transmitter), every time it is turned on, the data relating to pressures inside the lifting cyl-
inders are automatically reduced by a preset rate, which is equal to the increase in performance which
is achieved by the crane.
In case of cranes with the DMU 3000 PLUS, the operation of the F.P.I device occurs gradually, just as the
DMU gradually processes the pressure values inside the cylinders by reducing them. Therefore, start-
up of the operating stop is delayed.
9. Printing DMU setting data

Once the work of checking/changing the data inside the DMU is completed, it is recommended to
print the data relating to the personalization made and to insert the print in the technical handbook
of the crane; such data may be useful in case you install a new DMU provided for replacement.
u Display the screen related to the data

to be printed;
u Press the button PRINT on the key-

board.
The screen is stored by the computer.
u Open a word processor such as

WORD - WORD PAD – and in the menu
click the icon “Paste”.
u Save this new file to print it later, or

to insert it in a mail.
This operation is to be run for all

individual screens that you wish to print
or send by e-mail.
23
10. Instructions for diagnostics

By connecting the DMU to the computer it is possible to obtain more detailed information on a fault in
the crane, and the operating condition of the device.
It is also possible to print the diagnostic test that you carry out:
u Click on the icon “Tools”
Now you can access to six (6) work menu on which the
executable controls on the condition of connected
DMU are shown.
a) First Menu
Diagnostics of Sensors and DMU hard-
ware
u Click on the icon “Diagnostics of

Sensors and DMU hardware”
u “Diagnostics of Sensors and DMU

hardware” window appears
If the value 0 appears next to the menu,

this means that there are no faults, other-
wise the value 1 appears.
24
a1) Pressure and angular sensors

The indication of a fault next to one of
these errors requires a check as shown in
chapter 16.
a2) Hardware DMU

The indication of a fault next to one of
these errors requires a check as shown in
chapter 16.
a3) Pressure Bar (ist)

Indicates the instant pressure value inside
the various lifting cylinders to which the
pressure sensor is fitted. Structure swing-
ing leads to a continuous change in the
shown value. The percentage of load
applied corresponding to the pressure
value detected is shown nearby.
25
a4) Pressure Bar (filt)

Indicates the pressure value filtered in-
side the various lifting cylinders to which
the pressure sensor is fitted.
The filter applied in the software leads to
eliminate the variations in pressure re-
sulting from small structure swingings.
The percentage of load corresponding
to the pressure value is shown nearby.
a5) Angles/Degrees
Below is the explanation of highlighted
values within the box:
Tower / 1st boom (alpha 1) : Crane mod-

els fitted with the encoder to detect
the swinging position, the angle of the
column – tower is shown next to this in-
dication with respect to the zero point:
this zero point is located in the centre
of the working area with downgraded
lifting performance (area in front of the
truck cab).
On crane models where the slewing po-
sition is run by micro switches or by proximity switches, the value -247 appears next to the indication
for standard cranes, while if the anti-bridge function or boom height limitation to use the crane with
PLE, is enabled, the angle which the first boom has with respect to the horizontal line, appears.
2nd Boom (alpha 2): If cranes are built in the basic crane configuration, with the second boom without
uplifting, the value that appears on the side of this line is 0 and it is not to be considered (one ON-OFF
angle sensor is fitted to the second boom of the crane).
In the case of cranes equipped with additional jib or second boom with uplifting, a proportional angle
sensor is fitted to the second boom, and the value displayed relates to the boom angle with respect to
the horizontal line, with positive / negative sign when the boom is positioned above / below the hori-
zontal line (the crane operation, when the DMU load limiting device comes into operation, is different
whether the second boom is positioned above or under the angle of 30°
Jib (alpha 3) : the value shown is related to angle of additional jib with respect to the horizontal line,
with positive/negative mark when the jib is positioned above/under the horizontal line.
Delta : this box shows the mathematical value concerning the difference between the values of alpha2
and alpha3. When this value is zero, the additional jib is aligned with the second boom, and the DMU
emits a beep.
Link rod : this box shows the value of the position of the sensor fitted to jib, with respect to its horizon-
tality. Note that this has been used for crane setting in prototype phase by Sol.ge technicians.
26
b) Second Menu:
Control bank lever diagnostics
u Click on the icon “Control bank le-

ver diagnostics”
“Control bank lever diagnostics” win-

dow opens up
b1) Function lever
If the value 0 appears next to the menus

this means that the control lever of the
control bank is in its central position,
and it is OK.
If 1 appears and the control bank lever
is not operated, there is a fault in a con-
necting electrical cable or in an electric
microswitch fitted to the hydraulic con-
trol bank.
By operating the individual control
levers it is possible to run a check for the
electric functionality: This is reported
by the number 1 appearing next to the
manoeuvre that has been carried out.
b2) Conditions and Errors
The number 1 appearing next to the

heading “Conditions and Errors” indi-
cates that a fault is in the electrical part
of a control bank lever: it shows also that
one crane control bank lever is operated
at that moment.
27
c) Third Menu:
Lockout and alarm diagnostics
u Click on the icon “Lockout and

alarm diagnostics”
“Lockout and alarm diagnostics”

window appears.
The cause that has operated a lockout/

alarm can be seen by the presence of 1
next to the single description. The crane is
fully or partially stopped.
d) Fourth Menu:
Digital input diagnostics
u Click on the icon “Digital input

lever diagnostics”
“Digital input lever diagnostics” window

appears
This is the situation of the digital inputs of

DMU. It is necessary for a LEVEL 2 operator
to identify the cause for possible faults: a
level 1 operator is only asked to know this
work sheet. Sol.Ge. office can request it to
be sent to provide technical assistance.
28
Note: The values next to the headings “confidential”, are to be used by Sol.Ge. technicians only.
Note: If the crane it is not equipped with the winch or the jib, the files that manage the operation of
the winch or the jib are not included within the DMU: next to the items related to the winch or jib wear
condition, including BQ5, status 1 automatically appears.
d) Fifth Menu:
Adjustments and Maintenance
u Click on the icon “Adjustments and

Maintenance”
“Adjustments and Maintenance”

window appears.
All data relating to adjustments stored by
DMU appear in this work sheet.
Note: With this screen, the Sol.Ge.

technical office is able to establish the
life of the crane, or to determine its wear
condition.
We remember, among the most signifi-

cant, the heading “overload tests car-
ried out” (usable up to 10 times): records
within the first 100 hours of actual work of
the crane - time related to operated levers
– how many times the DMU has been by-
passed to run an overload test.
The “total working hours “ are the hours of work in which the DMU is turned on and the crane is not in
stand-by (the hour meter out of the panel records also the time of stand-by).
The hours of work made with the oil filter clogged, are reset automatically when the filter clogging sen-
sor works for about 30 min. without receiving clogging indications.
The hours of work made from filter replacement, are reset automatically when the filter clogging sensor
works for about 30 min. without receiving clogging indications after replacing the filtering element.
There are two levels of maintenance for the crane, and both are linked to the working hours: Level 2 cor-
responds to 500 working hours (ordinary maintenance), the level 3 corresponds to 1000 working hours
(extraordinary maintenance).
When these times expire the symbol of the spanner on the optional panel is turned on.
29
Upon completion of maintenance,

press the button F2 on the keyboard
of the computer.
A screen of confirmation of the
requested operation appears.
u CLICK OK
The spanner symbol turns off and next

to the individual headings the numera-
tor that shows the number of times that
have been achieved this operational
status turns on.
d) Sixth Menu:
Pressure gauge and working angles
u Click on the icon “Pressure gauge

and working angles”
“Pressure gauge and working angles”

window appears.
When the DMU device is operated, the

crane has a different operation in case
the second boom is located in a position
above/under the 30° angle.
The additional jib changes its operation
if it is in a position above/under the
horizontal line.
This distinction is indicated in the menu,
with 0 when the booms are under the
critical angle, and 1 when they are
above.
The explanation of the values relating to
Delta and Link rod, are reported at the
page 27.
30
11. Adjusting angle sensors

The previous paragraphs take into account two types of angle sensors:
1- with ON-OFF operation

2- with analog , or gradual operation, we repeat the concept of the two different applications:
a) BASIC CRANE, WITH THE SECOND BOOM

THAT DOES NOT UPLIFTS
ON-OFF ANGLE SENSOR ON SECOND BOOM

(type 1)
Adjusting type a) angle sensor:

Using the menu “Pressure gauges and working
angle” next to the words “the boom above critical
angle” 0 should appear when the boom is located
under the horizontal line or at a maximum angle
of + 30°, and 1 when it is positioned beyond +
30°.
To comply with the data referred to above, you
must intervene mechanically on fastening of the
sensor to jib crane.
b) BASIC CRANE, WITH THE SECOND BOOM

THAT DOES NOT UPLIFTS, BUT EQUIPPED
WITH ADDITIONAL JIB
ANALOG ANGLE SENSOR ON BOTH SECOND

BOOM AND JIB (both type 2)
Adjusting type b) angle sensor:

Using the menu “Pressure gauges and working
angle “ next to the words “alpha 2” 0 should ap-
pear when the boom is in its horizontal position,
and – 90° by placing the second boom in vertical
position and turned downwards.
Using the same menu, next to the word “Delta”, 0 should appear when the jib boom has a position
aligned with the basic crane second boom. If a jib opening manoevre is carried out, negative values
must be highlighted, vice versa, if a closing manoevre is carried out, positive values must be high-
lighted.
To comply with the data referred to above, you must intervene mechanically on fastening of the sensor
to crane boom.
31
C) BASIC CRANE, WITH THE SECOND BOOM THAT UP-

LIFTS
ANALOG ANGLE SENSOR ON SECOND BOOM (type 2)
Adjusting type c) angle sensor:

Using the menu “Pressure gauges and working angle “
next to the words “alpha 2” 0 should appear when the
boom is in horizontal position, and – 90° by placing the
second boom in vertical position and turned down-
wards.
To comply with the data referred to above, you must in-
tervene mechanically on fastening of the sensor to crane
boom.
d) BASIC CRANE, WITH THE SECOND BOOM THAT UP-

LIFTS, BUT EQUIPPED WITH ADDITIONAL JIB
ANALOG ANGLE SENSOR ON BOTH SECOND BOOM AND

JIB (both type 2)
The function of these sensors, is not only to discriminate

crane operation when the load limiting device on the
basis of geometric configuration of the booms comes
into operation, but also to limit the opening movements
of cylinders that operate the crane booms when you
reach configurations at safety limits: a typical example,
is to avoid going beyond the crane verticality following
an opening manoeuvre of boom handling cylinders.
Adjusting type d) angle sensor:

using the menu “Pressure gauges and working angle “ next to the words “alpha 2” 0 should appear
when the boom is in horizontal position, and - 90° by placing the second boom in vertical position and
turned downwards.
Using the same menu next to the word “Delta” 0 should appear when the jib boom has a position aligned
with the basic crane second boom. If a jib opening manoevre is carried out, negative values must be
highlighted, vice versa, if a closing manoevre is carried out, positive values must be highlighted.
Only for the analog sensor fitted to additional jib another very important test is the adjustment of
the opening maximum angle, to prevent the load limiting device from coming into operation after
the maximum pressure value is reached inside the cylinder (the DMU would have the maximum load
applied to jib). If a maximum jib opening manoeuvre is carried out, the load limiting device must not
come into operation.
32
In case the load limiting device comes into operation, follow the path:
u click on the icon “Current Crane”
u click on the icon Display/change DMU data sheet
- The software loads the data in DMU, you have to wait a few seconds for this operation.
u The twelfth parameter which can be displayed contains the words: “jib end-of-stroke final value”
(see page 16).
- A numerical value appears: decrease this value (decrease each attempt by 5 points)
u send a data sheet to DMU,
u run a test, after a minute from the transfer of data.
The electronic stop position of the jib opening movement is advanced.
u Reduce the value further in case there is still the intervention of the load limiting device.
Note: this function is turned on after 1 minute from DMU startup.
Practical functionality check: When operating the crane second boom, the DMU must emit two beeps
when you exceed the angle of 30° above the horizontal line, both with a rise and descent manoeuvre.
By operating the jib, the DMU must emit a beep when passing close to alignement to the 2nd boom,
both with a rise and descent manoeuvre.
33
12. Instructions to change “anti-bridge height “ intervention

point - optional
This adjustment is possible on cranes
provided with the DMU 2000 or DMU
3000, an analogue angle detector is also
installed on these cranes and applied to
crane 1st boom.
Using the following path: Current Crane
/ self-learning programming you have
access to the screen below:
u Click on the icon “Self-learning

programming”
“Self-learning programming” window

appears.
To set the anti-bridge height place the

1st boom of the crane at the point where
you want the alarm to be operated.
u Click on box indicated by the

arrow.
No value appears on the box.
u CLICK OK
The software stores the point where the

alarm arising from a high positioning
of crane first boom, beyond the limit
programmed, must be run.
34
13. Entering new parameters further to a change in crane

configuration/replacement of panel or dmu complete box
with fitting of similar component without data
Every configuration of cranes has its own

setting parameters: in case a change in the
configuration of the crane is made, e.g.: if
the number of extensions is changed, an
additional jib is added, a winch is fitted, …
or the device is changed for replacement
you must enter the new setting param-
eters within the DMU fitted to the crane.
Note: if any device is eliminated from

crane configuration, contact Sol.Ge. to
update parameters.
a) CHANGING THE DATA TO CHANGE

CRANE CONFIGURATION
In addition to mechanical transformation

Kit it is necessary to have the file (deliv-
ered by Sol.Ge. preferably by e-mail or on
CD).
u Save the file on your computer desk-

top.
u Open the DMU software:
u Click on the icon “Send Data Sheet
35
to DMU” . The screen “Open” is displayed.
u In the “Find in” box., select the item

Desktop. The file (extension.std) previous-
ly positioned on your desktop is displayed.
u Highlight the file to be loaded in this

screen.
u Click on the key “Open”
The software automatically runs the load-

ing and the replacement of the new set-
ting data inside the DMU.
b) LOADING DATA TO CHANGE THE

DMU
In addition to the DMU spare device it is

necessary to have the file (delivered by
Sol.Ge. preferably by e-mail or on CD), also
containing the crane identification data.
u Save the file on PC desktop.
u Fit the new DMU device to the crane.

Follow instructions in chapt. 4 and 5 for
loading and starting up.
u Click on the icon “Send Data Sheet

to DMU”
u In the “Find in” box, set the item

“Desktop”. The file (extension.std) previ-
ously positioned on your desktop is dis-
played.
u Select the file to load present in this

screen.
u Click on the key “Open”
The software automatically runs the load-

ing of the setting data.
36
For security reasons, it is cumpolsory to always check, by further reading the DMU data sheet, if the fol-
lowing data match the desired data:
- Model
- Serial number
- Revision of the data sheet (change the desired parameters and store them on DMU by following the
instructions given in Chapter 7).
c) LOADING DATA FROM AN E-MAIL
To make data loading in DMU easier it is recommended to copy the attachment provided by Sol.Ge. by
e-mail on an USB key or on a CD.
Then follow the instructions given in paragraph a) and b).
37
14. Overload test

Crane overload test
In order to run dynamic and static crane overload tests, through the sequence of movements indicated
below, you can increase the safety device setting by approximately 30% in a non-permanent way.
This is possible for a number of 10 times within maximum 100 hours of power supply to crane (with
lever operated!!!).
The sequence of movements for the overload test start is the following:
a) with the crane off (the switch “B” in the 0 position), turn the switch “D” related to acoustic alarm dis-
able to the “acoustic alarm on” position.
(b) turn on switch “B” by turning it to I position; now you have a time of 60 seconds available within
which, by holding down the RESET button “4” you have to run a manoeuvre with the first four levers of
the control bank, except for the lever of the stabilizers (if fitted):
- move the lever of rotation in one direction, than in the opposite direction
- continue with the other levers, up to that of basic crane extensions.
- a continuous beep is operated, which cannot be turned off with the switch “D” for the duration
of the tests. A B 4
5
2
6
3
7
D
1
Note: The impossibility to turn off the warning horn during the overload test is intended as a safety
measure for the operator and the people present at the tests. It is not allowed to remove the warning
horn electrical connection deliberately.
c) carry out the overload test.
d) turn off main switch “B” or press the STOP emergency button “A” only after having completed the
overload test.
Winch overload test

In case you have to carry out an overload test on a winch, the procedure to disable/enable the safety
device is the same indicated in the previous paragraph.
WARNING! With the device in overload test mode, the winch load limiting device and the rope rise
end-of-stroke are not enabled: you must therefore operate with the utmost caution and in conditions
of safety.
38
15. Quick Turning Off the “Pin” code

A PIN code can be stored as a safety anti-theft device for the crane (see DMU instruction manual). Upon
crane delivery, the PIN code is not stored.
If the PIN code is not known, follow the instructions given below in order to turn off the set code and
be able to move the crane again.
u Click on the icon “Tools”
u Click on the icon “Adjustments

and Maintenance”
u “Adjustments and
Maintenance” window appears.
u Press the button F1 on the PC

keyboard.
A screen of confirmation of the requested

operation appears.
u CLICK OK
The operation requires about one

minute.
After this time, to reuse the crane you

must shutdown and start the DMU
again. You can now move the crane and
if necessary reset the PIN code following
the instructions on the DMU manual.
39
16. DMU Diagnostics - Trouble shooting

In case a fault is in the DMU system, the fault may be identified if you look at the lights that light up on
the DMU main panel, see which ones are flashing and observe how they flash, and the sound emitted.
Here are some indications from main panel relating to faults.
The final part of the chapter also reports some indications of work situations which may be provided
by main panel.
Note: During the diagnostic work it is important that the acoustic alarm is not disabled to have
an indication on the exact type of sound.
A B 4
5
2
6
3
7
D
1
NOTE: The LED light that flashes on the DMU main panel shows the position of crane boom where
the failure is.
LIST:
FLASHING SLOWLY
FLASHING QUICKLY
LIGHTED UP PERMANENTLY
Biiiiiiiip CONTINUOUS ACOUSTIC ALARM
Bip - Bip - Bip - Bip INTERMITTENT QUICK ACOUSTIC ALARM
40
A) When starting the DMU, the warning lights

1, 2, 3, 4, and 7 are flashing slowly
and you have a continuous acoustic alarm Biiiiiiiip
CAUSE
The DMU receives the indication that a lever of the crane control bank is not in the central position: a
microswitch fitted behind a control bank lever is operated in one direction.
! FAILURE ANALYSIS
If the computer is connected to crane (tools control bank lever diagnostics conditions and
errors) the error state is displayed:
- “1” appears next to: “lever not in neutral position when DMU is started”
The indication “1” appears on the same page next to the direction to which the microswitch is turned
when the DMU is operated.
CHECK
Check the error state disappears on computer when carrying out the electric by-pass on microswitch
connecting cable, as outlined in Chapter 17.
SOLUTION
Replace the faulty microswitch fitted to control bank.
3
7
41
B) When starting the DMU, the warning lights

1, 2, 3, 4, and 7 are flashing slowly and
a continuous acoustic alarm is emitted Biiiiiiiip
CAUSE
The DMU receives the indication that a crane control bank lever is not in its central position: a micro-
switch fitted behind a control bank lever is operated.
! FAILURE ANALYSIS
errors) the error status is displayed:
On the same page the indication “1” DOES NOT appear next to any lever: it is an unstable fault of a
microswitch, that occurs only when starting.
CHECK
Check the error state disappears on the computer when carrying out the electric by-pass on ALL con-
necting cables, as outlined in Chapter 17.
Restore, one at a time, the various electrical connections to microswitches, to identify the faulty one.
SOLUTION
3
7
42
C) When starting the DMU, the warning lights 1, 2, 3, 4, and 7

are flashing quickly and a
continuous acoustic alarm is emitted Biiiiiiiip
CAUSE
switch applied behind a control bank lever is operated in both directions.
! FAILURE ANALYSIS
errors) three errors are displayed:
- “1” appears next to: “lever sensor disconnected (contrasting manoevres)”
- “1” appears next to: “any one lever operated”
The indication “1” on BOTH directions of a lever, (a lever of control bank is operated in BOTH direc-
tions)
CHECK
connecting cable, as outlined in Chapter 17.
SOLUTION
3
7
43
D) When starting the DMU, the warning lights 1, 2, 3, 4,

and 7 are flashing slowly and
CAUSE
switch fitted behind a control bank lever is operated in one direction.
! FAILURE ANALYSIS
errors) the error state is displayed:
- The indication “1” next to the words “lever not in neutral position when DMU is started” appears.
The indication “1”appears on the same page next to the direction of the lever whose microswitch is
operated when the DMU is started.
CHECK
connecting cable, as outlined in Chapter 17. If the error state does not disappear, this means that the
electrical connecting cable is interrupted between the DMU and the microswitch related the direction
operated.
SOLUTION
Restore electric connection.
3
7
44
E) When starting the DMU, the warning lights 1, 2, 3, 4,

and 7 are flashing quickly and
CAUSE
switch fitted behind a control bank lever is operated in both direction.
! FAILURE ANALYSIS
errors) three errors are displayed:
- “1” appears next to: lever sensor disconnected (contrasting manoevres)”
- “1” appears next to: “any one lever operated”
The indication “1” on BOTH directions of a lever appears, (a lever of control bank is operated in BOTH
directions)
CHECK
connecting cable, as outlined in Chapter 17. If the error state does not disappear, this means that the
electrical connecting cable is interrupted between the DMU and the microswitch.
SOLUTION
3
7
45
F) The warning light 3 flashes quickly,

the warning lights 1, 2, 4, and 7 are lighted permanently
and a continuous acoustic alarm is emitted Biiiiiiiip
CAUSE
The DMU does not receive any pressure value relating to first boom cylinder.
! FAILURE ANALYSIS
If the computer is connected to crane (tools sensor diagnostics DMU hardware) the error
state is displayed:
- “1” appears next to: “pressure sensors disconnected”
CHECK
Check the error state disappears and a pressure value of about 135 appears on computer when carrying
out the electric by-pass on transducer connecting cable, as outlined in Chapter 17 (This check is equiva-
lent to connecting a new transducer electrically only, without inserting it into cylinder, and you should
read a pressure value of 0 bar).
SOLUTION 1)
Replace the pressure transducer
! FAILURE ANALYSIS
state is displayed:
- The indication “1” appears next to: “pressure sensors disconnected”.
CHECK
Check thta the error state disappears and a pressure value of about 135 appears on computer when
carrying out the electric by-pass on transducer connecting cable, as outlined in Chapter 17 (This check
is equivalent to connecting a new transducer electrically only, without inserting it into cylinder, and
you should read a pressure value of 0 bar). If the error state continues, the pressure sensor connecting
cable is damaged.
SOLUTION 2)
Restore electric connection between DMU and pressure transducer.
4
3
7
46
G) While carrying out the first boom rise manoeuvre

the warning light 3 flashes quickly,
the warning lights 1, 2, 4, and 7 are lighted up permanently
CAUSE
The DMU receives a not allowed, anomalous pressure value relating to first boom cylinder.
! FAILURE ANALYSIS
state is displayed:
- “1” appears next to: “pressure sensor damaged (0 bar)
CHECK
Check that the error state disappears and a pressure value of about 135 appears on computer when
you should read a pressure value of 0 bar).
SOLUTION
Replace the pressure transducer.
3
7
! FAILURE ANALYSIS
state is displayed:
- “1” appears next to “pressure sensor damaged (out of range)
The pressure value displayed on the computer is 523 bar.
47
CHECK
you should read a pressure value of 0 bar).
SOLUTION
Replace the pressure transducer
! FAILURE ANALYSIS
state is displayed:
- “1” appears next to: “pressure sensor damaged (0 bar)
CHECK
cable is damaged.
SOLUTION
3
7
48
H) The warning light 2 flashes quickly,

the warning lights 1, 3, 4 and 7 are lighted up permanently
CAUSE
The DMU receives a not allowed, anomalous pressure value relating to second boom cylinder.
! FAILURE ANALYSIS
state is displayed:
CHECK
cable is damaged.
SOLUTION
3
7
! FAILURE ANALYSIS
state is displayed:
- “1” appears next to: “pressure sensor damaged (out of range)
49
CHECK
Check the error state disappears and a pressure value of about 135 appears on computer when car-
rying out the electric by-pass on transducer connecting cable, as outlined in Chapter 17 (This check is
equivalent to only connecting a new transducer electrically without inserting it into cylinder and you
should read a pressure value of 0 bar).
SOLUTION
! FAILURE ANALYSIS
state is displayed:
CHECK
cable is damaged.
SOLUTION
3
7
50
I) The warning light 2 flashes quickly,

CAUSE
The DMU receives an anomalous angle value relating to second boom position.
! FAILURE ANALYSIS
state is displayed:
- “1” appears next to: “ second boom angular sensor damaged “
A clearly anomalous angle value appears
CHECK
Check that the error state disappears on computer when carrying out the electric by-pass on transdu-
cer connecting cable, as outlined in Chapter 17. According to the type of angle sensor which can be
“analog” or “on-off” if the computer screen displays as follows:
- with analog sensor about –93°
- with “on-off” sensor: “1” appears next to: “second boom above critical angle”
the angle sensor is damaged.
SOLUTION
Replace angular sensor.
3
7
51
! FAILURE ANALYSIS
state is displayed:
- “1” appears next to: “second boom angular sensor damaged “
the electric cable connecting the angular sensor to DMU is short circuited: an angular value relating to
sensor of 173 degrees appears.
CHECK
Check the error state disappears on computer when carrying out the electric by-pass on transducer con-
necting cable, as outlined in Chapter 17. According to the type of angle sensor which can be “analog” or
“on-off” the computer screen displays as follows:
- with analog sensor: about –93°
If the error state continues, the angular sensor electric connection is damaged.
SOLUTION
Restore electric connection between DMU and angular sensor.
! FAILURE ANALYSIS
state is displayed:
- “1” appears next to: “second boom angular sensor damaged “
A sensor angular value of zero appears next to “alpha 2”.
CHECK
Check that the error state disappears on computer when carrying out the electric by-pass on transdu-
cer connecting cable, as outlined in Chapter 17. According to the type of angle sensor which can be
“analog” or “on-off” the computer screen displays as follows:
- with analog sensor: about –93°
If the error state continues, the angular sensor connection is damaged.
SOLUTION
Restore electric connection between DMU and angular sensor.
52
L) The warning light 1 flashes quickly,

CAUSE
The DMU receives a not allowed, anomalous pressure value relating to jib cylinder.
! FAILURE ANALYSIS
state is displayed:
CHECK
you should read a pressure value of 0 bar). The pressure transducer is damaged.
SOLUTION
3
7
! FAILURE ANALYSIS
state is displayed:
- “1” appears next to: “jib pressure sensor disconnected”
53
CHECK
you should read a pressure value of 0 bar). The pressure transducer is damaged.
SOLUTION
! FAILURE ANALYSIS
state is displayed:
CHECK
you should read a pressure value of 0 bar). If the error state continues and the pressure value is very
different from 135 bar, the pressure sensor connecting cable is damaged.
SOLUTION
54
M) The warning light 1 flashes quickly,

CAUSE
The DMU receives an anomalous angle value relating to jib position.
! FAILURE ANALYSIS
state is displayed:
- “1” appears next to: “jib angular sensor damaged”
CHECK
Check that the error state disappears on the computer when carrying out the electric by-pass on angu-
lar sensor connecting cable, as outlined in Chapter 17. The read angular value depends on the second
boom position and on the type of jib. If the error state continues, the angular sensor is short-circuited
or damaged.
SOLUTION
Replace angular sensor.
55
! FAILURE ANALYSIS
state is displayed:
- “1” appears next to: “jib angular sensor damaged”
the electric cable connecting the jib angular sensor to DMU is short circuited:
SOLUTION
3
7
56
N) The warning light 1 flashes quickly,

CAUSE
The DMU does not receive any pressure/angle value relating to jib.
! FAILURE ANALYSIS
If the computer is connected to crane (tools sensor diagnostics DMU hardware) two error
states are displayed:
- “1” appears next to: “jib angular sensor disconnected”
CHECK
Check that the error states disappear on computer when carrying out the electric by-passes on tran-
sducer and angular sensor connecting cables, as outlined in Chapter 17.
If only one or both error states continue, the connecting cable is damaged.
SOLUTION
3
7
57
O) Though the additional jib is not fitted to crane:

the warning light 1 flashes quickly,
and an intermittent quick acoustic alarm is emitted Bip -Bip - Bip - Bip
CAUSE
The DMU still receives a pressure value relating to jib cylinder
! FAILURE ANALYSIS
If the computer is connected to crane a jib pressure value of 514 bar is displayed.
The electronic card fitted to the connector fitted to the end of the basic crane extensions is damaged.
4
CHECK
Two checks are possible to verify the electronic card damage:
a) fit a new electronic card
b) disconnect the electronic card and fit the jib.
If the crane operates correctly (crane with jib), the electronic
card is damaged.
SOLUTION 2
Replace the electronic card. 3
7
P) The jib load limiting device comes into operation though a jib load lower than
the load allowed by the load diagram is applied.
The DMU comes into operation and stops jib extensions from exiting though the
load is lower by 30-40% than data on sheet.
CAUSE
The DMU receives an anomalous pressure value relating to jib cylinder which is higher than the value
resulting from the load applied.
! FAILURE ANALYSIS
When the computer is connected, it only indicates that 100% of the load is applied to jib:
The DMU advances its operation because it receives an increased pressure signal.
CHECK
Two checks are possible to verify the electronic card damage:
c) fit a new electronic card
d) disconnect the electronic card and fit the jib.
If the crane operates correctly (crane with jib), the electronic card is damaged.
SOLUTION
Replace the electronic card.
58
Q) At startup (or suddenly during normal work operations)

the warning lights 1, 2, 3, 4, 7 are lighted up permanently
and no acoustic alarm is emitted.
CAUSE
There is a short circuit between the DMU and the solenoid valve fitted to the crane (HSS, main discharge,
first boom discharge, ….)
! FAILURE ANALYSIS
If the computer is connected to crane (tools sensor diagnostics DMU hardware) the two error
states are displayed:
- “1” appears next to: “Feedback internal error”
- “1” appears next to: “Category 2 internal error”
CHECK
Check solenoid valve electric connections and their electric cable.
SOLUTION
Restore solenoid valve electric connections: otherwise the replacement of DMU central unit is requi-
red.
3
7
59
R) CRANES MANUFACTURED SINCE APRIL 2006: if a slewing manoeuvre is carried

out and downgraded work area is entered – this area is controlled by two proximity
switches – a quick intermittent sound is emitted
(one acoustic sound every second) Bip-Bip-Bip-Bip-……
No lightening indication appears on the DMU panel.
CAUSE
There is a short circuit in the electrical wiring controlling the downgraded work area: with this fault,
the rear work area on truck – area of maximum performance – has a higher operating angle: the truck
risks overturning.
! FAILURE ANALYSIS
This fault is not displayed on the computer: this type of failure can be confirmed if you carry out a visual
check of the state of the led lights on the proximity switches relating to the management of the slewing
angles.
CHECK
A lighted led is placed on each proximity switch: if you keep the crane boom positioned within the work
angle of the crane maximum capacity (proximity switches not covered by cam), the LED lights must be
on.
N.B.: This type of alarm is operated as a result of a slewing manoeuvre, while entering the
downgraded work area.
N.B.: After the DMU is electrically disabled, when it is restarted no sound is emitted for the
presence of the fault, although the fault is still there.
SOLUTION
Each proximity switch is connected with three electric wires: there are two polarities and the third wire
is the return of the signal to DMU. Check that the cables are intact and if no faults are found, replace the
proximity switches.
N.B.: If this alarm continues after repairing the failure, this is an indication that the two proximity
switches have been applied in an inverted position.
60
S) CRANES MANUFACTURED SINCE APRIL 2006: if a slewing manoeuvre is carried

out and downgraded work area is entered – this area is controlled by three proximity
switches – a quick intermittent sound is emitted
(an acoustic sound every second) Bip-Bip-Bip-Bip-…
Or you have an intermittent sound with descending tone of three beeps, repeated
every minute. Bip-Bip-Bip-… Bip-Bip-Bip-…
No lightening indication appears on the DMU panel.
CAUSE
There is a short circuit in the electrical wiring controlling the downgraded work area: with this fault,
the rear work area on truck – area of maximum performance – has a higher operating angle: the truck
risks overturning.
! FAILURE ANALYSIS
This fault is not displayed on the computer: this type of failure can be confirmed if you carry out a visual
check of the state of the leds on the proximity switches relating to the management of the slewing
angles.
CHECK
A lighted led is placed on each proximity switch: if you keep the crane boom positioned within the work
angle of the crane maximum capacity (proximity switches not covered by cam), the lighted LEDs must
be switched on. A quick intermittent sound indicates a failure on two proximity switches, a descending
sound indicates a failure on only one of the two proximity switches.
N.B.: This type of alarm is operated as a result of a slewing manoeuvre, while entering the down-
graded work area.
N.B.: after the DMU is electrically disabled, when it is restarted no sound is emitted for the pre-
sence of any fault, although the fault is still there.
SOLUTION
Each proximity switch is connected with three electric wires: there are two polarities and the third wire
is the return of the signal to DMU. Check that the cables are intact and if no faults are found, replace the
proximity switches.
N.B.: If this alarm can also be heard after repairing the failure, this is an indication that the two outer
proximity switches have been applied in an inverted position.
61
T) After switching on the unit, during the first slewing,

the warning light 3 flashes,
the warning lights 1, 2, 4, and 7lighted permanently ,
CAUSE
The rotary sensor reads an uncorrect value (out of range).
CHECK
Check electric cable integrity of the rotary sensor.
SOLUTION
If fault can not be found out, get in touch with an EFFER authorized workshop immediately.
U) The warning light 3 flashes and no acoustic alarm is emitted.
CAUSE
Faulty encoder for crane slewing.
CHECK
Check electric connections between rotary controlbank and and DMU.
SOLUTION
If fault can not be found out, get in touch with an EFFER authorized workshop immediately.
2
3
7
62
V) The hook for load attacchment to winch cable, is electronic, and it transmits the
value of the load applied (optional)
The warning lights 1, 2, 3, and 7 flashes in sequence,
and an intermittent quick acoustic alarm is emitted Bip -Bip - Bip - Bip

CAUSE
1) Pin battery low
2) Error of communication between DMU and pin
3) Error of radio communication between pin and its receiver.
CHECK
Check for pin switching ON, and check cables connecting DMU and pin (CAN-bus).
SOLUTION
Load the pin battery by the suitable cable or replace battery. If fault can not be found out, get in touch with an
EFFER authorized workshop immediately.
2
3
7
63
CRANE BLOCKED BY AN OPERATIONAL ERROR
a) The warning lights 1, 2, 3, 4, and 7

are lighted up permanently and
The manoeuvre for starting after switching off was too quick.
SOLUTION 1) turn off the DMU and restart it electrically after at least three seconds.
B) The warning lights 1, 2, 3 are flashing in succession and no acoustic alarm is

emitted
The CAUSE is the inclusion of the PIN code (see user manual)
SOLUTION 1) enter the PIN code to have the crane operating
SOLUTION 2) if you do not know the PIN code, you can cancel it with the computer (see chapter
13 of this manual)
c) When the DMU is turned on only, the warning light 5 is lighted, and the crane is
not operational
An emergency stop button is pressed.
SOLUTION identify the pressed emergency stop button and release it.
d) The warning light 4 is blinking, no acoustic alarm is emitted
The DMU is waiting for the start signal.

SOLUTION press the DMU start button, either on its panel, or its remote control – if fitted –
5
2
3
7
64
e) The warning light 7 is turned on with series of two flashes
The DMU entered Stand-By mode (30 minutes have passed since the crane has been moved for the last
time) –
SOLUTION press the emergency stop button, release it or press the reset button either on its
panel or on the DMU panel , or on its remote control push-button panel – if fitted –
f) The warning light 7 is turned on intermittently, and it

has an acoustic alarm of the intermittent/slow type Bip.…Bip.…Bip….
A pressure value equal to 90% of the maximum pressure value has been reached in a cylinder related
to boom lifting
SOLUTION the crane can operate with the speed reductions provided for the specific project.
g) One or several warning lights 1, 2, 3,

is turned on intermittently, and an acoustic alarm
of the intermittent/quick type is emitted. Bip -Bip - Bip - Bip - Bip
In the boom lifting cylinder related to the warning light which is turned on, the maximum allowed
pressure value for the project has been reached.
SOLUTION the crane can operate with the restrictions due to the load limiting device operation.
h) One or several warning lights 1, 2, 3 is turned on permanently and a continuous

acoustic alarm is emitted. Biiiiiiiip
A sharp load manoeuvre has created a pressure value higher than the maximum allowed pressure value
for the project within the boom lifting cylinder related to the warning light which is turned on.
SOLUTION the crane can operate only while carrying out the hydraulic extension retraction
manoevres.
3
7
65
i) During connection of computer to DMU the following message appears on the

monitor: ERROR 2, ERROR 26 or ERROR 28
The software on the diagnosis of the DMU is set to a COM port which is different from the USB port on
your computer.
SOLUTION setup the USB port following the instructions
in chapter 6 of this manual
l) No light flashes, there is an acoustic alarm

of intermittent/slow type Bip……Bip……Bip……
If you connect the computer to the crane you have no failure indication
The selector seal of anti-uplifting disable box has been removed and has been operated.
SOLUTION turn the anti-uplifting disable box selector to the correct position and place a new seal
(this work has to be carried out by an EFFER authorised workshop)
m) CRANES MANUFACTURED SINCE JANUARY 2005: after 30 minutes of work –

time measured since a control bank lever is operated – for a time of two minutes a
sound made up of a series of four beeps is emitted.
Bip-Bip-Bip-Bip / Bip-Bip-Bip-Bip / Bip-Bip-Bip-Bip-……
This type of allarm appears each time you turn on the DMU, with the procedures described above.
CAUSE
The DMU has received the indication of the oil filter delivery clogging.
! FAILURE ANALYSIS
This fault is displayed by the computer, and by the presence of the red band inside the clogging indi-
cator on the filter.
CHECK
You can check not only on the computer but also on the clogging indicator on the filter: when an acou-
stic alarm is emitted if you see a red band inside the clogging indicator, the filter cartridge is certainly
clogged.
SOLUTION
Replace the filter cartridge as soon as possible.
N.B.: following application of a new filter cartridge, the indication of filter clogged filter remains
on the computer for a time of 30 minutes of work, measured since a crane control bank lever is
operated.
66
17. CHECKING WIRING FUNCTIONALITY

If a fault occurs it can be useful to simulate the operation of certain wiring components, to find out if
the origin of the problem is in wiring or in a single component (microswitch, position of lever on control
bank, pressure sensors, angular sensors).
To determine if the fault is located in pressure sensors or angular sensors, rather than in the wiring,
you must use a 2k2 Ohm (2200 Ohm) heated
wire of at least 3 Watt. This heated wire must be
included in connectors instead of sensors that
should be checked.
2K2 W
POSITIVE
SIGNAL BP1
SIGNAL BP2
SIGNAL BA1
“E” Column wiring
Wiring 1° - 2°
boom F1
2K2 W
2K2 W
NOTE: An electric by-pass is useful for diagnostics only.

It is absolutely forbidden to use the crane with an electric by-pass connected.
67
SIMULATING PRESSURE TRANSDUCERS
Disconnect the pressure transducer to be checked electrically:

1) Fit a 2k2 Ohm (2200 Ohm) heated wire of at least 3 Watt to the transducer connecting cable
2) Connect the computer to crane
3) You read a pressure value of about “135 bar” next to transducer
SIMULATING ON/OFF ANGULAR SENSORS
Disconnect the angular sensor be checked electrically:

1) Fit a 2k2 Ohm (2200 Ohm) heated wire of at least 3 Watt to the angular sensor connecting cable
3) “1” is displayed next to: “2nd boom above critical angle”
SIMULATING ANALOG ANGULAR SENSORS
Disconnect the angular sensor be checked electrically:

1) Fit a 2K2 Ohm (2200 Ohm) heated wire of at least 3 Watt to the angular sensor connecting cable
3) An angle value of about “– 93 degrees” is displayed
N.B. The simulation of the jib angular sensor lead to the display of angle values depending upon the
position of the second boom and the type of jib.
68
SIMULATING CONTROL BANK LEVER POSITION MICROSWITCH
In order to check control bank lever position microswitches, by-pass wires (on the connector) by bridging the posi-
tive pin and the two return signal pins, as shown in the following diagram:
CONTROL BANK LEVER MICROSWITCH BY-PASS
CONTROL BANK TYPE HAWE CONTROL BANK TYPE HCD
Direction 1
Direction 2 Direction 1
Positive Direction 2
Negative Positive
Positive
Direction 1
Direction 2
ALTERNATIVE
Positive
Negative
CONTROL BANK TYPE NORDHYDRAULIC
Positive
Negative
Direction 2
Direction 1
CONTROL BANK TYPE DANFOSS
Direction 1
Direction 2
Negative
Positive
Direction 1
Direction 2 WIRE MARKING / CRANE FUNCTION
Negative
Positive
BQ1 = CRANE SLEWING DRIVE
BQ2 = 1ST BOOM DRIVE
Direction 1 BQ3 = 2ND BOOM DRIVE
Direction 2
BQ4 = STANDARD CRANE EXTENSION DRIVE
ALTERNATIVE
Negative
Positive BQ5 = WINCH DRIVE
BQ6 (X19) = WINCH / CS1 SUPPL. CONTROL DRIVE
BQ7 (X20) = CS2-CS1 SUPPL. CONTROL DRIVE
Positive
Negative
Direction 2
Direction 1 ITEM CODE PRINTED ON THE LOWER SIDE OF THE DMU
MAIN BOX
WIRE MARKING / CRANE FUNCTION

BQ3 = 2ND BOOM DRIVE
BQ5 = WINCH DRIVE
BQ6 (X19) = CS1 SUPPL. CONTROL DRIVE
BQ7 (X20) = CS2 SUPPL. CONTROL DRIVE
NOTE: the electric connection of wires to the corresponding feeding pins (module electric supply, posi-
tive wire and negative wire) must be kept activated for cranes equipped with Danfoss control bank and
radio remote control (in case you need to operate the crane temporaneously by remote radio control).
69
CONTROL BANK LEVER MICROSWITCH BY-PASS

DMU 3000 - DMU 3000PLUS
CONTROL BANK TYPE HAWE CONTROL BANK TYPE DANFOSS
Direction 1
Direction 2
Positive
Direction 1
Negative
Direction 2
Negative
Positive
WIRE MARKING / CRANE FUNCTION ITEM CODE PRINTED ON THE LOWER SIDE OF THE DMU
MAIN BOX
BQ3 = 2ND BOOM DRIVE
BQ5 = WINCH DRIVE
BQ6 = CS1 SUPPL. CONTROL DRIVE
BQ7 = CS2 SUPPL. CONTROL DRIVE
70
Sol.Ge. S.p.A.
Via Bonazzi, 12/14
40013 Castel Maggiore (BO) - I
tel. +39 051 4181211
fax +39 051 701492
web: www.effer.it
e-mail: info@effer.it
essebi-Bo-08

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THE POWER OF PERFORMANCE

DATA MONITOR UNIT

- PC with Pentium 100 MHz processor

The following optional items may be supplied:

Sol.Ge S.p.A. - 40013 Castel Maggiore (Bologna) - Italy

2. Glossary of terms used in the manual

3. Installing the software in the computer

4. Connecting the computer to crane

5. Using the software

6. Instructions for communication port setting

7. Explanation of various changeable parameters

8. Displaying/changing available data in the software

9. Printing DMU setting data

10. Instructions for diagnostics

11. Adjusting angle sensors fitted to booms

12. Instructions to change “anti-bridge height” intervention point -optional

13. Entering new parameters

14. Overload test

15. Quick Turning Off the “Pin” code

16. DMU diagnostics - Trouble shooting

2. Glossary of terms used in the manual

3. Installing the software in the computer

A- Insert the CD in the computer.

4. Connecting the computer to crane

u Connect the programming cable between

u Arrange the remote control- when fitted

5. Using the software

- The software is ready to be used.

u Select the dialogue language and CLICK OK

Then the software will always display

- A window “Enter the password to access” appears.

u Enter the password in CAPITAL LETTERS.

b) Changing the dialogue language

u Click on the icon “Options”

u Click on the icon “User Level Settings and Language”

- The window “DMU settings” appears

A list of the different languages present in the

c) Quitting the software

6. Instructions for communication port setting

u Insert the CD in the computer.

u Click the icon related to the USB

NOTE: Sol.ge can supply an USB adapter,

7. Explanation of changeable parameters

In the opening screen some setting values appear.

1 Serial number inside the DMU

4 Pressure 100% 2nd boom cylinder

8 % Downgrading 1st boom cylinder for bucket

9 % Downgrading 1st boom cylinder for CS exchange solenoid valve

10 % Downgrading 1st boom cylinder for basket/PLE

11 % Downgrading jib cylinder for basket/PLE

13 Disabling stand-by function

14 2nd boom safe opening device (ON=2; OFF=100)

15 Enabling angular sensor to detect 1st boom position

16 Winch maximum capacity ( maximum weight )

17 Detecting winch load with load cell ( enverr )

18 Detecting pin load on winch (enperno)

19 Enabling load reading with radio pin on winch or hook ( enpeso )

Other available data:

8. Displaying/changing available data in the software

To display and change the data in the

u Click on the icon “Current Crane”

u Click on the icon “Display/Change