LOAD CELL REPLACEMENT

The following technical information is referred to Faresin Inudstries SpA products listed
below
Model 6.25
Model 6.30
Model 6.32
Model 7.30 C
Model 7.30
Model 7.33
Model 7.35
Model 7.38

X
X
X
X
X
X
X
X

Model 7.42
Model 7.45
Model 8.40
Model 9.30
Model 10.50
Model 10.70
Model 11.30
Model 11.35

X
X
X
X
X
X
X
X

Model 14.35
Model 14.42
Model 17.30
Model 17.40
Model 18.45
Model 22.45

X
X
X
X

First of all you need to know the alarm code that is generated by the SAR system. These alarms are
to be read as described in the manual, by recognizing the sequence of flashing LEDs.
At the end of the procedure (page 12) you will find the sequence of alarms that may occur in the
controller with the corresponding description.
SEQUNCE ALLARM CODE

Channel Number:
CHANNEL 1 = 3 brief flashes
CHANNEL 2 = 4 brief flashes

Alarm Number: 1st DIGIT

1,,9 long flashes

PAUSE

Alarm number 2nd DIGIT

1,,9 long flashes

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

Pag. 1

SAFETY REGULATIONS
All maneuvering must be done by authorized personnel.
Is required to be equipped with all the adequate Protective equipment. gloves, goggles, safety shoes,
work overalls.
Materials needed for cell replacement:
Wrench 8mm hex
Torque wrench
Sandpaper various measures
Scissors
Ties different (from 10 cm to 30 cm)
Staple pull straps
Loctite 638
# 1 load cell kit mod: 38.0056.00A0 Rev B-1.01 side tag
EC and green dot.

Pag. 2

BEGINNING OF WORKS FOR CELL REPLACEMENT

First we will go to disconnect the connector of

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

We can remove the old load cell and start to

clean the surface of the axle with sandpaper and
dust cleaner.

The surface of the axle where it will be set the

sensor must be cleaned as shown in the photo

Pag. 3

At this point we proceed to Replace the load cell

by following this step:
1. Tight the screw completely on the two
thread to be sure that no residual of loctite
are present. When the screw is free remove
it and proceed on the next step.

2. Put loctite on the thread and the surface of

the load cell

3. Install the load cell on the axle and tighten

the screws by hand be sure that the machine
have the tyres on the leveled ground and the
boom fully close and fully down, then
proceed on the tightening with the torque
wrench set on 65 Nm (+5, -0) Nm , the
screws must be tighten alternate to dont
have false force accumulated, at the end put
the plastic cap come with the kit.

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

Pag. 4

CALIBRATION PROCEDURE OF ANTI-TIPPING CONTROL UNIT

We must be sure that the Loctite has dried (wait at least one hour) before proceeding with the
calibration. Remove any tool installed on the machine, find a flat surface and make sure you have
enough operating space in order to extend the arm along its entire length and height. Calibration
deletion is accessed by entering an access code during the second phase of the ignition panel.
NOTE: After entering the key sequence to wait 5 seconds before proceeding with the
otherwise the cancellation of the calibration unit does not perform the test.
DELETE CALIBRATION
CALIBRATION STEPS
To enter in the system procede with the
following step:
1. Start the system.
2. Wait that the system start make the self
checking.
3. Make the following sequenze of buttons
before that the self checkin leds switch off.

SAR PANEL

T3
T2

Push 2 times the button T3.

Push 3 times the button T2.
Push 1 times the button T1.

T1

Wait for 5 seconds.

Red led L5 flashes (Fig. S5).
Press key T3 to delete calibration from the
memory.

T3

Fig. S5
Led L6 flashes (fig. S6).
Press key T1 to delete calibration.
Led L6 lights up steady for 2 sec, confirming
calibration is deleted.
The device then switches to Operating Mode.

T1
Fig. S6
Pag. 5

CALIBRATION WITHOUT OUTRIGGERS

CALIBRATION STEPS

SYSTEM
CONFIGURATION

SAR PANEL

To enter in the system procede

with the following step:
1. Start the system.
2. Wait that the system start
make the self checking.
3. Make the following
sequenze of buttons before
that the self checkin leds
switch off.

T3
T2
T1

Push 2 times the button T3.

Push 3 times the button T2.
Push 1 times the button T1.
Led green L1 flashes (fig. S1).

P1

Set the system up in

configuration P1.
Press key T1 to
memorise the data.

T1

Led L1 lights up steady.

Fig. S1
Green led L2 flashes (Fig. S2).

Move the machine with the

boom completely retracted and
horizontal, with the fork
installed.
P2

Set the system up in

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

T1
Fig. S2
Move the machine with the
boom completely retracted and
completely lifted, with the fork
installed.

Pag. 6

Yellow led
(Fig. S3).

L3

flashes

P3

Set the system up in

configuration P3.
Press key T1 to memorise
the data.

T1

Led L3 lights up steady.

Fig S3

Move the machine with the

boom completely extended and
totally lifted, with the fork
installed.
Yellow led
(Fig. S4).

L4

flashes

P4

Set the system up in

configuration P4.
Press key T1 to memorise
the data.

T1

Led L4 lights up steady.

Fig. S4
WARNING:
pay
attention
to
this
operation its really dangerous.

Move the machine with the

boom completely extended and
horizontal, with the fork
installed.
P5

Red led L5 flashes (Fig. S5).

Set the system up in
configuration P5.
Press key T1 to memorise
the data.
Led L5 lights up steady.

T1
Fig. S5

Move the machine with the

boom completely lowered, the
maximum weight and extend
the boom till the tires touch a
little the round (limit of
tipping).

Pag. 7

Red led L6 flashes (Fig. S6).

Press key T1 to save the
calibration.
The device switches to
operating mode and is ready
for use.

T1
Fig. S6
Turn on the bypass key retract the boom till you reach the stable condition of the
machine.
Unload the weight from the fork.
Switch off the machine.
When you restart the machine the setting was done.
Two tests of performance to make sure that the system is stable. These tests must be performed on
and off-road for a time of 15 minutes and at the end of the operation let the shaft to cool and retest
the system.

Pag. 8

CALIBRATION WITH OUTRIGGERS

CALIBRATION STEPS

SYSTEM
CONFIGURATION

SAR PANEL

To enter in the system procede

with the following step:
1. Start the system.
2. Wait that the system start
make the self checking.
3. Make the following sequenze
of buttons before that the self
checkin leds switch off.

T3
T2
T1

Push 2 times the button T3.

Push 3 times the button T2.
Push 1 times the button T1.
Led green L1 flashes (fig. S1).

P1

Set the system up in

configuration P1.
Press key T1 to
memorise the data.

T1

Led L1 lights up steady.

Fig.S1
Green led L2 flashes (Fig. S2).

Move the machine with the

boom completely retracted
and horizontal, with the fork
installed.
P2

Set the system up in

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

T1
Fig.S2
Move the machine with the
boom completely retracted
and completely lifted, with the
fork installed.

Pag. 9

Yellow
led
(Fig. S3).

L3

flashes

P3

Set the system up in

configuration P3.
Press key T1 to memorise
the data.

T1

Led L3 lights up steady.

Fig.S3

Move the machine with the

boom completely extended
and totally lifted, with the
fork installed.
Yellow
led
(Fig. S4).

L4

flashes

P4

Set the system up in

configuration P4.
Press key T1 to memorise
the data.

T1

Led L4 lights up steady.

Fig.S4
WARNING:pay attention
to this operation its
really dangerous.

Move the machine with the

boom completely extended
and horizontal, with the fork
installed.
P5

Red led L5 flashes (Fig. S5).

Set the system up in
configuration P5.
Press key T1 to memorise
the data.
Led L5 lights up steady.

T1
Fig.S5

Move the machine with the

boom completely lowered, the
maximum weight and extend
the boom till the tires touch a
little the round (limit of
tipping).

Pag. 10

Yellow
led
(Fig. S5a).

L7

Set the system

configuration P5+S.

flashes

up

P5+S

in

L7

The led L7 will light constant

when the outriggers are down.
Press key T1 to memorise
the data.

T1
Fig.S5a

Led L7 switch off .

Led L5 lights up steady.

Please retract completely the

boom , lower completely the
stabilizers and extend the
boom until the calibration
point according to the loading
diagram of the machine.
(remember that the central
unit
will
calculate
automatically 30% less that
the maximum calibration).

Red led L6 flashes (Fig. S6).

Press key T1 to save the
calibration.
The device switches to
operating mode and is ready for
use.

T1
Fig.S6

Turn on the bypass key retract the boom till you reach the stable condition of the
machine.
Unload the weight from the fork.
Switch off the machine.
When you restart the machine the setting was done.
Two tests of performance to make sure that the system is stable. These tests must be performed on
and off-road for a time of 15 minutes and at the end of the operation let the shaft to cool and retest
the system.

Pag. 11

VIEW ALARMS ON SAR PANEL

Note: Led L6 on the LED bar signals the alarms, the buzzer is not used to signal alarms.
Description of operation
When the system registers an alarm/anomaly, led L6 will flash on the panel, while leds L1,..,L5 stay
off. Led L6 will emit a sequence of flashes according to a code below on to identify the faulty
channel and the alarm number. The system detects the alarms for each single channel (maximum
total of 10 alarms at the same time) and displays the first of the recorded alarms on the screen. The
alarm appears on the display until the condition is restored.
Note: When a system alarm occurs, all of the outputs switch off (including WDO).
Alarm code sequence
First sequence of flashes Channel Number
Second sequence of flashes Alarm Number: 1st DIGIT
Third sequence of flashes Alarm Number: 2nd DIGIT
HOW TO READ THE ALARM

Channel Number:
CHANNEL 1 = 3 brief flashes
CHANNEL 2 = 4 brief flashes

Alarm Number: 1st DIGIT

1,,9 long flashes

PAUSE

Alarm number 2nd DIGIT

1,,9 long flashes

Pag. 12

ALARM CODE LIST

CODE
11

DESCRIPTION
CRC error in the memory area that
contains the software

12

CRC error in the memory area that

contains the parameters

13

Programme flow control error

14

Data exchange error between two

microcontrollers

15

Supply voltage out of range error

(+7 Vdc +18 Vdc)

16
17

Supply voltage out of range inside 1st

channel error (+ 4.8 Vdc 5.2 Vdc)
Supply voltage out of range 2nd channel
error (+ 4.8 Vdc 5.2 Vdc)

21

Cut Off 1 output status congruency error

22

Cut Off 2 output status congruency error

23

WDO 1 output status congruency error

24

Output 1 status congruency error

25

Output 2 status congruency error

26

WDO 2 output status congruency error

31

Load cell A:
Load sensor internal parameters CRC error

32

Load cell A
Signal reading out of range error
(10 990)

33
34
35

Load cell A
Internal offset reading out of range error
(466 526)
Load cell A
Internal 5 Vdc supply voltage error
Load cell A
No thermal calibration error

WHAT TO DO
Replace the SAR
If the error persists, contact assistance
Replace the SAR
Delete and re-run calibration.
If the error persists, contact assistance
Replace the SAR
If the error persists, contact assistance
Replace the SAR
If the error persists, contact assistance
When the machine is off and on, make sure
that the battery voltage is within the stated
range
Replace the SAR
If the error persists, contact assistance
Replace the SAR
If the error persists, contact assistance
Make sure the cables are not damaged
Replace the SAR
If the error persists, contact assistance
Make sure the cables are not damaged
Replace the SAR
If the error persists, contact assistance
Make sure the cables are not damaged
Replace the SAR
If the error persists, contact assistance
Make sure the cables are not damaged
Replace the SAR
If the error persists, contact assistance
Make sure the cables are not damaged
Replace the SAR
If the error persists, contact assistance
Make sure the cables are not damaged
Replace the SAR
If the error persists, contact assistance
Replace the load cell
If the error persists, contact assistance
Run the calibration test
Run calibration again
Make sure the cell is clamped on
Replace the load cell
If the error persists, contact assistance
Replace the load cell
If the error persists, contact assistance
Replace the load cell
If the error persists, contact assistance
Replace the load cell
If the error persists, contact assistance
Pag. 13

36

Load cell A
Bus LIN message check sum error

37

Load cell A Sent data CRC error

38

Load cell A
Bus LIN message reception error

39
41

42

43
44
45
46
47
48
49
51
52

Load cell A
Bus LIN message control meter error
Load cell B
Load sensor internal parameters CRC error
Load cell B
Signal reading out of range error
(10 990)
Load cell B
Internal offset reading out of range error
(526 586)
Load cell B
Internal 5Vdc supply voltage error
Load cell B
No thermal calibration error
Load cell B
Bus LIN message check sum error
Load cell B
Sent data CRC error
Load cell B
Bus LIN message reception error
Load cell B
Bus LIN message control meter error
Difference between load cell A and B
readings too great
Difference between the load percentage
readings for channels 1 and 2 too great

61

Double safety input reading for outriggers

on the ground congruency error

62

Double safety input reading of retracted

boom congruency error

63

Inputs from mode selector congruency

error

Replace the load cell

If the error persists, contact assistance
Replace the load cell
If the error persists, contact assistance
Check cable integrity
Replace the load cell
If the error persists, contact assistance
Replace the load cell
If the error persists, contact assistance
Replace the load cell
If the error persists, contact assistance
Run the calibration test
Run calibration again
Make sure the cell is clamped on
Replace the load cell
If the error persists, contact assistance
Replace the load cell
If the error persists, contact assistance
Replace the load cell
If the error persists, contact assistance
Replace the load cell
If the error persists, contact assistance
Replace the load cell
If the error persists, contact assistance
Replace the load cell
If the error persists, contact assistance
Check cable integrity
Replace the load cell
If the error persists, contact assistance
Replace the load cell
If the error persists, contact assistance
Run Calibration Test
Run Calibration Test
Make sure the micro switches or
proximities installed on the machine are
working correctly
Check the cables
If the error persists, contact assistance
Make sure the micro switches or
proximities installed on the machine are
working correctly
Check the cables
If the error persists, contact assistance
Make sure the selector installed on the
machine is working correctly
Check the cables
If the error persists, contact assistance
Pag. 14

64

65

66

67

68

71

72

73

81

Do not turn the SAR on when the bypass

key is active
Make sure the key-operated selector
Exclusion key input active upon ignition
installed on the machine is working
error
correctly
Check the cables
If the error persists, contact assistance
Do not turn the SAR on when you re-arm
movement
Re-arm movements input when lock is
Make sure the switch installed on the
enabled upon ignition error
machine is working correctly
Check the cables
If the error persists, contact assistance
Check the cables
Make sure the internal control unit is
Feedback signal reading in frequency error
working correctly
If the error persists, contact assistance
Make sure the external drive is working
External drive 1 feedback signal reading
(relay or solenoid)
error
Check the cables
If the error persists, contact assistance
Make sure the external drive is working
External drive 2 feedback signal reading
(relay or solenoid)
error
Check the cables
If the error persists, contact assistance
Make sure the joystick is operating
Analogue signal from joystick reading
correctly
error, out of range
Check the cables
If the error persists, contact assistance
Make sure the pressure transducer is
Pressure transducer reading error, to check
operating correctly
joystick re-arming
Check the cables
If the error persists, contact assistance
CAN BUS message reception error, in the
Check the cables
optional external unit
If the error persists, contact assistance
Note: Not all the alarms force you to exit the calibration phase.
The alarm error codes that force you to exit the calibration phase are:
- from 11 to 17;
- from 31 to 39;
- from 41 to 49;
- 61.
Release the keys. Turn the system off and
Keys pressed upon ignition error
then back on again.
If the error persists, contact assistance
Note: The system displays an anomaly, but it is not working (deactivated outputs):
- other alarms may have occurred that block the outputs.

Pag. 15