Service Manual
Contents
1. ni 4 4 2 NO DISPLAY ins ap a e ii pl i ai i ieia 5 4 3 ANTI TWO BLOCK PROBLEM 2 ennt riii reino asa ana ask anonsai io sa anas ei 6 4 4 ANGLE READING PROBLEHM pintar Lene n Nn AN e mande ne crea pone secu o ran i ai anakan 8 4 5 LENGTH READING PROBLEM 9 4 6 LOAD READING PROBLEM sa na 11 ERROR CODE TABLE a a 13 SYSTEM DRAWINGS u uuu ha sento dao dinar iia rain 14 Connection Board 056 065 300 002 42402 14 6 1 DRAWING 1 SYSTEM WIRING DIAGRAM REFER TO INSTALLLATION MANUAL 031 300 190 008 ic concordia 14 6 2 DRAWING 2 CONNECTION BOARD LAYOUT L u 15 6 3 DRAWING 3 MAIN BOARD LAYOUT U u u 15 6 4 DRAWING 4 ANGLE SENSOR CIRCUIT u uu 16 6 5 DRAWING 5 LENGTH SENSOR CIRCUIT u 17 6 6 DRAWING 6 LINERIDER CIRCUIT u u u 18 6 7 DRAWING 7 LINERIDER SUPPLY VOLTAGES nn nn nn nn 19 6 8 DRAWING 8 CONSOLE PARTS u 20 PAT Rev 03 08 02 CLC 031 300 190007_b DOC GENERAL INFORMATION 1 1 GENERAL INFORMATION2. PAT Rev 03 08 02 CLC 031 300 190007_b DOC 12 PAT Es5 SERVICEMANUAL Previous Page 2 Remove hoist rope so there is no load on the load cell of the linerider Check the zero point of the Linerider on connection board between Main X1 26 sig and X1 27 sig Aux X1 30 sig and X1 31 sig Voltage 0 0 025V Refer to Drawing 6 Linerider Circuit in Section 5 and the Installation Manual for system wiring diagrams With no load on the load cell of the linerider Check the zero point of the linerider in the boom tip junction box or as close to the linerider as possible Check the Main and signal and or the Check the Aux and signal at Voltage 0 0 025V Refer to Drawing 6 Linerider Circuit in Section 5 and the Installation Manual for system wiring diagrams Correct No p No Y Check cable continuity Replace cable if necessary No Y Replace Load Cell or Linerider Assembly Yes y Lift test load and verify linerider output voltage increases after lifting the test load Main X1 26 sig and X1 27 sig Aux X1 30 sig and X1 31 sig Refer to Drawing 6 Linerider Circuit in Section 5 and the Installation Manual for system wiring diagrams y Complete steps 4 1 4 2 4 3 4 11 Main or 4 12 Aux through 4 16 in the Calibration Manual 031 300 190 009 Do NOT select Default in of section 4 4 or all other calibra
3. The purpose of this service manual is to provide additional information to assist a service or maintenance person in identifying malfunctions or system problems with the PAT System A digital voltmeter and regular maintenance and service tools will be required to troubleshoot the system Note Knowledge of how to use a digital voltmeter is assumed REFERENCE Operator s Manual 056 065 190 005 Calibration Manual 031 300 190 009 Installation Manual 031 300 190 008 SYSTEM MALFUNCTION MB 115 0 J1 85 0 In case of a malfunction of the system an error code which identifies the J2 50 0 04 15 0 E71 system malfunction will be displayed in the reeving portion of the display The error codes are listed in Section 4 Error Codes The table identifies various faults that can occur with the El65 explain each fault and describe the action which shall be taken to correct the fault Faults within the electronic microprocessor shall be repaired by factory trained service personnel When these faults occur contact your authorized dealer or service organization If the operator identifies a possible problem in the system perform the pre operation inspection Section 5 in the Operator s Manual 056 065 190 005 to define the problem SYSTEM DESCRIPTION The PAT Length Angle Radius Load Indicator System El65 has been designed to provide the crane operator with the essential information required to enable the machine to be used within its desig
4. 6 a a K EE Ka PAN T ORCE I pol A e I 55 28 nado ala J N ES PAT Rev 03 08 02 CLC 031 300 190007_b DOC DOC SYSTEM DRAWINGS 19 6 7 DRAWING 7 LINERIDER SUPPLY VOLTAGES The supply voltage can be checked directly at the cannon connection Using a digital voltmeter measure between pins A and B A 9v B 9v 18volts If this voltage is not correct refer to the system wiring diagram and verify all cable connections You may need to start at the console and check the supply voltages at their proper measuring points PAT Rev 03 08 02 CLC 031 300 190007_b DOC 20 PAT Es5 SERVICEMANUAL 6 8 DRAWING 8 CONSOLE PARTS LIST 4 P sa E B gt N To EIS si X R no NO PART NO QTY DESCRIPTION 01 050 000 100 075 1 HOUSING CONSOLE El65 02 050 350 110 183 2 KNOB MOUNTING KNOB 03 031 300 100 293 1 BRACKET MTG El65 CONSOLE 04 021 441 161 213 1 STRAIN RELIEF PG13 5 12 15mm GRAY WHITE INSERT 05 021 441 131 013 1 STRAIN RELIEF PG 13 5 8 12mm RED WHITE INSERT 06 000 214 210 013 2 NUT PG13 5 07 000 323 010 525 1 ALARM A2B El10 El20 08 056 065 300 002 1 BOARD TERMINAL El65 12V 09 031 300 100 294 2 FUSE 4 AMP FOR El 65 CONSOLE 10 056 065 300 010
5. PAT America Inc www patamerica com PAT LENGTH ANGLE RADIUS LOAD INDICATING SYSTEM El65 0005 112000lbs 1200 475 SERVICE MANUAL P N 031 300 190 007 Rev B 03 8 02 PAT 165 SERVICE MANUAL NOTICE The information in this document is subject to change without notice PAT makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose PAT shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this manual This document contains proprietary information which is protected by copyright All rights are reserved No part of this document may be photocopied reproduced or translated to another language without prior consent of PAT O 1999 PAT America Chambersburg PA 17201 USA PAT Rev 03 08 02 CLC 031 300 190007_b DOC PAT 165 SERVICE MANUAL 1 6 Table of Contents GENERAL INFORMATION usasse gana 1 REFERENCES an nag agan a a usah 1 SYSTEM MALFUNC TIONE Sii id 1 SYSTEM DESCRIPTION oras 1 WARNIN a M 2 TROUBLESHOOOTING USING THE ANALOG VALUES SCREEN 3 TROUBLESHOOTING FLOW 4 4 1 GENERAL FLOW CHART
6. 1 BOARD MAIN EI65 W RIBBON CABLE 11 050 000 100 078 1 DISPLAY 12 056 065 100 005 1 FACEPLATE El65 0005 CONSOLE 13 002 053 703 101 6 SCREW 3x10mm PANHEAD PHILLIPS 14 056 065 300 011 1 BOARD KEYBOARD El 65 CONSOLE 15 050 000 050 309 1 GASKET 108X256mm PAT Rev B 03 08 02 CLC 031 300 190007_b DOC DOC MANUAL REVISIONS SYSTEM DRAWINGS 21 DATE NAME DESCRIPTION 06 27 00 CSH El65 SERVICE Manual created A 10 09 01 CSH UPDATED THEORY SECTION B 03 08 02 CLC CORRECTED MEASURING POINT DESCRIPTION ECN 02 087 PAT Rev B 03 08 02 CLC 031 300 190007_b DOC
7. 27 A2B Ground 28 3rd Wrap Switch input 29 3rd Wrap Switch ground 30 Digital input 1 31 Digital input 2 32 6 1 DRAWING 1 SYSTEM WIRING DIAGRAM REFER TO INSTALLLATION MANUAL 031 300 190 008 O PAT Rev B 03 08 02 CLC 031 300 190007 b DOC SYSTEM DRAWINGS 15 6 2 DRAWING 2 CONNECTION BOARD LAYOUT M2 250V 056 065 300 002 MP1 GND L _ 2 5 6 5 6 MP4 5V min sig F2 M4 250V To 4 5V max sig 1234 8 12 16 20 24 28 52 A el 2 3 MP1 P4 6 3 DRAWING 3 MP13 MP12 MP8 MP7 MP4 MP5 MP6 MP9 MP10 MP11 XS1 XS2 MP2 MP1 MP3 MP 1 COMPONENT SIDE AIN ARD 065 300 012 SYSTEM EPROM MPO GND MP8 SIGNAL KMD2 MP1 AGND MP9 AN5 REFERENCE VOLATGE MP2 5 0V MP10 AN6 REFERENCE VOLTAGE MP3 5 0V MP11 AN7 REFERENCE VOLTAGE MP4 SIGNAL LENGTH CHANNEL MP12 0 5V MP5 SIGNAL ANGLE 2 MP13 5 0V MP6 SIGNAL ANGLE 1 MP15 5 25V MP7 SIGNAL KMD1 O PAT Rev B 03 08 02 CLC 031 300 190007 b DOC 16 PAT Es5 SERVICEMANUAL 6 4 DRAWING 4 ANGLE SENSOR CIRCUIT UN PAT Rev 03 08 02 CLC 031 300 190007_b DOC DOC SYSTEM DRAWINGS 17 6 5 DRAWING 5 LENGTH SENSOR CIRCUIT 4 e T d q gt e ep Ww Z I nz Wwe Se x S PAT Rev B 03 08 02 CLC 031 300 190007_b DOC 18 PAT Es5 SERVICEMANUAL 6 6 DRAWING 6 LINERIDER CIRCUIT ORC 2 l e 6
8. 3125 E l ANGLE 1 and ANGLE 2 LENGTH Hydraulic Machines Only With the boom at zero degrees this should read reading should be O with no sensor 3125 mv At maximum or 90 degrees the installed reading should be 1875 mv 25mv PAT Rev 03 08 02 CLC 031 300 190007_b DOC 4 PAT Es5 SERVICEMANUAL 4 TROUBLESHOOTING FLOW CHARTS This section explains how to handle a problem that may arise with the El65 PAT Load Indicator System The procedures are easy to follow and are given in flowcharts on the following pages Start with the general flowchart below that will guide you to one of the detailed flowcharts shown in this section Section 5 contains the necessary drawings needed for troubleshooting 4 1 GENERAL FLOW CHART CTT What s Wrong No display gt Go to Section 3 1 p Anti Two Block Problem m gt Goto Section 3 2 Angle Reading Problem gt gt Goto Section 3 3 gt Length Reading Problem Goto Section 3 4 p Load Reading Problem gt Goto Section 3 5 PAT Rev B 03 08 02 CLC 031 300 190007_b DOC TROUBLESHOOTING FLOW CHARTS 5 4 2 NO DISPLAY PROBLEM Blank console display with no warning light shown CT Check fuse F1 in console Refer to Drawing 2 Connection Board Section 5 Drawings No Replace
9. fuse 2amp 250V Measure voltage connection board between 1 1 UB X1 3 ground Refer to Drawing 1 System Diagram Section 5 Drawings Check crane power supply for faulty Correct No crane electric or if supply is too low Yes v Measure voltage on connection board between MP4 5 25V and MP 1 ground Refer to Drawing 2 Connection Board Section 5 Drawings Defect on connection board Replace No console connection board Yes y Measure voltage to main board between MP15 5 25V and MP1 ground Refer to Drawing 3 Main Board Section 5 Drawings 4 Replace console main board PAT Rev B 03 08 02 CLC 031 300 190007 b DOC 6 PAT Es5 SERVICEMANUAL 43 ANTI TWO BLOCK PROBLEM PROBLEM Function of Anti Two Block System is faulty C T Check to see whether or not crane is in two block condition Correct No gt Lower hook down into safe position Yes v Check weight position Refer to Operators Section of Handbook 056 065 190 005 Section 5 Pre Operation Inspection item 1 2 and 3 for switch weight positions for the main boom and extension No Position the weight properly Yes y Check the A2B circuit at the boom tip junction box With power off measure A2B s
10. reel Refer to Installation Manual Section 5 Mechanical Adjustments of Cable Reel Sensors If unable to adjust replace length potentiometer assembly Remove slip ring body from shaft and remove gear wheel from potentiometer axle Unscrew mounting plate and remove potentiometer assembly from mounting plate Remove lt Coree gt gt assembly wires form terminal block Connect new assembly to terminal block Reinstall mounting plate gear wheel and slip rings With boom fully retracted reset potentiometer by turning counter clockwise until it stops Refer to Installation Manual for system wiring diagrams and Section 5 Mechanical Adjustments of Cable Reel Sensors Yes Check out clutch in big gear wheel of length transducer Extend and retract boom to ensure that clutch is not sipping on potentiometer axle Replace the gear wheel clean potentiometer No axle Reset length potentiometer Refer to Installation Manual Section 5 Mechanical Adjustments of Cable Reel Sensors Yes y Check 5 0V power supply to length transducer on connection board Refer to Installation Manual for system wiring diagram or connection board designations this manual Check system power supply voltage lt gt No Refer to Section 3 2 No Display this manual Yes y q NEXT PAGE PAT Rev B 03 08 02 CLC 031 300 1900
11. voltage to angle sensor on connection board between X1 17 5VDC and X1 20 ground Refer to Installation Manual for system wiring diagram No Check system power supply voltage Refer to Section 3 2 No Display this manual Yes Check the voltage at angle sensor between connector pins AGND 5V Refer to Installation Manual for system wiring diagrams Cable defective replace cable or cable assembly No dm Refer to Installation Manual for system wiring diagrams Yes Y Check the voltage between X1 20 ground and X1 18 signal output voltage Voltage should be 3 125V 0 2 5V 45 1 875V 90 Refer to Drawing 4 Angle Sensor Circuit in Section 5 Replace Angle Sensor No Refer to Installation Manual Section 5 Mechanical Adjustments of Cable Reel Sensors Complete steps 4 1 4 2 4 3 4 8 4 8 1 and 4 14 through 4 16 in the Calibration Manual Yes 031 300 190 009 Do NOT select Default in of section 4 4 or all other calibration data will be lost and you will have to complete the entire calibration procedure END O PAT Rev B 03 08 02 CLC 031 300 190007 b DOC LOAD READING PROBLEM 9 4 5 LENGTH READING PROBLEM PROBLEM Length reading incorrect Crane is not in out of load chart condition 4 START Check mechanical adjustment of length potentiometer cable
12. 07 b DOC 10 PAT Es5 SERVICEMANUAL PREVIOUS PAGE Measure supply to length transducer in cable reel between Pin 1 ground and Pin 3 5v Refer to Installation Manual for system wiring diagram Cable defective replace cable or cable assembly No e Refer to Installation Manual for system wiring diagrams Yes y Measure signal from length transducer in cable reel at terminal between pin 2 signal and pin 1 ground Retract boom O Potentiometer turn 0 5v 10 Potentiometer turn 4 5v Refer to Drawing 5 Length Sensor Circuit Replace length potentiometer assembly Remove slipring body from shaft and remove gear wheel from potentiometer axle Unscrew mounting plate and Cones No Temove potentiometer assembly from mounting plate Remove assembly wires form terminal block Connect new assembly to terminal block Reinstall mounting plate gear wheel and slip rings With boom fully retracted reset potentiometer by turning counter clockwise until it stops Yes v Measure signal from length transducer at console connection board between X1 20 ground and X1 19 signal 0 5 and 4 5v Refer to Installation Manual for system wiring diagram or connection board designations this manual Cable defective cable cable assembly Refer to Installation Manual for system wiring diagrams M
13. SCREEN For a sensor error or problem with a sensor look at the output voltage of the linerider and angle sensors and compare the reading with the following Angle sensor 1 875 at 0 2 5 at 45 or 3 125 at 90 Linerider under no load is O to 15mV not to exceed 2500 mV To access the analog output screen use the following procedure 1 Power up the system The screen will display El 65 10 software version and date 2 To start calibration within 5 seconds of powering up simultaneously press the OK and SELECT buttons Hold these buttons approximately 15 seconds until the screen changes to CALIB PASSWORD If these buttons are not pressed and held the screen changes to the existing operating configuration Refer to Operator s section in this manual 3 Enter the calibration password 0815 Use the UP and DOWN buttons to select the number and the OK button to confirm each entry Enter 0 OK 8 OK 1 OK 5 OK 4 Scrole to the ANALOG VALUES screen by pressing the UP or DOWN arrows pressing OK to select and show the following screen All Analog input voltages shown in millivolts received from the sensors will be displayed here as described below The minimum values are show in the screen pictured FORCE 1 and FORCE 2 With no signal or weight applied this should read 15 mv or below At maximum load the reading should not exceed 2500 mv 25mv 15 VOLT 1000 3125
14. easure length signal on main board between test point MP4 signal andMP1 ground NOTE Negative signal at terminal X1 Pin 15 will be converted into positive signal at MP6 i e input at terminal X1 Pin 15 0 5V output test between MP15 and MP6 0 5v Refer to Drawing 3 Main Board Section 5 Main board defective O PAT Rev B 03 08 02 CLC 031 300 190007_b DOC LOAD READING PROBLEM 11 4 6 LOAD READING PROBLEM PROBLEM Displayed Load is out of tolerance The displayed load should be equal to or 10 greater than the actual load C START Complete Pre Operation Inspection in Section 5 of the Operator s Manual 056 065 190 005 Before changing calibration information complete the following steps Check the Main Aux voltages on connection board between X1 25 9V and X1 8 ground X1 28 9V and X1 8 ground Refer to Installation Manual for system wiring diagram or connection board designations this manual No Check system power supply voltage Complete to Section 3 2 No Display Yes Check the voltage at linerider between connector pins A 9V 9V Voltage 18V Refer to Drawing 7 in Section 5 and the Installation Manual for system wiring diagram N Cable defective replace cable or cable assembly e Refer to Installation Manual for system wiring diagrams Next Page
15. ignal boom tip junction box With the bypass plugs and switch weight in position the ohm meter reads 4 7K ohms Refer to Installation Manual for system wiring diagram No Replace Anti Two Block switch Yes v C Next Page PAT Rev 03 08 02 CLC 031 300 190007_b DOC ANTI TWO BLOCK PROBLEM 7 PREVIOUS PAGE With power off measure the A2B signal in the console at the X1 9 and X1 10 With the switch weight in position the ohm meter reads 4 7K ohms Refer to Installation Manual for system wiring diagrams Fault in cable assembly Check cable assemblies gt replace defective cable Refer to Installation Manual for system wiring diagrams Yes With power on and the switch weight in position If the Anti Two Block condition exists replace connection board A2B relay defective on connection board Refer to Drawing 2 in Section 5 Yes End PAT Rev 03 08 02 CLC 031 300 190007_b DOC PAT Es5 SERVICEMANUAL 4 4 ANGLE READING PROBLEM PROBLEM Displayed Angle Incorrect Actual measured angle is different from displayed angle q START 3 Y Use a calibrated inclinometer to measure the actual main boom angle and compare with displayed angle on console Refer to Installation Manual Section 5 Mechanical Adjustments of Cable Reel Sensors y Check the supply
16. n parameters The El65 System indicates the length and angle of the boom tip height working radius and the total weight being lifted by the crane Using the various sensors and the limits set by the operator the El65 System warns the crane operator of certain approaching hazardous conditions which could occur during the operation of his crane WARNING Always refer to operational instructions and load charts provided by the crane manufacturer for specific crane operation and load limits PAT Rev 03 08 02 CLC 031 300 190007_b DOC PAT Es5 SERVICEMANUAL 2 WARNINGS The El65 isan operational aid which warns a crane operator of certain approaching hazardous conditions which could cause damage to eguipment and personnel The device is not and shall not be a substitute for good operator judgment experience and use of accepted safe crane operating procedures The responsibility for the safe operation of the crane shall remain with the crane operator who shall ensure that all warnings and instructions supplied are fully understood and observed Prior to operating the crane the operator must carefully and thoroughly read and understand the information in the operator s manual to ensure that he she knows the operation and limitations of the indicating system and crane PAT Rev 03 08 02 CLC 031 300 190007_b DOC Troubleshoooting Using The Analog Values Screen 3 3 TROUBLESHOOOTING USING THE ANALOG VALUES
17. tion data will be lost and you will have to complete the entire calibration procedure No v Replace Load Cell or Linerider Assembly End O PAT Rev B 03 08 02 CLC 031 300 190007 b DOC SYSTEM DRAWINGS 13 5 ERROR CODE TABLE Error code Reason Action adjust operating data incorrect defective 96 ADC Measuring value WG2 too low Check luffing angle sensor circuit e Limit set by the operator refer to Operator s Manual Section 4 3 Activating and Setting Preset Limits PAT Rev 03 08 02 CLC 031 300 190007_b DOC 14 PAT E65 SERVICEMANUAL 6 SYSTEM DRAWINGS The PAT El65 System drawings in this section are provided as reference material for the troubleshooting flow charts Use the drawings in conjunction with the flow charts to help understand the operation of the El65 system Drawing List System Diagram Connection Board Layout Main Board Layout Anti Two Block Circuit Angle Sensor Adjustment Angle Sensor Circuit Linerider Circuit S rore NS Refer to the Operator s Manual for basic component layout on the crane and console drawing The El65 console connection board has the following terminal designations Connection Board 056 065 300 002 Designations Battery 17 Battery 18 Battery 19 Battery 20 Load Limit output 21 6 A2BRelay output 2 22 A2B Relay output 1 23 8 Peripheral ground 24 9 A2B1 input 25 A2B Ground 26 A2B 2 input
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