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Mark 4K LMI Service Manual

1. GAZI ddns Ja SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 16 DRAWING 13 Wiring Diagram Component Connections ROLLER LIND IVALNIO OL chmne Durr 6 Pin Plug for Alttachment or i Auxiliary S Extension Jib Attachment m s ui o m a E o E o o o ht E N o o D a oj x E om SUD G SkyAz l Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT R EF Mark 4K 17 SECTION 3 TROUBLESHOOTING FLOW CHARTS 1 GENERAL FLOWCHART This section explains how to handle a problem that may arise with the PAT Load Moment Indicator System Kruger Mark 4E 2 The procedures are easy to follow and are given in flowcharts on the following pages Start with the general flowchart below will guide you to one of the other detailed flowcharts shown in this section START What s Wrong Lever Lockout Length Cable No Display No Function Activated Problem
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3. Description of error s Description of error s Too many entries in the LMI Image List Too many entries in the List of Options Images Cause s Cause s Too many LMI images programmed in the Data Eprom 1 Too many options images programmed of the junction box or the list is too short Corrective action Corrective action Correct the Data Eprom 1 of the junction box or Correct the Data Eprom 1 of the junction box or possibly use a control program with a longer list possibly use a control program with a longer list SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT VSE Mark 4K 60 Communication errors CODE NO 2100 2107 CALL CUSTOMER SERVICE Description of error s An error has occurred during transmission of data to the display Corrective action Check cable connection to the display unit CODE NO 2110 2117 CALL CUSTOMER SERVICE Description of error s An error has occurred during reception of data to the display Corrective action Check cable connection to the display unit SkyAz l Equipment Solutions www skyazul com Hardware faults CODE NO E000 CALL CUSTOMER SERVICE Description of error s System timer not functioning Cause s Defective hardware Corrective action Replace display pc board CODE NO E000 CALL CUSTOMER SERVICE Description of error s Timer list is full Cause s The control p
4. Agaz l EQUIPMENT SOLUTIO Mark 4K SERVICE MANUAL NOTICE SkyAz l makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and or its fitness for a particular purpose SkyAzul will not be liable for errors contained in this manual 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 and all rights are reserved No part of this document may be photocopied reproduced or translated to another language without the prior written consent of SkyAzul SkyAzul reserves proprietary rights to all drawings photos and the data contained therein The drawings photos and data are confidential and cannot be used or reproduced without the written consent of SkyAz l The drawings and or photos are subject to technical modification without prior notice All information in this document is subject to change without notice r SkyAz l Inc gef 200 W Main Street Suite 2A Middletown MD 21769 EQUIPMENT SOLUTIONS Fax 301 371 0029 info skyazul com SkyAz l Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT KRE GER Mark 4K 1 Introduction 1 1 Foreword If the system or operator control errors occur during operation of the load moment indicator LMI these are indicated by overlaid error
5. Cover Rubber Seal Cable Reel Body Angle Clamp Slotted Flat Head Screw M5 x 14 Nylon Washer M5 Shielded Cable 1x1 Receiver Slip Ring Disk Angle Bracket Contact Holding Plate Terminal Strip Slotted Flat Head Screw MA x 10 Angle Transducer Complete Mounting Plate Pot Pendulum 1 0115468 00 QUANTITY KR KR P Ao 1 oc 2 45M me www skyazul com Spare Parts List 11 Ll 12 14 E LI X vw ey ARTICLE NUMBER 1 0016897 00 1 0010159 00 1 0010631 00 1 0010653 00 1 0010613 00 1 0012350 00 1 0010581 00 1 0102079 00 1 0010615 00 1 0021448 00 1 0010175 00 1 0116041 00 1 0011684 00 1 0010582 00 1 0015264 00 1 0010626 00 1 0012157 00 1 0010628 00 301 371 6126 Service Manual PAT E Mark 4K 14 Gear Drive Complete Pot 15 Mounting Bracket 16 Hex Head Cap screw M10 x 45 17 Lock Washer M10 SkyAz l Equipment Solutions a SS sch www skyazul com 1 0021212 00 1 0013697 00 1 0027856 00 1 0012207 00 1 0010096 00 301 371 6126 Service Manual PAT E Mark 4K DRAWING 4 ITEM NUMBER 14 15 16 17 SkyAz l Equipment Solutions Cable Reel 24 30 m 12 11 14 LL LIL S ITI 13 DESCRIPTION Cover Complete Cable Reel Body Angle Clamp Slotted Flat Head Screw M5 x 14 Nylon Washer M5 Shielded Cable 1x1 Receiver Slip Ring Disk Angle Bracket Contact Holding Plat
6. Data Eprom CODE NO 10C9 CALL CUSTOMER SERVICE Description of error s Options list PRE is full Cause s More options have been programmed in the Data Eprom 1 than the internal list can accept Corrective action Check the Data Eprom 1 as to whether all options are needed If they are a different control program must be used that can manage more options or the current version of the control program must be revised 301 371 6126 Service Manual PAT E Mark 4K 43 CODE NO 10CA CALL CUSTOMER SERVICE Description of error s List of options POST is full Cause s More options have been programmed in the Data Eprom 1 than the internal list can accept Corrective action Check the Data Eprom 1 as to whether all options are needed If they are a different control program must be used that can manage more options or the current version of the control program must be revised CODE NO 10CB CALL CUSTOMER SERVICE CODE NO 10CC CALL CUSTOMER SERVICE Description of error s Incorrect number of lengths programmed Option Cause s An incorrect number of lengths has been programmed in the Data Eprom 1 Corrective action Correct the Data Eprom 1 CODE NO 10CD CALL CUSTOMER SERVICE Description of error s List of options is full Cause s More options have been programmed in the Data Eprom 1 than the internal list can
7. CODE NO 10C5 CALL CUSTOMER SERVICE Description of error s Max Load Chart not found Cause s No max Load Chart has been programmed in the Data Eprom 1 for the current set up condition Corrective action Correct the Data Eprom 1 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 42 CODE NO 10C6 CALL CUSTOMER SERVICE CODE NO 10C8 CALL CUSTOMER SERVICE Description of error s Incorrect number of errors programmed in the Type 0 Max Load Chart Cause s An incorrect number of errors in the current set up condition has been programmed in the Data Eprom 1 under the Type 0 Max Load Chart Corrective action Correct the Data Eprom 1 CODE NO 10C7 CALL CUSTOMER SERVICE Description of error s Digital input has not been programmed Cause s An option has been programmed that requires a digital input that has not been programmed in the DI_CR_TABLE in the Data Eprom 1 Corrective action Enter the required input in the DI CR TABLE in the Data Eprom 1 SkyAz l Equipment Solutions www skyazul com Description of error s Digital output has not been programmed Cause s An option has been programmed that requires a digital output that has not been programmed in the DO CR TABLE in the Data Eprom 1 Corrective action Enter the required output in the DO CR TABLE in the
8. Retract the boom Boom up Set the correct set up condition Adjust the length sensor or angle sensor SkyAz l Equipment Solutions www skyazul com Description of error s The radius of the main boom is shorter than the lowest value in the load chart Cause s The boom has been retracted too far The angle of the boom is to high The incorrect set up condition has been set The length sensor or angle sensor is not correctly adjusted Corrective action Extend the boom Set the correct set up condition Adjust the length or angle sensor ANGLE BELOW LOAD CHART CORRECT ABOVE CONDITION Description of error s The angle of the main boom is less than the lowest value in the load chart Cause s The angle of the boom is to low The incorrect set up condition has been set The angle sensor is not correctly adjusted Corrective action Raise the boom Set the correct set up condition Adjust the angle sensor 301 371 6126 Service Manual PAT VSE Mark 4K 29 BOOM ANGLE ABOVE LOAD CHART CORRECT ABOVE CONDITION Description of error s The angle of the main boom is greater than the highest value in the load chart Cause s The angle of the boom is to high The incorrect set condition has been set The angle sensor is not correctly adjusted Corrective action Lower the boom Set the correct set up condition Adjust the angle sensor OUTRIGGER CONTROL CORRECT ABOVE CONDITION Descripti
9. Check the cable connection of the pressure sensor OPEN CIRCUIT PRESSURE SENSOR ROD Description of error s Cable short circuit at the analog input of the pressure sensor for the rodside of the cylinder Cause s The analog input which was programmed in the Data Eprom 1 in the ADC CR TAB for the pressure sensor has a short circuit or the voltage has dropped below the value programmed in the ADC MIMA TABLE in Data Epromo Corrective action Check the cable connection of the pressure sensor SHORT CIRCUIT LENGTH SENSOR Description of error s Cable break at the analog input of the pressure sensor for the rodside of the cylinder Cause s The analog input which was programmed in the Data Description of error s Cable short circuit at the analog input of the length sensor Cause s The analog input which was programmed in the Eprom 1 in the ADC CR TAB for the pressure sensor of the rodside of the derrick cylinder has a break analog input open or the voltage has dropped below the value programmed in the ADC MIMA TABLE in Data Eprom 4 q Data Eprom 1 in the ADC CR TAB for the length sensor has a short circuit or the voltage has dropped below the value programmed in the ADC MIMA TABLE in Data Eprom 1 Corrective action Corrective action Check the cable connection of the length sensor 1 Check the cable connection of the pressure sensor for the rodside of the
10. all geometrical information such as length and angle of main boom and working radius It also displays the actual load and the maximum load permitted by load chart Furthermore it has an alarm horn and a warning light for overload and a pre warning light The bar graph with green yellow and red indicator bar shows a percentage of the total permissible moment The console has pushbuttons to switch the operating modes for selection of crane configurations and reeving of the block It also has a warning light for overload anti two block conditions and an override push button for anti block condition SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 2 2 0 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UNIT All the data s of the crane are stored inside the central unit in E Proms The central unit gets all actual information of the crane This is computed against the reference data and the crane status continually monitored 2 1 Description of the Housing The central unit Mark 4k has a waterproof aluminum housing It is mounted in the cab The cables are led into the central unit via strain reliefs and connected with fast ons On the housing is mounted an override switch to override the LMI function The system is protected by a 2 AMP fuse which is mounted on the lower right side 2 2 Description of the Boards Inside the central unit there is one board The main board that has terminal str
11. angle shown on theangle protractor or digital level proceed to angle adjustment procedure 17 Lower boom and reinstall the cable reel cover The Angle Transducer has been replaced and adjusted The machine can be put back into service SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 62 ANGLE TRANSDUCER ADJUSTMENT Tools required Small flat blade screwdriver Digital Level or Magnetic base angle protractor Procedure Adjust angle a Set angle transducer as shown in drawing 2 b Plug Psion into Electronic box and power the system c When the NORM menu title is blinking then push EXE lowest most right button d Push left or right button until ANGLE menu title is blinking then push EXE button e Push left or right button until MINIMUM menu title is blinking then push EXE button Enter in the minimum value of boom angle normally 0 degrees verifying angle using angle finder magnetic base protractor or digital level g Boom to the highest possible boom angle staying within load chart value h Push left or right button until MAXIMUM menu title is blinking then push EXE button i Enter in the maximum angle verifying angle using angle finder magnetic base protractor or digital level j Push left or right button until ADJUST menu title is blinking then push EXE button k Push left or right button until EXIT menu title is blinking then push EXE button The Angle Transducer has bee
12. button Push the DOVVNJANGLE LENGTH 7 button to EXIT then the PROGRAM BUZZER 8 button until you get to the Program menu and enter the working display Verify length values to load chart lengths The Length Transducer has been adjusted The machine can be put back in service SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT KRE GER Mark 4K 65 7 LENGTH CABLE REPLACEMENT PROBLEM Damaged or broken length cable Replace length cable using the following procedure 1 2 3 4 5 10 11 12 13 14 Cut old cable at cable drum Disconnect damaged length cable from junction box at the boom nose Open cable reel cover and disconnect wiring from connection block Pull 7 conductor cable out of strain relief Remove cable reel from mounting brackets Remove damaged length cable which is mounted to the slip rings in the cable reel from slip ring connection Refer to Drawing 1 in Section 11 Drawings On the back side of the cable reel open the strain relief attached to the axle in the center of the drum Pull existing length cable out of the cable reel Pull new length cable through the hole pipe and strain relief and push it through the axle of the reeling drum Tighten strain relief to ensure sealing Reconnect the length cable to the slip ring Refer to Drawing 1 in Section 11 Drawings Remount cable reel to the boom Turn reeling drum clockwise to spool the new cable neat
13. dropped below the value programmed in Data Eprom 1 in the ADC MIMA TABLE Corrective action Check cable connection of the analog input xx OPEN CIRCUIT PRESSURE SENSOR PISTON Description of error s Cable short circuit at analog input xx Cause s The analog input xx has a short circuit or the voltage has dropped below the value programmed in Data Eprom 1 in the ADC MIMA TABLE Corrective action Check cable connection of the analog input xx T SkyAz l Equipment Solutions www skyazul com Description of error s Cable short at the analog input of the pressure Cause s The analog input which has been programmed in the Data Eprom 1 in the ADC MIMA TABLE for the pressure sensor has a short circuit or the voltage has dropped below the value programmed in the ADC MIMA TABLE in Data Eprom 1 Corrective action Check the cable connection of the pressure sensor 301 371 6126 Service Manual PAT E Mark 4K 53 SHORT CIRCUIT PRESSURE SENSOR PISTON SHORT CIRCUIT PRESSURE SENSOR ROD Description of error s Cable short at the analog input of the pressure sensor Cause s The analog input which has been programmed in the Data Eprom 1 in the ADC CR TAB for the pressure sensor has a break analog input open or the voltage has dropped below the value programmed in the ADC MIMA TABLE in Data Eprom 1 Corrective action
14. not transmitting any data Cause s During normal LMI operation the junction box has not set any data within the preset time Corrective action Check cable connection between junction box and display If the error cannot be remedied by switching the system on an doff all display values and set up condition should be noted down and the information sent to Kr ger for checking CODE NO 300A CALL CUSTOMER SERVICE Description of error s Incorrect CHECKSUM of the control program Cause s Loss of data in the Eprom of the control program o inadmissible modification of the control program Corrective action Install new Eprom with valid control program SkyAz l Equipment Solutions www skyazul com CODE NO 300B CALL CUSTOMER SERVICE Description of error s Invalid Telecontrol Code received Cause s The control programs in the junction box and the display are not compatible Corrective action Check versions of the control programs for compatibility and replace one or both CODE NO 300C CALL CUSTOMER SERVICE Description of error s Invalid LMI data received Cause s The control programs in the junction box and the display are not compatible Corrective action Check versions of the control programs for compatibility and replace one or both 301 371 6126 Service Manual PAT E Mark 4K 59 CODE NO 300D CODE NO 300E CALL CUSTOMER SERVICE CALL CUSTOMER SERVICE
15. vertical lift limit switch is defective Corrective action Lower the load or check the cable connection to the hoist limit switch BOOM LENGTH SHORTER THAN LOAD CHART CORRECT ABOVE CONDITION Description of error s The length of the main boom is shorter than the lowest value in the load chart Cause s The boom has been retracted too far The incorrect set up condition has been set The length sensor is not correctly adjusted Corrective action Extend the boom Set the correct set up condition Adjust the length sensor 301 371 6126 Service Manual PAT E Mark 4K 28 BOOM LENGTH LONGER THAN LOAD CHART CORRECT ABOVE CONDITION RADIUS SHORTER THAN LOAD CHART CORRECT ABOVE CONDITION Description of error s The length of the main boom is longer than the lowest value in the Load Chart Cause s The boom has been extended too far The incorrect set up condition has been set The length sensor is not correctly adjusted Corrective action Retract the boom Set the correct set up condition Adjust the length sensor RADIUS LONGER THAN LOAD CHART CORRECT ABOVE CONDITION Description of error s The radius of the load is greater than the highest value in the Load Chart Cause s The boom has been extended too far The angle of the boom is to small The incorrect set up condition has been set The length sensor or angle sensor is not correctly adjusted Corrective action
16. windows It is possible for up to 8 errors can be displayed at the same time To scroll through all errors indicated up or down buttons Operator errors are displayed as plain text messages and all other errors by a 4 character numeric code The exceptions are the hardware faults for cable break and cable short circuit in the sensor system which are displayed as plain text messages Those errors displayed in the form of code numbers will generally be hardware faults software errors or else programming errors in Data Eproms They can for example be cause by defective components incorrectly programmed memory chips etc Operator errors and faults that may occur and provides information on how to correct them Faults that are not operator will always require the services of an authorized service provider Error correction and troubleshooting will necessitate having the up to date circuit diagrams and associated connection diagrams in hand SkyAz l Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT KRE GER Mark 4K TABLE OF CONTENTS 1 0 MECHANICAL DESCRIPTION OF THE COMPONENTS 2 0 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UNIT 3 0 BASIC ADJUSTMENT OF THE HARDWARE SECTION 1 DEFINITIONS SECTION 2 DRAWINGS DRAWING 1 Indicator Panel MK4k DRAWING 2 Central Processor MK4k DRAWING 3 Cable Reel 34 50 m DRAWING 4 Cable Reel 24 30 m DRAWING 5 Angle Sensor Adjustment DRAWING 6 Anti T
17. 6 4 ITEM NUMBER DESCRIPTION QUANTITY ARTICLE NUMBER 1 Center Housing 1 1 0112531 00 2 Cover Left 1 1 0010045 00 3 Cover Right 1 1 0010044 00 4 Slotted Flat Head Screw M5 x 8 2 1 0013391 00 5 Lever 1 1 0010041 00 6 Straight Pin 1 1 0010042 00 7 Bushing 1 1 0010104 00 8 Spring 1 1 0100326 00 9 Micro Switch 1 1 0010039 00 10 Cable Connector 1 1 0010037 00 11 Blind Plug 1 1 0010038 00 12 Shackle with Cotter Pin 1 1 0009999 00 Required for Mounting Order Separately Weld Plate 1 1 0010046 00 Hex Head Cap screw M8 x 50 2 1 0010083 00 Lock Washer M8 2 1 0010097 00 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT K SE Mark 4K 12 DRAWING 7 Pressure Transducer 250 BAR 1 0108060 00 DRAWING 8 Pressure Transducer Cable Assembly Part Number is depends cable length Connector Cable Straight x 7M 1 0114293 00 Connector Cable Straight x 10M 1 0114294 00 Connector Cable 900 Connector 1 0101758 00 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 13 DRAWING 9 Jumper Cable Assembly for Extension 350 5004 en e tu in t DESCRIPTION CABLE 2 X 0 5 DS FER FHT Don 301 025 082 COHNECTOR ACY SERT 8 SOCKET FEMALE OO0 274 281 3511 STRAJN RELIEF AC PO 3 5 11 ACOUCER Oz1 441 110 014 STRAIN RELIEF BOT amp mm QRN WHT SkyAzul Equipment Solutions www skyazul com 301 371 6126 Ser
18. 6126 Service Manual PAT E Mark 4K 27 SECTION 4 OPERATOR ERROR CODE TABLE OPERATION ERRORS Operation errors are measurement errors i e the actual radius is lower than in the load chart The information will be shown on the second line of the display with an error message or description The error will be automatically reset when user corrects error ATTENTION SHUT OFF BYPASS TWO BLOCK CONDITION CORRECT ABOVE CONDITION Description of error s The shut off system is currently by passed Cause s The shut off contact has been by passed by the user with the aid of the key operated switch installed in the junction box Corrective action Cancel the bypass of the shut off unit or operate the crane with necessary caution Caution This condition is not any circumstances the normal operating condition ATTENTION TWO BLOCK BYPASS Description of error s The Hoist limit switch is currently by passed Cause s The hoist limit switch has been by passed with the key operated switch Corrective action Release the hoist limit switch or operate the crane with the necessary caution Caution This condition is not under any circumstances the normal operating status SkyAz l Equipment Solutions www skyazul com Description of error s The Hoist limit switch has come into operation Cause s The hook has activated the hoist limit switch or the cable connection to the
19. Anti Two Block Go to Section 2 Go to Section 3 Go to Section 4 Go to Section 5 Wrong Load Displayedi Wrong Load Displayed Go to Section 6 Go to Section 7 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT S EF Mark 4K 18 2 LEVER LOCKOUT ACTIVATED Problem The lever lockout system of the crane is activated Crane movements hoist up telescope out and boom down are stopped Crane is not in overload or two block condition I START Set the override key switch in electronic box into upper position to override LMI s c Oe If console display is blank fault is located in power supply wiring or Does light 6 indicate Anti Two fuse Block warning If Load Moment Limit Light 5 Fault in Anti Two Check lever lockout system in displays fault is located in LMI Block system crane B cables wiring fuses or console Read error code displayed on console display Go to Section 4 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 19 3 LENGTH CABLE PROBLEM PROBLEM Damaged or broken length cable STEP ACTION 1 Turn drum counter clock wise until drum is fully tensioned 2 Tighten locking nuts to drum to prevent recoil Refer to Drawing 1 in Section 11 Appendix 3 Take reel cover off and remove screw and cable clamp 4 Remov
20. Cause s Crane has been swung into the wrong working range Incorrect set up condition has been set Supply lead for roller switch is defective Roller switch input is defective Corrective action Slew crane into acceptable working range Check the set up condition Check the supply lead for the roller switch Check the roller switch input with the help of the Service Mode The Service Mode is activated by pressing the GREEN RED and PROGRAM keys simultaneously MANUAL EXTENSION PIN CORRECT ABOVE CONDITION Description of error s Man Ext Pin not switched on off Cause s The boom extension has either not been locked or not been unlocked Incorrect set up condition set The supply lead for the monitoring switch is defective The switch input is defective Corrective action Lock or unlock the boom extension as the case may be Check the set up condition Check the supply lead for the switch Check switch input with the help of the Service Mode The Service Mode is activated by pressing the GREEN RED and PROGRAM keys simultaneously SkyAz l Equipment Solutions www skyazul com AXLE BLOCKING REAR CORRECT ABOVE CONDITION Description of error s Rear axle blocking unit not activated Cause s The rear axle has not been blocked Incorrect set up condition set Supply lead for switch is defective Switch input is defective Corrective action Block the rear axle Check the set up c
21. DE NO F052 CALL CUSTOMER SERVICE Description of error s System Timer not functioning Cause s Hardware is defective Corrective action Replace junction box board SkyAz l Equipment Solutions www skyazul com Description of error s Extended Timer List full Cause s Within an external option the control program has attempted to activate more timers than are listed Corrective action If the error cannot be eliminated by switching the system on and off all display values and the set up condition should be noted down and this information sent to Kr ger for checking since there is an error either in the control program or in the Data Eproms 301 371 6126 Service Manual PAT E Mark 4K 52 CODE NO F053 CALL CUSTOMER SERVICE OPEN CIRCUIT CHANNEL XX Description of error s Extended Timer List full OPTION Cause s Within an external option the control program has attempted to activate more timers than are listed Corrective action If the error cannot be eliminated by switching the system on and off all display values and the set up condition should be noted down and this information sent to Kr ger for checking since there is an error either in the control program or in the Data Eproms SHORT CIRCUIT CHANNEL XX Description of error s Cable break at analog input xx Cause s The analog input xx has a break analog inout open or the voltage has
22. O 108A CALL CUSTOMER SERVICE Description of error s Invalid type of data recorder has been programmed Cause s A type of data recorder has been programmed in the Data Eprom 1 that is unknown to the control program Corrective action Check and possibly correct the Data Eprom 1 or check and possibly replace the control program version CODE NO 1089 CALL CUSTOMER SERVICE Description of error s Invalid present type has been programmed Cause s A present type has been programmed in the Data Eprom 1 that is unknown to the control program Corrective action Check and possibly correct the Data Eprom 1 or check and possibly replace the control program version SkyAz l Equipment Solutions www skyazul com Description of error s Invalid LMI data type has been programmed Cause s An LMI data type has been programmed in the Data Eprom 1 that is unknown to the control program Corrective action Check and possibly correct the Data Eprom 1 or check and possibly replace the control program version CODE NO 108B CALL CUSTOMER SERVICE Description of error s List of options is full Cause s More options have been programmed in the Data Eprom 1 than the internal list can accept Corrective action Check the Data Eprom 1 as to whether all options are needed If so a different control program must be used which can manage mo
23. PAT E Mark 4K 33 NON WORKING AREA ON TIRES Description of error s The crane has been swung into a working range that is unacceptable to a set up condition on tires This is a warning only no shut off Option Cause s The crane has been swung into the wrong working range Incorrect set up condition set Supply lead for the roller switch is defective Input of roller switch is defective Corrective action Swing the crane into the permissible working range Check the set up condition Check the supply lead for the roller switch NON WORKING AREA ON OUTRIGGERS Description of error s The crane has been swung into a working range that is unacceptable for a supported set up condition This is a warning only no shut of Option Cause s Crane has been swung into the wrong working range Wrong set up condition set Supply lead for the monitoring switch is defective Switch input is defective Corrective action Slew the crane into the acceptable working range Check the set up condition Check the supply lead for the switch SkyAz l Equipment Solutions www skyazul com MINIMUM CABLE ON LOAD HOIST DRUM CHECK FRONT DRUM Description of error s End of hoisting rope on main winch almost reached Cause s Hoisting rope on main winch reeled off too far Supply lead for monitoring switch is defective Switch input is defective Corrective action Do not reel off the main winch hoist
24. accept Corrective action Check the Data Eprom 1 as to whether all options are needed If they are a different control program must be used that can manage more options or the current version of the control program must be revised SkyAz l Equipment Solutions www skyazul com Description of error s It is not possible to determine the length lattice boom Cause s There is no Max Load Chart with a valid length programmed in the Data Eprom 1 Corrective action Correct the Data Eprom 1 301 371 6126 Service Manual PAT E Mark 4K 44 Programming errors Data Eprom 2 CODE NO 000F CALL CUSTOMER SERVICE CODE NO 1101 CALL CUSTOMER SERVICE Description of error s Identification of the pressure curve is invalid Cause s For the current set up condition a type of pressure curve has been programmed in the Data Eprom 2 that is not known to the current control program Corrective action Correct the Data Eprom 2 or change the control program CODE NO 1100 CALL CUSTOMER SERVICE Description of error s Incorrect CHECKSUM in the case of Data Eprom 2 Cause s An incorrect Eprom has been inserted in the Data Eprom 2 slot The contents of the Data Eprom 2 have been changed with the DSD terminal deflection etc Corrective action Replace the Data Eprom 2 with a valid version Update the CHECKSUM with the DSD termin
25. al CODE NO 1102 CALL CUSTOMER SERVICE Description of error s nvalid EEprom identification in the case of the Data Eprom 2 Cause s Incorrect Date Eprom inserted in the Data Eprom 2 slot Corrective action Replace the Data Eprom 2 with a valid version SkyAz l Equipment Solutions www skyazul com Description of error s Incorrect size of EEprom Data Eprom 2 Cause s The size of the EEprom Data Eprom 2 is incorrectly set in the Data Eprom 2 Corrective action Correct the Data Eprom 2 301 371 6126 Service Manual PAT E Mark 4K 45 CODE NO 1103 CALL CUSTOMER SERVICE CODE NO 1105 CALL CUSTOMER SERVICE Description of error s Incorrect number of pressure curves programmed Cause s A number of pressure curves have been programmed in the Data Eprom 2 that do not coincide with the number of programmed set up conditions Corrective action Correct the Data Eprom 2 CODE NO 1104 CALL CUSTOMER SERVICE Description of error s No set up condition has been released Cause s All set up conditions blocked via the Permission function of the DSD Corrective action At least one set up condition must be released CODE NO 1106 CALL CUSTOMER SERVICE Description of error s Incorrect length of Deflection Table Cause s The number or the structure of the data in the Deflection Table is incorrectly pr
26. check the input voltage with a multimeter If the voltage is higher than 24 V DC 20 check the 12 V DC with a multimeter at terminal 11 20 If this voltage is less than 12 V DC all loads connected to 12 V DC must be checked for short circuits CODE NO F040 F042 CALL CUSTOMER SERVICE Description of error s ADC Timeout Cause s Malfunction of the A D converter Corrective action Replace junction box board SkyAz l Equipment Solutions www skyazul com Description of error s Error when writing into the Data Eprom 2 EEprom Cause s Data Eprom 2 is defective Corrective action Replace the Data Eprom 2 301 371 6126 Service Manual PAT E Mark 4K 51 CODE NO F043 F047 CALL CUSTOMER SERVICE CODE NO F051 CALL CUSTOMER SERVICE Description of error s Error during access to the serial EEprom Cause s Serial EEprom or junction box board is defective Corrective action Replace junction box board CODE NO F050 CALL CUSTOMER SERVICE Description of error s Timer List full Cause s The control program has attempted to activate more timers than are listed Corrective action If the error cannot be eliminated by switching the system on and off all display values and the set up condition should be noted down and this information sent to Kr ger for checking since there is an error either in the control program or in the Data Eproms CO
27. cylinder SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 54 OPEN CIRCUIT LENGTH SENSOR Description of error s Cable break at the analog input of the length sensor Cause s The analog input which was programmed in the Data Eprom 1 in the ADC CR TAB for the length sensor has a break analog input open or the voltage has dropped below the value programmed in the ADC MIMA TABLE in Data Eprom 1 Corrective action Check the cable connection of the length sensor SHORT CIRCUIT ANGLE SENSOR MAIN BOOM Description of error s Cable short circuit at the analog input of the angle sensor for the main boom Cause s The analog input which was programmed in the Data Eprom 1 in the ADC CR TAB for the angle sensor of the main boom has a short circuit or the voltage has dropped below the value programmed in the ADC MIMA TABLE in Data Eprom 1 Corrective action Check the cable connection of the angle sensor for the main boom SkyAz l Equipment Solutions www skyazul com OPEN CIRCUIT ANGLE SENSOR MAIN BOOM Description of error s Cable break at the analog input of the angle sensor for the main boom Cause s The analog input which was programmed in the Data Eprom 1 in the ADC CR TAB for the angle sensor of the main boom has a break analog input open or the voltage has exceeded the value prog
28. e Terminal Strip Slotted Flat Head Screw MA x 10 Angle Transducer Complete Mounting Plate Pot Pendulum Gear Drive Complete Pot Mounting Bracket Hex Head Cap screw M10 x 45 Lock Washer M10 QUANTITY RR A a a 30M nn in in sech MA a gt a a a www skyazul com 1 0115463 00 Spare parts List ARTICLE NUMBER 1 0107886 00 1 0107885 00 1 0010613 00 1 0012350 00 1 0010581 00 1 0102079 00 1 0010615 00 1 0021448 00 1 0010175 00 1 0116041 00 1 0011684 00 1 0010582 00 1 0015264 00 1 0010626 00 1 0012157 00 1 0010628 00 1 0021212 00 1 0013697 00 1 0027856 00 1 0012207 00 1 0010096 00 301 371 6126 Service Manual PAT E Mark 4K 10 DRAWING 5 Angle Sensor WG203 Adjustment 1 0115294 00 The angle shown in drawing below 1 needs to be within t0 0 4 of the actual angle of the boom Check boom angle at base heel Section only After adjustment compare the actual boom angle with the displayed angle at about 0 30 and 60 To comply with the SAE J375 standards the displayed angle must be t0 0 to 2 0 of the actual angle Angle Transducer Pendulum Stop Set Angle Transducer Left Side of Boom Right Side Inside mja Right Side of Boom Left Side Inside SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K DRAWING 6 Anti Two Block Switch 1 0024849 00 12 5 T
29. e function of the Two Block switch by using lohmmeter between terminals 2 and 4 of the receptacle Safe condition switch pulled down 0 ohm Two Blocked switch up open Plug appropriate plug into socket of the receptacle Remove cover from cable reel Check with ohmmeter between terminals 2 and 3 on the slip ring disc with Two Block switch down 0 ohm Replace Anti Two Block switch NEXT PAGE SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 23 PREVIOUS PAGE E Replace length cable refer to Section 5 Check with ohmmeter between terminals 2 and 3 on the terminal strip with Two Block switch down 0 ohm Clean or replace slip ring disc or terminal strip p c board with plungers Check with ohmmeter between terminals 6 and 7 in the receptacle a boom pivot point with Two Block switch down 0 ohm Replace defective cable from cable reel to receptacle Check with ohmmeter between terminals X1 71 and X1 72 in the electronic box with Two Block switch down 0 ohm Replace cable from plug at boom pivot point to electronic box Use a voltmeter with ground lead on X1 41 50 and positive lead on X1 72 check for 12 vdc NEXT PAGE SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 24 PREVIOUS PAGE Electronic Box P C Board is defective With 12vdc on terminal X1 72 and all checks have been c
30. e pre set maximum value This is a warning only no shut off Corrective action Enlarge main boom angle Reduce boom length RADIUS BELOW OR EQUAL MAX PRESENT VALUE Description of error s The current radius is smaller or equal to the pre set minimum value This is a warning only no shut off Corrective action Reduce angle of the main boom Increase length of boom 301 371 6126 Service Manual PAT E Mark 4K 32 LENGTH LOAD BELOW OR EQUAL BELOW OR EQUAL MIN PRESET VALUE MIN PRESET VALUE Description of error s Description of error s The current main boom length is smaller than or equal The current load is less than or equal to the pre set to the pre set minimum value This is a warning only minimum value This is a warning only no shut off no shut off Corrective action Corrective action Increase weight of current load Increase length of main boom LENGTH LOAD ABOVE OR EQUAL ABOVE OR EQUAL MAX PRESET VALUE MAX PRESET VALUE Description of error s Description of error s The current main boom length is greater than or equal The current load is greater than or equal to the pre set to the pre set maximum value This is a warning only maximum value This is a warning only no shut off no shut off Corrective action Corrective action Reduce the weight of the current load Reduce length of main boom SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual
31. e wire from slip ring disc cut wire ends off and remove all old length cable from reel 5 Feed new length cable through drum Strip wire separate inner core from shield insulate shield by using heat shrink or electrical tape put spade lugs on and wire to slip ring disc terminals 2 and 3 Put cable clamp on and tighten screw to drum 6 Put silicone around hole where the new length cable is fed through the drum 7 While holding cable or drum Warning To prevent recoil loosen locking nuts and jam the nuts together 8 Slowly let cable spool on the drum keeping the cable tight together and layering properly Let cable spool until all tension is off of the cable reel 9 Re string cable through the roller guides and reconnect at the boom tip 10 After cable replacement refer to length adjustment procedure to reset length 11 Put cover on reel and crane is ready to put back in service SkyAz l Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E EF Mark 4K 20 4 BLANK DISPLAY PROBLEM Blank display No warning lights shown Crane movements stopped START Check fuse in Electronic Box Refer to Drawing 3 Electronic Box CPU Board wp cU De Check input voltage using a If fuses is open check for direct short to ground by using voltmeter put positive lead at a voltmeter checking for continuity between terminal X1 2 terminal X1 1 and ground at and X1 11 20 terminal X1 2 If there is no voltage t
32. ed in the slot of the Data Eprom 1 Corrective action Replace the Data Eprom 1 with a valid version CODE NO 10C1 CALL CUSTOMER SERVICE Description of error s Identification of the Set Up Condition Table is not valid Cause s A type has been programmed in the Data Eprom 1 for the current set up condition that is unknown to the current control program Corrective action Correct the Data Eprom 1 or change the control program SkyAz l Equipment Solutions www skyazul com Description of error s Incorrect CHECKSUM in Data Eprom 1 Cause s An incorrect Eprom has been inserted in the slot of Data Eprom 1 Corrective action Replace the Data Eprom 1 vvith a valid version 301 371 6126 Service Manual PAT VSE Mark 4K 41 CODE NO 10C2 CALL CUSTOMER SERVICE Description of error s Incorrect Country Code programmed Cause s Incorrect Country Code has been programmed in the Data Eprom 1 Corrective action Correct the Data Eprom 1 Program the valid Country Code or integrate the respective language module CODE NO 10C3 CALL CUSTOMER SERVICE This error message is currently deactivated CODE NO 10C4 CALL CUSTOMER SERVICE Cause s More set up conditions have been programmed in the Data Eprom 1 than are set up condition texts available Corrective action Correct the Data Eprom 1
33. ence of the main loop Cause s Error in the control program Corrective action If the error cannot be eliminated by switching the system on and off all display values and the set up condition should be noted down and the information sent Kr ger for checking because an error must have occurred either in the control program or in the Data Eproms CODE NO 3001 CALL CUSTOMER SERVICE Description of error s Error of division Cause s The system has attempted to divide by zero Corrective action If the error cannot be eliminated by switching the system on and off all display values and the set up condition should be noted down and the information sent to Kr ger for checking because an error must have occurred either in the control program or in the Data Eproms SkyAz l Equipment Solutions www skyazul com CODE NO 3002 CALL CUSTOMER SERVICE Description of error s Invalid interrupt vector Cause s The system has attempted to execute an interrupt that was not allowed Corrective action If the error cannot be eliminated by switching the system on and off all display values and the set up condition should be noted down and the information sent to Kr ger for checking CODE NO 3004 CALL CUSTOMER SERVICE Description of error s Error of division Cause s The system has attempted to divide by zero Corrective action If the error cannot be eliminated by sw
34. ering iron and needle nose pliers to remove the three 3 wires from the angle potentiometer WARNING Before removing wires make a diagram of there location With box end wrench loosen the nut and remove the pendulum from the angle potentiometer Remove the three new angle potentiometer clamps and install the new angle potentiometer Use the soldering iron to connect the wires to the angle potentiometer using the diagram made in step 4 Supply power to the Load Moment System Adjust stem of the potentiometer to indicate 0 degrees then put pendulum on and tighten nut using 8mm wrench gt 4 E m 0 After putting pendulum on recheck for 0 degree indication if panel agrees tighten all nuts and screws 1 If the angle displayed on the panel does NOT AGREE with the actual angle shown on the angle protractor proceed as follows 12 Loosen but DO NOT remove the three 3 screws holding the angle potentiometer clamps SLOWLY rotate the Potentiometer until the angle indication on the panel is the same as the actual angle 0 degrees with boom level 13 Tighten the 3 screws that hold the angle potentiometer clamps 14 Boom up to the maximum angle possible Be sure to verify the actual boom angle using the Magnetic base angle protractor or digital level 15 If the angle displayed on the panel AGREES with the actual angle shown on the angle protractor or digital level go to step 15 16 If the Angle displayed on the panel DOES NOT agree with the actual
35. for the transducers and console are going out via the terminal strip SkyAz l Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 3 3 0 BASIC ADJUSTMENT OF THE HARDWARE 3 1 Length Ensure that the length cable tension is correct with fully retracted boom by turning the cable reel 2 to 3 turns counterclockwise and check that reel fully retracts Then remove cover form cable reel and adjust arm mounted on the potentiometer till length indication is correct 3 2 Angle Set the boom to 0 degrees and set a digital level on the boom Adjust the angle sensor to the same angle as the boom Check the angle at 20 degrees 45 degrees 70 degrees Angle display should be less than 5 degrees of the value of the inclinometer 3 3 Pressure Channel Rest the boom and disconnect the pressure transducers Measure the voltage of both pressure transducers on the terminal board The output voltage of the pressure transducers should be 2 500vdc 025vdc 3 4 Check the function of the hoist limit switch anti two block 3 5 Check function of lever lockout 3 6 Measure and record the power supply voltages SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 4 SECTION 1 DEFINITIONS 1 BOOM LENGTH The straight line thru the centerline of boom pivot pin to the centerline of the boom point load hoist sheave pin measured along the longitudinal axis of the boom I
36. gram Corrective action Correct and or replace the Data Eprom or replace the control program 301 371 6126 Service Manual PAT E Mark 4K 37 CODE NO 1084 CALL CUSTOMER SERVICE This error message is currently deactivated CODE NO 1085 CALL CUSTOMER SERVICE CODE NO 1086 CALL CUSTOMER SERVICE Description of error s The instruction received from the display unit is invalid Cause s The control programs in the junction box and display are not compatible Corrective action Check versions of the control programs for compatibility and replace one or both CODE NO 1087 CALL CUSTOMER SERVICE Description of error s An invalid option has been programmed Cause s An option has been programmed in the Data Eprom 1 that is unknown to the control program Corrective action Check and correct the Data Eprom 1 if possible or check the version of the control program and possibly replace SkyAz l Equipment Solutions www skyazul com Description of error s Invalid type of deflection has been programmed Cause s A type of deflection has been programmed in the Data Eprom 2 that is unknown to the control program Corrective action Check and possibly correct the Data Eprom 2 or check version of the control program and replace if necessary 301 371 6126 Service Manual PAT SR CEE Mark 4K 38 CODE NO 1088 CALL CUSTOMER SERVICE CODE N
37. here is a problem with supply voltage from the crane Remove wires from terminals X1 11 1 20 and check for short circuit to ground Replace fuse with 2 amp fuse only If system returns to normal operation the crane is ready to be put back in service Replace or send electronic Check for short at each of the wires removed when the short is found trace out short using wiring diagram Refer to Drawing Wiring Diagram in Appendix After short has been removed replace fuse with 2 amp fuse only CPU board for repair NEXT PAGE SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 21 PREVIOUS PAGE Display working Then check output voltage to console using a voltmeter put positive lead at terminal X1 33 and ground at terminal X1 2 If system returns to normal operation the crane is ready to be put back in service M Voltage Ll Replace console Replace or repair Electronic box CPU SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E EF Mark 4K 22 5 ANTI TWO BLOCK PROBLEM PROBLEM Function of the Anti Two Block System is faulty START Check to see whether the crane is in Anti Two Block condition Two Blocked es Check if jumper or dummy plug if two winch crane in receptacle at boom Lower hook down into nose is plugged in safe position Remove jumper dummy plug and check th
38. ing rope any further Check supply lead for the switch Check input of switch with the help of the Service Mode The Service Mode is activated by pressing the GREEN RED and PROGRAM keys simultaneously MINIMUM CABLE ON LOAD HOIST DRUM CHECK REAR DRUM Description of error s End of hoisting rope on the auxiliary winch almost reached Cause s Hoisting rope on auxiliary winch reeled off too far Supply lead for monitoring switch is defective Corrective action Do not reel off the auxiliary winch hoisting rope any further Check supply lead for switch Check input of switch with the help of the Service Mode The Service Mode is activated by pressing the GREEN RED and PROGRAM keys simultaneously 301 371 6126 Service Manual PAT E Mark 4K 34 System Errors CODE NO 1040 CALL CUSTOMER SERVICE CODE NO 1042 CALL CUSTOMER SERVICE Description of error s Error of division Cause s The system has attempted to divide by zero Corrective action If the error cannot be eliminated by switching the system on and off all display values and the set up condition should be noted down and this information forwarded to Kr ger for checking because an error must have occurred either in the control program or in the Data Eproms CODE NO 1041 CALL CUSTOMER SERVICE Description of error s Invalid interrupt vector Cause s The system has attempted to execute an interrupt that is
39. ips where power and various components are connected with fast ons to the terminal strip The main board is the heart of the system It contains the main computer and the necessary electronics to receive evaluate process and direct the continuous data There are overload and anti two block relays which control the bosch relay for lever lockout also mounted on this board A 24 12 volt converter for 24 volt cranes which converts 24 volts to 12 volts on the main board An analogue input part which receives and prepares all the signals from the transducers for further processing An analoque digital converter part which converts all the processed analogue signals into digital ones A digital part which contains the main computer and the ancillary electronics 2 3 Incoming Signals The signals from the transducers are connected to the terminal board The signals of the angle length transducer are connected to terminal 56 angle The signal on terminal 56 ANGLE is between approximately 1 000V and 4 500V The signals from the load pin are connected to terminal 51 DMS The signals on terminals 51 range between 2 500V and 7 500V 2 4 Outgoing Signal The outgoing signal of the terminal board is the signal for lever lockout of Terminal 87 on the Bosch relay In normal working conditions there are 12 or 24 volts at this terminal When there is an overload or anti two block condition the signal becomes 0 volts Furthermore all voltages
40. itching the system on and off all display values and the set up condition should be noted down and the information sent to Kr ger for checking because an error must have occurred either in the control program or in the Data Eproms 301 371 6126 Service Manual PAT E Mark 4K 57 CODE NO 3005 CODE NO 3007 CALL CUSTOMER SERVICE CALL CUSTOMER SERVICE Description of error s Description of error s The junction box has requested a display image which is The received present text is too long unknown to the display program Cause s Cause s A present text programmed in the Data Eprom 1 The control programs in the junction box and the display are of the junction box is too long not compatible Corrective action Corrective action Correct the Data Eprom 1 in the junction box Check versions of the control programs for compatibility and replace one or both CODE NO 3006 CODE NO 3008 CALL CUSTOMER SERVICE CALL CUSTOMER SERVICE Description of error s This error message is currently deactivated The received set up condition text is too long Cause s A set up condition text programmed in the Data Eprom 1 of the junction box is too long Corrective action Correct the Data Eprom 1 in the junction box SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 58 CODE NO 3009 CALL CUSTOMER SERVICE Description of error s Junction box
41. kyazul com 301 371 6126 Service Manual PAT VSE Mark 4K 36 Errors on over ranging CODE NO 1080 CALL CUSTOMER SERVICE Description of error s Invalid sequence of the main loop Cause s Error in the control program Corrective action If the error cannot be eliminated by switching the system on and off all display values and the set up condition should be noted down and this information forwarded to Kr ger for checking CODE NO 1081 CALL CUSTOMER SERVICE CODE NO 1082 CALL CUSTOMER SERVICE Description of error s Invalid type has been programmed for an analog input Cause s An analog input has been programmed in the Data Eprom that is unknown to the control program Corrective action Correct and or replace the Data Eprom or replace the control program CODE NO 1083 CALL CUSTOMER SERVICE Description of error s Error image not available Cause s An error has been initiated that cannot be displayed because the appropriate error image has not been programmed Possibly an incorrect text version has been programmed in the Data Eprom Corrective action All conditions that have led to this error should be noted down and this information SkyAz l Equipment Solutions www skyazul com Description of error s Invalid type has been programmed for an analog input Cause s An analog input has been programmed in the Data Eprom that is unknown to the control pro
42. ly onto the drum Set preload on cable reel by turning the drum counter clockwise 5 to 8 turns Wrap the new length cable around the boom tip anchor pin 4 or 5 wraps and secure with tie wraps Leave enough length cable to connect into the boom tip junction box Connect the length cable into the boom tip junction box Refer to Drawing 1 in Section 11 Drawings Reset length potentiometer in length angle transducer screw is located in center of white gear with boom fully retracted turn potentiometer carefully counter clockwise until it stops Recheck length and angle display Refer to Drawing 6 in Section 11 Drawing SkyAzul Equipment Solutions www skyazul com 301 371 6126 SkyAz l Inc 200 W Main Street Suite 2A dr Middletown MD 21769 Phone 301 371 6126 EQUIPMENT SOLUTIONS Fax 301 371 0029 www skyazul com info skyazul com
43. n CHECKSUM CODE NO 1141 CALL CUSTOMER SERVICE CODE NO 1142 CALL CUSTOMER SERVICE Description of error s The Data Eprom 2 has been changed Cause s The Data Eprom 2 has been changed since the system was last switched off Corrective action The new Data Eprom can be legalized with the DSD function CHECKSUM CODE NO 1143 CALL CUSTOMER SERVICE Description of error s The Data Eprom 1 has been changed Cause s The Data Eprom 1 has been changed since the system was last switched off Corrective action The new Data Eprom can be legalized with the DSD function CHECKSUM SkyAz l Equipment Solutions www skyazul com Description of error s The current set up condition is blocked Cause s An attempt has been made to block the active set up condition with the DSD Corrective action It is not possible to block an active set up condition so a new set up condition must be selected first in order to block the old one 301 371 6126 Service Manual PAT E Mark 4K 49 CODE NO 1144 CALL CUSTOMER SERVICE Description of error s Data record of the data recorder not available Cause s Loss of data in the RAM Corrective action Reset the data recorder Communication errors CODE NO 2000 2007 CALL CUSTOMER SERVICE CODE NO 2010 2017 CALL CUSTOMER SERVICE Description of error s An error has occurred during
44. n replaced and adjusted The machine can be put back into service SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 63 SECTION 6 LENGTH TRANSDUCER REPLACEMENT AND ADJUSTMENT Length Transducer Replacement Tools required 1 5mm Allen wrench 13mm Open end wrench Medium flat blade screwdriver Needle nose pliers Digital Volt Ohm meter Procedure 1 Locate machine in an area that will allow you to safely extend the boom to it s full extension Powered sections plus manual section 2 Fully retract the boom and lower to an angle that will provide you with access to the cable reel mounted on the boom base section Turn off power to the Load Moment System Remove cable reel cover Store the 4 screws washers and clamps in a safe place 9 Rotate the arm attached to the length potentiometer until the setscrevv is accessible Loosen but DO NOT remove the setscrevv Rotate the arm until the second setscrew is accessible Loosen but DO NOT remove the setscrew Remove the arm from the Length potentiometer and store in a safe location Remove the nylon gear from the length potentiometer shaft Use the 13mm wrench to remove the length potentiometer from the mounting bracket a oo o 0 Use the soldering iron and needle nose pliers to remove the three 3 wires from the angle potentiometer WARNING Before removing wires make a diagram of there location 11 Install the new length potentiomete
45. ndicator 2 2 BOOM ANGLE The angle between the longitudinal centerline of the boom base section and the horizontal plane Indicator 65 to 90 boom angle 0 2 less than 65 boom angle 0 3 3 RADIUS OF LOAD The horizontal distance from a vertical projection of the crane s axis of rotation to the supporting surface before loading to the center of the vertical hoist line or tackle with rated load applied Indicator 10096 to 110 4 RATED LOAD The load value shown on the applicable load ratings chart of the crane for the particular crane configuration boom length boom angle or functions or these variables For radii outside those shown on the load ratings chart the rated load is to be considered as zero 5 ACTUAL LOAD The weight of the load being lifted and all additional equipment such as blocks slings sensors etc Also referred to as working load Indicator 100 to 110 6 CRANE CONFIGURATION The physical arrangement of the crane as prepared for a particular operation in conformance with the manufacturer s operating instructions and load rating chart 7 TWO BLOCKING Contact of the lower load block or hook with the upper load block boom point or boom point machinery 8 ANALOGUE Electrical signals that vary in proportion to the quantities they represent Boom length angle and pressure transducer 9 DIGITAL Electrical signals of an on and off state two different voltage levels to represe
46. not valid Corrective action If the error cannot be eliminated by switching the system on and off the system should be returned to Kr ger for checking because an error must have occurred either in the control program or in the hardware SkyAz l Equipment Solutions Description of error s Incorrect CHECKSUM of the control program Cause s Loss of data in the Eprom of the control program or invalid modification of the control program Corrective action Install new Eprom with valid control program CODE NO 1043 CALL CUSTOMER SERVICE Description of error s No real time clock Cause s A control program requiring a real time clock has been fitted on a pc board without a real time clock or the real time clock is defective Corrective action Check the version of the control program and the equipment status on the pc board If the control program version is in order and a real time clock U5 is fitted it will be necessary to replace the junction box pc board www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 35 CODE NO 1044 CODE NO 1046 CALL CUSTOMER SERVICE CALL CUSTOMER SERVICE This error message is currently deactivated This error message is currently deactivated CODE NO 1045 CALL CUSTOMER SERVICE CODE NO 1047 CALL CUSTOMER SERVICE This error message is currently deactivated This error message is currently deactivated SkyAzul Equipment Solutions www s
47. nsducer slip ring disc and slip ring pick up to feed and return A 2 B signal The PE cable goes through the drum and out to the tip where it is wired to the Anti Two Block switch The reel is driven by a tensioned spring and should be handled with caution 1 3 The Length Angle Transducer The length angle sensor LWG is a combination of two transducers in cable reel fitted at the base section of the boom It measures the length and the angle of the boom A reeling drum drives a potentiometer which is the length transducer Part of the length transducer is the length cable on the drum which is a two conductor cable shield and core It is connected to the anti two block switch at the boom head and to a slip ring body in the LWG The angle transducer is fitted in the cable reel A pendulum drives the axle of the angle potentiometer The power supply voltage for both is 5 00V The output signal for the length transducer is 1 000V up to t4 500V The output signal for the angle transducer is 1 000V up to 4 500V 1 4 Anti Two Block Switch The anti two block switch monitors the load block and it s relationship with the head of the boom n working condition the switch is closed When the hook block strikes the weight the circuit opens disengaging a relay output to the lock out solenoid valves where applicable The weight at the anti two block switch keeps the switch closed until the hook block strikes it 1 5 Console The console displays
48. nt some quantity of operation A2B area definition switch SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT SR CEE Mark 4K SECTION 2 DRAWINGS INDICATOR PANEL MARK 4K 1 0112197 00 Spare Parts List DRAWING 1 Rum de wmd 1 ITEM NUMBER 1 a N Supplies DESCRIPTION Housing Module LC Display P C Board Electronic Beeper Mount Connecting Cable SkyAz l Equipment Solutions E BERRE SSE DO COGI FL QUANTITY ARTICLE NUMBER 1 0113148 00 1 0112196 00 1 0010752 00 1 0112135 00 1 0112176 00 1 0112843 00 AS PS a www skyazul com 301 371 6126 Service Manual PAT E Mark 4K DRAWING 2 CENTRAL PROCESSOR 24VDC MARK 4K 1 0112757 00 Spare Parts List ITEM NUMBER DESCRIPTION QUANTITY ARTICLE NUMBER 1 Housing 1 1 0103719 00 2 P C Board Central Processor 1 1 0112111 00 3 Module DC DC Converter 1 1 0028174 00 4 Key Switch 1 1 0103247 00 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K DRAWING 3 4 1 i 7 P ITEM NUMBER 1 NI O O A U N 11 12 13 SkyAz l Equipment Solutions Cable Reel 34 50 m 10 17 DESCRIPTION Cover Complete
49. ogrammed in Data Eprom 2 Corrective action Correct the Deflection Table in Data Eprom 2 SkyAz l Equipment Solutions www skyazul com Description of error s Pointer to the routine of an external option has not been found Cause s The entry with the pointer of the routine of a programmed external option is missing from the Extension Table in the Data Eprom 2 Corrective action Add the necessary entry to the Extension Table 301 371 6126 Service Manual PAT E Mark 4K 46 CODE NO 1107 CALL CUSTOMER SERVICE CODE NO 1109 CALL CUSTOMER SERVICE Description of error s Pointer to an option specific data area not found in the Data Eprom 2 Cause s The entry for the pointer to the option specific data of a programmed option is missing from the Extension Table in the Data Eprom 2 Corrective action Add the necessary entry to the Extension Table and possibly add the missing data to the Data Eprom 2 CODE NO 1108 CALL CUSTOMER SERVICE Description of error s Pointer to an option specific data area not found in the Data Eprom 2 Cause s The entry for the pointer to the option specific data of a programmed option is missing from the Extension Table in the Data Eprom 2 Corrective action Add the necessary entry to the Extension Table and possibly add the missing data to the Data Eprom 2 SkyAz l Equipment Solutions www skyazul c
50. om Description of error s Invalid Length Correction programmed Cause s A type of Length Correction has been programmed in the Data Eprom 2 that is not available Amend the Extension Table to include the necessary entry and possibly the Data Eprom 2 to include the missing data CODE NO 110A CALL CUSTOMER SERVICE Description of error s Invalid Length Correction programmed Cause s A type of Length Correction has been programmed in the Data Eprom 2 that is not available Amend the Extension Table to include the necessary entry and possibly the Data Eprom 2 to include the missing data 301 371 6126 Service Manual PAT SR CEE Mark 4K 47 CODE NO 110B CODE NO 110C CALL CUSTOMER SERVICE CALL CUSTOMER SERVICE Description of error s Invalid memory size of the data recorder RAM This error message is currently deactivated Cause s The length programmed in Data Eprom 2 is invalid Corrective action Enter allowable size for the data recorder RAM in the Data Eprom 2 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 48 CODE NO 1140 CALL CUSTOMER SERVICE Description of error s Control program has been changed Cause s The Eprom with the control program has been changed since the last time the system was switched off Corrective action The new control program can be legalized with the DSD functio
51. ompleted you should have 12 vdc on terminal X1 71 If you have the correct voltages the Electronic Box P C Board is defective Send to PAT America Inc for repair or replace SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT R EF Mark 4K 25 6 LENGTH READING PROBLEM PROBLEM Length reading is incorrect Crane Is not out of load chart condition START Check mechanical adjustment of the length Potentiometer with boom fully retracted Indication should match load chart v cem E If indication is off by approximately 3 ft If indication is correct at short boom 1m add or remove 1 rap from cable and has bad indication the problem reel If this does not repair problem refer my be a defective length to Length Adjustment Procedure potentiometer Refer to Section section SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 26 7 ANGLE READING PROBLEM PROBLEM Angle reading incorrect Crane is not out of load chart condition START Check mechanical adjustment of the angle Potentiometer with boom at 0 degrees Indication should match load chart da REN If indication is off check the If indication is correct at 0 degrees and has mechanical adjustment of the angle bad indication the problem my be defective bracket Refer to Section 7 length potentiometer Refer to Section 7 SkyAzul Equipment Solutions www skyazul com 301 371
52. on of error s Crane outriggers not properly set Cause s Not all outriggers have been correctly extended or outriggers are not set The switch supply lead is defective The switch input is defective Corrective action Extend or lower outriggers correctly Check supply lead form the switch Check the switch input with the help of the Service Mode SkyAz l Equipment Solutions www skyazul com COUNTER WEIGHT CONTROL CORRECT ABOVE CONDITION Description of error s The counterweight currently being used in not correct Cause s Wrong counter weight mounted The set up condition is expecting a different counter weight The supply lead for the monitoring switch is defective The switch input i9s defective Corrective action Mount the correct counter weight Set the set up condition that is correct for the counter weight Check the supply lead for the switch MAXIMUM CAPACITY EXCEEDED REDUCE LOADMOMENT D Description of error s The current load is greater than the maximum permissible load Cause s The current load is too heavy The radius is too long Corrective action Reduce weight of the current load Reduce radius enlarge angle or reduce length 301 371 6126 Service Manual PAT SR CEE Mark 4K 30 NON WORKING AREA SWING INTO LOADCHART AREA Description of error s The crane has been swung into a working range that is unacceptable for this set up condition
53. ondition Check the supply lead for the switch Check the switch input with the help of the Service Mode The Service Mode is activated by pressing the GREEN RED and PROGRAM keys simultaneously AXLE BLOCKING FRONT CORRECT ABOVE CONDITION Description of error s Front axle blocking unit not activated Cause s The front axle has not been blocked Wrong set up condition set Supply lead for the monitoring switch is defective Switch input is defective Corrective action Block the front axle Check the set up condition Check supply lead for switch Check switch input with the help of the Service Mode The Service Mode is activated by pressing the GREEN RED and PROGRAM keys simultaneously 301 371 6126 Service Manual PAT E Mark 4K 31 BOOM ANGLE BELOW EQUAL MIN PRESET VALUE Description of error s The current main boom angle is smaller than or equal to the pre set minimum value This is a warning only no shut off Corrective action Enlarge main boom angle BOOM ANGLE ABOVE OR EGUAL MAX PRESET VALUE Description of error s The current main boom angle is greater than or equal to the pre set maximum value This is a warning only no shut off Corrective action Reduce the angle of the main boom SkyAz l Eguipment Solutions www skyazul com RADIUS BELOW OR EGUAL MIN PRESENT VALUE Description of error s The current radius is greater than or equal to th
54. r in the mounting bracket Tighten using 13 mm wrench 12 Install the large nylon gear on the potentiometer shaft Be sure that the brass spacer is facing toward the boom 13 Install the lever arm on the potentiometer shaft and tighten both setscrews 14 Use the soldering iron to connect the wires to the angle potentiometer using the diagram made in step 4 15 Set VOLT OHM meter to read OHMS Place one probe on terminal 1 of the terminal strip and the other probe on terminal 2 Turn the lever arm until the meter indicates approximately 95 OHMS Remove the meter from the circuit 16 Supply power to the Load Moment System 17 Follow system start up procedure to put the display panel in the normal operating mode 18 With all boom sections FULLY RETRACTED rotate lever arm on the length potentiometeruntil the length displayed on the panel indicates the shortest boom length shown on the crane capacity chart 19 FULLY EXTEND boom sections Panel should display the maximum extended boom length of the load chart 20 If the length displayed on the panel AGREES the machine can be put back in service 21 If the length displayed DOES NOT AGREE go to LENGTH TRANSDUCER ADJUSTMENT SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 64 Length Transducer Adjustment Tools required Medium screw driver Procedure 1 2 10 11 12 13 Locate machine in an area that will allow you to
55. rammed in the ADC MIMA TABLE in Data Eprom 1 Corrective action Check the cable connection of the angle sensor for the main boom SHORT CIRCUIT DMS SENSOR MAIN BOOM Description of error s Cable short circuit at the analog input of the strain gauge DMS for the main boom Cause s The analog input which was programmed in the Data Eprom 1 in the ADC CR TAB for the angle sensor of the strain gauge DMS for the main boom has a short circuit or the voltage has dropped below the value programmed in the ADC MIMA TABLE in Data Eprom 1 Corrective action Check the cable connection of the strain gauge DMS for the main boom 301 371 6126 Service Manual PAT E Mark 4K 55 OPEN CIRCUIT DMS SENSOR MAIN BOOM Description of error s Cable break at the analog input of the strain gauge DMS for the main boom Cause s The analog input which was programmed in the Data Eprom 1 in the ADC CR TAB for the strain gauge DMS of the main boom has a break analog input open or the voltage has exceeded the value programmed in the ADC MIMA TABLE in Data Eprom q Corrective action Check the cable connection of the strain gauge DMS for the main boom SkyAz l Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 56 Error messages display unit CODE NO 3000 CALL CUSTOMER SERVICE Description of error s Invalid sequ
56. re options or the current version of the control program must be revised 301 371 6126 Service Manual PAT E Mark 4K 39 CODE NO 108C CODE NO 108D CALL CUSTOMER SERVICE CALL CUSTOMER SERVICE Description of error s Description of error s Absence of an external table with error texts Absence of external error texts Cause s Cause s An option has been programmed in the Data Eprom 1 An option has been programmed in the Data Eprom 1 that requires external error texts and an external table that requires external error texts One of these texts Such a table has not been found has not been found Corrective action Corrective action Correct the Data Eprom 1 Correct the Data Eprom 1 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 40 Programming errors Data Eprom 1 CODE NO 0003 CALL CUSTOMER SERVICE Description of error s Identification of the Max Load Chart is not valid Cause s A max Load Chart has been programmed in the Data Eprom 1 for the current set up condition that is unknown to the current control program Corrective action Correct the Data Eprom 1 or change the control program CODE NO 000E CALL CUSTOMER SERVICE CODE NO 10C0 CALL CUSTOMER SERVICE Description of error s Invalid Eprom identification in Data Eprom 1 Cause s An incorrect Data Eprom has been insert
57. rogram has attempted to activate more timers than are listed If the error fault cannot be remedied by switching the system on and off all display values and the set up condition should be noted down and the information sent to Kru ger for checking since an error has occurred either in the control program or in the Data Eproms 301 371 6126 Service Manual PAT E Mark 4K 61 SECTION 5 ANGLE TRANSDUCER REPLACEMENT AND ADJUSTMENT This section will provide the user with step by step procedures to replace the Angle Transducers and to perform the necessary adjustments on these components Please read through the replacement and or adjustment procedures before you attempt to replace a component or make an adjustment If a component replacement is necessary order the component from PAT America Inc before removing the component Include crane model and serial number when ordering to allow PAT America technician s to test the potentiometer to ensure operation over the voltage range of the original system installation Angle Transducer Replacement Tools required Soldering Iron 8mm Box wrench Needle nose pliers Digital Level or Magnetic base angle protractor Small flat blade screwdriver Procedure 1 Lower the boom to an 0 degree angle to access the transducer mounted on the boom base section 2 Turn off power to the Load Moment System 3 Remove cable reel cover Store the 4 screws washers and clamps in a safe place 4 Use the sold
58. safely extend the boom to it s full extension Fully retract the boom and lower to an angle that will provide you with access to the cable reel mounted on the boom base section Open reel and adjust length voltage to 1 000 vdc measuring from terminal 1 to terminal 22 on the terminal strip in the cable reel Push the DOWN ANGLE LENGTH 7 or UP TARE 9 button until NORM menu title is blinking then push the PROGRAM BUZZER 8 button Push the DOWN ANGLE LENGTH 7 or UP TARE 9 button until LENGTH menu title is blinking then push the PROGRAM BUZZER 8 button Verify boom is at fully retracted Push the DOWN ANGLE LENGTH 7 or UP TARE 9 button until MINIMUM menu title is blinking then push the PROGRAM BUZZER 8 button Push the PROGRAM BUZZER 8 button until all digits have been verified with the proper value which will be minimum boom length of the load chart Telescope the boom all the way out Push the DOWN ANGLE LENGTH 7 or UP TARE 9 button until MAXIMUM menu title is blinking then push the PROGRAM BUZZER 8 button Push the PROGRAM BUZZER 8 button until all digits have been verified with the proper value which will be maximum boom length of the load chart Push the DOWN ANGLE LENGTH 7 or UP TARE 9 button until ADJUST menu title is blinking then push the PROGRAM BUZZER 8 button Push the DOWN ANGLE LENGTH 7 or UP TARE 9 button until EXIT menu title is blinking then push the PROGRAM BUZZER 8
59. transmission of data to the display Corrective action Check cable connection to the display unit SkyAz l Equipment Solutions www skyazul com Description of error s Fault in the shut off circuit Cause s Fault on the junction box pc board Corrective action Replace junction box board 301 371 6126 Service Manual PAT E Mark 4K 50 Hardware faults CODE NO F000 CALL CUSTOMER SERVICE CODE NO F001 CALL CUSTOMER SERVICE Description of error s 12 V DC voltage fault Cause s The 12 V DC supply voltage has dropped below 12 V DC 20 Corrective action On 12 V DC systems check the input voltage with a multimeter If the voltage is higher than 12 V DC 20 the voltage waveshape can still be checked with an oscilloscope for voltage dips On 24 V DC systems check the input voltage with a multimeter If the voltage is higher than 24 V DC 20 check the 12 V DC with a multimeter at terminal 11 20 If this voltage is less than 12 V DC all loads connected to 12 V DC must be checked for short circuits CODE NO F002 CALL CUSTOMER SERVICE Description of error s 12 V DC voltage fault Cause s The 12 V DC supply voltage has dropped below 12 V DC 20 Corrective action On 12 V DC systems check the input voltage with a multimeter If the voltage is higher than 12 V DC 20 the voltage waveshape can still be checked with an oscilloscope for voltage dips On 24 V DC systems
60. vice Manual PAT E Mark 4K 14 DRAWING 10 Wiring Diagram Basic w parts A 62 4 i 08 54 300 ibs 4 30 28 410 68 a 4 00 35 75 5 700 155 UNIT MARK 4K CENTRA used Allachment Dummy Plug for U sm 3d X 6 pin receptacle Z 2 conductor cable 7 oist Limit Switch A 2 B 1 5 2 3 N Cy N N m 2 H E l Si algo pepleug are Joonpueg PRESSURE TRANSDUCER n s Es E I Ja 2 ES t 5 ir o o Nome Znderung 3OUON 1LNOHLIM 39NvH2 OL 193rans SkyAz l Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT E Mark 4K 15 DRAWING 11 Wiring Diagram Central Unit Connections
61. wo Block DRAWING 7 Pressure Transducer DRAWING 8 Pressure Transducer Cable DRAWING 9 Jumper cable DRAWING 10 Basic Drawing DRAWING 11 Basic Parts Diagram DRAWING 12 Central Unit Wiring Diagram DRAWING 13 Component wiring Diagram SECTION 3 Troubleshooting Flow Charts 1 General Flowchart 2 Lever Lockout Activated 3 Load Reading Problem 4 Blank Display 5 Anti Two Block Problem 6 Length Reading Problem 7 Angle Reading Problem SECTION 4 Operation Error Code Table SECTION 5 Angle Transducer Replacement and Adjustments SECTION 6 Length transducer Replacement and Adjustments SECTION 7 Length transducer Replacement and Adjustments SkyAz l Equipment Solutions www skyazul com gt ON O O Q U O GO O M M M M N M M AS c c c c N oO G DON NN O CO O NI O U O UV N O 301 371 6126 Service Manual PAT IKFSSSEIS Mark A 1 1 0 MECHANICAL DESCRIPTION OF THE COMPONENTS 1 1 Pressure Transducer The pressure transducer transforms hydraulic pressure into an electric analogue voltage signal Two pressure transducers are connected one to the rod side and one to the piston side of the lift cylinder The pressure transducer is connected to the central unit with a four conductor double shielded cable The power supply voltage is 12V The output signal is 2 500V at 0 pressure to 7 500V at maximum pressure 250bar 1 2 Cable Reel The cable reel houses the length angle tra

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