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PRS 145 Service Manual

1. 3 4 5 21 8 13 9 ITEM DESCRIPTION QTY PART NUMBER 1 Cover Complete 1 1 0016897 00 Cover 1 1 0010159 00 Rubber Seal 1 1 0010631 00 2 Cable Reel Body 1 1 0010653 00 3 Angle Clamp 4 1 0010613 00 4 Slotted Flat Head Screw M5 x 14 4 1 0012350 00 5 Nylon Washer M5 4 1 0010581 00 6 Shielded Cable 1x1 45M 1 0102079 00 7 1 1 0010615 00 8 Slip Ring Disk 1 1 0021448 00 9 Angle Bracket 1 1 0010175 00 10 Contact Holding Plate 1 1 0116041 00 11 Terminal Strip 1 1 0011684 00 12 Slotted Flat Head Screw M4 x 10 1 1 0010582 00 13 Angle Transducer Complete 1 1 0015264 00 Mount ing Plate 1 1 0010626 00 Pot 1 1 0012157 00 Pendulum 1 1 0010628 00 14 Gear Drive Complete 1 1 0021212 00 Pot 1 1 0013697 00 15 Mounting Bracket 1 1 0027856 00 16 Hex Head Cap screw M10 x 45 1 1 0012207 00 17 Lock Washer M10 1 1 0010096 00 18 Shrink Tubing Alpha 1 4 x 2 1 1 0009986 00 19 Thimble 1 1 0009988 00 20 Thimble Link 1 1 0009987 00 21 Screw 2 3 mm slotted flat head 1 1 0011819 00 22 Contact Socket 3 1 0110095 00 23 Contact Pin 3 1 0110094 00 SkyAzul Equipment Solutions www skyazul com 301 371 6126 12 Service Manual PRS145 5 8 CABLE REEL 24 30 M 1 0115463 00 Spare parts List 1615 14 6 2 9 oe abols af 3 4 5
2. eree 9 AV 13H HOSO8 Console RS422 CLK 9991 VOIHANY LVd Q 5 a 2 Qo E N 1064 Vd e S 2 We S I gt gt NOLLdIHOS3G Console RS422 DATA E Console Power 24 12V E Console GND D Console 12VDC le poe 62 8 gt gt 3 El i 8 El 8 3 2 8 3 8 3 5 3 5 5 El 5 8 5 2 8 5 El 3 8 3 8 A 8 5 5 E 3 El E 8 2 3 ze El El g 5 5 5 8 a 5 3 3 8 El 8 8 El 3 5 5 8 8 3 El 8 E gt 2 gt 3 2 3 8 5 8 5 El El e Shutoff Q Q 9 2 o o le RS422 RXD RS422 RXD TVH3Ni9 Z6VL LIM SIOSUIS 3nd3no SY By pass out foren Ei e RS422 TXD e RS422 TXD youms SSeq g 21 9 s2 ez Console Heating GND 09 64 VS 82 ZE 92 SE ve 9 23 o o D 0 e o a o e Heating 24 12V oDejoA 7 4 re 89149Q yo mo 267 1014 008 120 uojsid OL 8178 1 2105 00 To PRS 145 Sensors 00 3ivo siv
3. ITEM DESCRIPTION QTY PART NUMBER 1 Cover Complete 1 1 0107886 00 2 Cable Reel Body 1 1 0107885 00 3 Angle Clamp 4 1 0010613 00 4 Slotted Flat Head Screw M5 x 14 4 1 0012350 00 5 Nylon Washer M5 4 1 0010581 00 6 Shielded Cable 1x1 30M 1 0102079 00 7 Receiver 1 1 0010615 00 8 Slip Ring Disk 1 1 0021448 00 9 Angle Bracket 1 1 0010175 00 10 Contact Holding Plate 1 1 0116041 00 11 Terminal Strip 1 1 0011684 00 12 Slotted Flat Head Screw M4 x 10 1 1 0010582 00 13 Angle Transducer Complete 1 1 0015264 00 Mounting Plate 1 1 0010626 00 Pot 1 1 0012157 00 Pendulum 1 1 0010628 00 14 Gear Drive Complete 1 1 0021212 00 Pot 1 1 0013697 00 15 Mounting Bracket 1 1 0027856 00 16 Hex Head Cap screw M10 x 45 1 1 0012207 00 17 Lock Washer M10 1 1 0010096 00 18 Shrink Tubing Alpha 1 4 x 2 1 1 0009986 00 19 Thimble 1 1 0009988 00 20 Thimble Link 1 1 0009987 00 21 Screw 2 3 mm slotted flat head 1 1 0011819 00 22 Contact Socket 3 1 0110095 00 23 Contact Pin 3 1 0110094 00 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Drawings 13 5 8 4 Length Sensor Assembly Part Number 1 0107887 00 Length Potentiometer SkyAzul Equipment Solutions www skyazul com 301 371 6126 14 Service Manual PRS145 5 8 2 Angle Sensor Assembly Part Number 1 0015601 00 5 9 ANTI TWO BLOCK ELECTRICAL DIAGRAM To Cable Reel Inner Core Outer Shield 6 Pin Boom
4. 2 3 BASIC ADJUSTMENT OF THE HARDWARE nnne 3 4 ne 4 5 DRAWINGS Aa 5 5 1 WIRING DIAGRAM CENTRAL UNIT SHUT OFF 5 5 2 CENTRAL PROCESSOR 12 24 VDO 6 5 3 ELECTRICAL DIAGRAM CONSOLE satan 7 5 4 INDICATOR PANEL CONSOLE ene enne nnnnh nh en nnn nnns sena nsns nnne nsns s sse sn sese rsen serene ns 8 5 5 ELECTRICAL DIAGRAM CABLE REEL TO CENTRAL UNI 9 5 6 ELECTRICAL DIAGRAM CABLE REEL TO CENTRAL UNIT 10 5 7 c 11 5 8 EC 12 5 8 1 Length Sensor Assembly akt ii 13 5 8 2 Angle Sensor ia 14 5 9 ANTI TwO BLOCK ELECTRICAL DIAGRAM 14 5 10 ANTI TWO BLOCK SWITCH c cccssssesscsssserscnenssrensouserenseucerenseusurencuserseneusavestanautensuueasenensousenenes 15 5 11 ELECTRICAL DIAGRAM PRESSURE TRANSDUCER TO CENTRAL 16 5 12 PRESSURE TRANSDUCER 250 1 0108060 00 coincida 17 5 13 PRESSURE TRANSDUCER CABLE ASSEMBLY 17 5 14 JUMPER CABLE ASSEMBLY FOR ESTENSION 18 PROCECOORES ts ss 19 6 1 ANGLE SENSOR ADJUSTMENT Tonic cc 19 6 2 EPROM REPLACEMENT IN CENTRAL UNI 20 6 3 PISTON amp ROD
5. RS422 DATA x 2 Switch Signal 2 Console Power 24 12 A2B Switch 12VDC BRISAS ez ez zz 9z sz vz ez 5 C Reel A2B in e GND RED BLU Console le 12VDC pue eu etj pue Bui 5 5 o o o o 2 BYPASS WHT Cons s siu 1 vd JO uesuoo eu A 2 B BYPASS To GND e Shutoff 3 o o le RS422 e RS422 RXD Not used TvH3Ni9 k Not used By pass out By pass out SI9NVY3 IOL r un RS422 5422 U91IMS SSed Ag 2 82 22 9 ez es Console Heating GND VS 6 ve o o o 3 3 3 5 Q 3 o Heating 24 12V eue1 7 rr queuoduuo5 1 euer yo mo XXX L0L 00 L 0 1 LSY 5 802 DMT M uojsid psueJJ d OL 8J0SUO9 133HS 30 133 8 To PRS 145 Sensors o0z 6z 60 ava _ ava PRS 145 Display Console 118418 5 ST Piston Pressure 11 KST Rod Pressure Transducer 250bar Transducer 250bar Sage eg 1 Rollerswitch S3 031 006 100 043 egy N 2 a o lt a
6. y CR EQUIPMENT SOLUTIONS PRS145 SERVICE MANUAL SkyAzul 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 SkyAz l 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 SkyAzul The drawings and or photos are subject to technical modification without prior notice All information in this document is subject to change without notice 7 SkyAzul Inc anl 200 W Main Street Suite 2A Middletown MD 21769 EQUIPMENT OLUTIONS Fax 301 371 0029 A info skyazul com SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PRS145 TABLE OF CONTENTS 1 MECHANICAL DESCRIPTION OF THE 1 2 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UNIT
7. 3358 N 3 E 2 c m 1 65422 CLK gt 55422 CLK 5188422 DATA 5422 DATA RS 422 LOAD BUTTON UP TARE BUTTON ANG LENG S BUTTON A2B BY PAS not used not used a e i Rollerswitch 51 031 006 100 043 12 2 5 213 14151517 zi xj 243 gt aja m Q gt 1 GND GND 12 VDC in Enclosure 12 VDC 2 5 V 7 5V Enclosure 12 VDC 12 VDC in 12 VDC in GRA PNK RED BLU optional BLK front rubber chart Rollerswitch 52 031 006 100 043 def arc chart on outriggers A le assembly 031 300 100 144 031 300 100 144 031 300 100 144 031 300 100 144 031 300 100 144 e 2 i o o 12 o E 006 100 043 Color code reference table LEGEND RI BROWN LK BLACK H WHITE GRAY GREEN BLUE 031 optional w z O w PH optional O r 20 2 12 VDC in 12 VDC in Rollerswitch 54 031 006 100 043 ole Ole U A N PINK R ORANGE EL YELLOW IO VIOLET Notes HD SHIELD ____ i gt gt Shield connected to strain relief insert 1 PAT AMERICA Inc SHIELD 1665 ORCHARD DRIVE Es SE CHAMBERSBURG PA 17201 SHIELDED 08 r Rollerswitch 55 eer eee lt lt Cha o PAT America Inc reserves propri ts to this dra
8. 21 22 23 24 25 26 27 28 20 30 31 32 33 34 35 36 37 38 39 40 153 154 55 56 57 58 59 60 61 62 53 64 65 66 67 68 70 71172 73 74 75 76 77 78 79 80 www skyazul com 301 371 6126 SkyAzul Equipment Solutions Drawings 17 5 12 PRESSURE TRANSDUCER 250 BAR 1 0108060 00 5 13 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 90 Connector 1 0101758 00 SkyAzul Equipment Solutions www skyazul com 301 371 6126 18 Service Manual 5145 5 14 JUMPER CABLE ASSEMBLY FOR EXTENSION 4 mo CABLE 2 X 08 DS PER FOOT 5 025 0 2 CONNECTOR ker INSERT B SOCKET 1090 301 025 061 CONNECTOR ACCY IMEERT 8 MALES 5 o l000 214 261 311 STRAIN RELIEF AGT 134 11 5 021 441 110 811 STRUM RELIEF WHT SkyAzul Equipment Solutions www skyazul com 301 371 6126 Procedures 19 6 PROCEDURES This section will provide the user with step by step procedures to adjust or replace different system components Please read through the replacement or adjustment procedures before you perform the task defined in the procedures to ensure you have positioned the crane boom and have the necessary spare parts an
9. Equipment Solutions www skyazul com 301 371 6126 Procedures 21 6 3 6 3 1 9 10 11 6 3 12 13 14 15 16 17 18 19 20 21 22 PISTON amp ROD PRESSURE CHANNEL ADJUSTMENT 1 Adjust pressure piston Turn power off to the system and wire simulator to the piston pressure channel blue to term 12 brown to term 45 green yellow to term 51 Put voltmeter ground on term 45 and positive to term 51 Go to Calibration menu pushing the up then P button while in the Program menu screen Push up or down button until NORM menu title is blinking then push P button Push up or down button until PRESSURE PIS menu title is blinking then push P button Adjust simulator to 2 500 Push up or down button until MINIMUM menu title is blinking then push P button Push P button until all digits have been verified with the proper value which will be 000 00 bar Adjust simulator to 7 500 Push up or down button until MAXIMUM menu title is blinking then push P button Push P button until all digits have been verified with the proper value which will be 250 00 bar Push up or down button until ADJUST menu title is blinking then push P button Push down button until EXIT menu title is blinking then push P button 2 Adjust pressure Rod Move positive lead of voltmeter to term 52 Push up or down button until PRESSURE ROD menu title is blinking then push P bu
10. GREEN BLUE RED N PINK R ORANGE EL YELLOW VIOLET Notes SHIELD CRE CREAM ____ gt Shield connected to strain relief insert INNER PAT AMERICA Inc PRS 145 4 20mA output sensors KIT 1492 amp E 1665 ORCHARD DRIVE P SINGLE ESE CHAMBERSBURG 1720 z TANT DOUBLE ECN J DESCRIPTION BY DATE DRAWN TE 09 28 2003 DS SHIELDED rove AAA REV PAT America Inc reserves proprietary rights to this drawing and to the data shown thereon The drawing and data are ECN confidential and are not to be used or reproduced without the written consent of PAT America Inc This drawing is subject to technical modification without prior notice C A G E 79760 optional optional cz eo lt gt Bia 12 VDC in 12 VDC in ee ee ere ey L Rollerswitch S4 031 006 100 043 Es m r Rollerswitch 55 031 006 100 043 lt lt DIA BCE gt 4 12VDC 1 4 20mA BLK 1 4 20mA 1 6 Pin Plug Extension A2B Switch 031 002 060 014 BOTTOM 6 Pin PES a 6 C 6 Main Boom only 1 Cable Reel ey ad 068 308 060 001 r L gt a a aa A2B Switch 031
11. 002 060 011 LEGEND BROWN BLACK HIH WHITE NOTES Lom mm mm mm al GRAY m SHIELD CONNECTED TO STRAIN RELIEF INSERT R L H To PRS 145 Central Uni r DADO 2 gt 44 YELLOW VIOLET SHIELD CREAM ___ 5 SHED PAT AMERICA Inc PRS 145 w 4 20mA output sensors KIT 1492 SINGLE 1665 ORCHARD DRIVE ECN T _DESCRIPTION_ BY JAPV DATE W8 09898063 PROVED et DS NOT NC CONNECTED AA AE SHEET 20f4 SHEET L LL DWG NO REV PAT America Inc reserves proprietary rights to this drawing and to the data shown thereon The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT America Inc This drawing is subject to technical modification without prior notice C A G E 79760 R od ora 7 MOTBA 19 N38 El El El 12 VDC 24 VDC GND Ref 3 8 VDC Ref 3 8 VDC Ref 1 0 VDC Ref 1 0 VDC RS232 TXD Rs232 RxD RS232 CTS RS232 DTR BRN Piston 12VDC BRN Rod 12VDC Analog Input 3 S 1 12VDC Analog Input 4 een sa 77 12VDC Analog Input 5 er 12VDC Analog Input 6 a 12 Analog Input 7 EY 12VDC Analog Input 8 AU eru iss 12VDC BLU Console RS422 LOAD as cc 12VDC RED Console 8 RS422 LOAD IL 12VDC
12. 2 500vdc 025vdc Check the function of the hoist limit switch anti two block Check function of lever lockout Measure and record the power supply voltages SkyAz l Equipment Solutions www skyazul com 301 371 6126 4 Service Manual 8145 4 DEFINITIONS 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 Indicator 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 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 100 to 110 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 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 CRANE CONFIGURATION The physical arrangement of the crane as prepared for a particular operation in conformance wit
13. BLU 2 51 Signal lo IRoler Switch 1 E VREF 5VDC ANALOG LU 2 S2 Signal B BRN 2 S3 Optional BRN 2 S4 Optional BRN 2 S5 Optional Roller Switch 5 GRA PNK Console B ANGLE LENGTH VIO Console El BLK Console YEL Cons GRA Cons Cons El A2B Switch Signal A2B Switch 12VDC BRN Cons A 2 B BYPASS A 2 B BYPASS Not used ION 131 5 5 asny BLK Piston Trans BLK Rod Trans 3 C reel GND By pass relay GND YANNI Wd 232 Q3193NNOO 319009 1 1 5 I3IHS LAO duelo c O IHM 18 Ll day CL 9 AVS 980 2 0 19j9J i lHASNI 4311148 NIVYLS OL 1 QTAIHS BLU Piston Signal BLU Rod Signal 2 C Reel Length elo ev ev 27 ov sv vv ev 27 19 Analog Input 1 Analog Input 2 Saul UO S Jeuondo Ge o uo 25 YIJMSI9 OY LINN SVL Sad 4 C Reel Angle 69 89 29 99 99 vs 6 L Roller Switch 2 VREF 5VDC ANALOG Roller Switch 3 VREF 5VDC ANALOG uomeoyipou letz Roller Switch 4 VREF 5VDC ANALOG VREF 5VDC ANALOG
14. OVDC GND Brown from indicator panel X1 33 Indicator panel 12VDC White from indicator panel X1 34 Indicator panel shut off Jumper to X1 41 X1 35 Indicator panel RxD X1 36 Indicator panel RxD X1 37 Indicator panel TxD X1 38 Indicator panel TxD X1 39 Indicator panel heating GND X1 40 Indicator panel heating 24 12VDC X1 41 50 GND 1 51 Analog input 1 Pressure transducer piston side X1 52 Analog input 2 Pressure transducer rod side 1 53 Analog input 3 length transducer X1 54 Analog input 4 X1 55 Analog input 5 X1 56 Analog input 6 angle transducer X1 57 Analog input 7 X1 58 Analog input 8 1 59 Interface RS422 Load Blue from indicator panel X1 60 Interface RS422 Load Red from indicator panel X1 61 Roller switch 1 Front rubber 1 62 Roller switch 2 Front Rear outrigger X1 63 Roller switch 3 1 64 Roller switch 4 X1 65 Roller switch 5 X1 66 Down button Grey pink from indicator panel X1 67 Prog button Violet from indicator panel X1 68 Up button Black from indicator panel X1 69 Roller switch GND 1 8 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Error Codes 41 1 70 X1 71 Hoist limit switch X1 72 Hoist limit switch 12VDC X1 73 Bypass hoist limit switch Red blue from indicator panel X1 74 Bypass hoist limit switch X1 75 Bypass LMI X1 76 Bypass LMI X1 77 78 Shutoff 1 X1 79 80 Shutoff 2 Console
15. Table 1 Console connection Terminal Description Lead Color X1 1 24VDC White X1 2 OVDC GND Brown X1 3 RS422 CLK Green 1 4 RS422 CLK Yellow X1 5 RS422 DATA Grey X1 6 RS422 DATA Pink X1 7 RS422 Load Blue X1 8 RS422 Load Red X1 9 Push button UP TARE Black X1 10 Push button PROGRAM BUZZER Violet X1 11 Push button DOWN ANGLE Grey pink LENGTH X1 12 Push button HOIST LIMIT SWITCH Red blue SkyAz l Equipment Solutions www skyazul com 301 371 6126 a a PRS 145 Display Console 118418 PASS J IKST Piston Pressure 1 KST Rod Pressure Transducer 250bar Transducer 250bar ds 7 BUTTON ANG LENG GRA PNK RED BLU Rollerswitch S1 031 006 100 043 S BUTTON A2B BY N 5 a o o a z E gt a 10 gt assembly I M M M B 488 BUTTON UP TARE 55 Sw c dc 85422 CLK gt 85422 CLK 9189422 DATA 45422 DATA not used not used 2 o 2 3 5 zlz lt x 012 Be Ber oy OF gt Cable assembly 112843 1112 GND GND 12 VDC in Enclosure 12 VDC 2 5 V 7 5V Enclosure 12 VDC 12 VDC in 12 VDC in BLK front rubber chart Rollerswitch S2 031 006 100 043 def arc chart on outriggers Rollerswitch S3 031 006 100 043 optional A Greeny V 1288 Ca
16. applicable The weight at the anti two block switch keeps the switch closed until the hook block strikes it Console The console displays 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 LED s instrument 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 two block condition SkyAzul Equipment Solutions www skyazul com 301 371 6126 2 Service Manual 8145 2 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UNIT All data of the crane are stored inside the central unit in EPROMs The central unit gets all actual information of the crane This is computed against the reference data and the crane status continually monitored Description of the Housing The PRS145 central unit has a water proof aluminum housing It is mounted on the left side of the turntable weldment or on the counterweight The cables are led into the central unit via strain reliefs and connected with fast ons An override switch is mounted on the housing to override the LMI function The system is protected by a 2 AMP fuse that
17. o ov ee vc ee ze O O o o gt o o o o Q 5 a le RS422 DATA Power 24 12V GND le 12VDC Shutoff le RS422 RXD RS422 RXD RS422 RS422 TXD Heating GND Heating 24 12V A REESE RETE PTT E PRS 145 Display Console 118418 r Piston Pressure 1 Rod Pressure 1 Transducer 300bar Transducer 300bar 031 300 060 452 031 300 060 452 043 4 mg BUTTON A2B BY PASS 100 RS 422 LOAD BUTTON UP TARE BUTTON PROG BUZ BUTTON ANG LENG a lt a o a I Rs422 CLK La 85422 CLK 9188422 DATA RS422 DATA 12 VDC not used 12 VDC not used a 2 o 2131415 7 24 1 ne ac uu ini oy gt 0 Cable assembly 112843 006 12 VDC in 12 VDC in 12 VDC in front rubber chart 031 BLK VIO GRA PNK Rollerswitch S1 031 006 100 043 CSS Se ee egy def arc chart on outriggers Rollerswitch 52 031 006 100 043 CoS ees y optional Rollerswitch 53 1288 assembly 031 300 050 619 455 Cable assembly 031 300 050 619 2 Cable 031 300 100 144 031 300 100 144 031 300 100 144 031 300 100 144 031 300 100 144 e 2 i E o gt v YN D Color code reference table LEGEND BROWN BLACK WHITE GRAY
18. 71 6126 36 Service Manual PRS145 8 ERROR CODES 8 1 OPERATOR ERROR CODE TABLE 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 ERROR DISPLAYED ERROR CAUSE ACTION A2B CONDITION Anti 2 Block circuit has been activated The hoist limit switch has been activated or open in A 2 B circuit Lower the hook Check all cables and connection to hoist limit switch A2B BYPASS The hoist limit switch The hoist limit by pass Error occurs when bypass has been by passed button has been pushed button on the panel is is defective pushed LOAD gt MAX The actual load is The crane is at maximum Lower load or move load into LOAD greater than the max lifting capacity safe working condition load SHUT OFF The shut off system is The shut off contact has Remove key from electronic BYPASS currently by passed been by passed by the user box with the aid of the key operated switch installed on the electronic box LENGTH lt CHART The length of the main boom is shorter than the lowest value in the Load Chart for the configuration selected The incorrect configuration has been selected The length indication is incorrect Select proper configuration Check length indicat
19. A G E 79760 SkyAz l Inc 200 W Main Street Suite 2A gr Middletown MD 21769 Phone 301 371 6126 EQUIPMENT SOLUTIONS Fax 301 371 0029 a www skyazul com info skyazul com
20. LE PLUG 7 12345 91011 V A T9 spring Operated N Cable Reel 2 Conductor Olflex Inner Core Outer Shield A 2 B SWITCH A 2 B Wiring for one 1 winch amp NO Attachment 6 PIN BOOM POINT PLUG RECEPTACLE www skyazul com 301 371 6126 SkyAz l Equipment Solutions Service Manual PRS145 3 ength ngle 1 2 5 11213 14 5 16 718 10 11 12 13 14 15 116 17 1 18 19 201 211 22 23 24 25 26 27 128 291 30 311 321 33 341 35 36 37 38 39 40 a lt 41 42 43 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 61 62 63 65 66 67 63 69 70 71 72 73 74 75 ve 77 78 79 80 6 7 1 7 Conductor Shielded Cable 2 2 Conductor Olflex 3 5 6 7 SHIELD 6 PIN BOOM POINT PLUG RECEPTACLE 5 6 ELECTRICAL DIAGRAM CABLE REEL 24 30 M TO CENTRAL UNIT 10 10 PIN BOOM PIVOT RECEPTACLE PLUG M Spring Operated A 2 B SWITCH A 2 B Wiring for one 1 winch amp NO Attachment www skyazul com 301 371 6126 SkyAzul Equipment Solutions Drawings 11 5 7 CABLE REEL 34 50 M 1 0115468 00 Spare Parts List 1 6 15 2 m10 11 m12 6 18 19 20 ESP 16 17
21. PRESSURE CHANNEL ADJUSTMENT nnne nennt nnn nnns nnns 21 6 3 1 Adjust pressure piston 21 6 3 2 Adjust pressure Rod 21 6 4 ANGLE TRANSDUCER REPLACEMENT AND ADJUSTMENT 22 6 5 LENGTH TRANSDUCER REPLACEMENT AND ADIUSTMENT 24 6 6 LENGTH CABLE REPLACEMENT 26 7 TROUBLESHOOTING FLOW CHARTS 27 71 GENERAL PIOWOMAR I EE 27 7 2 LEVERLOCKOUT ACTIVATED iiit xit id 28 BLANK RE NEE 29 7 4 ANTI TWO BLOCK 4 8 5 EN 31 7 9 LENGTH READING PROBLEM eege ege 34 0 ANGLE E Ee E 35 8 ERROR CODES ona 36 8 1 OPERATOR ERROR CODE TABLE E 36 8 2 SYSTEM ERROR CODE TABLE iaa 38 9 CONNECTION DESCRIPTION CONSOLE CENTRAL 40 SkyAz l Equipment Solutions www skyazul com 301 371 6126 Mechanical Description Of The Components 1 1 MECHANICAL DESCRIPTION OF THE COMPONENTS 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 v
22. Point Receptacle Plug Dummy Plug Main Boom Point A 2 B Wiring for machine with two 2 winches To Cable Inner Core Reel BLUE Outer Shield BROWN Attachment Point 6 Pin Boom Point Receptacle Plug Main Boom Point A 2 B Wiring for machine with one 1 winch SkyAzul Equipment Solutions www skyazul com 301 371 6126 Drawings 15 5 10 ANTI TWO BLOCK SWITCH 1 0024849 00 Spare parts List ITEM DESCRIPTION QTY PART 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 DESCRIPTION QTY PART NUMBER 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 PRS 145 16 5 11 ELECTRICAL DIAGRAM PRESSURE TRANSDUCER CENTRAL UNIT Pressure Transducer Piston Side Pressure Transducer Rod Side Quick Disconnect 11213 4 15 7 12 15 16 17 19 20
23. X1 72 and all checks have been completed 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 replacement SkyAz l Equipment Solutions www skyazul com 301 371 6126 34 Service Manual PRS145 7 5 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 If indication is correct at short boom and If indication is off by approximately 3 ft 1m has bad indication the problem my be a add or remove 1 rap from cable reel If this defective length potentiometer Refer to does not repair problem refer to Length Section Adjustment Procedure section SkyAzul Equipment Solutions www skyazul com 301 371 6126 Troubleshooting Flow Charts 35 7 6 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 Indication should match load chart If indication is correct at 0 degrees and If indication is off check the mechanical has bad indication the problem my be adjustment of the angle bracket defective length potentiometer Refer to Section 7 Refer to Section 7 SkyAz l Equipment Solutions www skyazul com 301 3
24. a PRS 145 CENTRAL UNIT 12VDC 12VDC GND Analog Input 2 lt Analog Input 1 gt gt 4 12 24 VDC a UDC Piston Pressure Rod Pressure Transducer 300bar Transducer 300bar 031 300 060 452 031 300 060 452 1 BRN Piston 1 BRN Rod el Crane Voltage refer to Crane DWG 3 BLK Piston Trans 3 BLK Rod Trans 2 BLU Piston Signal 2 BLU Rod Signal not used 12 VDC not used aa o o o 5 O I I Y gt 438 Cable assembly 031 300 050 619 455 Cable assembly 031 300 050 619 LEGEND BROWN BLACK WHITE GRAY GREEN BLUE RED PINK ORANGE YELLOW VIOLET SHIELD PAT AMERICA Inc PRS 145 PRESSURE TRANSDUCER WIRING 1492 CREAM INNER 1665 ORCHARD DRIVE GENERAL SHIELD CHAMBERSBURG PA 17201 GENERAL P N 031 300 101 492 SHIELDED ECN DESCRIPTION BY APV DRAWN SB DATE 02 25 2005 DOUBLE APPROVED DATE SHIELD CONNECTED TO STRAIN SCALE SHEET 1of1 SHIELDED RELIEF INSERT SIZE DWG NOT PAT America Inc reserves proprietary rights to this drawing and to the data shown thereon The drawing and data are ECN CONNECTED confidential and are not to be used or reproduced without the written consent of PAT America Inc This drawing is subject to technical modification without prior notice C
25. ble assembly Cable 031 300 100 144 031 300 100 144 031 300 100 144 031 300 100 144 031 300 100 144 E gt i E o LO v o D E Color code reference table LEGEND BROWN LK BLACK HT J WHITE RA GRAY GREEN LU BLUE RED N PINK RG ORANGE YELLOW VIOLET Notes HD SHIELD MER PAT AMERICA Inc PRS 145 w LWG 208 Voltage amp KST P Transducers 5 1665 ORCHARD DRIVE CHAMBERSBURG PA 17201 P N 031 300 101 xxx DESCRIPTON A BY DATE wB DATE 10 03 2003 pS D PROVED ______________ E ere REV PAT America Inc reserves proprietary rights to this drawing and to the data shown thereon The drawing and data are confidential and not to be used or reproduced without the written consent of PAT America Inc This drawing is subject to technical modification without prior notice C A G E 79760 oleis a de optional optional w 12 VDC in 12 VDC in Rollerswitch S4 031 006 100 043 Rollerswitch S5 031 006 100 043 D m ell ell LL SR 0 5V 4 5V BLK 1 1 875V 3 125V 2 Signal closed 12V Pin Plug Extension eos A2B Switch 031 002 060 014 BOTTOM
26. cer has been replaced and adjusted The machine can be put back into service SkyAzul Equipment Solutions www skyazul com 301 371 6126 Procedures 23 Angle Transducer Adjustment Tools required e Small flat blade screwdriver e Digital Level or Magnetic base angle protractor Procedure 1 Fully retract the boom and lower to an angle 0 degrees or level 2 Push DOVVN ANGLE LENGTH 7 or UP TARE 9 button until NORM menu title is blinking then push the PROGRAM BUZZER 8 button 3 Push the DOWN ANGLE LENGTH 7 UP TARE 9 button until ANGLE menu title is blinking then push the PROGRAM BUZZER 8 button 4 Verify boom is at 0 degrees using digital level 5 Push the DOWN ANGLE LENGTH 7 9 button until MINIMUM menu title is blinking then push the PROGRAM BUZZER 8 button 6 Push the PROGRAM BUZZER 8 button until all digits have been verified with the proper value which will be 000 0 at 0 degrees 7 Hoist the boom all the way up and check angle using a digital level 8 Push the DOWN ANGLE LENGTH 7 or 9 button until MAXIMUM menu title is blinking then push the PROGRAM BUZZER 8 button 9 Push the PROGRAM BUZZER 8 button to the first digit that has to be changed to the angle value found by using the digital level Change the digit value by pushing the DOWN ANGLE LENGTH 7 9 button until you get the proper number for that digit Con
27. d 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 Procedures 25 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 safely extend the boom to its 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 2 on the terminal strip in the cable reel Push DOVVN ANGLE LENGTH 7 or 9 button until NORM menu title is blinking then push the PROGRAM BUZZER 8 button Push the DOVVN 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 DOVVN 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 mi
28. d tools 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 technicians to test the potentiometer to ensure operation over the voltage range of the original system installation 6 1 ANGLE SENSOR ADJUSTMENT Part Number 1 0115294 00 The angle shown in drawing below 1 needs to be within 0 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 60 and 70 30 90 angles are more critical than 0 30 To comply with the SAE J375 standards the displayed angle must be 0 0 to 2 0 of the actual angle Angle Transducer Pendulum Stop Set Angle Transducer Left Side of Boom Right Side Inside Set Screw Locking Bolt tt Right Side of Boom Left Side inside SkyAzul Equipment Solutions www skyazul com 301 371 6126 20 Service Manual PRS145 6 2 EPROM REPLACEMENT IN CENTRAL UNIT 1 Loosen screws and remove electronic box cover 2 With power off to the system use small screwdriver to lift out of socket 3 Replace with notch down and flat side to the top as shown in diagram WARNING If I C is placed in wrong the will be destroyed and new will have to be ordered SkyAzul
29. e Defective pressure Replace pressure Transducer output transducer or cable transducer or cable voltage to low CH 2 OPEN Rod Pressure Defective pressure Replace pressure Transducer output transducer or cable transducer or cable voltage to high CH 3 SHORT Length Transducer Defective length transducer Replace length transducer output voltage to low or cable or cable CH 3 OPEN Length Transducer Defective length transducer Replace length transducer output voltage to high or cable or cable CH 6 SHORT Angle Transducer Defective angle transducer Replace angle transducer output voltage to low or cable or cable CH 6 OPEN Angle Transducer Defective angle transducer Replace angle transducer output voltage to high or cable or cable E 0001 0042 LMB Error Codes Errors occur from improper If problem recurs contact programming of data 1 5 PAT America Inc E 1040 Error of division The system has tried to Reset system by turning divide by zero power off then on If problem recurs contact PAT America Inc E 1041 Invalid interrupt The system has attempted Reset system by turning vector to execute an interrupt that power off then on If is in valid problem recurs contact PAT America Inc E 1042 Incorrect CHECKSUM Loss of data or invalid Install new EPROM 1 with of EPROM 1 modification of EPROM 1 valid control program E 1043 No real time clock A EPROM 1 program for Replace EPROM 1 with us
30. e wires from terminals X1 11 X1 20 power to sensors 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 into service Defective electronic CPU Check for short on the wires removed X1 11 X1 20 when the short is found trace out short using wiring diagrams Refer to wiring diagram in Section 5 After short has been removed replace fuse with 2 amp fuse only board NEXT PAGE SkyAzul Equipment Solutions www skyazul com 301 371 6126 30 Service Manual PRS145 PREVIOUS PAGE Then check output voltage to console using a If system returns to normal operation the voltmeter put positive lead at terminal X1 33 and crane is ready to be put back in service ground at terminal X1 2 Display working Voltage Replace console Replace or repair Electronic box CPU SkyAzul Equipment Solutions www skyazul com 301 371 6126 Troubleshooting Flow Charts 31 7 4 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 Check if jumper or dummy plug if two Lower hook down into winch crane in receptacle at boom nose is safe position plugged in Refer to Drawing 2 Anti Two Block Junction In Section 11 Appendix Remove jumper dummy plug and check the function of
31. eeh m Boom Tip Main Boom only Cable Reel 068 208 060 013 L A2B Switch 031 002 060 011 LEGEND NOTES LBRN BROWN EI BLACK WHITE gt SHIELD CONNECTED TO STRAIN RELIEF INSERT GRAY GREEN BLUE SHIELD IS USED AS CONDUCTER FOR A2B SWITCH CIRCUIT RED E gt Remove existing wire jumpers at terminal 5 amp 6 YEL YELLOW Swap jumper wires at terminal 5 8 6 Refer to L VIO VIOLET wiring diagram SHOT SHIELD g diagram CREAM INNER ESE O 33 PRS 145 w LWG 208 voltage amp KST P Transducers EIE c CHAMBERSBURG PA 17201 E PIN 031 300 101 xxx DOUBLE IOLERANGES DESCRIPTION BY DATE DRAWN WB pare 09 29 2003 SHIELDED esi __ _________ PTE ______ Pe SCALE __________ Es CONNECTED ___ T SCALE III REV PAT America Inc reserves proprietary rights to this drawing and to the data shown thereon The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT America Inc This drawing is subject to technical modification without prior notice C A G E 79760 To PRS 145 Central Uni El 2 12 VDC 24 Ref 3 8 VDC Ref 3 8 VDC GND Ref 1 0 VDC GND 1 0 GND RS232 TXD GND RS232 RXD RS232 CTS RS232 DTR BRN Pis
32. h the manufacturer s operating instructions and load rating chart TWO BLOCKING Contact of the lower load block or hook with the upper load block boom point or boom point machinery ANALOGUE Electrical signals that vary in proportion to the quantities they represent Boom length angle and pressure transducer DIGITAL Electrical signals of an on and off state two different voltage levels to represent some quantity of operation A2B area definition switch SkyAzul Equipment Solutions www skyazul com 301 371 6126 Drawings 5 DRAWINGS 5 1 WIRING DIAGRAM CENTRAL UNIT SHUT OFF 12V 24V Power Supply Ground 3 8 VDC 3 8 VDC 1 0YDC 1 0VDC RS 232 TxD RS 232 RxD RS 232 CTS RS 232 DTR Ground Ground Ground Ground Ground Ground Ground Ground Ground Ground 2 12 VDC 12 VDC 12 VDC 12 VDC 5 VDC Analog Analog Input 1 Ana oginput 2 Ana oglnput 3 Ana og Input 4 Anal og Input 5 Ana og Input 6 Anal og Input 7 Anal og Input 8 Disp lay RS 422 LOAD Disp lay RS 422 LOAD 5 VDC Analog Roller Switch 1 Roller Switc h 2 Roller Switch 3 Roller Sw
33. hout the written consent of PAT America Inc This drawing is subject to technical modification without prior notice C A G E 79760 2 J C GH 13 031 3 LON ad T3IHS 319NIS Q I3IHS YANNI INV3HD A I3iHS MOTIJA 4014 NHO VHo __ i LYASNI 331133 NIVULS OL Q3193NNOO 5 LINN SVL Sud 10221 Vd QHVHOMWO 999 Sy AN DO HOSOd 8 E 5 g 3 E E 3 El 5 2 5 E e 2 3 5 2 El 8 i 5 S 3 E 5 s 8 H 9 3 3 3 5 8 El El 5 E El 5 5 5 3 8 El El gt 8 8 3 E 2 3 E 5 5 8 5 TVH3N39 LSM Y 80 OM 4 GYL Sad CEH Si S3ONVH3 10L 09 64 d 9 VO as ___ ___ ON OMG M Suelo 7 4 uauoduo7 suelo eoi eg yo mo XxX 101 00 1 0 GRN Piston Trans GRN Rod Trans 3 C reel GND el a YEL Rod Signal 2 C Reel Length es zs es vs es zs RED Console 2 BLU 2 81 Signal o BLU 2 S2 Signal BLU 2 S3 Signal BLU 2 54 Signal BLU 2 55 Signal Console PROG BUZZER BLK Console E GND nput 1 npu
34. ing data logger has been proper programming installed and pc board has replace pc board with real no real time clock or time clock defective real time clock E 1080 108D Range Check Errors Errors occur from improper If problem reoccurs contact programming of data PAT America Inc 10 10CE Data Programming Programming errors in If problem recurs contact Errors EPROM 1 EPROM 1 PAT America Inc SkyAzul Equipment Solutions www skyazul com 301 371 6126 Error Codes 39 ERROR ERROR CAUSE ACTION DISPLAYED E 1100 Invalid EEPROM Incorrect EEPROM inserted Replace the EEPROM with identification in EEPROM 2 slot valid programming E 1101 Incorrect Information has been With error message CHECKSUM changed in EPROM 2 and displayed push down EEPROM 2 not checksum before button Enter ACCESS turning power off to system code and CHECKSUM EEP then RESET 1102 110E Data Programming Invalid programming of If problem reoccurs contact Errors EPROM 2 PAT America Inc E F000 Error in shut off Fault on electronic box P C Replace electronic box P C circuit board board E F001 12 Volt DC fault The 12 Volt DC power If crane is 12 volt check supply voltage has dropped supply voltage of crane If below 12 Volt DC 20 crane is 24 volt check for fault of 12 24 volt converter on electronic box P C board E F002 ADC timeo
35. ings 7 53 ELECTRICAL DIAGRAM CONSOLE White Brown Green Yellow Grey Pink Blue Red Violet Grey Pink Red Blue 68 4 9 9 P tc L 8iqE5 Jojonpuo SkyAz l Equipment Solutions www skyazul com 301 371 6126 8 Service Manual PRS145 5 4 INDICATOR PANEL CONSOLE 1 0118417 00 Spare Parts List 6 6 1 ITEM DESCRIPTION QTY PART NUMBER 1 0116046 00 1 0118389 00 1 0012135 00 1 0116059 00 1 010667800 1 0115673 00 1 0114234 00 6 1 LCD Matrix Display SkyAzul Equipment Solutions www skyazul com 301 371 6126 Drawings 5 5 ELECTRICAL DIAGRAM CABLE REEL CABLE REEL 34 50 M TO CENTRAL UNIT Li 2 Es La Es 1617 8 12 14 Les 16 17 18 20 22 22 231 241 251 26 127 28 20 30 311 321 33 34 35 36 1 37 39 40 3 51 162 63 54 65 66 67 68 70 71 72 73 74 75 76 77 78 79 80 o o o o c lt 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 5 g Sos pc 7 Conductor Shielded Cable 7 1 1 2 2 3 3 5 5 6 6 7 7 SHIELD DR SHIELD L Hol 10 PIN BOOM PIVOT RECEPTAC
36. ion with boom fully retracted if incorrect length is indicated Refer to Section 7 5 LENGTH gt CHART The length of the main boom is longer than the highest value in the Load Chart for the configuration selected The incorrect configuration has been selected The length indication is incorrect Select proper configuration Check length indication with boom fully extended if incorrect length is indicated Refer to Section 7 5 RADIUS lt CHART The Radius is shorter than the lowest value in the Load Chart for the configuration selected The crane has exceeded the shortest radius for the configuration that has been selected Lower or extend boom to return to a working radius in the load chart Check radius indication to actual radius RADIUS gt CHART The Radius is longer than the highest value in the Load Chart for the configuration selected The crane has exceeded the longest radius for the configuration that has been selected Raise or retract boom to return to a working radius in the load chart Check radius indication to actual radius SkyAzul Equipment Solutions www skyazul com 301 371 6126 Error Codes 37 ERROR DISPLAYED ERROR CAUSE ACTION ANGLE lt CHART The Angle of the main boom is lower than the lowest value in he Load Chart for the configuration selected The crane has exceeded the lowest angle for the configuratio
37. is mounted on the lower right side Description of the Boards Inside the central unit there is one board The main board that has terminal strips 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 analogue 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 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 and terminal 53 length The signal on terminal 56 angle is between approximately 1 000V and 4 500V The signal on terminal 53 length is between 1 000V and 4 500V The signals from the pressure transducers are connected to terminal 52 rod side and terminal 51 piston side The signals on terminals 51 and 52 range between 2 500V and 2 500V The signal fr
38. itch 4 Roller Switch 5 PanelDown Button 5 VDC Analog 5 VDC Analog 5 VDC Analog 5 VDC Analog SOLENOID VALVE Display RS 422 CLK SHUT OFF Display RS 422 CLK Disp ay RS 422 DATA Disp ay RS 422 DATA Dis Disp ay Power 12 24 ay Power GND Disp ay Power 12V Disp ay Shut Off ay RS 422 RxD Disp ay RS 422 RxD Disp ay RS 422 TXD ay RS 422 TxD Disp GND 4 fo IN IN IN IN NIN JR IN fo o JO JE IN JO IN a n JO apa ay Heating Panel P Button Panel Up Button Roller Switch GND 1 8 A 2 B Return A 2 B 12V A 2 B By Pass A 2 B Bypass Shut Off By Pass Shut Off By Pass Shut Off 1 Shut Off 1 Shut Off 2 Shut Off 2 www skyazul com 301 371 6126 SkyAzul Equipment Solutions Service Manual PRS 145 5 2 CENTRAL PROCESSOR 12 24 VDC 1 0116440 00 Spare Parts List 2 1 ITEM DESCRIPTION QTY PART NUMBER 1 Housing 1 1 0103719 00 2 P C Board Central Processor 1 1 0116073 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 Draw
39. le 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 allow cable to spool onto the drum keeping the cable tight together and layering properly spool until all tension is off 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 Crane is ready to put back into service SkyAzul Equipment Solutions www skyazul com 301 371 6126 Troubleshooting Flow Charts 27 7 TROUBLESHOOTING FLOW CHARTS 7 1 GENERAL FLOWCHART This section explains how to handle a problem that may arise with the PAT Load Moment Indicator Kruger Mark 4E 2 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 other detailed flowcharts shown in this section d START d What s Wrong Lever Lockout Activated Go to Section 7 2 Blank Display Go to Section 7 3 Anti Two Block Problem Go to Section 7 4 Length Reading Pr
40. meter until the setscrew is accessible Loosen but DO NOT remove the setscrew 6 Rotate the arm until the second setscrew is accessible Loosen but DO NOT remove the setscrew 7 Remove the arm from the Length potentiometer and store in a safe location 8 Remove the nylon gear from the length potentiometer shaft 9 Use the 13mm wrench to remove the length potentiometer from the mounting bracket 10 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 their location 11 Install the new length potentiometer 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 potentiometer until the length displaye
41. n that has been selected Raise the boom to return to a working angle in the load chart ANGLE gt CHART The Angle of the main boom is higher than the highest value in the Load Chart for the configuration selected The crane has exceeded the highest angle for the configuration that has been selected Lower the boom to return to a working angle in the load chart SWING AREA The crane has swung into a non working area unacceptable to the Load Chart for the configuration selected The crane has swung into the wrong working range May have defective roller switch or open wire to the roller switch Swing to return to a working rang Replace defective roller switch Replace wire from electronic box to roller switch SkyAz l Equipment Solutions www skyazul com 301 371 6126 38 Service Manual PRS145 8 2 SYSTEM ERROR CODE TABLE System errors will occur if a system component has failed or been damaged and must be corrected The system has to be reset after error has been corrected ERROR ERROR CAUSE ACTION DISPLAYED CH 1 SHORT Piston Pressure Defective pressure Replace pressure Transducer output transducer or cable transducer or cable voltage to low CH 1 OPEN Piston Pressure Defective pressure Replace pressure Transducer output transducer or cable transducer or cable voltage to high CH 2 SHORT Rod Pressur
42. nimum boom length of the load chart Telescope the boom all the way out Push the DOVVN 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 DOVVN ANGLE LENGTH 7 or UP TARE 9 button until ADJUST menu title is blinking then push the PROGRAM BUZZER 8 button Push the DOVVN ANGLE LENGTH 7 or 9 button until EXIT menu title is blinking then push the PROGRAM BUZZER 8 button Push the DOVVN ANGLE 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 SkyAz l Equipment Solutions www skyazul com 301 371 6126 26 Service Manual PRS145 6 6 LENGTH CABLE REPLACEMENT PROBLEM Damaged or broken length cable Replace length cable using the following procedure 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 Remove wire from slip ring disc cut wire ends off and remove all old length cable from reel 5 Feed new length cab
43. oblem Go to Section 7 5 Angle Reading Problem Go to Section 7 6 SkyAzul Equipment Solutions www skyazul com 301 371 6126 28 Service Manual PRS145 7 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 START Set the override key switch in electronic box into upper position to override LMI Refer to Drawing 8 If console display is blank fault is Does light 6 located in power supply wiring or Anti Two Block warning If Load Moment Limit Light 5 displays Fault in Anti Two Check lever lockout system in fault is located in LMI cables wiring Block system crane fuses or console Read error code Refer to Section 7 4 displayed on console display Refer to Section 8 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Troubleshooting Flow Charts 29 7 3 BLANK DISPLAY PROBLEM Blank display No warning lights shown Crane movements stopped Check input voltage using a If fuse is open check for direct short to ground by using a voltmeter put positive lead at voltmeter checking for continuity between terminal X1 2 and terminal X1 1 and ground at X1 11 20 terminal X1 2 If there is no voltage there is a problem with supply voltage from the crane Remov
44. oltage is 12V The output signal is 2 500V at 0 pressure to 7 500V at maximum pressure 250bar Cable Reel The cable reel houses the length angle transducer 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 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 5 000V The output signal for the angle transducer is 1 000V up to 5 000V Anti Two Block Switch The anti two block switch monitors the load block and its relationship with the head of the boom In 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
45. om the force transducer is connected to the terminals 51 and 52 range between 2 500V and 7 500V The supply voltage 12vdc for the anti two block switch is terminal 72 and return signal on terminal 71 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 for the transducers and console are going out via the terminal strip SkyAzul Equipment Solutions www skyazul com 301 371 6126 Basic Adjustment of Hardware 3 3 BASIC ADJUSTMENT OF THE HARDWARE 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 from cable reel and adjust arm mounted on the potentiometer till length indication is correct 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 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
46. t 2 nput 3 nput 4 nput 5 nput 6 nput 7 nput 8 RS422 LOAD RS422 LOAD Roller Switch 1 Roller Switch 2 Roller Switch 3 Roller Switch 4 UP TARE To PRS 145 Sensors A 2 B BYPASS A 2 B BYPASS Not used Not used By pass Gpe P fores youms Sseq g 52 v e zz 1 91 QU ANGLE LENGTH A2B Switch Signal A2B Switch 12VDC VS OGA0E uojsid OL 817811 aJosuog OL OM 5 oe ES YI MSIA OY uo 25 YIMSIA O Y 12 VDC 24 VDC N w Ref 3 8 VDC Ref 3 8 VDC Ref 1 0 VDC D Ref 1 0 VDC 85232 TXD RS232 Rs232 CTS RS232 DTR BRN Piston 12v0C BRN 5 12 0 BRN 1 5 1 12VDC BRN 1 52 SUE BRN 1 S3 42VDC B S5 UO Le Ls ue RN 1 S4 a 12v0c BRN 1 12VDC 1 C Reel Rm S 12v0C 02 6 VREF 5VDC ANALOG D ANAL OG D 5VDC ANALOG VREF 5VDC ANALOG VREF 5VDC ANALOG 9c VREF 5VDC ANALOG Console RS422 CLK 5 o 2 n N T Console RS422 DATA YEL Cons EI BRN Cons D OF 62 82 12 Q 5 n Consol Consol Conso Conso O 5
47. the Two Block switch by using ohmmeter 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 Replace Anti Two Block switch with Two Block switch down 0 ohm NEXT PAGE SkyAzul Equipment Solutions www skyazul com 301 371 6126 32 Service Manual PRS145 PREVIOUS PAGE Replace length cable refer to Section 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 Troubleshooting Flow Charts 33 PREVIOUS PAGE Electronic Box P C Board is defective Send to PAT America Inc for repair or replacement With 12vdc on terminal
48. tinue this process until at digit values have been corrected For Example if the angle given by digital level was 76 5 degrees then the display should read 076 5 before the PROGRAM BUZZER 8 button is pushed for the last time 10 Push the DOVVN ANGLE LENGTH 7 or UP TARE 9 button until ADJUST menu title is blinking then push the PROGRAM BUZZER 8 button 11 Push the DOVVN ANGLE LENGTH 7 or UP TARE 9 button until EXIT menu title is blinking then push the PROGRAM BUZZER 8 button 12 Boom down to 60 degrees using crane angle indicator and verify angle with magnetic base protractor or digital level 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 24 Service Manual PRS145 6 5 LENGTH TRANSDUCER REPLACEMENT AND ADJUSTMENT Tools required e 1 5mm Allen Wrench e 13mm Open End Wrench e Medium Flat Blade Screwdriver e Needle Nose Pliers e Digital Volt Ohm Meter Procedure Locate machine in an area that will allow you to safely extend the boom to its 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 3 Turn off power to the Load Moment System 4 Remove cable reel cover Store the 4 screws washers and clamps in a safe place 5 Rotate the arm attached to the length potentio
49. ton 12v00 BRN Rod 12VDC jog Input 3 BRN S 1 12VDC og Input 4 52 12VDC Input 5 lee ry 12VDC e Input 6 og Input 7 HESS es 12VDC oie H erns eu RS422 LOAD E 12VDC RED Console RS422 LOAD 12VDC Roller Switch 1 5VDC ANALOG BRN 52 Signal Toller switch 2 ee S vREF 5 ANALOG BRN 53 Optional 8 yz asny LON GRN Piston Trans GRN Rod Trans 1 C reel GND By pass relay GND c O Q3193NNOO 9ue12 0 oue12 vb ev zr T 9J0N GND LYASNI 43 7138 NIVYLS OL 1 GND Input 1 Input 2 euondo 95 ES uo 25 YIJMSI9 OY UO S YI MSI9 OY LINN IWYLNAD SVL Sd Le 02 Roller Switch 3 nou 5VDC ANALOG BRN S4 Optional BRN 85 Optional Roller Switch 5 GRA PNK Console El VIO Console PROGR BUZZER BLK Console YEL Cons GRA Cons Cons Roller Switch 4 VREF 5VDC ANALOG VREF 5VDC ANALOG VREF 5VDC ANALOG Sy AVI38 HISO8 e RS422 CLK zU 2 gt o 2 E lt zm 2 o e RS422 CLK e RS422 DATA gt 0 m 2 w 2 e v gt N Q 0 9 o o o o o
50. tton Adjust simulator to 2 500 Push up or down button until MINIMUM menu title is blinking then push P button Push P button until all digits have been verified with the proper value which will be 000 00 bar Adjust simulator to 7 500 vdc Push up or down button until MAXIMUM menu title is blinking then push P button Push P button until all digits have been verified with the proper value which will be 250 00 bar Push up or down button until ADJUST menu title is blinking then push P button Push down button until EXIT menu title is blinking then push P button Push down button to EXIT then P button until you get to the Program menu and enter the working display SkyAzul Equipment Solutions www skyazul com 301 371 6126 22 Service Manual PRS 145 6 4 ANGLE TRANSDUCER REPLACEMENT AND ADJUSTMENT Angle Transducer Replacement Tools required Soldering Iron e 8mm Box wrench e Needle Nose Pliers e Digital Level Or Magnetic Base Angle Protractor e Small Flat Blade Screwdriver Procedure Fully retract the boom and lower to an 0 degree angle to access the cable reel 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 soldering iron and needle nose pliers to remove the three 3 wires from the angle potentiometer WARNING Before removing wires make a diagram of their location 5 With box end
51. ut Malfunction of A D Replace electronic box P C converter board E F040 FE43 Hardware Error The system has a hardware Contact PAT America Inc failure or replace electronic box P C board SkyAz l Equipment Solutions www skyazul com 301 371 6126 40 Service Manual PRS145 9 CONNECTION DESCRIPTION CONSOLE CENTRAL UNIT The tables below show the connection terminal wire color and terminal description for the 7m long supplied cable between the console and central unit Connections to the central unit Terminal Function Lead Color 1 1 Supply voltage 12VDC opt 24VDC X1 2 Input GND OV X1 3 Output Uref 3 8VDC for slewing angle sensor X1 4 Output Uref 3 8VDC for slewing angle sensor X1 5 Output Uref 1 0VDC for slewing angle sensor X1 6 Output Uref 1 0VDC for slewing angle sensor X1 7 Interface RS232 TxD X1 8 Interface RS232 RxD 1 9 Interface RSRS232 CTS 1 10 Interface RS232 X1 11 20 12VDC X1 21 26 5VDC Vref X1 27 Interface RS422 CLK Green from indicator panel X1 28 Interface RS422 CLK Yellow from indicator panel X1 29 Interface RS422 Data Grey from indicator panel X1 30 Interface RS422 Data Pink from indicator panel X1 31 Supply voltage indicator panel 24 12VDC 1 32 Supply voltage indicator panel
52. wing and to the data shown thereon The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT America Inc This drawing is subject to technical modification without prior notice D LO m o 12 E pest A i 12VDC 1 4 20mA BLK 1 4 20mA ls Pin Plug Extension A2B Switch 031 002 060 014 BOTTOM 6 Pin S ze La enl Boom Tip Main Boom only 1 a 5 Cable Reel Ll 068 308 060 001 Ll 6i E A2B Switch 031 002 060 011 LEGEND RN BROWN LK BLACK WHITE NOTES A i ie GRAY E gt SHIELD CONNECTED TO STRAIN RELIEF INSERT RED RED 5 LENK PINK gt SHIELD IS USED AS CONDUCTER FOR 2 SWITCH CIRCUIT ORG ORANGE YEL YELLOW VIO VIOLET SHD SHIELD CRE CREAM _ PAT AMERICA ne PRS 145 w LWG 308 amp KST P Transducers EIE CHAMBERSBURG PA 17201 PIN 031 300 101 xxx OLERANCES EES ECN DESCRIPTION APY DATE DRAWN CE Tome 09292003 SAE CECOT NO REV PAT America Inc reserves proprietary rights to this drawing and to the data shown thereon The drawing and data are confidential and are not to be used or reproduced wit
53. wrench loosen the nut and remove the pendulum from the angle potentiometer 6 Remove the three new angle potentiometer clamps and install the new angle potentiometer 7 Use the soldering iron to connect the wires to the angle potentiometer using the diagram made in Step 4 8 Supply power to the Load Moment System 9 Adjust stem of the potentiometer to indicate 0 degrees then put pendulum on and tighten nut using 8mm wrench 10 After putting pendulum on recheck for 0 degree indication If panel agrees tighten all nuts and screws 11 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 angle shown on theangle protractor or digital level proceed to angle adjustment procedure 17 Lower boom and reinstall the cable reel cover 18 The Angle Transdu

PRS 145 Service Manual

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