EI-65 System Service Manual
Contents
1. y aan EQUIPMENT SOLUTIONS 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 SkyAz l 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 SkyAz l 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 SkyAzul Inc 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 PAT 5 SERVICE MANUAL 1 1 REFERENCE ese A r r 1 SYSTEM MALFUNCTION i2. Check weight position Refer to Operators Section of Handbook 056 065 190 005 Section 5 Pre Operation Inspection item 1 2 and 3 for switch weight positions for the main boom and extension No gt Position the weight properly Yes v Check the A2B circuit at the boom tip junction box With power off measure A2B signal boom tip junction box With the bypass plugs and switch weight in position the ohm meter reads 4 7K ohms Refer to Installation Manual for system wiring diagram No Replace Anti Two Block switch Yes v C Next Page SkyAz l Equipment Solutions www skyazul com 301 371 6126 ANTI TWO BLOCK PROBLEM PREVIOUS PAGE With power off measure the A2B signal in the console at the X1 9 and X1 10 With the switch weight in position the ohm meter reads 4 7K ohms Refer to Installation Manual for system wiring diagrams Fault in cable assembly Check cable assemblies No and replace defective cable Refer to Installation Manual for system wiring diagrams Yes With power on and the switch weight in position If the Anti Two Block condition exists replace connection board A2B relay defective on connection board Refer to Drawing 2 in Section 5 Yes End SkyAzul Equipment Solutions www skyazul com 301 371 6126 PAT 65 SERVICEMANUAL 4 4 ANGLE READING PROBLEM
3. PROBLEM Displayed Angle Incorrect Actual measured angle is different from displayed angle C START 3 Y Use a calibrated inclinometer to measure the actual main boom angle and compare with displayed angle on console Refer to Installation Manual Section 5 Mechanical Adjustments of Cable Reel Sensors y Check the supply voltage to angle sensor on connection board between X1 17 5VDC and X1 20 ground Refer to Installation Manual for system wiring diagram Nos Check system power supply voltage Refer to Section 3 2 No Display this manual Yes y Check the voltage at angle sensor between connector pins A AGND and 5V Refer to Installation Manual for system wiring diagrams Cable defective replace cable or cable assembly dm Refer to Installation Manual for system wiring diagrams Yes Y Check the voltage between X1 20 ground and X1 18 signal output voltage Voltage should be 3 125V 0 2 5V 45 1 875V 90 Refer to Drawing 4 Angle Sensor Circuit in Section 5 Replace Angle Sensor No Refer to Installation Manual Section 5 Mechanical Adjustments of Cable Reel Sensors Complete steps 4 1 4 2 4 3 4 8 4 8 1 and 4 14 through 4 16 in the Calibration Manual Yes 031 300 190 009 Do NOT select Default in of section 4 4 or all other calibration data
4. shown in millivolts received from the sensors will be displayed here as described below The minimum values are show in the screen pictured FORCE 1 and FORCE 2 With no signal or weight applied this should read 15 mv or below At maximum load the reading should not exceed 2500 mv 25mv 15 VOLT 1000 3125 3125 amp l ANGLE 1 and ANGLE 2 LENGTH Hydraulic Machines Only With the boom at zero degrees this should read reading should be O with no sensor 3125 At maximum or 90 degrees the installed reading should be 1875 mv 25mv SkyAz l Equipment Solutions www skyazul com 301 371 6126 4 PAT 65 SERVICEMANUAL 4 TROUBLESHOOTING FLOW CHARTS This section explains how to handle a problem that may arise with the EI65 PAT Load Indicator System The procedures are easy to follow and are given in flowcharts on the following pages Start with the general flowchart below that will guide you to one of the detailed flowcharts shown in this section Section 5 contains the necessary drawings needed for troubleshooting 4 1 GENERAL FLOW CHART CTT What s Wrong display gt Go to Section 3 1 p Anti Two Block Problem m gt Goto Section 3 2 gt Angle Reading Problem gt gt Section 3 3 gt Length Reading Problem Section 3 4 X Load Reading Problem gt Go
5. the pre operation inspection Section 5 in the Operator s Manual 056 065 190 005 to define the problem SYSTEM DESCRIPTION The PAT Length Angle Radius Load Indicator System El65 has been designed to provide the crane operator with the essential information required to enable the machine to be used within its design parameters EI65 System indicates the length and angle of the boom tip height working radius and the total weight being lifted by the crane Using the various sensors and the limits set by the operator the El65 System warns the crane operator of certain approaching hazardous conditions which could occur during the operation of his crane WARNING Always refer to operational instructions and load charts provided by the crane manufacturer for specific crane operation and load limits SkyAz l Equipment Solutions www skyazul com 301 371 6126 PAT 65 SERVICEMANUAL 2 WARNINGS The EI65 is an operational aid which warns a crane operator of certain approaching hazardous conditions which could cause damage to equipment and personnel The device is not and shall not be a substitute for good operator judgment experience and use of accepted safe crane operating procedures The responsibility for the safe operation of the crane shall remain with the crane operator who shall ensure that all warnings and instructions supplied are fully understood and observed Prior to operating the crane the operator must carefu
6. transducer at console connection board between X1 20 ground and X1 19 signal 0 5 and 4 5v Refer to Installation Manual for system wiring diagram or connection board designations this manual rw No Cable defective replace cable or cable assembly Refer to Installation Manual for system wiring diagrams Measure length signal on main board between test point MP4 signal andMP1 ground NOTE Negative signal at terminal X1 Pin 15 will be converted into positive signal at MP6 i e input at terminal X1 Pin 15 0 5V output test between 15 and MP6 0 5v Refer to Drawing 3 Main Board Section 5 Main board defective SkyAz l Equipment Solutions www skyazul com 301 371 6126 LOAD READING PROBLEM 11 4 6 LOAD READING PROBLEM PROBLEM Displayed Load is out of tolerance The displayed load should be equal to or 10 greater than the actual load START Complete Pre Operation Inspection in Section 5 ofthe Operator s Manual 056 065 190 005 Before changing calibration information complete the following steps Check the Main Aux voltages on connection board between X1 25 9V and X1 8 ground X1 28 9V and 1 8 ground Refer to Installation Manual for system wiring diagram or connection board designations this manual No Check system power supply voltage Complete to Section 3 2 No Display Yes Check the
7. voltage at linerider between connector pins 9V and 9V Voltage 18V Refer to Drawing 7 in Section 5 and the Installation Manual for system wiring diagram N Cable defective replace cable or cable assembly e Refer to Installation Manual for system wiring diagrams Next Page SkyAz l Equipment Solutions www skyazul com 301 371 6126 12 PAT E15 SERVICEMANUAL Previous Page Remove hoist so there is load on the load cell of the linerider Check the zero point of the Linerider on connection board between Main X1 26 sig and X1 27 sig Aux X1 30 sig and X1 31 sig Voltage O 0 025V Refer to Drawing 6 Linerider Circuit in Section 5 and the Installation Manual for system wiring diagrams With no load on the load cell of the linerider Check the zero point of the linerider in the boom tip junction box or as close to the linerider as possible Check the Main and signal and or the Check the Aux and signal at Voltage 0 0 025V Refer to Drawing 6 Linerider Circuit in Section 5 and the Installation Manual for system wiring diagrams Correct No No y Check cable continuity Replace cable if necessary No v Replace Load Cell or Linerider Assembly Yes Y Lift test load and verify linerider output voltage increases after lifting
8. www skyazul com 301 371 6126 16 PAT 65 SERVICEMANUAL 6 4 DRAWING 4 ANGLE SENSOR CIRCUIT SkyAz l Equipment Solutions www skyazul com 301 371 6126 SYSTEM DRAWINGS 6 5 DRAWING 5 LENGTH SENSOR CIRCUIT SkyAz l Equipment Solutions www skyazul com 301 371 6126 18 PAT 65 SERVICEMANUAL 6 6 DRAWING 6 LINERIDER CIRCUIT ORC 2 I e 26 6 I I I a a I K I E E O E ORCE I pol I e I SA I I l ZO nado ala 1 N Co ES SkyAz l Equipment Solutions www skyazul com 301 371 6126 SYSTEM DRAWINGS 19 6 7 DRAWING 7 LINERIDER SUPPLY VOLTAGES The supply voltage can be checked directly atthe cannon connection Using a digital voltmeter measure between pins and A 9v B 9v 18volts If this voltage is not correct refer to the system wiring diagram and verify all cable connections You may need to start atthe console and check the supply voltages at their proper measuring points SkyAz l Equipment Solutions www skyazul com 301 371 6126 20 PAT 65 SERVICEMANUAL 6 8 DRAWING 8 CONSOLE PARTS LIST N Ag an M v 6 a BOR x SI X S 2 q NO PART NO QTY DESCRIPTION 01 050 000 100 075 1 HOUSING CONSO
9. LE El65 02 050 350 110 183 2 KNOB MOUNTING KNOB 03 031 300 100 293 1 BRACKET MTG El65 CONSOLE 04 021 441 161 213 1 STRAIN RELIEF PG13 5 12 15mm GRAY WHITE INSERT 05 021 441 131 013 1 STRAIN RELIEF PG 13 5 8 12mm RED WHITE INSERT 06 000 214 210 013 2 NUT PG13 5 07 000 323 010 525 1 ALARM A2B EI10 EI20 08 056 065 300 002 1 BOARD TERMINAL EI65 12V 09 031 300 100 294 2 FUSE 4 AMP FOR EI 65 CONSOLE 10 056 065 300 010 1 BOARD MAIN EI65 W RIBBON CABLE 11 050 000 100 078 1 DISPLAY 12 056 065 100 005 1 FACEPLATE EI65 0005 CONSOLE 13 002 053 703 101 6 SCREW 3x10mm PANHEAD PHILLIPS 14 056 065 300 011 1 BOARD KEYBOARD EI 65 CONSOLE 15 050 000 050 309 1 GASKET 108X256mm SkyAz l Equipment Solutions www skyazul com 301 371 6126 SkyAz l Inc y 200 W Main Street Suite 2A Middletown MD 21769 EQUIPMENT SOLUTIONS Phone 301 371 6126 Fax 301 371 0029 www skyazul com info skyazul com
10. OLTAGES uunnnnsssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnannnnen 19 6 8 DRAWING 8 CONSOLE PARTS LIST inii etia ahi rn and kan kl aha ann Lr aaa paa EE ads 20 SkyAz l Equipment Solutions www skyazul com 301 371 6126 Table of Contents GENERAL INFORMATION 1 1 GENERAL INFORMATION The purpose of this service manual is to provide additional information to assist a service or maintenance person in identifying malfunctions or system problems with the PAT System A digital voltmeter and regular maintenance and service tools will be required to troubleshoot the system Note Knowledge of how to use a digital voltmeter is assumed REFERENCE Manual 056 065 190 005 Calibration Manual 031 300 190 009 Installation Manual 031 300 190 008 SYSTEM MALFUNCTION MB 115 0 J1 85 0 In case of a malfunction of the system an error code which identifies the J2 50 0 04 15 0 E71 system malfunction will be displayed in the reeving portion of the display The error codes are listed in Section 4 Error Codes The table identifies various faults that can occur with the EI65 explain each fault and describe the action which shall be taken to correct the fault Faults within the electronic microprocessor shall be repaired by factory trained service personnel When these faults occur contact your authorized dealer or service organization If operator identifies a possible problem in the system perform
11. ck 5 0V power supply to length transducer on connection board Refer to Installation Manual for system wiring diagram or connection board designations this manual Check system power supply voltage No Refer to Section 3 2 No Display this manual Yes Y C NEXT PAGE SkyAz l Equipment Solutions www skyazul com 301 371 6126 10 PAT 65 SERVICEMANUAL PREVIOUS PAGE Measure supply to length transducer in cable reel between Pin 1 ground and Pin 3 Sv Refer to Installation Manual for system wiring diagram Cable defective replace cable or cable assembly No0 Refer to Installation Manual for system wiring diagrams Yes y Measure signal from length transducer in cable reel at terminal between pin 2 signal and pin 1 ground Retract boom O Potentiometer turn 0 5v 10 Potentiometer turn 4 5v Refer to Drawing 5 Length Sensor Circuit Replace length potentiometer assembly Remove slipring body from shaft and remove gear wheel from potentiometer axle Unscrew mounting plate and Cones emove potentiometer assembly from mounting plate Remove assembly wires form terminal block Connect new assembly to terminal block Reinstall mounting plate gear wheel and slip rings With boom fully retracted reset potentiometer by turning counter clockwise until it stops Yes v Measure signal from length
12. lly and thoroughly read and understand the information in the operator s manual to ensure that he she knows the operation and limitations of the indicating system and crane SkyAz l Equipment Solutions www skyazul com 301 371 6126 Troubleshoooting Using The Analog Values Screen 3 3 TROUBLESHOOOTING USING THE ANALOG VALUES SCREEN For a sensor error or problem with a sensor look at the output voltage of the linerider and angle sensors and compare the reading with the following Angle sensor 1 875 at 0 2 5 at 45 or 3 125 at 90 Linerider under no load is O to 15mV not to exceed 2500 mV To access the analog output screen use the following procedure 1 Power up the system The screen will display El 65 10 software version and date 2 To start calibration within 5 seconds of powering up simultaneously press the OK and SELECT buttons Hold these buttons approximately 15 seconds until the screen changes to CALIB PASSWORD If these buttons are not pressed and held the screen changes to the existing operating configuration Refer to Operator s section in this manual 3 Enter the calibration password 0815 Use the UP and DOWN buttons to select the number and the OK button to confirm each entry Enter 0 OK 8 OK 1 OK 5 OK 4 Scrole to the ANALOG VALUES screen by pressing the UP or DOWN arrows pressing to select and show the following screen All Analog input voltages
13. r basic component layout on the crane and console drawing The El65 console connection board has the following terminal designations Connection Board 056 065 300 002 Designations Battery 17 Battery 18 Battery 19 Battery 20 Load Limit output 21 6 A2BRelay output 2 22 A2B Relay output 1 23 8 Peripheral ground 24 9 A2B1input 25 A2B Ground 26 A2B 2 input 27 A2B Ground 28 3rd Wrap Switch input 29 3rd Wrap Switch ground 30 Digital input 1 31 Digital input 2 32 6 1 DRAWING 1 SYSTEM WIRING DIAGRAM REFER TO INSTALLLATION MANUAL 031 300 190 008 SkyAz l Equipment Solutions www skyazul com 301 371 6126 SYSTEM DRAWINGS 15 6 2 DRAWING 2 CONNECTION BOARD LAYOUT M2 250V 056 065 300 002 MP1 GND MP2 5 6V MP3 5 6V MP4 5V min sig 2 4 250 4 5V max sig 2 8 20 24 2 32 im A el MP2 3 1 P4 6 3 DRAWING 3 m m m m 15 12 MP8 MP7 MP4 MP5 MP6 MP9 10 MP11 K A 51 X52 m m MP2 1 1 P 15 COMPONENT SIDE AIN ARD 300 012 056 065 300 012 SYSTEM EPROM MPO GND MP1 AGND MP2 5 0V MP3 5 0V MP4 SIGNAL LENGTH CHANNEL MP5 SIGNAL ANGLE 2 MP6 SIGNAL ANGLE 1 MP7 SIGNAL KMD1 MP8 SIGNAL KMD2 MP9 ANS REFERENCE VOLATGE MP10 AN6 REFERENCE VOLTAGE MP11 AN7 REFERENCE VOLTAGE MP12 0 5 MP13 5 0V MP15 5 25V SkyAz l Equipment Solutions
14. rr a a aa a cda EAR RAE TIE 1 SYSTEM DESCRIPTION ans ee ee hen s 1 2 WARNINGS 0 2 3 TROUBLESHOOOTING USING THE ANALOG VALUES 3 4 TROUBLESHOOTING FLOW CHARTS icono 4 4 1 GENERAL FLOW CHART ana AZn tah sb a oba oa E Duda i dB EA 4 4 2 NO DISPLAY sitie si io ii vv ca 5 4 3 ANTI TWO BLOCK PROBLEM ssa si ter axo tape ape E bu anna SR o nn 6 4 4 ANGLE READING 211 1 1 1 1 2 44 8 4 5 LENGTH READING PROBLEM coran nor 9 4 6 LOAD READING PROBLEM tz v v oh Za a va a 11 9 ERROR CODE TABLE itio Uit SIE SII ILLIC 13 6 SYSTEM DRAWINGS 5c 0 Gen peo tnit ice ta dota 14 Connection Board 056 065 300 002 40 2 14 6 1 DRAWING 1 SYSTEM WIRING DIAGRAM REFER TO INSTALLLATION MANUAL 031 300 190 008 saia icis 0510000000 2d ca ia Tv bata disce 14 6 2 DRAWING 2 CONNECTION BOARD LAYOUT 15 6 3 DRAWING 3 MAIN BOARD LAYOUT 2 42 2 40042 1 15 6 4 DRAWING 4 ANGLE SENSOR CIRCUIT 16 6 5 DRAWING 5 LENGTH SENSOR 17 6 6 DRAWING 6 LINERIDER CIRCUIT eani aan kur 18 6 7 DRAWING 7 LINERIDER SUPPLY V
15. the test load Main X1 26 sig and X1 27 sig Aux X1 30 sig and X1 31 sig Refer to Drawing 6 Linerider Circuit in Section 5 and the Installation Manual for system wiring diagrams Y Complete steps 4 1 4 2 4 3 4 11 Main or 4 12 Aux through 4 16 in the Calibration Manual 031 300 190 009 Do NOT select Default in of section 4 4 or all other calibration data will be lost and you will have to complete the entire calibration procedure I No v Replace Load Cell or Linerider Assembly End SkyAz l Equipment Solutions www skyazul com 301 371 6126 SYSTEM DRAWINGS 13 5 ERROR CODE TABLE Error code Reason Action adjust operating data incorrect defective 96 ADC Measuring value WG2 toolow Checkluffing angle sensor circuit e Limit set by the operator refer to Operator s Manual Section 4 3 Activating and Setting Preset Limits SkyAzul Equipment Solutions www skyazul com 301 371 6126 14 PAT 165 SERVICEMANUAL 6 SYSTEM DRAWINGS The PAT EI65 System drawings in this section are provided as reference material for the troubleshooting flow charts Use the drawings in conjunction with the flow charts to help understand the operation of the EI65 system Drawing List System Diagram Connection Board Layout Main Board Layout Anti Two Block Circuit Angle Sensor Adjustment Angle Sensor Circuit Linerider Circuit NOARWN gt Refer to the Operator s Manual fo
16. to Section 3 5 SkyAz l Equipment Solutions www skyazul com 301 371 6126 TROUBLESHOOTING FLOW CHARTS 5 4 2 NO DISPLAY PROBLEM Blank console display with no warning light shown C sm 7 Check fuse F1 in console Refer to Drawing 2 Connection Board Section 5 Drawings No Replace fuse 2amp 250V ae Measure crane voltage on connection board between X1 1 UB and X1 3 ground Refer to Drawing 1 System Diagram Section 5 Drawings Check crane power supply for faulty Correct No crane electric or if supply is too low Yes v Measure voltage on connection board between MP4 5 25V and MP 1 ground Refer to Drawing 2 Connection Board Section 5 Drawings Defect on connection board Replace gt console connection board Yes y Measure voltage to main board between MP15 5 25V and MP1 ground Refer to Drawing 3 Main Board Section 5 Drawings q Replace console main board SkyAz l Equipment Solutions www skyazul com 301 371 6126 6 PAT 65 SERVICEMANUAL 4 3 ANTI TWO BLOCK PROBLEM PROBLEM Function of Anti Two Block System is faulty C T Check to see whether or not crane is in two block condition Correct No gt Lower hook down into safe position Yes v
17. will be lost and you will have to complete the entire calibration procedure END SkyAz l Equipment Solutions www skyazul com 301 371 6126 LOAD READING PROBLEM 9 4 5 LENGTH READING PROBLEM PROBLEM Length reading incorrect Crane is not in out of load chart condition C START Check mechanical adjustment of length potentiometer in cable reel Refer to Installation Manual Section 5 Mechanical Adjustments of Cable Reel Sensors If unable to adjust replace length potentiometer assembly Remove slip ring body from shaft and remove gear wheel from potentiometer axle Unscrew mounting plate and remove potentiometer assembly from mounting plate Remove lt Coree gt assembly wires form terminal block Connect new assembly to terminal block Reinstall mounting plate gear wheel and slip rings With boom fully retracted reset potentiometer by turning counter clockwise until it stops Refer to Installation Manual for system wiring diagrams and Section 5 Mechanical Adjustments of Cable Reel Sensors Yes Check out clutch in big gear wheel of length transducer Extend and retract boom to ensure that clutch is not sipping on potentiometer axle Replace the gear wheel clean potentiometer No axle Reset length potentiometer Refer to Installation Manual Section 5 Mechanical Adjustments of Cable Reel Sensors Yes Y Che
Download Pdf Manuals
Related Search