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PAT DS-85 Service Manual

1. 35 16 2 PRESSURE TRANSDUCER BLOCK 36 16 3 ANGLE SENSOR BoXx 36 16 4 CABLE REEL ASSEMBLY 37 16 5 CABLE REEL ASSEMNBLY 38 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT ps 85 17 SERVICE SCREEN FOR SENSOR CALIBRATION 40 17 1 ACTIVATING THE SERVICE SCREEN FOR SENSOR CALIBRATION 40 17 2 ZERO SETTING THE TRANSDUCER INPUTS 40 17 3 CALIBRATE LENGTH NIT WEEN 41 17 4 CALIBRATE ANGLE INPUT 42 18 ERROR CODES 45 19 TROUBLESHOOTING MOISTURE U CS ER Fea 51 19 1 WATER le 51 19 2 CONDENSATION 52 SkyAzul Equipment Solutions www skyazul com 301 371 6126 General Information 1 1 GENERAL INFORMATION This service manual is designed to assist a service or maintenance person in identifying system problem areas or malfunctions A digit
2. 7 S JN AN AN N N ZIN N ee ve 9 9 X X A e d d i N Z N fe E EL N A2B TRANSMITTER SWITCH 031 300 060 593 e 33 SkyAz l Eguipment Solutions www skyazul com 301 371 6126 Service Manual PAT ps 85 34 15 3 HARDIWRED A2B WIRING DIAGRAM 10 101 010 1 0 A18N3SSV 318v2 e a e e o x MARAA Z Z Z Aces AAAA 22225252 N AN de Sr 090 00 L 0 A1d8N3SSV 318VO PS 4 YYYY ZN YN 98 090 006 160 HJ10SNOJ LINN TVH1IN3O YL0 090 vLE VO M3OnGSNVH L 3HOSS3Hd gt gt gt gt vSV 090 00 L 0 ATd8W3SSV d18vO Y 01 00 000 890 HOSN3S 5 NVO 900 090 291 890 HONG SNE NVO 319NV H1SN31 29191 301 371 6126 www skyazul com SkyAzul Equipment Solutions Part Listings 35 16 SPARE PART LISTINGS 16 1 CONSOLE CENTRAL UNIT NS 031 300 060 455 NO PARTNO QTY DESCRIPTION 1 024 085 100 002 1 FRONTFACE PREASSEMBLED 2 024 000 050 002 1 HOUSING DS85 3 024 000 100 095 1 CENTRAL UNIT ACCY
3. a a a 26m hja aa QTY DESCRIPTION Angle Sensor WG143 0006 Length Angle sensor CAN board Sensor Accy Plate for Length Dual Pots Slip Ring 2 pole Sensor Accy Gear Wheel T 36 center shaft Sensor Accy Gear Wheel T 64 length pot Potentiometer 10Kohm Cable Length Sensor 1 Core NS Strain Relief Accy 90 for PG7 Strain Relief Pg7 BLK Hardware Standoff 6mm x 117mm MM Hardware Gasket Sensor Accy Cover KT152 Sensor Nuts 4 amp Washer 4 for KT152 Cover SkyAzul Equipment Solutions www skyazul com 301 371 6126 Listings 39 BESZ 3 Radio A2B 031 300 060 597 Radio Receiver TRS05 2 031 300 060 593 Radio A2B transmitter assy 031 300 050 537 Battery cover includes screws gasket and cardboard tubes 031 300 050 264 A2B mounting plate 031 300 210 012 Weight and chain 031 100 037 Ch nnector quick link 031 300 050 272 Lynch pin 031 300 050 763 Neoprene rubber gasket SkyAz l Equipment Solutions www skyazul com 301 371 6126 40 Service Manual PAT ps 85 17 SERVICE SCREEN FOR SENSOR CALIBRATION 17 1 ACTIVATING THE SERVICE SCREEN FOR SENSOR CALIBRATION Enter the calibrate sensors menu by using the following procedure To start function press ii CALIB SENSORS SENSOR OUTPUTS Press to calibrate sensors ii USER No OK EXIT Press to enter user number USER 54545 At this point a five dig
4. EQUIPMENT SOLUTIONS DS85 0002 Central unit console SERVICE MANUAL Service Manual PAT ps 85 NOTICE Hirschmann 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 Hirschmann 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 Hirschmann Hirschmann 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 Hirschmann The drawings and or photos are subject to technical modification without prior notice All information in this document is subject to change without notice MANUAL REVISIONS REV DATE NAME DESCRIPTION 02 27 08 SC ECN 08 022 4 SkyAzul Inc gal 200 W Main Street Suite 2A Middletown MD 21769 EQUIPMENT SOLUTIONS Fax 301 371 0029 info skyazul com SkyAzul Equipment Solutions www skyazul com 301 371 6126 4 Service Manual PAT ps 85 TABLE OF CONTENTS 1 GENERAL INFO
5. the box is sealed just fine which is what prevents the trapped air from exiting the box There are two ways to deal with condensation 1 If the volume is very small a desiccant bag might be able to soak up the air s humidity 2 If the effect is more severe the only way to get rid of this effect is then to give the box the ability to breath without sacrificing its water tightness Contact your SkyAzul representative for breathing elements to than can be added to the box and will help to reduce the effects of humid climates SkyAzul Equipment Solutions www skyazul com 301 371 6126 g SkyAzul Inc 200 W Main Street Suite 2 Middletown MD 21769 EOUIPMENT SOLUTIONS Phone 2013710126 Fax 301 371 0029 www skyazul com info skyazul com
6. How many turns you get at full extension depends on the gear ratio the boom length the length cable used and the spooling pattern so we cannot provide a standard table for it What we can give you for trouble shooting however is the following table that shows the expected output voltage measured between X20 5 and X20 3 Signal for each complete turn of the length potentiometer Note that this does not sync to the number of turns of the cable reel though Length Sensor Signal on Pin 3 Potentiometer Voltage X20 5 Voltage GND to X20 3 Turns to X20 3 0 0 00 0 16 1 0 46 0 62 2 0 93 1 09 3 1 40 1 56 4 1 87 2 03 5 2 34 2 50 6 2 81 2 97 7 3 28 3 44 8 3 75 3 91 9 4 22 4 38 10 4 68 4 84 Note Actual voltages will vary slightly SkyAzul Equipment Solutions www skyazul com 301 371 6126 Length THEORY 11 6 1 16105 CABLE REEL LENGTH CABLE REPLACEMENT PROCEDURE Replace length cable using the following procedure Refer to system electrical wiring diagram and cable reel parts list 1 Remove cable reel and guide from mounting brackets 2 Remove old length cable from cable drum and machine 3 Remove cover from cable reel 4 Disconnect the 4 conductor cable from terminal strip 5 Remove strain relief outer nut and slide cable out of strain relief 6 Replace length cable Loosen 7mm standoff nut holding pot bracket e Slide bracket and pot away from worm gear NOTE The c
7. 031 300 060 437 Angle Sensor 064 143 060 009 CAN Bus converter board 068 000 300 103 SkyAz l Equipment Solutions www skyazul com 301 371 6126 Part Listings 37 16 4 CABLE REEL ASSEMBLY PART NO 031 300 060 438 NO PARTNO QTY DESCRIPTION 1 npn 1 HARDWARE DRUM FACTORY SERVICEABLE 2 031 300 050 131 1 BRACKET LG105 WITH CABLE GUIDE 3 031 300 060 374 1 CABLE ASSY 15 3 COND WITH 4 PIN PLUG 4 031 300 060 685 1 CABLE ASSY LENGTH 50 w RING TERMINAL amp CLAMP 5 031 300 060 409 1 STRAIN RELIEF PG9 4 6mm YELLOW WHITE 6 031 300 060 682 1 HARDWARE LG105 COVER SCREW SET M4x12 7 209 032 010 501 1 GASKET O RING FOR LG105 COVER 8 031 300 060 683 4 HARDWARE LG105 EXTERNAL SET 9 031 300 060 684 1 HARDWARE LG105 INTERNAL SET 10 031 300 060 578 1 LENGTH POT ASSY LG105 0006 11 067 105 110 001 1 GEAR WHEEL LG105 2 WORM WHEELCOMPLETE W FIXING MATERIAL 12 031 300 100 462 1 TERMINAL STRIP 4 POS 14 15 Ame SkyAz l Equipment Solutions www skyazul com 7301 371 6126 38 16 5 Service Manual PAT ps 85 CABLE REEL ASSEMBLY PART NO 068 152 060 005 NO PART NO 01 02 03 04 05 06 07 08 09 10 11 12 13 14 064 143 060 006 068 000 300 103 067 000 050 093 068 000 100 042 067 000 110 040 067 000 100 068 067 000 300 009 000 673 020 001 000 214 504 180 021 444 010 407 000 268 030 003 067 000 110 020 067 000 050 059 067 000 110 025 1
8. change angle calibration Mark if CHANG 65 6 change is necessary D M BOOM 656 DEG Use and keys to change CHANGE angle to match the BOOM T OK DEANS angle Press to calibrate the main boom angle BOOM T 749 DEG Move boom so the CHANGE angle is with in 2 of the BOOM T angle to 65 4 continue press LE OK BOOM 74 9 DEG Mark CHANGE and press to change angle calibration Mark OK if CHANG 76 1 DEG nochange is necessary 2 m BOOM T 749 DEG Use and keys to change CHANGE angle to match the BOOM T OK UID DEG angle Press to calibrate the main boom angle H CALIB 7 YES To continue press 5 ii YES Mark YES and press to change angle calibration Mark NO if the NO changes are not to be saved OK OK EXIT Mark OK and press to save changes SkyAzul Equipment Solutions www skyazul com 301 371 6126 44 Service Manual PAT ps 85 Using a calibrated inclinometer placed flat on the main boom verify that the indicated boom angle matches the measured boom angle within 0 2 degrees Check the sensor outputs screen for 0 45 60 and 70 0502mV 2025mV 30 6 ft 55 7 main boom angle millivolts 0 45 60 70 SkyAz l Equipment Solutions www skyazul com 301 371 6126 Error Codes 18 ERROR CODES 45 The following Error Code Table gives a brief description of Error Codes elimination Refer to
9. defective Blown fuse in console Replace 2 amp fuse Error in the can bus data transfer of the pressure transducer sensor unit Error in the can bus pressure transducer sensor unit Error in the can bus data transfer of the length angle sensor unit Error in the can bus length angle sensor unit Error in the can bus data transfer of the 2 length angle sensor unit Error in the can bus of the 2 length angle sensor unit Error in the can bus data transfer of the force sensor unit Error in the can bus force sensor unit e Cable between the e Check the cable to the central unit and the sensor unit wiring sensor unit defective or harness See section not connected CAN Bus Communication Blown fuse in console Replace 2 amp fuse e Sensor unit is defective Replace the sensor unit e The analog values of the e Replace the sensor unit sensor unit are invalid See section CAN Bus Communication Cable between the e Check the cable to the pressure transducer and sensor unit See section cable reel defective or not CAN Bus connected Communication e Sensor unit is defective Replace the electronic board in the cable reel see section CAN Bus Communication Angle sensor defective Replace the angle sensor see section CAN Bus Communication e Length sensor defective e Replace the length sensor see section CAN Bus Communication e Sensor unit is defective Replace the electronic board in th
10. that measures the length of the boom This sensor is connected to the CAN bus sensor board Angle Sensor The angle sensor is a potentiometer driven by oil damped and weighted pendulum that measures the angle of the boom This sensor is connected to the CAN bus converter board in the angle sensor box or located in the LWG length angle sensor cable reel Radio Anti Two Block Receiver The anti two block receiver console has 4 LED lights for anti two block conditions such as POWER LINK communication link LOW BATTERY and A2B an impending two block condition exists When the weight is lifted on the 2 switch or a signal is not received from the transmitter the receiver disengages a relay output and drops power from the lock out solenoid valves Radio Anti Two Block Transmitter and 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 The weight at the anti two block switch keeps the switch closed until the hook block strikes it When the hook block strikes the weight the circuit opens and the transmitter sends a signal to the receiver The transmitter has an LED on the bottom for diagnostics The LED should be on when in a two block condition or when the weight is lifted The LED will flash rapidly during a 2 block condition and will stop flashing after the switch is in a two block condition for more than 15 seconds The LED will flash randomly appro
11. transmit the signal correctly or not at all If your readings are off chances are the pressure transducer is defective Replace Note After exchanging the pressure transducer block BOTH transducer channels need to be zeroed see procedure Zero Setting The Transducer Inputs SkyAzul Equipment Solutions www skyazul com 301 371 6126 16 Service Manual PAT ps 85 8 LOAD THEORY Please note that the load displayed by the LMI is not a direct measurement but a calculated value that is based on a lot of factors Outside of the measured values sensors those include Operator settings such as o Operating mode configuration o Parts of Line Reeving Rigging parts such as Hook block weight Sling weights etc Tip height length of load line used Boom weights Before checking the system for a load reading problem make sure all of the above has been ruled out When you still feel the system is reading a sensor wrong and thus displaying an incorrect load use the following Use the above sections and the sensor signal display screen to check the following boom length reading angle transducer reading pressure transducer readings If all are correct use the zero setting and calibration screens to zero pressure transducers calibrate angle and length If you still have a problem replace pressure transducer block 9 A2B PROBLEM RADIO A2B OPTION CHECK FOR ANTI TWO BLOCK CONDITION Are the control levers locked out and is the cr
12. 0500 20 0500mV 0494mV 0 0 Ps 0 0 Ps 17 3 CALIBRATE LENGTH INPUT For extended boom the adjustment is done by software as described in 6 section Length Sensor Adjustment Procedure Use keys mark the main boom length calibration MB ANGLE Pressing to activate length calibration II CALIB SENSORS 2 YES to continue press w to calibrate press ll FULLY RETRACT MAINBOO 30 6 ft fully retract the main boom to continue press 9 MAINBOO 30 6 ft acknowledge main boom fully retracted to continue press w OK EXIT Press to calibrate FULLY EXTEND 100 ft fully extend the main boom continue press M 100 ft acknowledge main boom fully extended to continue press OK EXIT Press to calibrate HE HE HE HE O O 2 lt lt Al IX S IQ om m z O I SkyAzul Equipment Solutions www skyazul com 301 371 6126 42 Service Manual PAT ps 85 Check the sensor outputs screen retracted and extended lengths Retracted length should be correct at 0500mV and extended boom length will depend on the model 0502mV 2025mV Extended main boom millivolts 30 6 ft 55 7 174 CALIBRATE ANGLE INPUT The angle sensor is calibrated at four different reference angles of approximately 0 40 60 and 70 The BOOM specifies the calibration angle the boom should be moved to When CHANG is displayed by the actual boom a
13. 2 PROBLEM HARDWIRED A2B 19 11 CONSOLE DISPLAY eege 20 12 RADIO ANTI TWO BLOCK SYSTEM 21 12 1 SETUP OVERVvVvIEVW 21 12 2 CLEAR EXISTING SETUP SWITCHES 21 12 3 FIRST ID SETUP U 21 12 4 SETUP uuu yu 21 12 5 BATTERY REPLACEMENT 22 13 CAN BUS COMMUNICATION 23 14 TROUBLESHOOTING A SENSOR PROBLEM USING THE DISPLAY 31 15 DRAWINGS uuu u u Sau 32 15 1 CONSOLE CENTRAL UNIT TO CRANE WIRING 32 15 2 LENGTH ANGLE SENSOR WIRING DIAGRAM 33 15 3 HARDIWRED A2B WIRING DIAGRAM 34 16 SPARE PART LISTINGS 35 16 1 CONSOLE CENTRAL
14. Boom length and boom angle are transmitted by length angle CAN bus node mounted the side of the boom in the angle sensor box The length sensor cable reel is mounted inside the base which measures the boom length The PAT RATB works like our normal Anti Two Block It alerts to an impending two block condition This alert can come in the form of an audible alarm and visual LED or with the optional function lockout if the crane is so equipped The radio anti two block transmitter switch transmits a error condition when the switch closes or transmits an OK signal no less than every two seconds to the receive The transmitters send a unique serialized frequency on up to three separate channels to ensure accurate and consistent reception of data and to reduce the possibility of unnoticed failure The transmitter is powered by 4 C batteries The receiver is mounted into a receiver box locate near the operating station The receiver box provides the following indications Power status LINK Low Battery and A2B The receiver will work 10 32VDC and fused to 1 Amp SkyAz l Equipment Solutions www skyazul com 301 371 6126 System Description 3 3 1 DESCRIPTION OF THE SYSTEM COMPONENTS Fig 1 Components of the LMI system PAT DS 85 o 3 m SLIP RING FROM UPPER o LOWER WILL BE ONE THESE TWO 1 e 7 1 Operating B 2 Pressure 3 Length i bou d 4 Angle Sensor CA
15. ED BY THE CRANE MANUFACTURER 4 Hold plate and hook bolt up to boom and affix to boom by placing the inside curve of the hook bolts facing outward Mount cable reel to holes Front of cable reel should be 1 8 closer to boom than rear Front 2 7 8 Rear 3 5 Adjust nuts up and down to tighten and to mount the cable reel 6 Plate should be parallel with boom INSTALLATION 1 Set pretension of the cable reel by turning the drum counter clockwise 5 to 8 turns 2 Run the length cable through the cable guides and wrap the length cable around the boom tip anchor pin 4 or 5 wraps and secure with tie wraps Leave enough length cable to connect to boom tip junction box 3 Check the spooling If spooling is not layered properly carefully pull the cable out and respool the length cable SkyAzul Equipment Solutions www skyazul com 301 371 6126 4 Service Manual PAT 05 85 CALIBRATION 1 After installation remove cover from cable reel With the boom full retracted and boom stops disengaged if applicable adjust the length potentiometer by turning the screw in the center of the large nylon gear on the length sensor counter clockwise until a soft stop occurs and reinstall the cover on the reel ADJUST LENGTH POTENTIOMETER WITH BOOM FULLY RETRACTED TURN THE CENTER SCREW COUNTER CLOCKWISE SOFT STOP The length should be calibrated to be about 0 1 feet or 0 05m accurate for both retraced and extende
16. MEMBRANE VENT PG11 4 024 050 300 101 1 MAINBOARD CAN w o FLASH E EPROM 5 024 050 300 106 1 CONNECTION BOARD 6 031 300 050 223 2 FUSE 2 AMP 7 024 050 300 110 1 KEYBOARD 8 050 000 100 271 1 LC DISPLAY UNIT 9 092 000 060 391 1 CAN BUS CONNECTOR 5 PIN FEMALE 120 ohms 10 024 050 290 101 1 RIBBON CABLE ASSY 11 031 300 060 700 1 CABLE ASSEMBLY W GROUND CONNECTIONS 12 031 300 060 696 1 MOUNTING ASSEMBLY 1 5 BALL 13 031 300 050 624 1 MOUNTING ARM 4 63 DOUBLE SOCKET FOR 1 5 BALL 1 092 000 060 390 CAN BUS TERMINATOR 120 OHMS my Cable assemblies not included with console 1 Power Cable assembly wiring harness PART NO 031 300 060 443 2 CAN bus from console 90 connector to pressure transducer block PART NO 031 300 060 453 3 CAN bus from pressure transducer to angle sensor box PART NO 031 300 060 454 not shown See next page 36 Service Manual PAT ps 85 Power Cable assembly wiring harness CAN bus from console 90 connector to pressure PART NO 031 300 060 443 transducer block PART NO 031 300 060 453 e SE bus from pressure transducer to angle sensor box see below PART NO 031 300 060 454 16 2 PRESSURE TRANSDUCER BLOCK DAV314 0014 PART NO 044 314 060 014 Rod Side Cutting ring for pressure transducers PART NO 000 209 140 016 Hydraulic bulkhead adapter 9 16 18 JIC 37 x 16m x 1 5 PART 000 214 600 093 16 3 ANGLE SENSOR BOX PART NO
17. N Bus tw Y 5 Radio A2B 2 POWER 5 6 Radio Anti Two Block LOCKOU ALARM A2B i CR A S 5 ee Hardwired Anti Two Block Option u e 8 AE DE 1 Operating Console 2 Pressure Transducers i 3 Length Angle Sensor with connector LWG152 with tele length lt 49 or 2 LWG508 with tele length 105ft POWER 4 Length cable assembly to A2B switch via 6 pin receptacle LOCKOUT 5 Anti Two Block Switch ALARM DO3 SkyAzul Equipment Solutions www skyazul com 301 371 6126 4 Service Manual PAT ps 85 Central Unit Console Inside the console there is a CPU and connection board The board has hard mounted connector for power ground bus controller and slew indication Displays all geometrical information such as actual load maximum load permitted by load chart working radius and length angle and head height of main boom It also has LED s for operating condition OK overload and a pre warning An output to an alarm horn and a warning light are also available The display allows for a simple configuration setup as well as sensor calibration zero adjustment and troubleshooting sensor output screen Pressure Sensor The pressure sensor transforms hydraulic pressure into an electric signal pressure sensor block houses two sensors CAN bus controller and two bus connectors One pressure sensor is connected to the piston side of the lift cylinder and the other to the rod side Length Sensor reeling drum drives a potentiometer
18. RMATION U u 1 2 WARNINGS EE 1 3 SYSTEM DESCRIPTION U U u 2 3 1 DESCRIPTION OF THE SYSTEM COMPONENTS 3 4 FREQUENTLY ASKED QUESTIONS 5 5 ANGLETHEORY acera 6 6 LENGTH 4 1 9 6 1 LG105 CABLE REEL LENGTH CABLE REPLACEMENT PROCEDURE 11 6 2 LG105 CABLE REEL REPLACEMENT PROCEDURE 12 6 3 LG105 CABLE REEL LENGTH SENSOR REPLACEMENT PROCEDURE 12 6 4 LWG CABLE REEL LENGTH ANGLE SENSOR REPLACEMENT PROCEDURE 13 7 PRESSURE THEORY I u u 15 8 LOAD THEORY UU UU UU U UU 16 9 2 PROBLEM RADIO A2B OPTION 16 Controlldentification U 17 10
19. able should roll over the 7 8 inch guide when the cable is extended Replace and feed the cable through the cable guides e Install the cable thimble and clamp at the end of the cable e Remove the slack in the cable so the clamp is 1 to 2 inches from the roller guides e Pretension the cable reel with 4 full turns on the drum e Check the spooling If spooling is not layered properly carefully pull the cable out and respool cable Zero pot by turning it counterclockwise until it stops e Slide pot and bracket so gears mesh e Tighten 7mm nut e Pull cable and inspect gears for binding or slippage e Replace 4 conductor cable and connect to terminal strip Refer to Drawing 1 in Appendix e Replace cover 7 Install cable reel into mounting brackets 8 Run cable through U shaped guide in boom if applicable 9 Connect thimble to stud in boom 10 Check length measured and displayed tum SkyAz l Equipment Solutions www skyazul com 301 371 6126 Service PAT 05 85 6 2 LG105 CABLE REEL REPLACEMENT PROCEDURE Replace cable reel using the following procedure Refer to system electrical wiring diagram and cable reel parts list 1 Remove cable reel and guide from mounting brackets 2 Remove cover from cable reel 3 Disconnect the 4 conductor cable from terminal strip 4 Remove strain relief outer nut and slide cable out of strain relief 5 Install new cable reel preset from factory e Loosen 7mm standoff nut
20. ace central unit Error in the crane No valid data in the crane Upload valid crane data data file data file file Flash EPROM defective Replace central unit Error in load chart No valid data in the load Upload valid load chart file chart file file Flash EPROM defective Replace central unit Error in crane data No valid data in the crane Restore or upload valid file data file during crane data file calibration Flash EPROM defective Replace central unit Error in serial crane Calibration data file does Upload calibration data data file not contain valid data file Flash EPROM defective Replace central unit The number of the No valid data in the load Upload valid load chart selected File base chart file file and the programmed value are not identical Base number not Program the correct programmed base number 1 for base 1 2 for base 2 Load chart file wrongly Check base programmed programming in the load chart file E61 Error in the CAN CAN Bus cable between e Check the connection bus data transferfor the central unit and the between the central unit all CAN units sensor units defective or and the sensor units not connected wiring harness See section CAN Bus Communication Short circuit in a Replace Can Bus cable cable SkyAzul Equipment Solutions www skyazul com 301 371 6126 Error Codes 49 Error Code Error Possible Cause Elimination e Can bus port in the e Replace the central unit central unit
21. ake sure the module is getting power from the crane receiver Check wiring Ensure correct polarity of the power Replace OEM receiver Crane functions locked out all the time No power to the receiver Check LED lights on module Make sure the module is getting power from the crane Check wiring Ensure correct polarity of the power Replace OEM receiver Crane functions locked out all the time Incorrect wiring Check for power to lockout device Crane functions locked out all the time No reception Check if the green Link LED is on The green Link1 LED must be on for single hoist operation Link1 and Link2 must be on for 2 hoist operation See Link 1 LED troubleshooting Crane functions locked out all the time Fault in receiver module Check relay output voltage from receiver to lockouts Transmitter LED does not flash Pull switch wire rope Red LED will flash each 2 sec Replace batteries Replace transmitter Link 1 LED not on ID1 not set Set the ID of the transmitter See Section 5 Setup SkyAz l Equipment Solutions www skyazul com 301 371 6126 2 Problem hardwired a2b option 19 10 A2B PROBLEM HARDWIRED A2B OPTION A2B problem Are the control levers locked out and is the crane in an anti two block condition Is the anti two block warning light on YES Lower the hook block and or headache
22. al 5 GND Verify that the sensor is being supplied with 5V by measuring between pin 5 GND and Pin 1 of terminal X21 If the voltage is outside of a range of 4 75 to 5 25V the converter board might be defective Unplug angle sensor and measure again If the voltage is still off exchange converter board If unplugging the angle sensor made the voltage return into the acceptable range exchange angle sensor If the voltage is correct continue SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT 05 85 The angle sensor returns a voltage between 1 875V at 90 degrees and 3 125V at 0 degrees Angle Sensor Signal on Pin 3 Angle Voltage 90 1 875 75 2 083 60 2 292 45 2 500 30 2 708 15 2 917 0 3 125 Note Actual voltages will vary slightly Measure this voltage between Pin 5 GND and Pin 3 of Terminal X21 If you need to determine the angle for voltages other than the above do so by using the following formula Angle degrees 90 degrees Voltage 1 875 72 If this angle matches your actual angle but the indicated angle varies significantly more than 0 4 degrees the angle sensor is fine and the error is somewhere else If this angle varies significantly from your actual angle the angle sensor is bad and needs to be exchanged Otherwise continue At this point you have verified that the angle sensor is giving you the right output to match
23. al voltmeter with the capability to measure current will be reguired along with standard maintenance and service tools NOTE Knowledge of how to use a voltmeter to measure both voltage and current is assumed REFERENCE For system operation refer to the consoles 5 manual 031 300 190 165 2 WARNINGS The LMI is an operational aid that warns a crane operator of approaching overload conditions and of over hoist conditions that could cause damage to eguipment and personnel The device is not and shall not be a substitute for good operator judgment experience and use of accepted safe crane operating procedures The responsibility for the safe crane operation shall remain with the crane operator who shall ensure that all warnings and instructions supplied are fully understood and observed Prior to operating the crane the operator must carefully and thoroughly read and understand the information in this manual to ensure that he knows the operation and limitations of indicator and crane Proper functioning depends upon proper daily inspection and observance of the operating instructions set forth in this manual Refer to Section 6 Pre Operation Inspection and Calibration Verification of this handbook N WARNING The LMI can only work correctly if all adjustments have been properly set For correct adjustment the operator has to answer thoroughly and correctly all guestions asked during the setup procedure in accord
24. ance with the real rigging state of the crane To prevent material damage and serious or even fatal accidents the correct adjustment of the LMI has to be ensured before starting the crane operation SkyAzul Equipment Solutions www skyazul com 301 371 6126 BS vice 058 3 SYSTEM DESCRIPTION The DS 85 system is a CAN bus system consisting of a central micro processor unit operating console length angle sensor pressure transducers and anti two block switches The Load Indicator system operates on the principle of reference real comparison The real value resulting from the pressure measurement is compared with the reference data stored in the central processor memory and evaluated in the micro processor When limits are reached an overload warning signal is generated at the operators console At the same time the aggravating crane movements such as hoist up telescope out and boom down will be stopped The fixed data regarding the crane such as capacity charts boom weights centers of gravity and dimensions are stored in memory in the central processor unit This data is the reference information used to calculate the operating conditions The operating modes are selected by the operating mode key on the console by scrolling through the text messages defining the boom truck configuration The crane load is measured by pressure transducers attached to the piston and rod side of the hoist cylinders
25. ane in an anti two block condition YES Lower the hook block and or headache ball to correct two block condition If two 2 hoists are in use both hooks must be lowered e CHECK THE LED S ON THE RADIO ANTI TWO BLOCK RECEIVER BOX Red Power LED Red Alarm LED Sensor On Line Green LED 1 Green LED 2 Green LED 3 Green LED 4 Sensor Low Battery Yellow LED 1 Yellow LED 2 Yellow LED 3 Yellow LED 4 SkyAz l Equipment Solutions www skyazul com 301 371 6126 2 Problem Radio a2b option 17 Red Power LED Power is applied to the circuit board Red alarm LED An installed sensor is indicating an alarm or communication as been lost to an installed sensor Green LED 1 ON Sensor on channel 1 is installed and communicating correctly Green LED 1 FLASHING Sensor 1 is not communicating correctly Green LED 1 OFF No sensor is installed on channel 1 Yellow LED 1 ON Sensor 1 batteries are low and need replaced Note that the sensor is still operating correctly Green LED 2 ON Sensor 2 is installed and communicating correctly Green LED 2 FLASHING Sensor 2 is not communicating correctly Green LED 2 OFF No sensor is installed on channel 2 Yellow LED 2 ON Sensor 2 batteries are low and need replaced Note that the sensor is still operating correctly Green LED 3 ON Sensor 3 is installed and communicating correctly Green LED 3 FLASHING Sens
26. as 3 5 turns of pre loading on the reel Go back to your indication screen and compare length indicated and actual again If the indicated length varies significantly from your actual length more than 0 3 feet the length sensor might be bad and needs to be exchanged Note however that the error could be in the converter board The length sensor has a potentiometer built in that is driven by a gear drive from the cable drum As the length changes the cable drum will turn and with it the potentiometer s axle The converter board supplies a voltage of about 4 7V to the length potentiometer and in return monitors the output voltage of the potentiometer The terminal used is X20 The length sensor is connected as follows SkyAz l Equipment Solutions www skyazul com 301 371 6126 9 PAT 05 85 Terminal 20 1 4 8 3 Signal 5 0 2V Verify that the sensor is being supplied with about 4 7V by measuring between pin 5 and Pin 1 of terminal X20 If the voltage is outside of a range of 4 5 to 5 V the converter board might be defective Unplug length sensor and measure again If the voltage is still off exchange converter board If unplugging the length sensor made the voltage return into the acceptable range exchange length sensor If the voltage is correct continue The length sensor returns a voltage between 0 16V at 0 turns of the length pot fully retracted and 4 84V at 10 turns
27. aud Wireless Modulo gt w Nc Power on X XC09 009N 1 5 Blinking yellow green LED calibrate channel sensor 1 oe 12 vet Pr 2 Ag a g Blinking yellow and green LED calibrate channel sensor 2 12 2 CLEAR EXISTING SETUP SWITCHES Press and hold the yellow ID button for 15 seconds the ID LED will begin to blink and then go off when cleared Note It is only necessary to complete this operation when changing from a duel switch setup to a single switch When setup is complete the new transmitter switch will over write the old ID code with a new one 12 3 FIRST ID SETUP To configure the system install batteries into the transmitter to be used Turn on the crane power Open the receiver enclosure and slide out the receiver board Press and hold the yellow ID button on the OEM module for 7 seconds until the ID 1 LED blinks Release the yellow ID button The receiver will search for a transmitter for the next 30 seconds Pull on the cable of the transmitter and then release it The yellow ID 1 LED should now be on solid The transmitter and receiver are now set up and will work only with each other 12 4 SECOND ID SETUP Only setup a second transmitter switch after the first has been setup To program second radio a2b switch Ground pin 3 of the receiver and use the first ID setup instructions above Note Use ID 2 LED to
28. ball to correct the Ensure the two block problem If two Turn power off remove bypass plug and bypass hoists are in use both measure the resistance at the boom nose box plug is hooks must be lowered installed between terminals 1 and 3 with an ohmmeter Switch closed 0 ohms weight installed Switch open 1 Megaohm weight removed Are the ohmmeter Ensure bypass plug is plugged into the readings correct boom nose box Remove wires and measure the A2B signal in the cable reel between the X1 brown an X2 red wires on the slip ring with an ohmmeter Switch closed 4700 500 Ohms Switch open gt 1 Meqaohm Are the ohmmeter readings correct Plug the bypass plug into the boom nose box and refer to system wiring to check wire connections in boom nose box Check for damaged length cable and wiring If broken length cable refer to system wiring Remove wires and measure the A2B signal in the cable reel between terminal 7 and 8 with an ohmmeter Switch closed 4700 500 Ohms Switch open gt 1 Megaohm If wiring is correct replace A2B Are the ohmmeter readings correct NO Replace the slip ring A problem lies with either the wiring YES harness cable reel length angle boards and or the central unit SkyAz l Equipment Solutions www skyazul com 301 371 6126 20 Service Manual PAT ps 85 11 CONSOLE DISPLAY If the console is not show
29. ch Replace A2B switch Replace cable to the A2B switch If an error message is displayed which is not contained in above list please contact the SkyAzul service department SkyAzul Equipment Solutions www skyazul com 301 371 6126 Troubleshooting Moisture 51 19 TROUBLESHOOTING MOISTURE The PAT DS85 LMI contains electronic components in various locations such as central unit sensors junction boxes etc These internal components cannot be designed to withstand exposure to moisture over a longer period of time For this reason the housings of the components are water protected according to IP 65 If you find water or moisture inside any of the housings the source for the water ingress has to be detected and corrected to ensure proper operation There are two major possibilities for the occurrence of excessive moisture inside an enclosure 1 Water ingress 2 Condensation This outline gives instructions for detecting the cause for excessive moisture by using simple troubleshooting methods and how to prevent the moisture ingress from happening again 19 1 WATER INGRESS There are 6 possibilities for water to enter an enclosure 1 Spray Cleaning 2 Missing Loose Screws 3 Bent Lid 4 Defective Gasket 5 Loose Strain Relieves 6 Water Entry Through External Cabling It is possible to find out the source of water ingress by going through the following steps and ruling out one possibility after the other unti
30. d lengths 2 The angle sensor must be level Remove cover from reel Adjust the level of the angle sensor by loosening the socket head cap screws and aligning the top of the angle sensor until parallel with the boom Reinstall the cover on the reel SkyAz l Eguipment Solutions www skyazul com 301 371 6126 Pressure THEORY 15 7 PRESSURE THEORY The System measures the pressure of the boom lift cylinder for both rod and piston side Both sensors are contained within one box that also contains the electronics needed for amplification and creation of the CAN Bus signal Block Diagram 2 Pressure CAN Bus Measuring Converter DS 85 Console The signal runs from the pressure transducer as digital information on the CAN Bus to the central n unit Pressure Transducer Cells CU So what do you do when you are having a problem with your length read out Start by checking the pressure display Refer to the section Troubleshooting A Sensor Problem Using The Display to call up the sensor signal on your console display The easiest spot to check the signal at is when there is no pressure applied to the sensor at all The only time this is for certain is when your pressure lines are drained and disconnected In that case the readout should show about 500mV 25mV and 0 PSI Small variations could be adjusted see section Service Screen For Sensor Calibration The CAN Bus is digital and as such will either
31. e cable reel see section CAN Bus Communication e See E63 e See E63 e See E62 e See E62 e See E63 e See E63 SkyAzul Equipment Solutions www skyazul com 301 371 6126 50 Service Manual PAT ps 85 Error Code __ Possible Cause Elimination Error in the slewing angle measurement Wrong rigging condition Error in the radius determination Short circuit in the A2B switch circuit A2B switch circuit disconnected No valid A2B switch status Operating mode switchover with load Note The difference between the average of the slewing angle and one of the wipers of the slewing potentiometer is out of the tolerance The selected rigging condition is not contained in the crane data file The computed radius is too small negative deflection The operating mode on the console has been switched over with the boom loaded Short circuit in the A2B switch Short circuit in the cable to the A2B switch Disconnected cable in the A2B switch Disconnected cable to the A2B switch Sensor wrong function CAN bus delay e See section Slewing Sensing Select another rigging condition Check the programming in the crane data file Check the programming in the crane data file Select operating mode without load on the boom Replace A2B switch Replace cable to the A2B switch Connect or replace cable in the A2B switch Connect or replace cable to the A2B swit
32. een exceeded Upper limit value in refer to E1A refer to E1A measuring channel slewing angle 2 has been exceeded Error in the system The system program file Upload valid system program is defective software Error in the logical program flow System program and crane data file do not match System program and load chart file do not match Flash EPROM defective System program file is defective Flash EPROM defective The system program in the LMI does not match to the programming in the crane data file The system program in the LMI and the programming in the load chart file do not match Replace central unit Upload valid system software Replace central unit Upload valid system program file or the valid crane data file Upload valid system program file or the valid load chart file SkyAzul Equipment Solutions www skyazul com 301 371 6126 48 Service Manual PAT ps 85 Error Code __ Possible Cause Elimination Error in the Write read memory e Replace central unit write read memory RAM or central unit defective E47 Error in the The CRC sign of the e Restart the LMI monitored write monitored write read read memory memory is wrong The The buffer battery is Replace buffer battery verification of the discharged 2 at on the central unit monitored 1kOhm write read memory provides an incoherent result Central unit defective Repl
33. holding pot bracket e Slide bracket and pot away from worm gear NOTE The cable should roll over the 7 8 inch guide when the cable is extended e Install the cable thimble and clamp at the end of the cable Pretension the cable reel with 4 full turns on the drum e Check the spooling If spooling is not layered properly carefully pull the cable out and respool cable e Zero pot by turning it counterclockwise until it stops e Slide pot and bracket so gears mesh e Tighten 7mm nut e Pull cable and inspect gears for binding or slippage e Replace 4 conductor cable and connect to terminal strip Refer to Drawing 1 in Appendix e Replace cover 6 Install cable reel into mounting brackets 7 Run cable through U shaped guide in boom if applicable 8 Connect thimble to stud in boom 9 Check length measured and displayed 6 3 LG105 CABLE REEL LENGTH SENSOR REPLACEMENT PROCEDURE Replace length sensor using the following procedure Refer to system electrical wiring diagram and cable reel parts list 1 Remove cable reel and guide from mounting brackets 2 Remove cover from cable reel 3 Disconnect the 4 conductor cable from terminal strip 4 Remove strain relief outer nut and slide cable out of strain relief 5 Replace potentiometer e Loosen 7mm standoff nut holding pot bracket e Slide bracket and pot away from worm gear NOTE The cable should roll over the 7 8 inch guide when the cable is extended e Replace potentiometer e Zero pot b
34. indicate status of second switch The transmitter s and receiver are now set up to work only with each other Test the system using the instructions in section 7 System Testing SkyAz l Equipment Solutions www skyazul com 301 371 6126 22 Service Manual PAT ps 85 12 5 BATTERY REPLACEMENT The only maintenance required is to change the batteries when required Also check the mounting hardware daily to ensure that there is no damage Replace any damaged parts before operating the crane To replace the batteries remove the 4 screws from the transmitter housing During battery replacement use caution when opening the battery cover and transmitter to avoid damage to the gasket causing moisture ingress which could corrode the batteries and terminals Inspect the gasket surface on the transmitter for nicks or other damages that may prevent the gasket from sealing If it appears to be damaged a replacement gasket should be installed Install 4 fresh batteries into the proper location and direction as indicated on the battery holder Make sure that the cardboard tube is installed as shown LOOSEN 4 SCREWS INSPECT CONDITION OF GASKET 922 umante Tm EINO en INSTALLED BATTERIES SkyAz l Eguipment Solutions www skyazul com 301 371 6126 CAN Bus Communication 23 13 CAN BUS COMMUNICATION e BRIEF DESCRIPTION OF A CAN BUS SYSTEM CAN stands for Controller Area Netwo
35. ing If not most likely power is missing CAN Bus electronics in length angle sensor Verify by measurement on connector X1 LED X1 CAN Measure between pins GND and 2 Next check all pins of the CAN bus cable for continuity and cross check for short circuits E 64 means that the pressure transducer is working fine but the cable reel is not so we most likely have a defective connection between those two components If this is tested to not be the case missing connections short circuits measure with Ohm meter the board in the cable reel might be defective see also chapter Angle Sensing If you suspect a sensor error or problem with a sensor compare the indicated physical value of the sensor on the display screen with the real value i e length angle etc The voltages given are internal calculation values only you will not be able to actually measure them anywhere on the electronics Typical values to be expected are e Pressure transducers piston and rod 500mV 0 PSI 4500mV maximum PSI e Length sensor 500mV retracted boom length voltage extended depends on the various boom lengths e Angle sensor 4500mV at 0 2500mV at 45 or 500mV at 90 SkyAz l Equipment Solutions www skyazul com 301 371 6126 28 Service Manual PAT ps 85 Please refer to table below for more values Voltage Values displayed mV 10mV Value di
36. ing any lights such as warning lights backlighting etc it is most likely missing power Start with the following Warning Lights WE Backlighting Check if power is being supplied to the console central unit Measure on the 16 socket connector Pin 1 is Ub 12V Pin is GND If you have no power check wiring harness and crane power Otherwise open console Check fuses in console F1 and F2 are 2amp fuses located the connection board Test the F2 fuse by placing an OHM meter across pin 1 of the 16 pin connector and pin 2 of the 5 pin can bus connector Check for power by using the LED on the underside of the connection board and at Pin 1 Ub and Pin 3 GND If the LED is on and you have power on the connector either the software is defective or the console electronics need to be replaced H Fuses F1 and F2 SkyAz l Equipment Solutions www skyazul com 301 371 6126 radio Anti two Block system Setup Calibration 21 12 RADIO ANTI TWO BLOCK SYSTEM SETUP CALIBRATION 121 SETUP OVERVIEW The RATB is easily configured to communicate with up to 2 transmitters Simply by pressing and holding the yellow ID button for 7 seconds the receiver can sense the transmitters being used and configure the receiver to listen to only those transmitters There are no numbers ID s or codes to remember or write down LED on increase load LED off decrease load ID Set Button h HIRSCHMANN 9XCite 900 MHz 9600 B
37. is calculated by the system from the geometry information in the computer the operator s selections and all the sensor inputs If the load display is off it can therefore be due to an error in any or several of these inputs Refer to section Load sensing to narrow down the source of your problem e THE CONSOLE DISPLAY IS BLANK If the console does not show any sign at all no lights no buzzer no display the problem is either the wiring between console and crane power or the console itself Refer to section No console display for further troubleshooting HAVE AN A2B PROBLEM Please go to sectionA2B PROBLEM HAVE A CAN BUS PROBLEM Please go to section CAN Bus Communication e NEED TO IDENTIFY A SPARE PART Please go to the Spare Part Listings HAVE NOTICED WATER IN SOME PART OF THE SYSTEM Please go to section Troubleshooting Moisture SkyAzul Equipment Solutions www skyazul com 301 371 6126 6 Service Manual PAT ps 85 5 ANGLE THEORY The System measures the angle of the main boom of the machine with an angle sensor The angle sensor is contained within the angle sensor box Radio A2B option or within the Cable Reel Hardwired A2B option located on the left side of the main boom Block Diagram CAN Bus DS 85 Console Converter x CU Cable Reel Angle Sensor Box Pressure Transducer ERE ud CS RIS ud EC Qa Sa ieu nu yq ed eei The signal runs from the angle
38. it Authorization Number must be entered OK Use and keys to increase and decrease each digit Use to confirm entry Having successfully entered a valid password use and D keys to mark the piston side the rod side Zero setting and length and angle calibration The calibration sensor screen will remain available and accessible without entering the user number until system is power off 17 2 ZERO SETTING THE TRANSDUCER INPUTS NOTE The only thing adjustable for the pressure transducers is the zero point which is the voltage the transducer outputs when there is no zero pressure sensed CAUTION Ensure there is no pressure in the hydraulic line when disconnecting the hoses from pressure transducers Use and 4 keys to mark the piston side or rod side zero setting PISTON PRESS The piston side or rod side zero ROD PRESS B ROD PRESS point setting function is activated MB LENGTH as shown in the screens above and pressing to calibrate selected sensor CALIB SENSORS 2 YES ex SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Screen Sensor Calibration 41 BOOM DOWN COMPL When the boom is in the rest position bleed to continue DISCONNECT HYDR ja 4 press D H DISCONNECT HYDR GH OK Press continue K T Press to calibrate Check the sensor outputs screen to check the zero point At the zero point the millivolt should be
39. itted area Refer to Section 8 Extend retract boom to the correct length Retract boom Check the prestress of the cable reel cable must be taut Open the length sensor and carefully turn the length sensor pot counterclockwise until the detent by means of a screw driver Replace the complete clutch including drive wheel and adjust length sensor pot as described above SkyAzul Equipment Solutions www skyazul com 301 371 6126 46 Service Manual PAT ps 85 Error Code __ Possible Cause Elimination Fallen below lower limit value for measuring channel length main boom Fallen below the lower limit value in the measuring channel pressure piston side Fallen below lower limit value in the measuring channel pressure rod side Fallen below lower limit value in measuring channel force Fallen below lower limit value in measuring channel angle main boom e Length potentiometer is defective e Replace length potentiometer see section Length Sensing Pressure transducer is defective refer to E12 Force transducer defective Angle potentiometer defective Angle potentiometer defective Replace pressure transducer see section Pressure Sensing refer to E12 Replace force transducer Replace sensor unit Replace angle sensor see section Angle Sensing Refer to E 15 telescope 11 Fallen below lower limit value in measuring channel
40. l the cause is identified 1 Spray Cleaning The enclosures used for the PAT LMI system are water protected to IP 65 This means protection against the environment such as rain However through the use of spray cleaner at short distances it is possible to force water through the gasket or strain relieves For this reason avoid spraying any components from short distances with spray cleaners Convey this fact to any member of a maintenance crew 2 Missing Loose Screws All screws have to be present and to be equally tight to ensure water protection of the enclosure If there are screws missing replace them If no screw is missing check the tightness If any were loose then open all screws and then re tighten them equally 3 Bent Lid An enclosure will only seal correctly if the lid is not bent To check this loosen all screws of the lid take the lid off the box and visually inspect it for deflection If the lid is bent or damaged it needs to be replaced Try to determine what has caused the lid to be bent and eliminate the reason for that Order a new lid through your PAT representative SkyAzul Equipment Solutions www skyazul com 301 371 6126 S250 PAT 05 85 4 Defective Gasket The gasket underneath the lid seals the unit The gasket needs to be in good condition in order to seal correctly If the gasket is torn brittle or severely bent it needs to be replaced Order a new gasket through your PAT represe
41. low chart Check and verify length sensor voltages and signals as described in length sensor error flow chart If sensor signal voltage is incorrect replace sensor If you suspect a sensor error or problem with a sensor compare the indicated physical value of the sensor on the display screen with the real value i e length angle etc The voltages given are internal calculation values only you will not be able to actually measure them anywhere on the electronics Typical values to be expected are e Pressure transducers piston and rod 500mV 0 PSI 4500mV maximum PSI e Length sensor 500mV retracted boom length voltage extended depends on the various boom lengths Angle sensor 4500mV at 0 2500 at 45 or 500mV at 90 X20 length X21 angle X14 A2B SkyAzul Equipment Solutions www skyazul com 301 371 6126 Troubleshooting Sensor Problem The Display 31 14 TROUBLESHOOTING A SENSOR PROBLEM USING THE DISPLAY To determine whether there is a problem with a sensor the system has sensor output screen built in to make trouble shooting easier This is the right place to start if you are suspecting a problem with a sensor and you dont have an error code displayed The screen will show all sensor inputs as in the example below For each sensor an eguivalent voltage is shown in millivolts along with the physical sensor value that that voltage refers to Pressure sensors are show
42. n with physical values of bar angle sensors in degrees and length sensors feet or meter for metric 5 Enter the service screen using the procedure is described below To start function press x SENSOR OUTPUTS EXIT OK press to select the limit marked at the upper left of the screen Scroll through the following screen to see piston and rod side voltages and pressures PISTON ROD 1532mV 0685mV 1131 Ps 206 4 Ps length angle voltages measurements LENGTH ANGLE 0502mV 2025mV 30 6 ft 55 77 The values shown in the screen here are just examples of actual values Refer to the table listed below for actual value ranges SkyAz l Equipment Solutions www skyazul com 301 371 6126 32 Service Manual PAT ps 85 15 DRAWINGS 151 CONSOLE CENTRAL UNIT TO CRANE WIRING DIAGRAM eg W 2 y 2 5 y J J N ak Y XX M 2 Z 4 k p e o o E XK LOW 2 POWER LINK ALARM RATB RECEIVER MODULE A o 9 9 e l e o D eee oo SkyAzul Equipment Solutions www skyazul com 301 371 6126 Drawings 15 2 LENGTH ANGLE SENSOR WIRING DIAGRAM ga 25 VYY Yy e Ge NN
43. ngle the boom angle maybe calibrated The previously calibrated angles define the reference angles NOTE This process should be repeated if sensor is ever removed or replaced Use and D keys to mark the main boom angle calibration MB ANGLE Press to activate angle calibration CALIB ANGLE 2 YES cx to calibrate press BOOM T is calibration angle CHANG is actual angle move boom HM BOOM 0 0 DEG the CHANGE angle is with in 2 of the BOOM T angle to CHANG 0 0 DEG continue press D CHANGE 0 0 DEG Mark CHANGE and press to change angle calibration OK Mark OK if no change is necessary S BOOM T 00 DEG Use and keys to change angle to match the BOOM T CHANGE DEG OK angle Press to calibrate the main boom angle y BOOM 403 DEG Move boom so the CHANGE angle is with in 2 of the BOOM T 2 OK 0 1 DEG angle to continue press H BOOM T 40 3 DEG Mark CHANGE and press to change angle calibration CHANG 40 0 DEG Mark if no change is necessary SkyAz l Equipment Solutions www skyazul com 301 371 6126 Service Screen Sensor Calibration 43 BOOM T 403 DEG Use D keys to change CHANGE angle to match the BOOM CHANG 40 0 DEG NM angle Press to calibrate the main boom angle BOOM T 656 DEG Move boom so the CHANGE angle is with in 2 of the BOOM T angle to 40 3 DEG continue press 4 M BOOM 656 Mark CHANGE and press to
44. not very likely that there is a problem with it since the same cable carries also the signals from the cable reel and those appear to be fine You can verify that power is being supplied to the sensor by testing the CAN connectors per the above pin layout If you are sure that the sensor is being supplied you have to replace the pressure transducer Ohm the cable from the console to the transducer block Cable checks good Replace Cable Is power being Verify that power is being supplied supplied by to the sensor by testing the CAN sensor connectors per the pin layout Replace sensor Replace pressure transducer Connector M12 5 contacts Pin Layout CiA DR 303 1 7 2 Pin 1 Shield 2 U Pin3 Ground Pin 4 CAN High Pin5 CANLow e E63 In case of an E63 the pressure transducer is reporting an internal problem You cannot troubleshoot any further but need to replace the pressure transducer SkyAz l Equipment Solutions www skyazul com 301 371 6126 CAN Bus Communication 27 4 In case of E64 the CU is reporting no signal from the CAN Bus converter board in the angle sensor box Start by checking your cabling between pressure transducer and cable reel You can verify that power is being supplied to the sensor by testing the CAN connectors per the above pin layout or by opening up the angle sensor box remove the lid and making sure the red LED on the board is blink
45. ntative 5 Loose Strain Relieves The strain relieves allow cabling to enter the box without allowing water to enter it The strain relieves have to be correctly tightened in order to do this Check the tightness by taking the external cable into one hand and carefully trying to turn it If the internal wires turn with the outer cable the strain relief is loose Get a new grommet insert through your SkyAzul representative and replace the existing one with the new one Tighten the strain relief correctly Note Whenever a strain relief is opened i e to replace a cable a new grommet needs to be used Never re use any grommet or the strain relief will not seal properly 6 Water Entry Through External Cabling Even with a tight strain relief water may still enter the box through the inside of the cable In this case you have to find out why and where water enters the cable Look for damages to the cable itself and inspect the opposite side of the cable In example if the cable comes from a connector that is full of water the water will run through the inside of the cable and fill up the central unit too 19 2 CONDENSATION In a climate with high humidity and rapidly changing temperatures condensation can happen inside any enclosure usually the larger the volume of the box the more likely In this case water drops build up on the inner components when humid air is trapped inside the box With condensation water tightness is not a problem
46. or 3 is not communicating correctly Green LED 3 OFF No sensor is installed on channel 3 Yellow LED 3 ON Sensor 3 batteries are low and need replaced Note that the sensor is still operating correctly Green LED 4 ON Sensor 4 is installed and communicating correctly Green LED 4 FLASHING Sensor 4 is not communicating correctly Green LED 4 OFF No sensor is installed on channel 4 Yellow LED 4 ON Sensor 4 batteries are low and need replaced Note that the sensor is still operating correctly Green Heartbeat LED This will flash during normal operation If it is a solid or off the receiver has a software error or the board has a component failure All LEDs are located inside the receiver box e Control Identification Sensor Channel 1 output jumper J4 Sensor Channel 2 output jumper J3 Sensor 3 2 output jumper J2 Sensor 4 Channel 2 output jumper J1 ID button power red sensor on line 1 4 left to right green noo xxx wan 4 J r 10 4 LEDS 1 4 left to right yellow CURRENT 2 az LEDS Green Heartbeat LED located just under radio module software chip radio module 031 300 300 024 omn 00 Baud 44 odule SkyAz l Equipment Solutions www skyazul com 301 371 6126 18 Service Manual PAT ps 85 Problem Cause Solution No LEDS light on No power to receiver M
47. rk Its intended use is as a serial bus system for a network of controllers Each controller connected through a CAN chip is called a node and is mostly used to acquire data from a sensor All nodes are connected to a common bus and all nodes are able to simultaneously read the data on that bus Also all nodes are able to transmit data on that bus however only one node at a given time has write access to the bus If the message is relevant it will be processed otherwise it is ignored The unique identifier also determines the priority of the message The lower the numerical value of the identifier the higher the priority The cable bus is a twisted pair of shielded wire Data can be transmitted in blocks from 0 8 bytes at a maximum transfer rate of 1 Mbit s for networks up to 40 meters For longer network distances the maximum transfer rate must be reduced to 50 Kbit s for a 1 km network distance CAN will operate in extremely harsh environments and the extensive error checking mechanisms ensure that any transmission errors are detected The system measures the length of the main boom the angle of the main boom and the pressures of the lift cylinder via CAN Bus connection Since this is digital bus connection it is not possible to measure the signals on the bus with a multimeter Instead the LMI provides you with error codes that give you an indication of the bus state The error codes are one of the following E61 Error in the CAN bu
48. s are present Finally check the 2 amp fuses in the console If a fuse is blown replacement of the 2 amp fuse is reguired This condition can be tested by placing an OHM meter across pin 1 of the 16 pin connector and pin 2 of the 5 pin can bus connector 9 Shield U Ground CAN High CAN Low d Es D Z x S LCS m 2 amp fuse location N SkyAz l Eguipment Solutions www skyazul com 301 371 6126 CAN Bus Communication e E61 continued Connect the two cables on the Transducer block together Connect the angle sensor can bus cable to the transducer block Remove the can bus connector at angle sensor Ohm the cable from the console to the transducer block If cable checks qood then replace the console Replace the can bus cable between the angle sensor and transducer block DIEPLAY STATION Ohm out connector at the angle sensor If the connector Checks good then replace can bus converter board FRESSURE TRANSDUCER EXTEND SIDE PISTON SIDE PRESSURE TRANSDUCERS LOCATED INSIDE TURRET SkyAz l Equipment Solutions www skyazul com 301 371 6126 OPERATOR CONTROL 25 26 Service Manual PAT ps 85 E62 In case of an E62 the CU is reporting no signal from the pressure transducer Start by checking your cabling between CU and pressure transducer even though it is
49. s data transfer for all CAN units E62 Error in the can bus data transfer of the pressure transducer sensor unit E63 Error in the can bus pressure transducer sensor unit E64 Error in the can bus data transfer of the length angle sensor unit E65 Error in the can bus length angle sensor unit Block Diagram CAN Bus Converter Console CU Pressure Transducer Angle sensor box The block diagram tries to clarify that If the CU does not see any CAN Bus componert it will report E61 If it sees only the cable reel it will report an E62 pressure transducer missing If it sees only the pressure transducer it will report an E64 cable reel missing E63 means that the pressure transducer is available but is reporting an internal error E65 means that the cable reel unit is available but is reporting an internal error SkyAzul Equipment Solutions www skyazul com 301 371 6126 24 Service Manual PAT ps 85 So what do you do when you are having a problem with one of those codes e E61 In case of 61 start by checking your cabling You can verify that power is being supplied to the sensor by testing the CAN connectors per this layout Connector M12 5 contacts Pin Layout CiA DR 303 1 7 2 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Measure between pins 3 and 2 for crane voltage If you see voltage check all pins for continuity Remember the CU is reporting that neither CAN Bus converter board nor pressure transducer
50. sensor to the Can Bus converter board both located in the angle sensor box From there it travels as digital information on the CAN Bus to the pressure sensor which acts as a T connector to the main CAN Bus running to the console central unit So what do you do when you are having a problem with your angle read out Start by verifying the angle display Refer to the section Troubleshooting A Sensor Problem Using The Display to call up the sensor signal on your console display The CAN Bus is digital and as such will either transmit the signal correctly or not at all If your readings are off you have to determine what is causing the problem Start by opening the angle sensor box and locate the angle sensor top and the CAN Bus converter board bottom CAN Bus electronics in cable reel CAN Bus electronics in angle sensor box SkyAzul Equipment Solutions www skyazul com 301 371 6126 Angle THEORY 7 X20 length Ken X21 angle X1 CAN X14 A2B X20 length X21 angle LED CAN Bus electronics in cable reel The angle sensor has a potentiometer built in that is driven by pendulum As the angle changes so will the pendulum and with it the potentiometers axle The converter board supplies a constant voltage of 5V to the angle sensor and return monitors the voltage of the potentiometer The terminal used is X21 The angle sensor is connected as follows Terminal X21 1 DM 3 Sign
51. slewing angle 1 Fallen below lower limit value in measuring channel slewing angle 2 Upper limit value in measuring channel main boom length E16 Fallen below lower limit value in measuring channel angle 2 E17 Fallen below lower limit value length has been exceeded Length potentiometer defective Cable between the central unit and the slewing angle sensor defective or loose Slewing angle potentiometer is defective refer to E1A refer to E11 Replace length sensor see section Length Sensing Check cable as well as plugs replace if need be Replace slewing angle sensor refer to E1A refer to E11 SkyAz l Equipment Solutions www skyazul com 301 371 6126 Error Codes 47 E22 Upper limit value in refer to E12 to 12 measuring channel pressure piston side has been exceeded Upper limit value in refer to E12 refer to E12 measuring channel pressure rod side has been exceeded Upper limit value in refer to E14 refer to E14 measuring channel force has been exceeded Upper limit value in refer to E15 refer to E15 measuring channel main boom angle has been exceeded Upper limit value in refer to E16 refer to E16 measuring channel angle 2 has been exceeded Upper limit value in refer to E17 refer to E17 measuring channel length telescope 1 has been exceeded Upper limit value in refer to refer to measuring channel slewing angle 1 has b
52. splayed Value Pressure Transducers 300 bar type 314 PSI Bar 500 0 0 1500 1088 75 2500 2176 150 3500 3263 225 4500 4351 300 Angle Sensor degrees 500 90 boom vertical 1500 67 5 2500 45 3500 22 5 4500 0 boom horizontal Length Sensor feet 500 0 fully retracted 1500 2500 3500 4500 If the displayed value does differ from the actual value please refer to the following sections to find the cause of the problem If the displayed angle is incorrect please go to section Angle Sensing SkyAz l Equipment Solutions www skyazul com 301 371 6126 CAN Bus Communication 29 Cable checks good Connector checks good Replace connector PRESSURE TRANSDUCER EXTEND SIGE PISTON SIDE RETRACT SIDE ROD SIDE Ss V PRESSURE TRANSDUCERS LOCATED INSIDE TURRET SkyAzul Equipment Solutions www skyazul com 301 371 6126 30 Service Manual PAT ps 85 E65 In case of E65 the converter board in the angle sensor box or cable reel is reporting internal problem In most cases this will be an angle sensor or length potentiometer Go to those chapters Angle Sensing Length Sensing to continue trouble shooting Open Cable Reel Locate CanBus board and sensor locations Check and verify angle sensor voltages and signals as described below Are signals and voltages correct Replace sensor or board as described in angle sensor f
53. the noted sections for detailed Troubleshooting information ErrorCodelErrrr Possible Cause Elimination Fallen below radius e Fallen below the range or angle range minimum radius or gone exceeded past the maximum angle specified in the respective load chart due to luffing up the boom too far Radius range e Gone past the maximum exceeded or fallen radius or fallen below the below angle range minimum angle specified in the respective load chart due to luffing down the boom too far Luff down the boom to a radius or angle specified in the load chart Luff up the boom to a radius or angle specified in the load chart Non permitted slewing The slewing zone with e Slew to permitted area zone no load area load is not permitted Operating mode not acknowledged or non permitted slewing zone e An incorrect operating mode has been selected The boom is in a non permitted slewing zone Prohibited length range Boom has been extended either too far or not far enough e g if it is prohibited to go beyond a certain maximum boom length or with load curves for jibs where the main boom has to be extended to a certain length Length sensor adjustment has changed e g the cable slid off the length sensor reel Clutch between length sensor pot and drive is defective e Set the correct operating mode for the operating configuration in question Refer to Operator s Handbook Slew the boom to a perm
54. ximately every 2 seconds when the switch is transmitting When in sleep mode the LED will not flash Hardwired Anti Two Block Switch The anti two block switch monitors the load block and it s relationship with the head of the boom working condition the switch is closed When the load block strikes the weight the circuit opens disengaging a relay output to the lock out solenoid valves where applicable To check the cable for damage short circuit to ground there is a 4 7k resistor between ground and the contact of the switch to give a signal back to the central unit The weight at the anti two block switch keeps the switch closed until the load block strikes it SkyAzul Equipment Solutions www skyazul com 301 371 6126 FREQUENTLY ASKED QUESTIONS 4 FREQUENTLY ASKED QUESTIONS So what s wrong Assuming you reading these pages because of some of problem with the PAT system let us try to guide you quickly to solving the problem In most cases your problem will fall under the following categories HAVE AN ERROR CODE INDICATED ON THE CONSOLE Please go to section Error Codes e THE DISPLAYED ANGLE DOES NOT MATCH THE ACTUAL BOOM ANGLE Start in section Angle Sensing to check the indicated angle e THE DISPLAYED LENGTH DOES NOT MATCH THE ACTUAL BOOM LENGTH Start in section Length Sensing to check the indicated length e THE DISPLAYED LOAD DOES NOT MATCH THE ACTUAL LOAD Please note that the indicated load
55. y turning it counterclockwise until it stops e Slide pot and bracket so gears mesh e Tighten 7mm nut e Pull cable and inspect gears for binding or slippage e Replace 4 conductor cable and connect to terminal strip Refer to Drawing 1 in Appendix e Replace cover 6 Install cable reel into mounting brackets 7 Run cable through U shaped guide in boom if applicable 8 Connect thimble to stud in boom 9 Check length measured and displayed SkyAz l Equipment Solutions www skyazul com 301 371 6126 Length THEORY 13 64 LWG CABLE REEL LENGTH ANGLE SENSOR REPLACEMENT PROCEDURE MOUNTING Mount cable reel on cab side of boom to ensure adequate visibility Length cable should spool from the top of the drum NOTE Boom with a flat side Use four 4 2 inch hook bolts Trapezoidal Boom with a slanted side Use two 2 2 inch and two 2 4 inch hook bolts There are four 4 72 holes on the mounting plate 1 Thread a nut onto the upper threaded part of the hook bolt then place a lock washer and washer onto hook bolt Slide bushing on to free end curved part of hook bolt 2 Insert the hook bolt into the holes in the cable reel mounting plate NOTE For a trapezoidal boom the 4 hook bolts go into the top two 2 holes of the mounting plate 3 Thread a nut onto the threaded part of the hook bolt then place a lock washer and washer onto bolt to fasten it into place Repeat for each hook bolt NOTE ALL WELDS MUST BE APPROV
56. your actual angle but the system is displaying the wrong angle If you can rule out software and operator error it is most likely that the converter board is defective and it needs to be exchanged SkyAz l Equipment Solutions www skyazul com 301 371 6126 Length THEORY 9 6 LENGTH THEORY The system measures the length of the main boom of the machine with a length sensor The length sensor is contained within the cable reel located in the base of the main boom Block Diagram Radio A2B Option CAN Bus DS 85 Console Converter 7 CU Pressure Transducer Angle Sensor Box Length CAN Bus Sensor Converter DS 85 Console CU Pressure Transducer Cable Reel The signal runs from the length sensor to the CAN Bus converter board located in the angle sensor box From there it travels as digital information on the CAN Bus to the pressure transducer which acts as a to the main CAN Bus running to the central unit So what do you do when you are having a problem with your length read out Start by verifying the length display Refer to the section Troubleshooting A Sensor Problem Using The Display to call up the sensor signal on your console display The CAN Bus is digital and as such will either transmit the signal correctly or not at all If your readings are off you have to determine what is causing the problem Start by checking the length cable tension the cable reel h

PAT DS-85 Service Manual

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