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PAT DS350GM Service - Bode Technical Services

1. 30 c 32 4 1 DRAWING 1 ELECTRICAL WIRING FOR CENTRAL UNIT TO PRESSURE TRANSDUCERS AND URAIE peterent repe ern 32 4 2 DRAWING 2 ELECTRICAL WIRING FOR CENTRAL UNIT TO CONSOLE 33 4 3 DRAWING ELECTRICAL WIRING FOR CENTRAL UNIT TO CABLE REEL ANTI TW BLOCK 34 4 4 DRAWING 4 CENTRAL UNIT PARTS 5 35 45 DRAWING 5A CONSOLE 05350 1319 PARTS 37 4 66 DRAWING 5B CONSOLE 05350 1318 PARTS 39 4 7 DRAWING 6 CABLE REEL PARTS 16 41 4 8 DRAWING 7 CENTRAL UNIT MAIN BOARD 43 4 9 DRAWING 8 CONSOLE CONNECTION 44 4 10 DRAWING 9 CENTRAL UNIT ANALOG INPUT 45 9 Proced reS 46 5 1 PROCEDURE 1 STRAIN RELIEF INSTALLATION 46 5 2 PROCEDURE 2 EPROM LOCATION AND 47 53 PROCEDURE MAIN BOARD REPLACEMENT 48 5 4 PROCEDURE 4 PRESSURE TRANSDUCER ZERO ADJUSTMENT 49 5 4 1 USING GRAPHIC CONSOLE FOR ZERO SETTING OF PRESSURE TRANSDUCER amp FORCE INPUTS ii ped
2. 0 Faulty wiring between central unit and length transducer Check wiring Y Measure signal from length transducer in cable reel The return signal is a current output and must be measured in series Set Voltmeter to measure amps Remove Wire 2 from X1 2 in the cable ree and connect one voltmeter lead to wire 2 and the other lead to X1 2 The measurement should be between 4 20ma 4ma with the boom fully retracted and the length potentiometer set fully counter clockwise to a soft stop 20ma with the length potentiometer turned completely clockwise 10 turns to the soft stop Refer to Drawings 3 amp 6 in Section 4 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 assembly wires NO from terminal block Connect new assembly to terminal block Reinstall mounting plate gear wheel and slip rings With boom fully retracted reset potentiometer by turning it slowly counter clockwise until it reaches a soft stop Refer to Drawing 6 in Section 4 and adjustment Procedure 5 in Section 5 YES Measure signal from length transducer in central unit The return signal is current output and must be measured in series Set Voltmeter to measure amps Remove Wire 2 from X1 27 in the central unit and connect one voltmeter lead to wire 2 and the ot
3. EAT Hirschmann Rev 12 05 05 SB 190041_K ay 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 Drawings 35 4 4 DRAWING 4 CENTRAL UNIT PARTS LIST Item 21 digital output board refer to section 6 6 for location Hirschmann Rev K 12 05 05 SB 190041_K 38 Years Specializing Bode Technical Services Inc BODE in Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 36 Service Manual PAT DS 350 GM DRAWING 4 CENTRAL UNIT PARTS LIST continued PART NO A PAT 024 350 063 001 GROVE 9 333 103280 12V PART NO B PAT 024 350 063 002 GROVE 9 333 103281 24V NO PART NO PAT GROVE QTY DESCRIPTION 01 024 350 050 292 9333103549 1 HOUSING W COVER CENTRAL UNIT 02 024 350 110 067 9333101591 1 GASKET 03 024 352 300 001 9333103287 1 MAIN BOARD 04 024 352 300 020 9333103290 1 ANALOG INPUT MODULE 05 024 351 300 007 9333103288 1 CPU MODULE 06 024 351 300 011 9333103289 1 EPROM MODULE 07A 000 304 140 112 9333103550 1 RELAY 12V 07B 000 304 140 241 9333101597 1 RELAY 24V 08 024 350 100 135 9333101978 1 SCREW SET 09 000 314 022 006 9333102542 2 FUSE HOLDER 10 000 313 062 002 7482000019 1 FUSE 10amp 250V FAST ACT
4. is used to measure current at the slew angle input signal Remove the wire from X1 30 slew signal 1 in the central unit and measure the current with the ammeter in series And then measure current at terminal X1 34 slew signal 2 The measurement should be between 4 20mA Measuring voltage The voltmeter is used to measure voltage between pins X1 30 slew signal 1 and 1 35 and between pins X1 34 slew signal 2 and X1 35 gnd on the main board 024 352 300 001 9333103287 The resistors are there to show that at 4mA the voltage is 1 1V because current multiplied with resistance equals voltage therefore 4mA x 275 ohms total resistance 1 1V RATING WINDOW CENTRAL UNIT 06350 MODULAR 250 ohms 4mA 1 10V mI 150 250 ohms 20 5 50 ZE2A E2I y 1 1V 5 5V SS AINS SLEW 1 AIN6 SLEW 2 12V GND 1 1V 5 5V m CA 4 20 4 20ma 4 x 0 5 DS SLEW POTENTIOMETER IN SLIP RING ASSY REF Hirschmann Rev 12 05 05 SB 190041 K 38 Years Specializing Bode Technical Services Inc BODE in Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 57 6 6 THEORY 6 OPERATION AXLE OSCILLATION OUTPUT Axl
5. 12 05 05 SB 190041 K 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 Procedures 49 5 4 PROCEDURE 4 PRESSURE TRANSDUCER ZERO ADJUSTMENT 5 4 1 USING GRAPHIC CONSOLE FOR ZERO SETTING OF PRESSURE TRANSDUCER amp FORCE INPUTS The zero setting consists of defining zero point offset The zero point offset is added to the transducer measurement to calculate the real physical pressure or force To define the zero point offset the pressure transducer or force sensor must be in equilibrium no load condition Therefore the boom must be lowered all the way down no rest pressure and the hydraulic hoses disconnected from the pressure transducers CAUTION Ensure there is no pressure in the hydraulic line when disconnecting the hoses from pressure transducers 5 4 1 A ACTIVATING THE ZERO SETTING FUNCTION To activate the zero setting Function press the INFO key on the console to activate the INFO Function Now press the CTRL key At this point a five digit Authorization Number must be entered Only authorized personnel may adjust the zero point settings Example 6 4356 5 4 1 B ZERO SETTING THE TRANSDUCER INPUTS Now having successfully entered a valid password the piston side zero point setting function is activated The display shows which transducer piston side rod side or force
6. We are glad to help ACTION Refer to Section 3 7 a Check cable and connector b Check and reset length sensor Potentiometer Refer to Procedure 5 c Check signal on main board and analog input module Refer to Section 3 9 a Check cable and connector b Check pressure transducer and reset pressure channel c Check signal on main board and analog input module Refer to Section 3 9 a Check cable and connector b Check pressure transducer and reset pressure channel c Check signal on main board and analog input module a Check cable and connectors as well and replace if necessary b Check force transducer c Check signal on main board and analog input module Refer to Section 3 8 a Check cable b Check angle sensor and reset adjustment Refer to Procedure 5 c Check signal on main board and analog input module 190041_K Bode Technical Services Inc Email contact us bodetechnical com Phone No 1 303 433 8878 6 Service Manual DS 350 ERROR ERROR CAUSE ACTION CODE E16 Fallen below lower limit a Cable from central unit to a Check cable value for measuring angle sensor defective or b Check angle sensor and reset channel Luffing Jib disconnected or water inside adjustment Angle the plug C Check signal on main board and b Angle sensor defective analog input module c Electronic component in the measuring channel defective E17 Fallen below lower li
7. amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 Flowcharts 29 PREVIOUS PAGE Check if additional ground link between main board MP1 and central unit box mounting bracket is in place Refer to Drawing 7 in Section 4 Install ground line single cable minimum of AWG14 2 0mm between terminal MP1 and central unit box mounting bracket NO Refer to Drawing 7 in Section 4 YES Ensure that cable shields are connected correctly Refer to connection and wiring diagrams Drawings 1 2 3 in Section 4 and Procedure 1 in Section 5 Make correct shield connection Refer to connection and wiring diagrams Drawings 1 2 3 in Section 4 and Procedure 1 Section 5 YES Find out which component of the crane electric is spiking out e g dump valve outrigger relay Install a diode or resistor across terminals of spiking component Diode type such as 1N4001 can be used watch and connection for diode Refer to Crane Electrical Diagrams END P Hirschmann Rev 12 05 05 SB 190041 K Bode Technical Services Inc 38 Years Specializing Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 30 Service Manual DS 350 3 11 SLEWING A
8. 1 303 433 8878 General Information 1 1 GENERAL INFORMATION This troubleshooting manual is designed to assist a service or maintenance person in identifying system problem areas or malfunctions A digital voltmeter with the capability to also measure current will be required Regular maintenance and service tools will also be required NOTE Knowledge of how to use a voltmeter to measure both voltage and current is assumed REFERENCE For system operation refer to the operator s manual for the console This may differ from crane manufacturer and model Section 3 1 is a general flow chart that directs you to detailed flow charts and sections Section 3 2 provides a list of error codes error cause and possible action for the error Sections 3 3 3 11 provide detailed flow charts to define and correct the root cause Section 4 provides drawings that will be referenced for troubleshooting Section 5 provides procedures that will be referenced for troubleshooting Section 6 provides drawings for the theory of operation of all the different sensing devices used in the DS350G Modular System Use these reference drawings to better understand the operation of the system Hirschmann Rev K 12 05 05 SB 190041_K ay 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 2 Service Manual D
9. 38 Service Manual PAT DS 350 GM DRAWING 5A CONSOLE DS350 1319 PARTS LIST continued GRAPHIC CONSOLE VERTICAL PARTS LIST PART NO PAT 050 350 061 319 GROVE 9 333 103278 NO PART PAT GROVE QTY DESCRIPTION 01 031 300 1 10 048 9333103587 1 CONSOLE ACCY FRONT FACE amp DIS 02 050 000 100 212 9333103552 1 HOUSING 03 050 150 300 053 9333103302 1 BOARD PUSHBUTTON SET KEYBRDS 04 003 051 905 235 9333103406 1 SWITCH KEY 05 050 350 110 139 9333101691 1 KEY SPARE 06 002 053 806 058 9333102359 6 SCREWS FRONT PANEL MOUNTING 07 050 150 300 050 9333103299 1 BOARD 08 050 000 050 625 9333103223 1 SEALING FRONT PANEL 09 050 150 300 051 9333103300 1 TERMINAL BOARD 10 000 214 210 011 9333101727 1 LOCKNUT PG11 11 000 208 010 210 9333103169 1 TOOTHWASHER M12 12 000 214 210 013 9333101547 1 LOCKNUT PG13 5 13 031 300 100 392 9333103433 1 CANNON CONN 7 SOCKET RECPT 14 000 214 340 011 9333102047 1 HOLE PLUG PG11 15 021 448 161 213 9333102746 1 STRAIN RELIEF PG13 5 GREY WHT 16 031 300 100 173 9333103226 1 GASKET 17 031 300 100 024 9333103227 1 DUST CAP 18 050 350 300 076 9333103222 1 BOARD TERMINAL INTERFACE FOR LIGHTBAR Hirschmann Rev 12 05 05 SB TECHNICAL SERVICES 38 Years Specializing in Crane Electronic Repair amp Parts Sales Call Us We are glad to help 190041_K Bode Technical Services Inc Email contact us bodetechnical com Phone No 1 3
10. Between Central Unit and _ Console Go to Section 3 10 Slewing Angle Reading Problem Go to Section 3 11 Hirschmann Rev K 12 05 05 SB ay 38 Years Specializing Crane Electronic Repair amp Parts Sales Call Us We are glad to help 190041_K Bode Technical Services Inc Email contact us bodetechnical com Phone No 1 303 433 8878 4 3 2 Service Manual PAT DS 350 ERROR CODE DISPLAY PROBLEM Error code displayed Lever lockout activated Warning lights on ERROR CODE Minimum radius or maximum angle range exceeded ERROR CAUSE Fallen below the minimum radius or above the angle given in the load chart due to raising the boom to far ACTION Lower boom back to a radius or angle given in the load chart Maximum radius or minimum angle range exceeded no load area The maximum radius or minimum angle given in the load chart was exceeded due to lowering the boom too far Prohibited slewing range Slewing range prohibited with load Raise boom back to a radius or angle given in the load chart Slew back into admissible range Operating mode not available or non Length range not permitted Fallen below angle range with luffing jib operation No acknowledgment signal from overload relay K1 No A NETT signal from Anti Two Block switch relay K2 Hirschmann Rev 12 05 05 SB TE
11. CODE Upper limit value in measuring channel length telescope 11 has been exceeded Reference voltage defective Above limiting value for slewing angle 1 Above limiting value for slewing angle 2 Error in the system program Error in the program run System program and Data EPROM do not match System program and TLK EPROM do not match Error in the external RAM Hirschmann Rev K 12 05 05 SB TECHNICAL SERVICES CAUSE a Cable between the central unit to the length sensor defective or loose Water inside the length sensor plug b Length potentiometer defective c Electronic component in the measuring channel defective a The total of the supply and the reference voltages on 10 is more than 3 3V b A D converter defective a Cable from central unit to the slewing angle sensor defective or loose b Slewing angle potentiometer defective c Electronic component in the measuring channel defective on main board a EPROM with system program defective b Electronic component on the main board defective a EPROM with system program defective b Electronic component on the main board defective The system program in the LMI does not correspond to the programming in the data EPROM The system program in the LMI does not correspond to the programming in the data EPROM Defective electronic component 38 Years Specializing in Crane Electronic Repair amp Par
12. Remove Wire 2 from X1 2 on the amplifier board and connect one voltmeter lead to wire 2 and the other lead to 1 2 Signal 2 Remove Wire from X1 3 on the amplifier board and connect one voltmeter lead to wire and the other lead to X1 3 The measurements should be between 4 20ma Refer to Drawing 3 amp 6 in Section 4 NO Replace slew pot and amplifier board YES Y Measure signals 1 and 2 from the slew pot amplifier board in the central unit The return signala are current output and must be measured in series AMPS Signal 1 Remove Wire 2 from X1 30 on the main board and connect one voltmeter lead to wire Z2 and the other lead to X1 30 Signal 2 Remove Wire 3 from X1 34 on the main board and connect one voltmeter lead to wire and the other lead to X1 34 The measurements should be between 4 20ma Refer to Drawing 3 amp 6 in Section 4 Faulty wiring between central unit and cable reel Check wiring Refer to Drawing 3 in Section 4 Y Measure slew angle signals 1 and 2 from the analog input module Signal 1 Measure between MPO AGND and X1 5 analog input module board Signal 2 Measure between MPO AGND and X1 6 analog input module board The measurement should be between 0 5 4 5 0 5v 500mv with the boom at 0 or 4 5v with the boom at 90 Refer to Drawing 9 in Section 4 NO NO Faulty ana
13. ground for piston side and X1 23 12 24v and X1 25 ground for rod side Refer to Drawing 1 and 4 in Section 4 YES Fault in pressure transducer cable Refer to Drawing 1 in Section 4 D NO Main board defective Replace main board Refer to Drawing 4 in Section 4 and Replacement Procedure 3 in Section 5 Correct NO gt YES Hirschmann Rev K 12 05 05 SB 190041_K ay 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 Flowcharts 27 PREVIOUS PAGE D Measure signal from pressure transducers in central unit The return signal is a current output and mus be measured in series Set Voltmeter to measure amps Piston Side remove Wire 2 from X1 21 in the central unit and connect one ammeter lead to wire 2 and the other lead to X1 21 The measurement should be between 4 20ma 4ma when there is no pressure in the hydraulic lines O psi Rod Side remove Wire 2 from X1 24 in the central unit and connect one voltmeter lead to wire Z2 and the other lead to X1 24 The measurement should be between 4 20ma when there is no pressure in the hydraulic lines 0 psi Refer to Drawing 1 in Section 4 t Check continuity of wire 2 and pin B in pre
14. on main board Hirschmann Rev K 12 05 05 SB 190041_K ay 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 Flowcharts ERROR CODE ERROR Upper limiting value for the measuring channel pressure piston side exceeded Upper limit value for the measuring channel pressure transducer rod side exceeded Upper limit value for the measuring channel force exceeded Upper limit value for the measuring channel angle main boom exceeded Upper limit value for the measuring channel Luffing Jib Angle exceeded Hirschmann Rev K 12 05 05 SB TECHNICAL SERVICES CAUSE a Cable from central unit to the pressure transducer defective loose or water in the plug b Pressure transducer on piston side defective c Electronic component in the measuring channel defective on main board a Cable lead in from the central unit to press trans defective not connected or water in the connectors b Pressure transducer on rod side defective c Electronic component in the measuring channel defective a Cable leading from the central unit to the force transducer defective not connected or water in the connectors b Force transducer defective c Electric component in the measuring channel defective a Cable leadi
15. 03 433 8878 Drawings 39 4 6 DRAWING 5B CONSOLE DS350 1318 PARTS LIST 12 13 14 Hirschmann Rev 12 05 05 SB 190041_K ay 38 Years Specializing Bode Technical Services Inc BODE in Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 40 Service Manual PAT DS 350 DRAWING 5B CONSOLE DS350 1318 PARTS LIST continued GRAPHIC CONSOLE HORIZONTAL PARTS LIST PART NO PAT 050 350 061 318 GROVE 9 333 103279 NO PART PAT GROVE QTY DESCRIPTION 01 031 300 1 10 049 9333103588 1 CONSOLE ACCY FRONT FACE amp DIS 02 050 150 300 052 9333103301 1 BOARD PUSHBUTTON SET KEYBRDS 03 003 051 905 235 9333103406 1 SWITCH KEY 04 050 350 110 139 9333101691 1 KEY SPARE 05 002 053 703 101 9333102298 6 SCREWS FRONT PANEL MOUNTING 06 050 150 300 050 9333103299 1 BOARD 07 050 150 300 051 9333103300 1 TERMINAL BOARD 08 050 000 050 625 9333103223 1 SEALING FRONT PANEL 09 050 000 100 180 9333103439 1 HOUSING 10 050 350 110 263 9333103225 1 MOUNTING KIT FOR HOUSING 11 021 448 161 213 9333102746 1 STRAIN RELIEF PG13 5 GREY WHT 12 031 300 100 173 9333102482 1 GASKET 13 031 300 100 392 9333103043 1 CANNON CONN 7 SOCKET RECPT 14 031 300 100 024 9333102612 1 DUST CAP 15 000 208 010 210 9333103169 1 TOOTHWASHER M12 16 000 214 210 013 9333101547 1 LOCKNUT PG13 5 17 050 350 300 076 93331032
16. 22 1 BOARD TERMINAL INTERFACE FOR LIGHTBAR Hirschmann Rev 12 05 05 SB TECHNICAL SERVICES 38 Years Specializing in Crane Electronic Repair amp Parts Sales Call Us We are glad to help 190041_K Bode Technical Services Inc Email contact us bodetechnical com Phone No 1 303 433 8878 Drawings 41 47 DRAWING 6 CABLE REEL PARTS LIST 9 Hirschmann Rev K 12 05 05 SB 190041_K ay 38 Years Specializing Bode Technical Services Inc BODE in Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 42 Service Manual PAT DS 350 DRAWING 6 CABLE REEL PARTS LIST continued CABLE REEL ASSEMBLY PARTS LIST PART NO PAT 068 308 060 001 GROVE 9333103306 NO PART NO PAT GROVE QTY DESCRIPTION 01 068 000 300 060 9333103309 1 BOARD TERMINAL W EMC FILTERS 02 064 103 060 007 9333103303 1 ANGLE SENSOR WG103 0007 03 068 000 300 018 9333103308 1 LENGTH POTENTIOMETER UNIT 04 002 050 206 012 7121152154 2 SCREW M6 X 12 HEX SOCKET CAP 05 000 207 010 064 9333101567 2 WASHER M6 FLAT 06 068 000 100 152 9333103376 1 HOUSING KT200 07 000 214 340 013 9333101732 1 PG13 5 HOLE PLUG 08 000 673 020 002 9333102382 139 CABLE LENGTH SINGLE CORE 09 002 148 131 013 9333102477 1 STRAIN RELIEF PG13 5 RED WHT 10 031 300 100 206 7296000504 1 CHEMICAL CORROSION INHIBITOR 11 068 000 100 064 933
17. 3 433 8878 Hirschmann Rev 12 05 05 SB 190041_K 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 TABLE OF CONTENTS 1 General Information c 1 2 ru E E X 2 9 E E E E 3 3 1 GENERAL FLOWCGHAR e _ 3 32 ERROR DUP Py one 4 go 14 3 4 BROKEN LENGTH CABLE sii 19 29 NO DISPLAY ane recta reer crete 16 20 BLOCK PROBLEM 18 3 7 LENGTH READING 21 3 8 lt 24 49 LOAD READING PROBLEM soe 26 3 10 BAD DATA TRANSFER BETWEEN CONSOLE amp CENTRAL UNIT INTERFERENCE PROBLEM nani ease 28 3 11 SLEWING ANGLE READING
18. 3 433 8878 46 PROCEDURES PROCEDURE 1 STRAIN RELIEF INSTALLATION VITH Service Manual PAT DS 350 GM Hirschmann Rev K 12 05 05 SB 190041_K 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 Procedures 47 5 2 PROCEDURE 2 EPROM LOCATION AND INSTALLATION e Ensure the notch is in the correct direction The DATA EPROMs fill the bottom of the socket as shown by the arrows e Place EPROMs the correct EPROM socket as shown Hirschmann Rev K 12 05 05 SB 190041 K 38 Years Specializing Bode Technical Services Inc BODE in Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 5 3 PROCEDURE 3 MAIN BOARD REPLACEMENT Refer to Drawing 4 central unit parts list for board location 1 Turn system power off 2 Remove the central unit lid NOTE Take care not to damage the boards with the screwdriver when removing and inserting screws NOTE Use care when lifting the CPU module board and analog input module from the main board due to the fact that these boards have pins on the bottom side which insert into the main board 3 Remove CPU module board by taking out the 4 small Philips screws holding it in place 4 Remove analog input module boar
19. 3102732 1 SLIP RING ASSEMBLY 2 POLE Hirschmann Rev 12 05 05 SB TECHNICAL SERVICES 38 Years Specializing in Crane Electronic Repair amp Parts Sales Call Us We are glad to help 190041_K Bode Technical Services Inc Email contact us bodetechnical com Phone No 1 303 433 8878 Drawings 4 8 DRAWING 7 CENTRAL UNIT MAIN BOARD LAYOUT MP24 MP26 MP4 MP9 MP8 11 DIL G THRU DI6 7 1 25 Hirschmann Rev 12 05 05 SB 38 Years Specializing in Crane Electronic Repair amp Parts Sales Call Us We are glad to help TECHNICAL SERVICES 43 BOARD P N 024 352 300 001 9333103287 MP1 KGND MP4 5V MP8 9V MP9 6V MP24 BATT MP25 UBS console sensors 015 MP26 GND MP29 5V hand terminal LED S H08 LOAD H09 A2B H10 MAIN IN OUT 11 POWER H12 TxD 190041_K Bode Technical Services Inc Email contact us bodetechnical com Phone No 1 303 433 8878 44 Service Manual DS 350 GM 4 9 DRAWING 8 CONSOLE CONNECTION BOARD MP5 T5V MP2 7V MP3 24V MP4 24V MP6 7 GND 1 UB 3 21 BOARD PART NUMBER 050 150 30 0051 9333103300 Hirschmann Rev K 12 05 05 SB 38 Years Specializing SODE in Crane Electronic Repair amp Parts Sales TECHNICAL SERVICES Call Us We are glad to help 3s X5 ENW IS 1 00 190041_ Bode Technical Services In
20. CHNICAL SERVICES permitted slewing zone Error in length measurement non existing operating mode has been selected The boom Is in a non permitted slewing zone Boom has been extended too far or not far enough Length sensor adjustment changed i e length sensor cable slid off the cable drum Fallen below the minimum jib angle specified n the respective load chart due to luffing out the jib too far Overload relay is stuck defective or not being selected Anti Two Block switch relay is defective or not being selected With the boom fully retracted the length differs by more than 2 38 Years Specializing in Crane Electronic Repair amp Parts Sales Call Us We are glad to help Set operating mode switch correctly to the code assigned to the operating mode of the crane Slew the boom to a permitted area Refer to Section 3 7 Retract or extend boom to correct length given in the load chart Luff in the jib to a radius or angle specified in the load chart Replace main board in central unit Refer to Drawing 4 and Procedure 3 in Section 5 3 Replace main board in central unit Refer to Drawing 4 and Procedure 3 in Section 5 3 Refer to Section 3 7 190041_K Bode Technical Services Inc Email contact us bodetechnical com Phone No 1 303 433 8878 Flowcharts ERROR CODE ERROR Fallen below limit for the measuring channel length Fallen below lower limit value for the measur
21. E amp CENTRAL UNIT OR INTERFERENCE PROBLEM PROBLEM Error Code E93 E94 No data transfer to and from console interference from crane electric or console display frozen START Y Check the H12 TxD LED on the main board ON OFF Refer to Drawing 7 in Section 4 ON Make sure that eprom s are correct and plugged into the Eprom Module on the main board Refer to Procedure 2 in Section 5 Place EPROM in correct socket 2 Correct No Refer to Procedure 2 Section 5 YES Measure process voltage on the Main Board central unit between MP42 5v and MPO ground Refer to Drawing 4 amp 7 in Section 4 hei Make sure external and internal power supply is correct Refer to Section 3 5 No Display YES Y Turn off system power Check the continuity of the receive RXD and transfer TXD wires Check continuity between central unit main board X1 5 and console X1 3 central unit main board X1 6 and console X1 4 Refer to Drawing 2 in Section 4 Check connections and replace cable from central unit to NO console if necessary Refer to Drawing 2 in Section 4 and Procedure 1 in Section 5 C NEXT PAGE Hirschmann Rev 12 05 05 SB 190041_K ay 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair
22. HIRSCHMANN www hirschmann com PAT LOAD MOMENT INDICATOR DS 350GM for Grove Cranes SERVICE MANUAL P N 031 300 190 041 REV K 12 05 2005 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 Service Manual PAT DS 350 NOTICE The information in this document is subject to change without notice Hirschmann Electronics Inc makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose Hirschmann shall 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 All rights are reserved No part of this document may be photocopied reproduced or translated into another language without the prior written consent of Hirschmann Hirschmann reserves proprietary rights to all drawings and to the data shown thereon The drawings and data are confidential and are not to be used
23. ING 11 000 313 064 001 9333103456 1 FUSE 4amp 250V FAST ACTING 12 000 214 340 013 9333101732 1 HOLE PLUG PG13 5 13 021 441 131 013 9333101440 2 STRAIN RELIEF PG13 5 RED WHT 14 021 441 161 213 9333101735 1 STRAIN RELIEF PG13 5 W GREY WHT 15 021 441 090 709 9333101995 3 STRAIN RELIEF PG9 W BLACK WHITE 16 024 000 100 260 9333103315 5 FERRITE FILTER PG13 5 17 024 000 100 261 9333103551 1 FERRITE FILTER PG16 18 024 350 100 661 9333102541 1 KEYSWITCH 19 031 300 101 131 9333103058 1 SPARE KEY 20 024 000 100 095 9333103532 2 MEMBRANE ELEMENT BREATHER 21 024 352 300 041 9333103291 1 BOARD DIGITAL OUTPUT Hirschmann Rev K 12 05 05 SB TECHNICAL SERVICES 38 Years Specializing in Crane Electronic Repair amp Parts Sales Call Us We are glad to help 190041_K Bode Technical Services Inc Email contact us bodetechnical com Phone No 1 303 433 8878 Drawings 37 45 DRAWING 5A CONSOLE 08350 1319 PARTS LIST GRAPHIC CONSOLE VERTICAL PARTS LIST PART NO 050 350 061 319 9333103278 16 a7 7 x Sas s be 10 18 id 11 D 12 6 E w 2 5 4 3 vw 9 5 3 8 1 Hirschmann Rev 12 05 05 SB 190041_K ay 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878
24. M E45 Redundancy error in Replace analog input module Refer A D conversion component to Drawing 4 and Procedure 3 Steps 1 2 4 11 12 E46 Error in A D Defective electronic Replace analog input module Refer conversion component to Drawing 4 and Procedure 3 Steps 1 2 4 11 12 E47 Malfunction in the Internal defect in digital part of Replace CPU module Refer to monitored write read CPU Drawing 4 and Procedure 3 Steps memory 1 3 13 14 E48 Cyclic RAM test Error Internal defect in digital part of Replace CPU module Refer to in the internal CPU Drawing 4 and Procedure 3 Steps write read memory 1 3 13 14 Error in data EPROM EPROM Module not bridged Replace Data EPROM Make sure correctly BR3 on the main board is installed Data EPROM on the main Refer to Procedure 2 board defective Error in load chart EPROM Module not bridged Replace EPROM Module and reset EPROM correctly pressure channels Refer to Data EPROM on the main Drawing 4 and Procedure 4 board defective Error in crane data Memory module wrongly Bridge memory module acc To EEPROM bridged memory type Replace crane data EEPROM Crane data EEPROM defective Replace EPROM Module and reset pressure channels Refer to Drawing 4 and Procedure 4 Hirschmann Rev K 12 05 05 SB 190041_K ay 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to h
25. N 3 Hirschmann Rev 12 05 05 SB 190041 K 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 54 Service Manual DS 350 GM 63 THEORY 3 OPERATION OF ROD SIDE LOAD SENSOR Measuring current The ammeter is used to measure current at the rod side input signal Remove the wire from X1 24 terminal in the central unit and measure the current with the ammeter in series The measurement should be between 4 20mA Measuring voltage The voltmeter is used to measure voltage between pins 1 24 rod side signal 1 25 gnd on the main board 024 352 300 001 9333103287 The resistors are there to show that at 4mA the voltage is 1 1V because current multiplied with resistance equals voltage therefore 4mA x 275 ohms total resistance 1 1V CENTRAL UNIT DS350 MODULAR TIN 250 ohms VINDOV 7 i 150 hme 250 ohms Li A 5 i 5 ORKING 8 x1 23 24 25 V 1 1 5 5V 4 20mA 1 2 3 2 o x pe M e 1 2 3 A C B PRESS TRANS ROD Hirschmann Rev 12 05 05 SB 190041_K 38 Years Specializing Bode Technical Services Inc Crane Electron
26. NGLE READING PROBLEM PROBLEM Slew Angle displayed incorrect C START Check for damages inside the slip ring to the slew pot assembly Repair or replace cable and or slew pot with NO gt ie amplifier board YES Position the super structure over the front engage the house lock pin Measure the slewing sensor supply voltage in the central unit between terminals X1 33 12 24v and X1 35 ground Refer to Drawing 3 in Section 4 Main board defective Replace main board NO Refer to Drawing 4 in Section 4 and Replacement Procedure 3 in Section 5 YES Remove the slip ring cover and measure the slewing sensor supply voltage on the amplifier board between X1 1 12 24v and X1 4 ground Refer to Drawing 3 in Section 4 Faulty wiring between central unit and slew pot Check wiring Refer to Drawing 3 in Section 4 Yes Y C NEXT PAGE Hirschmann Rev 12 05 05 SB 190041 K 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 Flowcharts 31 PREVIOUS PAGE Measure signals 1 and 2 from the slew pot amplifier board in the slip ring The return signals are current output and must be measured in series AMPS Signal 1
27. OM LENGTH SENSOR The system sensors provide a 4 to 20mA output however due to a fixed resistor circuit in the central unit the input signal can be measured using ammeter current or voltmeter voltage The input signal operating window is 4 to 20mA measured in series at the analog input terminal OR 1 1 to 5 5V measured in parallel between the analog input and ground GND terminals At 4mA the voltage is 1 1V and at 20mA the voltage is 5 5V When troubleshooting this system a current or voltage needs to be measured to determine the status or condition of the sensor Measuring current The ammeter A is used to measure current at the length input signal Remove the wire from X1 27 terminal in the central unit and measure the current with the ammeter in series The measurement should be between 4 20mA Measuring voltage The voltmeter V is used to measure voltage between pins X1 27 length signal and X1 28 gnd on the main board 024 352 300 001 9333103287 The resistors are there to show that at 4mA the voltage is 1 1V because current multiplied with resistance equals voltage therefore 4mA x 275 ohms total resistance 1 1V OPERATING WINDOW Nu Amm JN RANGE OmA 5 5V 20 NA 221 2 221 4 oct tare 2 WORKING Hirschmann Rev 12 05 05 SB 190041_K 38 Years Speciali
28. Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 24 Service Manual PAT DS 350 3 8 ANGLE READING PROBLEM PROBLEM Angle displayed incorrect Crane is not in out of load chart condition C START Check the cable reel for damages movement of mounting bracket Refer to Drawing 6 in Section 4 and Adjustment Procedure 5 in Section 5 Repair or replace cable reel if damaged or adjustments can not be made Place the boom at 0 Measure the angle sensor supply voltage in the central unit between terminals X1 26 12 24v and X1 28 ground Refer to Drawing 3 in Section 4 Main board defective Replace main board NO Refer to Drawing 4 in Section 4 and Replacement Procedure 3 in Section 5 Open cable reel cover Measure the angle sensor supply voltage in the cable reel between terminals X1 1 12 24v and X1 3 ground Refer to Drawing 3 in Section 4 gt Yes Y Faulty wiring between central unit and cable reel Check wiring Refer to Drawing 3 in Section 4 C NEXT PAGE 24 Hirschmann Rev 12 05 05 SB TECHNICAL SERVICES 190041_K 38 Years Specializing Bode Technical Services Inc in Crane Electronic Repair amp Parts Sales Email contact us bodetechnical co
29. S 350 GM 2 WARNINGS The LMI is an operational aid that warns a crane operator of approaching overload conditions and overhoist conditions that could cause damage to equipment and personnel Therefore 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 the crane s operating manuals to ensure that the operator knows the operation and limitations of indicator and crane PAT Load Moment Indicator LMI DS 350 Modular The PAT Load Moment Indicator LMI DS 350 Modular has been designed to provide the crane operator with the essential information required to operate the machine within the designed parameters Using different sensing devices the DS 350 Modular LMI monitors various crane functions and provides the operator with a continuous display of the crane s capacity The display continually changes as the crane moves through the motions needed to make a lift If non permitted conditions are approached the DS 350 LMI will warn the operator by sounding an audible alarm and lighting a warning light In addition the LMI system has the capability to provide a signal to
30. able Reel Drawing 6 Cable Reel Parts List Cut old cable at cable drum 2 Disconnect damaged length cable from junction box at the boom nose Refer to Drawing 3 3 Open cable reel cover and disconnect wiring from terminal block Pull 7 conductor cable out of strain relief Note Mark wires to make re connection simpler 4 Remove cable reel from mounting brackets 5 Remove damaged length cable which is mounted to the slip rings in the cable reel from slip ring terminal Refer to Drawings 3 6 Onthe back side of the cable reel open the strain relief attached to the axle in the center of the drum Pull existing length cable out of the cable reel 7 Pull new length cable through the hole pipe and strain relief and push it through the axle of the reeling drum Tighten new strain relief to ensure sealing 8 Reconnect the length cable to the slip ring Refer to Drawing 3 9 Remount cable reel to the boom 10 Turn reeling drum clockwise to spool the new cable neatly onto the drum 11 Set pre load on cable reel by turning the drum counter clockwise 5 to 8 turns 12 Run the new 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 into the boom tip junction box 13 Connect the length cable into the boom tip junction box Refer to Drawing 3 14 Reset length potentiometer in length angle transducer screw is locat
31. c Email contact us bodetechnical com Phone No 1 303 433 8878 Drawings 45 4 10 DRAWING 9 CENTRAL UNIT ANALOG INPUT MODULE BOARD P N 024 352 300 020 9333103290 X1 1 7 ADC INPUT 0 5V 4 5V Note If channel adjustments are made through the software and graphic console DO NOT adjust offset with P1 P7 1 8 TEMP 0 5V 10mV C 1 9 VREFA 5 000V reference X1 10 AGND reference GND X1 11 VREF 5 0V power ADC X1 12 15 CH01 04 DIN1 4 10 X1 16 5 UBS 10 X1 17 CH06 HESIN A2B 4 1 18 CHO7 9 4 X1 19 VREFA 2 2 500V X1 20 UKLEMM app VREFA limits ADC input to 5 0V MP1 AGND MP8 5V MP1 7 Input channels 1 7 0 5V AmA 2 5V 20mA 14 13V REF02 MP16 HESIN input voltage MP17 app 5 4V clamp for inputs The analog input module converts the sensor signals on channels 1 7 to signals that will be process at the CPU and software The incoming signal measured at the measuring points MP will be 0 5V 4mA 2 5V 20mA The analog input module then converts the channel signals to 0 5V 4 5V which can be measured on X1 1 through X1 7 The signal voltage can be measured at either point using ground and the signal input Hirschmann Rev K 12 05 05 SB 190041_K ay 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 30
32. cope has a percentage Read out the percentages on the least one telescope 25 or 106 console If a telescope has to be extended too far retract tele and b Length measurement Tele bolt is defective b Check length measurement Tele 1 see E17 c Measurement of overall Check length measurement see length is defective E11 Hirschmann Rev 12 05 05 SB 190041 K 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 12 Service Manual PAT DS 350 ERROR ERROR CODE Change of the operating code during lifting a load CAUSE The operating mode switch in the console was used during lifting a load ACTION Lower the load and set the operating mode switch correctly to the code assigned to the actual operating mode of the crane No data transmission from console to central unit Refer to Section 9 a 24V supply of console interrupted b Interruption or accidental ground in the line from console electronics to central unit c Transmitter receiver module defective a Check 24V at terminal X1 of console electronics b Check the connection between console electronics and central unit C If accidental ground occurs the transmitter module in the console electronics can be damaged Replace the console electroni
33. cs or main board respectively Error in the data transmission from console to central unit Refer to also Section Error in the data transmission from central unit to console Refer to also Section 3 10 No data transmission for central unit to console Refer to also Section 3 10 Hirschmann Rev 12 05 05 SB TECHNICAL SERVICES a Temporary interruption of the data line from console electronics to central unit b Transmitter receiver module defective a Temporary interruption of the data line from console electronics to central unit b Transmitter receiver module defective a Interruption or accidental ground in the line from console electronics to central unit b Transmitter receiver module defective c Data EPROM defective d CPU defective e Electromagnetic interference when switching contractors or valves 38 Years Specializing in Crane Electronic Repair amp Parts Sales Call Us We are glad to help a Check the connection between console electronics and central unit Refer to Section 3 10 a Check the connection between console electronics and central unit b Replace console electronics or main board respectively Refer to Section 3 10 a Check the connection between console electronics and central unit If you find an accidental ground the transmitter module in the console electronics can be damaged Replace the console electronics b Replac
34. d by taking out the 6 small Philips screws holding it in place 5 Remove the relay from the main board item 7 on Drawing 4 in Section 4 4 6 Mark all connection wires before removing to identify location for reconnecting Disconnect all X1 terminal wires from the main board 7 Remove the 14 large Philips screws holding the main board in place 8 Take notice of the orientation of the main board in the central unit Remove main board and place in the packing material that the replacement main board came in 9 Carefully insert the new main board in place Refer to Drawing 4 in Section 4 4 for location 10 Insert the 14 Philips mounting screws be sure to attach the ground wire to the KGND screw in the lower left corner Refer to Drawing 4 11 Insert analog input module board by lining up the pins into the sockets X16 and X17 and the 6 screw holes 12 Insert the 6 small Philips screws and washers 13 Insert CPU module board by lining up the pins into the sockets X11 and X12 and the 4 screw holes 14 Insert the 4 small Philips screws and washers 15 Insert the relay on to the main board item 7 on Drawing 4 16 Connect the X1 terminal wires to the main board Refer to Drawings 1 2 and 3 17 Inspect the gasket for nicks cuts or damages Refer to 031 300 340 003 DS 350 Central Unit Gasket Recommendations Revision and 031 300 340 002 Central Unit Cover Installation and Tightening Procedure Revision A Hirschmann Rev
35. e console electronics or main board respectively c Check data EPROM d Replace CPU module Refer to Drawing 4 and Procedure 3 Steps 1 3 13 14 e Eliminate interference source by inverse diodes or varistors 190041 K Bode Technical Services Inc Email contact us bodetechnical com Phone 1 303 433 8878 Flowcharts 13 ERROR ERROR CODE E97 E98 Error in the crane data EPROM Error in the internal RAM of the CPU of the console Error in the external RAM of the CPU of the console Wrong jumper position in the console CAUSE a Data EPROM defective b Position of jumper for the selection of the type of EPROM wrong Electronics component on w main board defective CPU or main board of the console defective External RAM of the 2 defective b Electronic component on the main board defective a The jumper position BR 9 BR 10 in the console does not correspond to the actual type of central unit b Electronic component on the main board defective ACTION a Replace data EPROM b Check the jumper position c Replace CPU module Refer to Drawing 4 and Procedure 3 Steps 1 3 13 14 Replace CPU module Refer to Drawing 4 and Procedure 3 Steps 1 3 13 14 a Replace console main board b Replace console main board Refer to Drawing 5 a Check the jumper position b Replace console main board Refer to Drawing 5 EAB Shor
36. e oscillation is the ability of the crane axle suspension to articulate to the changing terrain The digital output module sends power to energize a solenoid valve to allow axle oscillation This current is sent when determined by the LMI software the crane is in pick and carry mode and within in a preset angle tolerance e g 12 over the front of the crane To troubleshoot this module first check if the on board light is lit This light indicates that the board is receiving both power and a proper ground If the light is out check the condition of the fuse and board connection To determine if a signal is present refer to the Measuring Voltage section Measuring voltage The voltmeter is 9 used to measure voltage between pins X2 1 1 digital output 1 and X2 1 3 gnd on digital output module 024 352 300 041 9333103291 6 Sm S Qul Digital po voue ars Output X13 212 _ Module Connector 8555 8 xi 1 2412 11 13 x2 1 1 215 To solenoid Hirschmann Rev K 12 05 05 SB 190041_K ay 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878
37. ection 4 Analog Input board defective Replace analog input board 5 Correct Refer to Drawing 4 in Section 4 and Replacement Procedure 3 steps 4 11 amp 12 in Section 5 END 2 Hirschmann Rev 12 05 05 SB 190041_K ay 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 26 Service Manual DS 350 GM 3 9 LOAD READING PROBLEM PROBLEM Load reading incorrect START Check boom length reading on display Reset length potentiometer With fully retracted boom turn potentiometer axle counter clockwise until it stops Refer to Section 3 7 YES v Measure radius and check with the displayed radius Check if mechanical adjustment of angle transducer is correct Angle transducer NO box should be in line with boom and adjusted to actual boom angle Refer to Section 3 8 YES Check power supply to pressure transducers piston and rod side Check each transducer by unpluging the transducer cable from transducer Measure voltage at the cable connection between A 12 24v and C ground at each connector Refer to Drawing 1 in Section 4 Check power supply in the central unit between 1 20 12 24v and X1 22
38. ed in center of white gear with boom fully retracted turn potentiometer carefully counter clockwise until it stops Recheck length and angle display Refer to Procedure 5 in Section 5 5 O Hirschmann Rev K 12 05 05 SB 190041 K 38 Years Specializing Bode Technical Services Inc in Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 16 3 5 NO DISPLAY Service Manual PAT DS 350 PROBLEM Blank console display with no warning light shown All crane moments have been stopped C Check fuses central unit NO gt Replace fuses YES Measure voltage on the main board terminal strip between X1 1 12 24V and X1 2 ground This is an input voltage from the crane Refer to Drawing 1 in Section 4 YES crane electric Check crane power supply for faulty Measure voltage on the main board between 1 3 12 24V and X1 4 ground This is an output voltage to the console Refer to Drawing 1 in Section 4 NO Replace the main board in central unit Refer to Drawing 4 in Section 4 and Replacement Procedure 3 in Section 5 YES Y C NEXT PAGE n Hirschmann Rev 12 05 05 SB 38 Years Specializing Crane Electronic Repair amp Parts Sales Call Us We are glad to h
39. elp 190041_K Bode Technical Services Inc Email contact us bodetechnical com Phone No 1 303 433 8878 Flowcharts 17 PREVIOUS PAGE Measure voltage console between 1 1 12 24V X1 2 ground Refer to Drawing 2 amp 8 in Section 4 Check connections of the cable between NO console and central unit Replace cable if necessary Refer to Drawing 2 in Section 4 YES Console Display is defective Replace the console Refer to Drawing 3 in Section 4 YES C END Hirschmann 12 05 05 SB 190041_K Bode Technical Services Inc 38 Years Specializing Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 18 Service Manual DS 350 GM 3 6 ANTI TWO BLOCK PROBLEM PROBLEM Function of Anti Two Block System is faulty START Check to see whether not crane is two block condition Correct NO gt Lower hook down into safe position YES Check Bypass plug installed Refer to Drawing 3 in Section 4 Plug appropriate bypass plug into socket of gt junction box YES Y Turn power off or disconnect wire from connection board X1 31 in central unit Remove the bypass plug and measure the
40. elp Phone No 1 303 433 8878 10 Service Manual PAT DS 350 ERROR ERROR CAUSE ACTION CODE E57 Error in serial crane data Serial crane data EEPROM Write data on the serial crane data EEPROM does not contain valid data EEPROM by means of test program or on line function then restart the LMI Replace EPROM Module and reset Memory module defective pressure channels Refer to Drawing 4 and Procedure 4 E58 Error in the serial analog No valid data in the serial Write data on the serial analog data data EEPROM analog data EEPROM EEPROM by means of the test program then restart the LMI Replace LMI main board LMI main board defective E60 The number of the Load chart EPROM defective Replace load chart EPROM selected EPROM base and the programmed value are not identical Base number not programmed Program the correct base number 1 for base 1 2 for base 2 Load chart EPROM wrongly Check base programming in the load programmed chart EPROM E61 Error in the boom control Cable between the central unit Check the cable to the boom control extension and the boom control extension extension defective Profibus adapter in the central Replace the profibus adapter unit defective Profibus adapter in the Boom Replace the profibus adapter control extension defective Boom control extension Replace the boom control extension defective E62 Error digital inputs 1 8 in Module for digital input
41. eso 49 55 PROCEDURE 5 LENGTH AND ANGLE SENSOR ADJUSTMENT 50 5 6 PROCEDURE 6 SLEW POT POTENTIOMETER ZERO ADJUSTMENT 51 5 6 1 USING GRAPHIC CONSOLE FOR ZERO SETTING OF SLEW POT pnr 51 Hirschmann Rev 12 05 05 SB 190041_K ost 38 Years Specializing Bode Technical Services Inc SSE in Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 Service Manual PAT DS 350 D Theory uu iesu ree 52 6 1 THEORY 1 OPERATION OF BOOM LENGTH SENSOR 52 INNIS UII E 52 o 52 6 2 THEORY 2 OPERATION OF PISTON SIDE LOAD SENSOR 53 63 THEORY OPERATION ROD SIDE LOAD 54 6 4 THEORY 4 OPERATION OF ANGLE SENSOR 55 6 5 THEORY 5 OPERATION OF SLEW POTENTIOMETER SENSOR 56 6 6 THEORY 6 OPERATION AXLE OSCILLATION 57 Hirschmann Rev K 12 05 05 SB 190041 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No
42. etween X1 31 and X1 32 in central unit With resistor connected alarm should be inactive Refer to Drawing 3 in Section 4 Defect on main board Replace main board NO Refer to Drawing 4 in Section 4 and Replacement Procedure 3 in Section 5 Y Reconnect Wire 5 to X1 31 and Wire 6 to X1 32 Refer to Drawing 3 in Section 4 Hirschmann Rev 12 05 05 SB 190041 K 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 Flowcharts 21 3 7 LENGTH READING PROBLEM PROBLEM Length displayed incorrect Crane is not in out of load chart condition START Check mechanical adjustment of length potentiometer cable reel With boom fully retracted reset potentiometer by turning it slowly counter clockwise until it reaches a soft stop Refer to Drawing 6 in Section 4 and Adjustment Procedure 5 in Section 5 Replace length potentiometer assembly Refer to Drawing 6 in Section 4 Remove slip ring body from shaft and remove gear wheel from potentiometer axle Unscrew mounting plate and remove potentiometer assembly from mounting plate Remove assembly wires form terminal block Connect new assembly to terminal block Reinstall mountin
43. g 3 Section 4 Replace slip ring Refer to Drawing 3 amp 6 in Section 4 Y Measure the A2B signal in the boom base box between terminals 5 and 6 with an ohmmeter Switch closed 24700 5000hms Switch open gt 1 Megaohm Reconnected slip ring wires Refer to Drawing 3 Section 4 Fault in 7 conductor cable between cable reel and N boom base box Check connections and replace o gt cable if necessary Refer to Drawing 3 in Section 4 C NEXT PAGE Hirschmann Rev 12 05 05 SB 190041_K ay 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 20 Service Manual DS 350 GM 6 PREVIOUS PAGE Connect wire 5 back to the terminal X1 31 on the connection board Refer to Drawing 3 in Section 4 Turn system power off Check Anti Two Block signal in central unit with ohmmeter measure between X1 31 and X1 32 Anti Two Block switch closed 4700 Ohms 50 Anti Two Block switch open gt 1 Megaohm Refer to Drawing 3 in Section 4 Faulty wiring between boom base box and central unit NO gt Check connections and replace cable if necessary YES Disconnect X1 31 and X1 32 Check main board function by installing a temporary resistor 4700 Ohms b
44. g plate gear wheel and slip rings With boom fully retracted reset potentiometer by turning it slowly counter clockwise until it reaches a soft stop Refer to Drawing 3 amp 6 in Section 4 and Adjustment Procedure 5 in Section 5 NO Y YES Y Check out clutch in big gear wheel of length transducer Extend and retract boom to ensure that clutch is not slipping on potentiometer axle Refer to Drawing 6 in Section 4 and Adjustment Procedure 5 in Section 5 Replace the gear wheel clean potentiometer axle Reset length potentiometer Refer to Drawing 6 in Section 4 and Adjustment Procedure 5 in Section 5 YES Check power supply to length transducer on main board terminal X1 28 ground and X1 26 12 24v Refer to Drawing 3 in Section 4 Main board defective Replace main board Refer to Drawing 4 in Section 4 and Replacement gt Procedure 3 in Section 5 YES C NEXT PAGE Hirschmann Rev 12 05 05 SB 190041 K Bode Technical Services Inc 38 Years Specializing Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 22 Service Manual DS 350 GM previous PAGE Y Measure supply to length transducer in cable reel between terminal 1 ground and 3 12 24v Refer to Drawing 3 in Section 4
45. her lead to X1 27 The measurement should be between 4 20ma 4ma with the boom fully retracted and the length potentiometer set fully counter clockwise to a soft stop 20ma with the length potentiometer turned completely clockwise 10 turns to the soft stop Refer to Drawing 3 amp 6 in Section 4 Faulty wiring between central unit and cable reel Check wiring YES Y C NEXT PAGE Hirschmann Rev 12 05 05 SB 190041 K 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 Flowcharts 23 PREVIOUS PAGE Measure length signal of amplified output on analog input module between test point MPO and X1 3 The measurement should be between 0 5 4 5v 0 5v 500mv with the boom fully retracted and the length potentiometer set fully counter clockwise to a soft stop OR 4 5v with the length potentiometer turned completely clockwise 10 turns to the soft stop Refer to Drawing 9 in Section 4 Analog Input board defective Replace analog input board au NO Refer to Drawing 4 in Section 4 Replacement Procedure 3 steps 4 11 amp 12 in Section 4 YES END D Hirschmann Rev K 12 05 05 SB 190041_K Bode Technical Services Inc 38 Years Specializing Crane Electronic
46. ic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 55 6 44 THEORY 4 OPERATION ANGLE SENSOR Measuring current The ammeter is used to measure current at the angle input signal Remove the wire from X1 29 terminal in the central unit and measure the current with the ammeter in series The measurement should be between 4 20mA Measuring voltage The voltmeter is V used to measure voltage between pins X1 29 angle signal and X1 28 gnd on the main board 024 352 300 001 9333103287 The resistors are there to show that at 4mA the voltage is 1 1V because current multiplied with resistance equals voltage therefore 4mA x 275 ohms total resistance 1 1V OPERATING WINDOW ERROR P easel 1 p7 go kcu TS po c ETE 77 MEN ME i 4 ES Ne Hirschmann Rev 12 05 05 SB 190041_K ay 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 6 5 THEORY 5 OPERATION SLEW POTENTIOMETER SENSOR Measuring current The ammeter
47. ing channel pressure transducer piston side Fallen below lower limit value for the measuring channel pressure transducer rod side Fallen below lower limit value for the measuring channel force Fallen below lower limit value for the measuring channel angle main boom Hirschmann Rev K 12 05 05 SB TECHNICAL SERVICES CAUSE a Cable between length sensor and central unit defective not connected or water in the connectors b Length sensor Potentiometer defective c Electronic board in the measuring channel defective a Cable leading from the central unit to the pressure transducer defective loose or water in the connector b Pressure transducer on piston side defective c Electronic component in the measuring channel defective a Cable leading from the central unit to the pressure transducer defective loose or water in the connector b Pressure transducer on rod side defective c Electronic component in the measuring channel defective a Cable leading from the central unit to the pressure transducer defective loose or water in the connector b Force transducer defective c Electronic component in the measuring channel defective a Cable from central unit to the length angle sensor defective or loose b Angle sensor defective c Electronic component in the measuring channel defective 38 Years Specializing in Crane Electronic Repair amp Parts Sales Call Us
48. is being zeroed and a horizontal dial marks the present pressure or force difference in By pressing the key the input pressure or force is adjusted upwards and by pressing the minus key the input value is adjusted downwards When the plus and minus keys are pressed simultaneously the zero setting occurs automatically Manual adjustments may be preformed using or The return key toggles between the piston side the rod side and the force zero setting When the operator is finished pressing the EXC or INFO key returns the console display to normal Hirschmann Rev K 12 05 05 SB 190041_K ay 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 Service Manual PAT DS 350 GM 50 5 5 PROCEDURE 5 LENGTH AND ANGLE SENSOR ADJUSTMENT n n 7 JL 2 2 ue Hirschmann Rev K 12 05 05 SB 190041 K 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 51 5 6 PROCEDURE 6 SLEW POT ZERO ADJUSTMENT 5 6 1 USING GRAPHIC CONSOLE FOR ZERO SETTING OF SLEW POTENTIOMETER The zero setting consists of defining zero point offset The zero point offset is added to the transducer meas
49. log input module or CPU module in central unit END Hirschmann Rev 12 05 05 SB 190041_K ay 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 32 Service Manual DS 350 GM 4 DRAWINGS 41 DRAWING 1 ELECTRICAL WIRING FOR CENTRAL UNIT TO PRESSURE TRANSDUCERS AND CRANE CENTRAL UNIT DS350GM MAIN BOARD PAT 024 352 300 001 GROVE 9 333 103287 es x B 5 i ir 1 2 gt 2 o 1 m gt d a E pe 833 888 b fs 1 6 2 i B 21 22 25 24 25 35 E i i 1 2 5 1 2 3 i 2 5 2 1 3 4 172557222270 Bp Bp Geyer ce ere Ween gt gt gt B gt xL gt x gt in M o 2 ian 7 73 Op i i E i 12 3 1 2 3 2 3 Sj E gt uus Bose A B 4 8 1 2 3 4 4 o N 1 1 rf fo Powe om h
50. m Call Us We are glad to help Phone No 1 303 433 8878 Flowcharts PREVIOUS PAGE Measure signal from angle transducer in cable reel The return signal is a current output and must be measured in series Set Voltmeter to measure amps Remove Wire 4 from X1 4 in the cable reel and connect one voltmeter lead to wire 4 and the other lead to X1 4 The measurement should be between 4 20ma 20ma with the boom at O or 4ma with the boom a 90 Refer to Drawing 3 amp 6 in Section 4 Replace angle sensor Correct NO Refer to Drawing 6 in Section 4 and Adjustment Procedure 5 in Section 5 YES Measure signal from angle transducer central unit The return signal is a current output and must be measured in series Set Voltmeter to measure amps Remove Wire 4 from X1 4 in the central unit and connect one voltmeter lead to wire 4 and the other lead to X1 4 The measurement should be between 4 20ma 20ma with the boom at 0 with the boom at 90 Refer to Drawing 3 amp 6 in Section 4 Faulty wiring between central unit and cable reel Correct Check wiring Refer to Drawing 3 in Section 4 YES Measure angle signal analog input module between test point MPO AGND and 1 ang sig The measurement should be between 0 5 4 5v 0 5v 500mv with the boom at 0 or 4 5v with the boom at 90 Refer to Drawing 9 in S
51. mit a Cable between the central a Check cable and connectors value length telescope unit to the length sensor 1 defective loose Water inside the length sensor plug b Length potentiometer b Replace length sensor defective c Electronic component in c Replace LMI main board or the measuring channel processor board defective outrigger overloaded Front outrigger overloaded Check outrigger sensor E19 Error in the reference Electronic component on the Replace main board Refer to voltage main board defective Drawing 4 and Procedure 3 E1A Below limiting value a Cable from central unit to Refer to Section 3 11 slewing angle 1 the slewing angle sensor a Check cable defective or loose b Check and reset slewing angle E1B Below limiting value for b Slewing angle potentiometer Refer to Procedure E21 slewing angle 2 potentiometer defective 6 c Electronic component in the c Check signal on main board and measuring channel defective analog input module on main board Upper limiting value for a Cable from central unit to Refer to Section 3 7 the measuring channel the length angle sensor a Check cable and connector length exceeded defective or loose b Check and reset length sensor b Length potentiometer Potentiometer Refer to Procedure defective 5 c Electronic component in the c Check signal on main board and measuring channel defective analog input module
52. ng from the central unit to the length angle sensor defective loose or water in the connectors b Angle sensor defective c Electronic component in the measuring channel defective a Cable leading from the central unit to the jib angle sensor defective loose or water in the connectors b Jib angle sensor defective c Electronic component in the measuring channel defective 38 Years Specializing in Crane Electronic Repair amp Parts Sales Call Us We are glad to help ACTION Refer to Section 3 9 a Check cable and connector b Check pressure transducer and reset pressure channel c Check signal on main board and analog input module Refer to Section 3 9 a Check cable and connector b Check pressure transducer and reset pressure channel c Check signal on main board and analog input module a Check cable and connectors as well and replace if necessary b Check force transducer Check signal on main board and analog input module Refer to Section 3 8 Check cable b Check angle sensor and reset adjustment Refer to Procedure 5 Check signal on main board and analog input module a Check cable b Check angle sensor and reset adjustment Check signal on main board and analog input module 190041 K Bode Technical Services Inc Email contact us bodetechnical com Phone 1 303 433 8878 Service Manual PAT DS 350 ERROR ERROR
53. olon m Eod D z 5 tot i H 9 gt i EN SLEW POTENTIOMETER IN m PRES TRANS PRES 5 SLIP RING ASSY REF PISTON ROD i bd i lt SS 4 EE E HARNESS Hirschmann Rev K 12 05 05 SB 190041 K 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 Drawings 33 4 2 DRAWING 2 ELECTRICAL WIRING FOR CENTRAL UNIT TO CONSOLE CENTRAL UNIT DS350GM MAIN BOARD PAT 024 352 300 001 GROVE 9 333 103287 por cr tete A EE NE See reference notes on Drawing 1 Hirschmann Rev K 12 05 05 SB 190041_K ay 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 4 3 DRAWING 3 ELECTRICAL WIRING FOR CENTRAL UNIT CABLE TWO BLOCK CENTRAL UNIT DS350GM MAIN BOARD PAT 024 352 300 001 GROVE 9 333 103287 a ee Ee 4 Le see e ee sei _____ N g 5 NIRE 5 r r i i 2 m MM 1 x fm mno eher cs o
54. or reproduced without prior written consent from Hirschmann The drawings are subject to technical modification without prior notice MANUAL REVISIONS DATE DESCRIPTION 11 18 98 CSH Preliminary troubleshooting manual created for customer review and feedback A 01 08 98 CSH Add measuring points and jumper positions to drawings Add Theory Section 13 Change Table of Contents 02 20 98 Add LED S to DWG 7 and LED H12 TxD to 17 Correct pg 25 E91 E94 see to section 9 06 17 99 CSH Correct reference notes pg 5 15 16 Correct troubleshooting action pg 19 Add rest boom no pressure hydraulic lines procedure 4 Correct minor verbiage in Theory 1 3 D 10 15 99 Add slewing angle reading problem Section11 Add slew potentiometer adjustment Procedure 6 Move error codes to Section 2 Update correct flow charts and drawings E 11 15 99 CSH Correct Section numbers and reference numbers Change Theory Section Change to double sided pages F 01 24 00 SB Add Grove Part Numbers G 04 25 01 SB ECN 01 139 H 04 23 02 CH ECN 02 141 J 11 07 02 CH ECN 02 267 K 12 05 05 SB ECN 05 216 2000 Hirschmann Chambersburg PA 17201 USA Hirschmann Rev K 12 05 05 SB 190041 ay 38 Years Specializing Bode Technical Services Inc in Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 30
55. out and boom down are stopped Crane is not in overload or two block condition Use the key switch and the LMI by pass button on the console to override the LMI Refer to the Operator s Handbook for LMI override instructions pages12 and 13 Corrected 5 Does console indicate Anti Two block warning NO v YES Fault in crane electric or hydraulic system If console display are blank The fault is located in power supply wiring or fuses Fault in Anti Two Block system v If the display Load Moment Limit Light is lit The fault is located in LMI cables wiring fuses or console Check lever lockout system in crane service manual Go to Section 3 5 Go to Section 3 6 Hirschmann Rev K 12 05 05 SB TECHNICAL SERVICES 38 Years Specializing in Crane Electronic Repair amp Parts Sales Call Us We are glad to help Read error code displayed on console amp go to Section 3 2 190041_K Bode Technical Services Inc Email contact us bodetechnical com Phone No 1 303 433 8878 Flowcharts 15 3 4 BROKEN LENGTH CABLE PROBLEM Damaged or broken length cable Replace length cable using the following procedure Refer to Section 4 for the following drawings Drawing Electrical Wiring Central Unit to C
56. resistance at the boom nose box between terminals 1 and 6 with a ohmmeter This checks the function of the Anti Two Block switch Switch closed OOhms weight installed Switch open gt 1 Megaohm weight removed Pug the bypass plug into the boom nose box Refer to Drawing 3 in Section 4 Check wire connections in boom nose Correct No box Replace Anti Two Block switch Refer to Drawing 3 in Section 4 Yes C Next Page Hirschmann Rev 12 05 05 SB 190041_K ay 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 Flowcharts 19 PREVIOUS PAGE Ensure the byass plug is plugged into the boom nose box Measure the A2B signal in the cable reel between X1 Brown and X2 Red wires on the slip ring with an ohmmeter Switch closed 24700 x500Ohms Switch open gt 1 Megaohm Reconnected slip ring wires Refer to Drawing 2 amp 6 Section 4 Fault in wiring between boom nose box and cable reel Check for damaged length cable wiring Refer to Drawing 3 Section 4 If broken length cable Refer to Section 3 4 Measure the 2 signal the cable reel between terminal 7 and 8 with ohmmeter Switch closed 24700 5000hms Switch open gt 1 Megaohm Reconnected slip ring wires Refer to Drawin
57. s in the Replace the module for the digital the boom control Boom control extension inputs extension defective Boom control extension Replace the boom control extension defective E63 Error digital inputs 9 16 Module for digital inputs in the Replace the module for the digital in the boom control Boom control extension inputs extension defective Boom control extension Replace the boom control extension defective Hirschmann Rev 12 05 05 SB TECHNICAL SERVICES 38 Years Specializing in Crane Electronic Repair amp Parts Sales Call Us We are glad to help 190041_K Bode Technical Services Inc Email contact us bodetechnical com Phone No 1 303 433 8878 Flowcharts 11 ERROR ERROR CAUSE ACTION CODE E64 Error analog output 1 in Module for analog output 1 Replace the module for the analog the boom control the Boom control extension output 1 extension defective Boom control extension Replace the boom control extension defective E65 Error analog output 2 in Module for analog output 2 in Replace the module for the analog the boom control the Boom control extension output 2 extension defective Boom control extension Replace the boom control extension defective E66 Error analog outputs in Module for analog outputs in Replace the module for the analog the boom control the Boom control extension outputs extension defective Boom control extension Replace the boom control extension defec
58. ssure transducer cable by first unplugging the transducer cable from transducer and second moving wire 2 to Correct NO the ground terminal X1 22 or X1 25 Measure voltage at the cable connection i between A 12 24v and B ground for each connector Re connect the wiring a shown on Drawing 1 in Section 4 Refer to Drawing 1 in Section 4 Fault in cable v Adjust zero point on pressure transducers Adjustment Procedure 4 in Section 5 If transducer s are not adjustable Replace pressure transducer s and adjust zero point Refer to Procedure 4 in Section 5 YES Y Measure pressure transducer signals on the analog input module between test points Piston Side MPO ground and X1 1 Rod Side MPO ground and X1 2 The measurements should be between 0 5 4 5v 0 5v 500mv at Opsi to 4 5v at 4410psi Refer to Drawing 4 amp 9 in Section 4 Analog Input board defective Replace analog input board a Refer to Drawing 4 in Section 12 and Replacement Procedure 3 steps 4 11 amp 12 in Section 5 YES Hirschmann Rev 12 05 05 SB 190041_K Bode Technical Services Inc ay 38 Years Specializing Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 28 Service Manual DS 350 GM 3 10 BAD DATA TRANSFER BETWEEN CONSOL
59. t circuit in the A2B Short circuit in the A2B switch Refer to Section 3 6 switch circuit Short circuit in the cable to the Replace A2B switch A2B switch Replace cable to the A2B switch Electronic component on the analog input module defective Check analog input module Replace if necessary Refer to Drawing 4 and Procedure 3 Steps 1 2 4 11 12 EBO Free fall switch on Free fall monitoring DGA 9 4 0 DGA 9 5 0 1 Free fall solenoid Free fall monitoring DGA 9 4 0 DGA 9 5 0 EB2 Free fall switch and Free fall monitoring DGA 9 4 0 DGA 9 5 0 solenoid on ECO Prohibited area Boom is about to collide with Check values in the data prom DGA the engine hood switch off 11 5 EC1 Approaching prohibited Boom is about to collide with Check values in the data prom DGA area the engine hood prewarning 11 5 Free fall monitoring only used with data logger DL352 Note If an error message is displayed which is not contained in above list please contact the Hirschmann service department Hirschmann Rev K 12 05 05 SB ICALSERVICES 38 Years Specializing in Crane Electronic Repair amp Parts Sales Call Us We are glad to help 190041_K Bode Technical Services Inc Email contact us bodetechnical com Phone No 1 303 433 8878 14 3 3 LEVER LOCKOUT ACTIVATED Service Manual PAT DS 350 PROBLEM The lever lockout system of the crane is activated Crane movements hoist up telescope
60. the solenoids and thereby locking out those functions that may aggravate the crane s condition Hirschmann Rev K 12 05 05 SB 190041_K 38 Years Specializing Bode Technical Services Inc SODE in Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 Flowcharts 3 FLOWCHARTS 3 1 GENERAL FLOWCHART This section explains how to handle a problem that may arise with the PAT DS 350 Modular LMI The procedures are given in flowchart format for the following sections Start with the general flowchart below that will guide you to one of the detailed flowcharts shown in Sections 2 through 11 The drawings and procedures that are referenced in these sections can be found in Sections 12 and 13 What s Wrong gt Error Code Displayed c orl Go to Section 3 1 gt Lever Lockout Activated p Go to Section 3 3 Broken Length Cable gt Go to Section 3 4 p gt No display gt Go to Section 3 5 Anti Two Block Problem p Go to Section 3 6 gt Length Reading Problem gt Go to Section 3 7 m Angle Reading Problem gt Go to Section 3 8 gt Load Reading Problem c l Go to Section 3 9 Bad Data Transfer Interference
61. tive E69 Error in the load chart Memory module wrongly Bridge memory module acc to EPROM bridged memory type The number of the Load chart EPROM defective Replace load chart EPROM selected EPROM base and the programmed value are not identical E70 Error in digital output Central unit unable to Check supply voltage module correspond with digital output Replace digital output module refer module to section 14 theory 6 E71 Incorrect a Anti Two block relay is Replace main board Refer to acknowledgment of the stuck or defective Drawing 4 and Procedure 3 1 Relay on the main b Anti Two Block relay is not board being selected due to a break on the main board 72 Analogous to E71 for the Analogous to E71 for the Analogous to E71 for the relays E77 relays 2 7 relays 2 7 2 T E80 Error in the slewing angle The difference between the Check the slewing potentiometer measurement average of the slewing angle adjustment and one of the wipers of the slewing potentiometer is out of Replace the slewing potentiometer the tolerance The selected rigging condition is not contained in the data EPROM Wrong rigging condition Select another rigging condition Check the programming in the data EPROM E85 Error in the radius The computed radius is too Check the programming in the data determination small negative deflection EPROM E86 Faulty percentage for at Teles
62. ts Sales Call Us We are glad to help ACTION a Check cable and connectors b Replace length sensor c Replace LMI main board or processor board a Check supply voltages b Replace main board or analog input module Refer to Drawing 4 and Procedure 3 Steps 1 2 4 11 12 Refer to Section 3 11 a Check cable 6 b Check and reset slewing angle potentiometer Refer to Procedure 6 c Check signal on main board and analog input module a Replace system program EPROM b Check signal on main board and analog input module a Replace system program EPROM b Check signal on main board and analog input module Replace system program EPROM or Data EPROM Refer to Procedure 2 Replace system program EPROM or TLK EPROM Refer to Procedure 2 Replace main board or analog input module Refer to Drawing 4 and Procedure 3 Steps 1 2 4 11 and 12 190041_K Bode Technical Services Inc Email contact us bodetechnical com Phone No 1 303 433 8878 Flowcharts 9 ACTION Error in the external Internal defect in digital part of Exchange write read memory write read memory CPU CMOS RAM Replace CPU RAM Part 1 module Refer to Drawing 4 and Procedure 3 Steps 1 3 13 14 Error in the external Internal defect in digital part of Exchange write read memory write read memory CMOS RAM Replace CPU Part 2 module Refer to Drawing 4 and Procedure 3 Steps 1 3 13 14 RA
63. urement to calculate the real physical pressure or force To define the zero point or the slew potentiometer the super structure must be positioned so the boom is in the zero degree position over the front and the house lock pin engaged 5 6 1 A ACTIVATING THE ZERO SETTING FUNCTION To activate the zero setting Function press the INFO key on the console to activate the INFO Function Now press the CTRL key At this point a five digit Authorization Number must be entered Only authorized personnel may adjust the zero point settings Example 6 4356 Press Return 5 6 1 B ZERO SETTING THE TRANSDUCER INPUTS Now having successfully entered a valid password the piston side zero point setting function is activated Press return two times to display the slew adjustment screen The display shows a scale from 5 to 5 degree a horizontal mark shows the current position of the slew pot wiper By pressing the and keys simultaneously the zero setting occurs automatically Note The indicator line will move to zero on the bar graph When the operator is finished pressing the EXC or INFO key returns the console display to normal Hirschmann Rev K 12 05 05 SB 190041_K ay 38 Years Specializing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 6 6 1 THEORY 1 OPERATION OF BO
64. zing Bode Technical Services Inc Crane Electronic Repair amp Parts Sales Email contact us bodetechnical com Call Us We are glad to help Phone No 1 303 433 8878 53 6 2 THEORY 2 OPERATION OF PISTON SIDE LOAD SENSOR Measuring current The ammeter is used to measure current at the piston side input signal Remove the wire from X1 21 terminal in the central unit and measure the current with the ammeter in series The measurement should be between 4 20mA UNIT 1 Measuring voltage 25550 MODULAR 250 ohms 1 HII j i 159 250 oh The voltmeter is used to measure voltage between pins ohms canas X1 21 piston side signal and X1 22 gnd on the main board Ls 024 352 300 001 9333103287 The resistors are there to show that at 4mA the voltage is 1 1V because current multiplied D with resistance equals voltage therefore 4mA x 275 ohms total e resistance 1 1V d a 2 po 9 OPERATING WINDOW 55 2122 ERROR 7 CODE 5 12 AmA 1 1V 1 1 5 5 4 20mA WORKING RANGE 20mA 5 5V 12 8 ERROR 2 E22 1 cul DRM ER 9 190 1O I oe A B C A B A ANN 1 1 PRESS TRANS PISTON EME

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