DS-350 GM Service Manual
Contents
1. 152552757227 1 A i Roper eal lt gt ss m m e EO NOISId 9 N a cx U 1 i i i URN zy Exfl T ram 4 Man Z 7 gt AO EL U N9 TA NO S MOOINN INT S lt a SS GLX y m 105 INT a lt i S D gt 41 z 301 371 6126 www skyazul com SkyAz l Eguipment Solutions 30 Service Manual PAT DS 350 GM 4 2 DRAWING 2 ELECTRICAL WIRING FOR CENTRAL UNIT TO CONSOLE CENTRAL UNIT DS350GM MAIN BOARD PAT 024 352 300 001 TRAL UNIT lt I 09 a a lt gt gt a oO m gt tn M Die 20 vzd 22 NN gt L C H x a lt L 22153 144 105 PANES 21 3 4 5 6 7 1 12 3 1 LO ee o 2 TI ONS 8 1 2 4 8 11 12 1 4 2 415 8 x1 m a O m i gt Z gt gt lt N Y L 1 gt Gaw 48 a _ UBE 7 2 4 ND 2 2 4 i ZN A BO XD UE AN AN AN 2 13 TBAR See reference notes on Drawing 1 SkyAz l Eguipment Solutions www skyazul com 301 371 6126 31 DRAWING 3 ELECTRICAL WIRING FOR CENTRAL UNIT TO CABLE REEL ANTI TWO BLOCK CENTRAL UNIT DS2. 2 EQUIPMENT SOLUTIONS DS350GM SERVICE MANUAL NOTICE SkyAz l makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and or its fitness for a particular purpose Sky Az l will not be liable for errors contained in this manual for incidental or consequential damages in connection with the furnishing performance or use of this manual This document contains proprietary information which is protected by copyright and all rights are reserved No part of this document may be photocopied reproduced or translated to another language without the prior written consent of SkyAz l SkyAz l reserves proprietary rights to all drawings photos and the data contained therein The drawings photos and data are confidential and cannot be used or reproduced without the written consent of SkyAzul The drawings and or photos are subject to technical modification without prior notice All information in this document is subject to change without notice SkyAzul Inc 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 Service Manual PAT DS 350 GM TABLE OF CONTENTS 1 GENERAL INFORMATION isse ex Supe zd vr i n 1 2 WARNINGS 2 3 FLOWCHARTS iek A a 3 3 0 GENERAL FLOWCH
3. CH05 UBS 10 X1 17 CH06 HESIN A2B 4 X1 18 CH07 9V 4 X1 19 CH08 VREFA 2 2 500V X1 20 UKLEMM app VREFA limits ADC input to 5 0V AGND MP8 5V 1 7 Input channels 1 7 0 5V 4mA 2 5V 20mA MP14 13V REFO2 MP16 HESIN input voltage 17 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 SkyAz l Eguipment Solutions www skyazul com 301 371 6126 41 5 PROCEDURES 5 1 PROCEDURE 1 STRAIN RELIEF INSTALLATION OUTTER SHIELD GROUNDED REI BODY MOUNTED IN C P U FERRITE FILTER ATTACHED TO STRAIN RELIEF INSIDE STRAIN INSERT NNER SHIELD GROUNDED ON CONNECTION BOARD p CUT INNER SHIELD BACK TO APPROXIMATELY 1 2 INCH TO INNER JACKI 50 IE INNER SHEILD IS 0 6 INCHES IN LENGTH COVER INNER JACKET EDGE OF INNER SHIELD W S HEAT SHRINK TUBING C
4. DU QU A E A 1 1771 92 2 Z gt A 24 5 A FT A JBE 5 i cl3 5 sas 521 amp 718 X2 X 8 615 2 X1 i I SkyAz l Eguipment Solutions www skyazul com 301 371 6126 SkyAz l Inc y 200 W Main Street Suite 2A Middletown MD 21769 EQUIPMENT SOLUTIONS Phone 301 371 6126 Fax 301 371 0029 www skyazul com info skyazul com
5. GRAPHIC CONSOLE HORIZONTAL PARTS LIST PART NO PAT 050 350 061 318 NO PART NO QTY DESCRIPTION 01 031 300 110 049 1 CONSOLE ACCY FRONT FACE 6 DIS 02 050 150 300 052 1 BOARD PUSHBUTTON SET KEYBRDS 03 003 051 905 235 1 SWITCH KEY 04 050 350 110 139 1 KEY SPARE 05 002 053 703 101 6 SCREWS FRONT PANEL MOUNTING 06 050 150 300 050 1 BOARD 07 050 150 300 051 1 TERMINAL BOARD 08 050 000 050 625 1 SEALING FRONT PANEL 09 050 000 100 180 1 HOUSING 10 050 350 110 263 1 MOUNTING KIT FOR HOUSING 11 021 448 161 213 1 STRAIN RELIEF PG13 5 GREY WHT 12 031 300 100 173 1 GASKET 13 031 300 100 392 1 CANNON CONN 7 SOCKET 14 031 300 100 024 1 DUST CAP 15 000 208 010 210 1 TOOTHWASHER M12 16 000 214 210 013 1 LOCKNUT PG13 5 17 050 350 300 076 1 BOARD TERMINAL INTERFACE FOR LIGHTBAR SkyAz l Eguipment Solutions www skyazul com 301 371 6126 36 Service Manual PAT DS 350 4 5 DRAWING 6 CABLE REEL PARTS LIST I ES K A SkyAz l Equipment Solutions www skyazul com 301 371 6126 Drawings 37 DRAWING 6 CABLE REEL PARTS LIST continued CABLE REEL ASSEMBLY PARTS LIST PART NO PAT 068 308 060 001 NO PART NO QTY DESCRIPTION 01 068 000 300 060 1 BOARD TERMINAL W EMC FILTERS 02 064 103 060 007 1 ANGLE SENSOR WG103 0007 03 068 000 300 018 1 LENGTH POTENTIOMETER UNIT 04 002 050 206 012 2 SCREW M6 X 12 HEX SOCKET CAP 05 000 207 010 064 2 WASH
6. N VY A QD a ame di ss 301 371 6126 www skyazul com SkyAzul Equipment Solutions Drawings 33 DRAWING 4 CENTRAL UNIT PARTS LIST continued PART NO A PAT 024 350 063 001 PART NO B PAT 024 350 063 002 NO PART NO QTY DESCRIPTION 01 024 350 050 292 1 HOUSING W COVER CENTRAL UNIT 02 024 350 110 067 1 GASKET 03 024 352 300 001 1 MAIN BOARD 04 024 352 300 020 1 ANALOG INPUT MODULE 05 024 351 300 007 1 CPU MODULE 06 024 351 300 011 1 EPROM MODULE 07A 000 304 140 112 1 RELAY 12V 078 000 304 140 241 1 RELAY 24V 08 024 350 100 135 1 SCREW SET 09 000 314 022 006 2 FUSE HOLDER 10 000 313 062 002 1 FUSE 10amp 250V FAST ACTING 11 000 313 064 001 1 FUSE 4 250V FAST ACTING 12 000 214 340 013 1 HOLE PLUG PG13 5 13 021 441 131 013 2 STRAIN RELIEF PG13 5 RED WHT 14 021 441 161 213 1 STRAIN RELIEF PG13 5 W GREY WHT 15 021 441 090 709 3 STRAIN RELIEF PG9 W BLACK WHITE 16 024 000 100 260 5 FERRITE FILTER PG13 5 17 024 000 100 261 1 FERRITE FILTER PG16 18 024 350 100 661 1 KEYSWITCH 19 031 300 101 131 1 SPARE KEY 20 024 000 100 095 2 MEMBRANE ELEMENT BREATHER SkyAz l Eguipment Solutions www skyazul com 301 371 6126 34 DRAWING 58 CONSOLE D5350 1318 PARTS LIST Service Manual PAT DS 350 GM SkyAz l Eguipment Solutions www skyazul com 301 371 6126 Drawings 35 DRAWING 5B CONSOLE DS350 1318 PARTS LIST continued
7. Eprom Module on Refer to Procedure 2 in Section 5 the main board Correct NO YES Place EPROM in correct socket Refer to Procedure 2 in Section 5 process voltage on the Main Board in the central unit between MP42 5v and MPO ground Refer to Drawing 4 8 7 in Section 4 NO Make sure external and internal power supply is correct Refer to Section 3 5 No Display YES Y Check the continuity of the receive RXD and transfer TXD wires central unit main board X1 5 and console 1 3 central unit main board X1 6 and console X1 4 Turn off system power Check continuity between Refer to Drawing 2 in Section 4 NO Check connections and replace cable from central unit to console if necessary Refer to Drawing 2 in Section 4 and Procedure 1 in Section 5 NEXT PAGE SkyAz l Equipment Solutions www skyazul com 301 371 6126 27 28 Service Manual PAT DS 350 GM 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 NO gt between terminal MP1 and central unit box mounting bracket Refer to Drawing 7 in Section 4 YES Ensure that cable shi
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 to the main board 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 SkyAzul Equipment Solutions www skyazul com 301 371 6126 44 Service Manual PAT DS 350 5 4 PROCEDURE 4 PRESSURE TRANSDUCER ZERO ADJ USTMENT 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 p
9. chart below that will guide you to one of the detailed flowcharts shown in this section The drawings and procedures that are referenced in these sections can be found in Sections 4 and 5 Wha s Wrong gt Error Code Displayed gt Goto Section 3 1 Lever Lockout Activated gt to Section 3 3 Broken Length Cable gt Goto Section 3 4 e No display gt Go to Section 3 5 Anti Two Block Problem gt Goto Section 3 6 gt Length Reading Problem 5 Go to Section 3 7 gt Angle Reading Problem gt Goto Section 3 8 gt Load Reading Problem gt Go to Section 3 9 Bad Data Transfer Interference gt Between Central Unit Goto Section 3 10 Console SkyAzul Equipment Solutions www skyazul com 301 371 6126 4 Service Manual PAT DS 350 GM 3 2 ERROR CODE DISPLAY PROBLEM Error code displayed Lever lockout activated Warning lights on ERROR p CAUSE ACTION CODE Minimum MN or Fallen below the minimum Lower boom back to a radius or maximum angle range radius or above the angle angle given in the load chart exceeded given in the load chart due to raising the boom to far M aximum radius or The maximum radius or Raise boom back to a radius or minimum angle range minimum angle g
10. component b Replace console main board on the main board Refer to Drawing 5 defective EAB Short circuit in the A2B Short circuit in the A2B Refer to Section 3 6 Switch circuit switch Replace A2B switch Short circuit in the cable to the A2B switch Replace cable to the A2B switch Electronic component on the analog input module Check analog input module defective Replace if necessary Refer to Drawing 4 and Procedure 3 Steps 1 2 4 11 12 Note If an error message is displayed which is not contained in above list please contact the PAT service department SkyAzul Equipment Solutions www skyazul com 301 371 6126 Flow charts 13 3 3 LEVER LOCKOUT ACTIVATED PROBLEM The lever lockout system of the crane is activated Crane movements hoist up telescope out and boom down are stopped Crane is not in overload or two block condition Start 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 YES m Does console indicate Anti Two block warning NO YES If console display are If the display Load Moment Fault in crane electric blank The fault is Fault in Anti Two Limit Light is lit The fault is or hydraulic system located in power supply Block system located in LMI cables wiring wiring or
11. ground for piston side and 1 23 12 24v and X1 25 ground for rod side Refer to Drawing 1 and 4 in Section 4 VES Fault in pressure transducer cable Refer to Drawing 1 in Section 4 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 v C NEXT PAGE SkyAz l Equipment Solutions www skyazul com 301 371 6126 26 Service Manual PAT DS 350 GM 3 10 BAD DATA TRANSFER BETWEEN CONSOLE amp CENTRAL UNIT OR INTERFERENCE PROBLEM PREVIOUS PAGE y Measure signal from pressure transducers in central unit The return signal is a current output and must 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 1 24 in the central unit and connect one voltmeter lead to wire 2 and the other lead to X1 24 The measurement should be between 4 20ma 4ma when there is no pressure in the hydraulic lines O psi Refer to Drawing 1 in Section 4 Check continuity of wire 2 and pin B in pressure transducer cable by first unplugging the transducer cable from transducer and second moving wire 2 to the ground terminal
12. 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 Correct No Check wire connections in boom nose Yes v 4 Next Page gt SkyAz l Eguipment Solutions www skyazul com box Replace Anti Two Block switch Refer to Drawing 3 in Section 4 301 371 6126 18 Service Manual PAT DS 350 GM PREVIOUS PAGE Ensure the byass plug is plugged into the boom nose box Measure the 2 signal in the cable reel between X1 Brown and X2 Red wires on the slip ring with ohmmeter Switch closed 4700 5000hms 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 and wiring Refer to Drawing 3 Section 4 If broken length cable Refer to Section 3 4 Measure the 2 signal in the cable reel between terminal 7 and 8 with ohmmeter Switch closed 4700 5000hms Switch open gt 1 Megaohm Reconnected slip ring wires Refer to Drawing 3 Section 4 Replace slip ring N ame gt Refer to Drawing 3 amp 6 in Section 4 v Measure the A2B signal in the boom base box between terminals 5 and 6 with an o
13. 350GM Drawings 4 3 i i 1 1 1 b 1 z S X i a OU Le i i i o lt gt o lt 9 4 1 E o TOM n an 5 z 1 Y NI r N IS HL9N31 gt TE 9 Mm 1 a 2 i aa rq an v 1 gni La 0 i 9 i yI N S X o N o 1 A E a N gt 5 lt 1 i 4 i a 1 A y gag OS ATA CC E 1 s 2 s N n 4 i S e i 1 i 1 I O i 7 i i 1 ES A ASA AAA A AA i i 1 i i i i 1 1 i 1 1 CAL rA i 1 lt 1 1 i 01 1 1 1 OI 1 um i i 1 1 A gt i APR zx i L E end i OWN i WO Lio 1 i Q A m gt 1 V T 1 i E 1 N 1 1 i 1 lt N i 1 x 1 1 i 1 Z 1 ty 1 A A ru ei A Tii S date 301 371 6126 www skyazul com MAIN BOARD PAT 024 352 300 001 SkyAz l Eguipment Solutions Service Manual PAT DS 350 GM 32 DRAWING 4 CENTRAL UNIT PARTS LIST 4 4 Lm 0 SY Y of gt gt 07 o CN 4 NG gt
14. 6350 MODULAR 47 250 ohms OPERATING WINDOW B ges 250 ohms ERROR CODE E13 EP A H Q 4 1 1 2 WORKING gt RANGE m U 20mA 5 5V ERROR d iis x1 23 24 25 CODE 4 4 20mA 1 1 5 5V 1 2 3 EA 2 S oet Ei 1 2 3 A B A B C PRESS TRANS ROD SkyAz l Eguipment Solutions www skyazul com 301 371 6126 49 6 4 THEORY 4 OPERATION OF 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 used to measure voltage between pins 1 29 angle signal X1 28 on the main board 024 352 300 001 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 r Yj 250 ohms ERROR CODE 4 150 250 ohms 4mA 1 1V WORKING RANGE 5 20 5 5 CODE 3 SE a ENGTH ANGLE TRAN CER 1 e i
15. A A vla anna Anl Ce u 3 222 ERROR CODE DISPLAY a nn 4 3 3 LEVER LOCKOUT ACTIVATED osada 13 24 BROKEN LENGTH GABLE a 14 3457 SNO DISPLAY A D 15 3 6 BLOCK PROBLEM unid NN e oco ET eg 17 3 7 LENGTH READING PROBLEM sucia ies 20 3 8 ANGLE READING PROBLEM xa ever Uta cord Ede ca 23 3 9 LOAD READING PROBLEM oca reir rt MAX RR ra e RU sg Cou a 25 3 10 BAD DATA TRANSFER BETWEEN CONSOLE amp CENTRAL UNIT OR INTERFERENCE PROBLEM 2 26 4 DRAWINGS der ot 29 4 1 DRAWING 1 ELECTRICAL WIRING FOR CENTRAL UNIT TO PRESSURE TRANSDUCERS AND CRANE oni salsu ch Grut eh Oe eter e x LR egy lak 29 4 2 DRAWING 2 ELECTRICAL WIRING FOR CENTRAL UNIT TO CONSOLE 30 4 3 DRAWING 3 ELECTRICAL WIRING FOR CENTRAL UNIT TO CABLE REEL ANT PTW BLOCK nta iaa 31 4 4 DRAWING 4 CENTRAL UNIT PARTS 5 4 4 32 4 5 DRAWING 6 CABLE REEL PARTS eoi eoo duo can aula 36 4 6 DRAWING 7 CENTRAL UNIT MAIN BOARD LAYOUT 38 4 7 DRAWING 8 CONSOLE CONNECTION 2 1 39 4 8 DRAWING 9 CENTRAL UNIT ANALOG INPUT MODULE 40 5 PROCEDURES su
16. ER M6 FLAT 06 068 000 100 152 1 HOUSING KT200 07 000 214 340 013 1 PG13 5 HOLE PLUG 08 000 673 020 002 139 CABLE LENGTH SINGLE CORE 09 002 148 131 013 1 STRAIN RELIEF PG13 5 RED W HT 10 031 300 100 206 1 CHEMICAL CORROSION INHIBITOR 11 068 000 100 064 1 SLIP RING ASSEMBLY 2 POLE SkyAz l Eguipment Solutions www skyazul com 301 371 6126 38 Service Manual PAT DS 350 GM 4 6 DRAWING 7 CENTRAL UNIT MAIN BOARD LAYOUT SkyAz l Eguipment Solutions www skyazul com BOARD P N 024 352 300 001 1 KGND MP4 5V MP8 9V MP9 6V 24 MP25 UBS console sensors 01 5 MP26 GND MP29 5V hand terminal LED S HO8 LOAD H09 A2B H10 MAIN IN OUT H11 POWER H12 TxD 301 371 6126 Drawings 39 4 7 DRAWING 8 CONSOLE CONNECTION BOARD v V GND PNW BUG BOARD PART NUMBER 050 150 30 0051 SkyAz l Eguipment Solutions www skyazul com 301 371 6126 0 Service Manual PAT 05 350 GM 4 8 DRAWING 9 CENTRAL UNIT ANALOG INPUT MODULE BOARD P N 024 352 300 020 1 1 7 ADC INPUT 0 5V 4 5V Note If channel adjustments are made through the softw are and graphic console DO NOT adjust offset with P1 P7 X1 8 TEMP 0 5V 10mV C X1 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
17. LAMP SHIELD TO GROUND ZONNECTION BOARD IN C U WING 3 CENTRAL UNI SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual PAT 05 350 5 2 PROCEDURE 2 EPROM LOCATION AND INSTALLATION e Ensure the notch is in the correct direction The DATA and EPROMs fill the bottom of the socket as shown by the arrows e Place EPROMs in the correct EPROM socket as shown SkyAzul Equipment Solutions www skyazul com 301 371 6126 43 5 3 PROCEDURE 3 MAIN BOARD REPLACEMENT Refer to Drawing 4 central unit parts list for board location 1 Tum system power off 2 Remove the central unit lid NOTE Take care not to damage the boards with the screw driver when removing and inserting screws NOTE Use care when lifting the CPU module board and analog input module from the main board because 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 board 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
18. ROR CAUSE CODE E22 Upper limiting value for the measuring channel pressure piston side exceeded Upper limit value for the measuring channel pressure transducer rod side exceeded channel force exceeded Upper limit value for the measuring channel angle main boom E Upper limit value for the measuring channel Luffing J ib Angle exceeded SkyAz l Eguipment Solutions Upper limit value for the measuring E23 E24 E25 26 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 w ater 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 Electric component in the measuring channel defective a Cable leading 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 w ater in the connecto
19. X1 22 or X1 25 Measure voltage at the cable connection 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 Correct NO v No Fault in cable v Adjust zero point on pressure transducers Adjustment Procedure 4 in Section 5 If transducer s 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 1 2 The measurements should be between 0 5 4 5v 0 5 500 at Opsi to 4 5v at 4410psi Refer to Drawing 4 amp 9 in Section 4 Analog Input board defective Replace analog input board Refer to Drawing 4 in Section 12 and Replacement Procedure 3 steps 4 11 amp 12 in Section 5 NO YES 6 END SkyAzul Equipment Solutions www skyazul com 301 371 6126 Flow charts interference PROBLEM Error Code E93 E94 No data transfer to and from console G from crane electric or console display frozen START Check H12 TxD LED on the main board ON OFF Refer to Drawing 7 in Section 4 ON Make sure that the eprom s are correct and plugged into the
20. XC or INFO key returns the console display to normal SkyAzul Equipment Solutions www skyazul com 301 371 6126 45 5 5 PROCEDURE 5 LENGTH AND ANGLE SENSOR ADJ USTMENT ADJUST LENGTH POTENEIOMETER TH BOOM FULLY RETRACTED TURN THE CENTER SCR COUNTER CLOCKWISE TO A SOFT STOP SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual 05 350 6 6 1 THEORY 1 OPERATION OF BOOM LENGTH SENSOR OPERATING WINDOW The system sensors provide a 4 to 20mA output however due cae to a fixed resistor circuit in the central unit the input signal can CODE E11 be measured using ammeter current or voltmeter voltage 4mA 1 1V The input signal operating window is 4 to 20mA measured in WORKINC series at the analog input terminal OR 1 1 to 5 5V measured in RANGE parallel betw een the analog input and ground GND terminals 20mA 5 5V At 4mA the voltage is 1 1V and at 20mA the voltage is 5 5V ERROR When troubleshooting this system a current or voltage needs OE 7 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 250 ohms input signal Remove the wire from X1 27 terminal in the central 150 unit measure the current with the ammeter in series The
21. acted the length differs by more than 2 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Flow charts ERROR ERROR CAUSE CODE E11 Fallen below limit for the measuring channel length Fallen below lower limit value for the measuring channel pressure transducer piston side E E Fallen below lower limit value for the measuring channel pressure transducer rod side E Fallen below lower limit value for the measuring channel force E Fallen below lower limit value for the measuring channel angle main boom SkyAzul Equipment Solutions 12 13 14 15 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 c
22. azul com 301 371 6126 20 3 7 LENGTH READING PROBLEM Service Manual PAT DS 350 GM PROBLEM Length displayed incorrect Crane is not in out of load chart condition START 2 Check mechanical adjustment of length potentiometer in 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 Y Replace length potentiometer assembly Refer to Drawing 6 in Section 4 Remove slip ring body from shaft and remove gear wheel from potentiometer assembly to terminal block Reinstall mounting plate gear wheel and slip axle Unscrew mounting plate and remove potentiometer assembly from Coree gt NO mounting plate Remove assembly wires form terminal block Connect new counter clockwis rings With boom fully retracted reset potentiometer by turning it slowly e until it reaches a soft stop Refer to Drawing 3 amp 6 in Section 4 and Adjustment Procedure 5 in Section 5 YES y Check out clutch in big gear wheel of length to ensure that clutch 15 not slipping on potentiometer axle Refer to Drawing 6 in Section 4 and Adjustment Procedure 5 in Section 5 transducer Extend and retract boom Replace the gear wheel cl
23. e c Electronic component in the measuring channel defective Fallen below lower a Cable leading from the a Check cable and limit value for the central unit to the sensor of connectors measuring channel 7 channel 7 defective loose b Check sensor of channel 7 or water in the connectors and reset adjustment b Sensor of channel 7 c Check signal on main board defective and analog input module c Electronic component in the measuring channel 7 defective voltage the main board defective Drawing 4 and Procedure 3 Below limiting value a Cable from central unit a Check cable for slewing angle 1 to the slewing angle sensor b Check and reset slewing defective or loose angle potentiometer Below limiting value b Slewing angle c Check signal on main board for slewing angle 2 potentiometer defective and analog input module c Electronic component in the measuring channel defective on main board Upper limiting value a Cable from central unit Refer to Section 3 7 for the measuring to the length angle sensor Check cable and connector channel length defective or loose b Check and reset length exceeded b Length potentiometer sensor Potentiometer Refer to defective Procedure 5 c Electronic component in c Check signal on main board the measuring channel and analog input module defective on main board SkyAzul Equipment Solutions www skyazul com 301 371 6126 Flow charts ERROR ER
24. e 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 Refer to Drawing 4 in Section 4 and Replacement Procedure 3 steps 4 11 amp 12 in Section 4 Correct NO YES C mb SkyAz l Equipment Solutions www skyazul com 301 371 6126 Flow charts 23 3 8 ANGLE READING PROBLEM PROBLEM Angle displayed incorrect Crane is not in out of load chart condition START Check the cable for damages or 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 gt adjustments not be made VES 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 YES Open cable reel cover 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 Faulty
25. e load chart EPROM selected EPROM base defective and the programmed value are not identical E70 Error in digital output Central unit unable to a Check supply voltage module correspond with digital b Replace digital output output module module E71 Incorrect a Anti Two block relay is Replace main board Refer to acknow ledgment of stuck or defective Drawing 4 and Procedure 3 the 1 Relay on the b Anti Two Block relay 15 main board not being selected due to a break on the main board E77 the relays 2 7 relays 2 7 2 7 Wrong rigging The selected rigging Select another rigging condition condition condition is not contained in Check the programming in the the data EPROM data EPROM Error in the radius The computed radius is too Check the programming in the determination small negative deflection data EPROM Change of the The operating mode switch Lower the load and set the operating code during in the console was used operating mode switch correctly lifting a load during lifting a load to the code assigned to the actual operating mode of the crane SkyAzul Equipment Solutions www skyazul com 301 371 6126 Flow charts ERROR ERROR CAUSE CODE E 91 No data transmission from console to central unit Refer to Section 9 E Error in the data transmission from console to central unit Refer to also Section 3 10 E 92 93 Error in the data transmission f
26. e to the console Refer to Drawing 1 in Section 4 Replace the main board in central unit NO Refer to Drawing 4 in Section 4 and Replacement Procedure 3 in Section 5 YES y NEXT PAGE gt SkyAz l Eguipment Solutions www skyazul com 301 371 6126 16 Service Manual PAT DS 350 GM PREVIOUS PAGE Measure voltage in the console between X1 1 12 24V and 1 2 ground Refer to Drawing 2 8 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 i END SkyAzul Equipment Solutions www skyazul com 301 371 6126 Flow charts 3 6 ANTI TWO BLOCK PROBLEM PROBLEM Function of Anti Two Block System is faulty START i Check to see whether or not crane is in two block condition Correct NO YES y v Lower hook down into safe position Check Bypass plug installed Refer to Drawing 3 in Section 4 No gt Plug appropriate bypass plug into socket of 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 resistance at
27. ean potentiometer axle Reset length potentiometer Refer to Drawing 6 in Section 4 and Adjustment Procedure 5 in Section 5 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 lt gt NO gt Main board defective Replace main board Refer to Drawing 4 in Section 4 and Replacement Procedure 3 in Section 5 VES NEXT PAGE k SkyAz l Equipment Solutions www skyazul com 301 371 6126 Flow charts 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 gt 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 reel 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 sli
28. elds 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 NO Refer to connection and wiring diagrams Drawings 1 2 3 in Section 4 and Procedure 1 in Section 5 YES Y 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 i END SkyAzul Equipment Solutions www skyazul com 301 371 6126 29 Drawings DRAWINGS 4 DRAWING 1 ELECTRICAL WIRING FOR CENTRAL UNIT TO PRESSURE TRANSDUCERS AND CRANE 4 1 CENTRAL UNIT DS350GM MAIN BOARD PAT 024 352 300 001 z ono 8 eL A 25 Z 9NIV 5 5 1004 5 15 ER 2 lt 1 mats SNV Q Tg 1 M DWG E ano A SS gOx 1 m me HO 004 d m 2 X lt lt Bev a an 2 i pm
29. er with the capability to also measure current will be reguired Regular maintenance and service tools will also be reguired 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 SkyAzul Equipment Solutions www skyazul com 301 371 6126 2 Service Manual PAT DS 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 wi
30. fuses fuses or console Check lever lockout system in crane service manual Go to Section 3 5 Go to Section 3 6 Read error code displayed on console amp go to Section 3 2 SkyAzul Equipment Solutions www skyazul com 301 371 6126 3 4 14 Service Manual PAT DS 350 GM BROKEN LENGTH CABLE PROBLEM Damaged or broken length cable Replace length cable using the follow ing procedure Refer to Section 4 for the following drawings 10 11 12 13 14 Drawing 3 Electrical Wiring Central Unit to Cable Reel Drawing 6 Cable Reel Parts List Cut old cable at cable drum Disconnect damaged length cable from junction box at the boom nose Refer to Drawing 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 Remove cable reel from mounting brackets Remove damaged length cable which is mounted to the slip rings in the cable reel from slip ring terminal Refer to Drawing 3 On the back side of the cable reel open the strain relief attached to the axle in the center of the drum Pull existing length cable out of the cable reel Pull new length cable through the hole pipe and strain relief and push it through the axle of the reeling drum Tighten new strain relief to ensure sealing Reconnect the length cable to the slip ring Refer
31. hannel 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 www skyazul com 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 301 371 6126 6 Service Manual PAT DS 350 GM ERROR ERROR CAUSE ACTION CODE Fallen below lower a Cable from central unit a Check cable limit value for to angle sensor defective or b Check angle sensor and measuring channel disconnected or water reset adjustment Luffing J ib Angle inside the plug c Check signal on main board b Angle sensor defective and analog input modul
32. hmmeter Switch closed 4700 5000hms Switch open gt 1 Megaohm Reconnecteg 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 cable if necessary Refer to Drawing 3 in Section 4 C NEXT PAGE SkyAzul Equipment Solutions www skyazul com 301 371 6126 Flow charts PREVIOUS PAGE 2 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 1 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 gt x 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 between 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 m 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 SkyAz l Eguipment Solutions www sky
33. hysical 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 64356 5 4 1 8 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 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 E
34. iven in the angle given in the load chart exceeded load chart was exceeded due to lowering the boom too far Prohibited slew ing Slewing range prohibited Slew back into admissible range no load area with load range Operating mode not Operating mode switch in Set operating mode switch available the console set incorrectly correctly to the code assigned Operating mode is not to the operating mode of the permissible with actual crane crane configuration E05 Length range not Boom has been extended Refer to Section 3 7 permitted too far or not far enough Retract or extend boom to Length sensor adjustment correct length given in the load changed i e length sensor chart cable slid off the cable drum Fallen below angle Fallen below the minimum Luff in the jib to a radius or range with luffing jib jib angle specified n the angle specified in the load operation respective load chart due to chart luffing out the jib too far No acknowledgment Overload relay is stuck Replace main board in central signal from overload defective or not being unit Refer to Drawing 4 and relay K1 selected Procedure 3 in Section 5 3 acknowledgment Anti Two Block switch Replace main board in central signal from Anti Two relay is defective or not unit Refer to Drawing 4 Block switch relay being selected Section 4 4 and Procedure 3 in Section 5 3 Error in length With the boom fully Refer to Section 3 7 measurement retr
35. l of the supply a Check supply voltages defective and the reference voltages b Replace main board or on MP10 is more than analog input module Refer to 3 3V Drawing 4 and Procedure 3 b A D converter Steps 1 2 4 11 12 defective Above limiting value a Cable from central unit a Check cable for slewing angle 1 to the slewing angle sensor b Check and reset slew ing defective or loose angle potentiometer A bove limiting value b Slew ing angle Check signal on main board for slewing angle 2 potentiometer defective and analog input module c Electronic component in the measuring channel defective on main board Error in the system a EPROM with system a Replace system program program program defective EPROM b Electronic component b Check signal on main board on the main board and analog input module defective Error in the program a EPROM with system a Replace system program run program defective EPROM b Electronic component b Check signal on main board on the main board and analog input module defective System program and system program in the Replace system program Data EPROM do not LMI does not correspond to EPROM or Data EPROM Refer match the programming in the to Procedure 2 data EPROM System program and The system program in the Replace system program TLK EPROM do not LMI does not correspond to EPROM or TLK EPROM Refer match the programming in the to Procedu
36. o Section 3 10 a Check the connection betw een 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 Replace 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 301 371 6126 2 I Service Manual 05 350 GM ERROR ERROR CAUSE ACTION CODE Error in the crane data a Data EPROM defective a Replace data EPROM b Position of jumper for b Check the jumper position the selection of the type of EPROM is wrong c Replace CPU module Refer Electronics component to Drawing 4 and Procedure 3 on the main board Steps 1 3 13 14 defective E96 Error in the internal CPU or main board of the Replace CPU module Refer to RAM of the CPU of console defective Drawing 4 and Procedure 3 the console Steps 1 3 13 14 E97 Error in the external a External RAM of the a Replace console main board RAM of the CPU of console defective the console b Electronic component b Replace console main board on the main board Refer to Drawing 5 defective E98 Wrong jumper position a The jumper position BR a Check the jumper position in the console 9 BR 10 in the console does not correspond to the actual type of central unit b Electronic
37. og input module Refer to Drawing 4 and Procedure 3 Steps 1 2 4 11 12 Replace analog input module Refer to Drawing 4 and Procedure 3 Steps 1 2 4 11 12 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 Replace Data EPROM Make sure BR3 on the main board is installed Refer to Procedure 2 Replace EPROM Module and reset pressure channels Refer to Drawing 4 and Procedure 4 Bridge memory module acc To memory type Replace crane data EEPROM Replace EPROM Module and reset pressure channels Refer to Drawing 4 and Procedure 4 301 371 6126 10 Service Manual PAT DS 350 GM ERROR ERROR CAUSE ACTION CODE E57 Error in serial crane Serial crane data EEPROM W rite data on the serial crane data does not contain valid data data EEPROM by means of test program or on line function then restart the LMI Replace EPROM Module and Memory module defective reset pressure channels Refer to Drawing 4 and Procedure 4 E58 Error in the Serial No valid data in the serial Write data on the serial analog analog data EEPROM data EEPROM data EEPROM by means of the test program then restart the LMI LMI main board defective Replace LMI main board 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 Replac
38. ohms measurement should be between 4 20mA Measuring voltage The voltmeter is used to measure between pins 1 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 eguals voltage therefore 4mA x 275 ohms total resistance 1 1V ENGTH ANGLE TRANSDUCER I SHIELD 1 D cont 2 i COR La A Y gt 7111771 i A Cm BAJA 5 3 1 5 311 3 513 PU ol 2 m allo ze e zm 2 2 7 5 51 53 1 i 2 4 X yo ss sie Se he 9 ig 4 z 1 EN v 1 Iz 817 4 211 E i i iz o 5 4 2 1 pue Pee tw i is i MCN RU EA c c IC MM ak SkyAz l Eguipment Solutions www skyazul com 301 371 6126 47 6 2 THEORY 2 OPERATION OF PISTON SIDE LOAD SENSOR Measuring current The ammeter A 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 I CENTRAL UNIT 0 E Meas
39. p 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 gt 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 a current output and must be measured in series Set Voltmeter to measure amps Remove Wire 2 from 1 27 in the central unit and connect one voltmeter lead to wire 2 and the other 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 Section 4 Faulty wiring between central unit and cable reel Check wiring YES Y S NEXT PAGE SkyAz l Eguipment Solutions www skyazul com 301 371 6126 22 Service Manual PAT DS 350 GM PREVIOUS PAGE 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 th
40. re 2 data EPROM Error in the external Defective electronic Replace main board or analog RAM component input module Refer to Drawing 4 and Procedure 3 Steps 1 2 4 11 and 12 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Flow charts ERROR ERROR CAUSE CODE Error in the external write read memory RAM Part 1 E45 Error in the external write read memory RAM Part 2 Redundancy error in A D conversion Error in A D conversion Malfunction in the monitored write read memory Cyclic RAM test Error in the internal write read memory E47 E48 E51 Error in load chart EPROM Error in crane data EEPROM SkyAzul Equipment Solutions Error in data EPROM Internal defect in digital part of CPU Internal defect in digital part of CPU Defective electronic component Defective electronic component Internal defect in digital part of CPU Internal defect in digital part of CPU EPROM Module not bridged correctly Data EPROM on the main board defective EPROM Module not bridged correctly Data EPROM on the main board defective Memory module wrongly bridged Crane data EEPROM defective www skyazul com ACTION Exchange write read memory CMOS RAM Replace CPU module Refer to Drawing 4 and Procedure 3 Steps 1 3 13 14 Exchange write read memory CMOS RAM Replace CPU module Refer to Drawing 4 and Procedure 3 Steps 1 3 13 14 Replace anal
41. rom central unit to console Refer to also Section 3 10 94 E No data transmission for central unit to console Refer to also Section 3 10 SkyAz l Eguipment Solutions 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 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 www skyazul com 11 ACTION a Check 24V at terminal X1 of console electronics b Check the connection betw een console electronics and central unit c If accidental ground occurs the transmitter module in the console electronics can be damaged Replace the console electronics or main board respectively a Check the connection between console electronics and central unit Refer to Section 3 10 a Check the connection betw een console electronics and central unit b Replace console electronics or main board respectively Refer t
42. rs b ib angle sensor defective c Electronic component in the measuring channel defective www skyazul com 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 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 a Check cable b Check angle sensor and reset adjustment c Check signal on main board and analog input module 301 371 6126 8 Service Manual PAT DS 350 GM ERROR ERROR CAUSE ACTION CODE E27 Upper limit value for Cable leading from the a Check cable and the measuring central unit to the sensor of connectors channel 7 exceeded channel 7 defective loose b Check sensor of channel 7 or water in the connectors and reset adjustment b Sensor of channel 7 c Check signal on main board defective and analog input module c Electronic component in the measuring channel 7 defective Reference voltage a The tota
43. sie WR YR vive Ca tres SEU z VER EY EGET 41 5 1 PROCEDURE 1 STRAIN RELIEF INSTALLATION us bec hr e e SR pan 41 5 2 PROCEDURE 2 EPROM LOCATION AND INSTALLATION 42 5 3 PROCEDURE 3 MAIN BOARD REPLACEMENT 43 5 4 PROCEDURE 4 PRESSURE TRANSDUCER ZERO ADJ USTMENT 44 5 4 1 USING GRAPHIC CONSOLE FOR ZERO SETTING OF PRESSURE TRANSDUCER FORGEINPUTS o LO 44 5 5 PROCEDURE 5 LENGTH AND ANGLE SENSOR ADJ USTMENT 45 O THEOR Visa EXE Er DAC ERO XP C VR ERO S EAR lk da 46 6 1 THEORY 1 OPERATION OF BOOM LENGTH SENSOR 46 CU VP 46 Measuring voltage ante d 46 6 2 THEORY 2 OPERATION OF PISTON SIDE LOAD 47 6 3 THEORY 3 OPERATION OF ROD SIDE LOAD SENSOR 48 6 4 THEORY 4 OPERATION OF ANGLE 5 49 SkyAzul Equipment Solutions www skyazul com 301 371 6126 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 voltmet
44. test point MPO AGND and X1 4 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 Section 4 Analog Input board defective Replace analog input board Refer to Drawing 4 in Section 4 and Replacement Procedure 3 steps 4 11 8 12 in Section 5 END SkyAzul Equipment Solutions www skyazul com 301 371 6126 Correct NO Flow charts 25 3 9 LOAD READING PROBLEM PROBLEM Load reading incorrect START v Check boom length reading on display Reset length potentiometer With fully retracted boom turn potentiometer axle NO D 3 bs 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 gt 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 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 X1 20 12 24v and X1 22
45. th 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 the solenoids and thereby locking out those functions that may aggravate the crane s condition SkyAzul Equipment Solutions www skyazul com 301 371 6126 Flow charts 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 follow ing sections Start with the general flow
46. to Drawing 3 Remount cable reel to the boom reeling drum clockwise to spool the new cable onto the drum Set pre load on cable reel by turning the drum counter clockwise 5 to 8 turns Run the new length cable through the cable guides and wrap the length cable around the boom tip anchor pin 4 5 wraps and secure with tie wraps Leave enough length cable to connect into the boom tip junction box Connect the length cable into the boom tip junction box Refer to Drawing 3 Reset length potentiometer in length angle transducer screw is located in center of white gear with boom fully retracted potentiometer carefully counter clockwise until it stops Recheck length and angle display Refer to Procedure 5 in Section 5 5 SkyAz l Eguipment Solutions www skyazul com 301 371 6126 Flow charts 15 3 5 NO DISPLAY PROBLEM Blank console display with no warning light shown All crane moments have been stopped START v Check fuses in central unit Correct NO Replace fuses YES 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 Check crane power supply for faulty crane electric YES y Measure voltage on the main board between X1 3 12 24V and X1 4 ground This is an output voltag
47. uring voltage per Maun DE doga MEE The voltmeter V is used to measure voltage between pins ans 250 ohms X1 21 piston side signal and X1 22 gnd on the main board 024 352 300 001 The resistors are there to show that 4 voltage is 1 1V because current multiplied with resistance a equals voltage therefore 4mA x 275 ohms total resistance S 1 1V St OPERATING WINDOW x1 20 21 22 ERROR Y V CODE P 1 1 5 5 4 AmA A 1V ES WORKING ERROR CODE E22 il 0 PA REN 11 2 5 A B 1 PRESS TRANS PISTON SkyAz l Eguipment Solutions www skyazul com 301 371 6126 48 Service Manual PAT DS 350 GM 6 3 THEORY 3 OPERATION OF ROD SIDE LOAD SENSOR Measuring current The ammeter A 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 1 24 side signal X1 25 on the main board 024 352 300 001 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 ae CENTRAL UNIT 105
48. wiring between central unit and cable reel NO gt Check wiring Refer to Drawing 3 in Section 4 Yes y NEXT PAGE SkyAz l Eguipment Solutions www skyazul com 301 371 6126 24 Service Manual PAT DS 350 GM PREVIOUS PAGE signal from angle transducer in cable 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 with the boom 90 Refer to Drawing 3 8 6in 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 in 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 8 6in Section 4 Faulty wiring between central unit and cable reel Correct NO Check wiring Refer to Drawing 3 in Section 4 YES Measure angle signal analog input module between
Download Pdf Manuals
Related Search