PAT America, Inc. LOAD MOMENT INDICATOR SERVICE MANUAL
Contents
1. asss 26 7 5 CANT TWO BLOCK PROBLEM veea rte astute TRE PEE ped cr ad 28 7 60 LENGTH READING PROBLEM ar e Eee perdete tin d ets 31 f EOAB READING PROBEEM irte nete ete a Rede dra 34 7 8 DATA TRANSFER BETWEEN CONSOLE amp CENTRAL 9 37 7 9 INTERF RENCE PROBLEME DU SPORE 39 7510 ANGLE PROBLEM ag aet bete ae testet NE 40 8 ERROR CODE TABLE 6 EE x UO LYRA n IEEE aA T 41 ADDENDUM A BASIC ADJUSTMENT AND VOLTAGE 50 ADDENDUM B REFERENCE TABLES FOR MEASURING SUPPLY AND SIGNAL VOLTAGES FOR SENSOR CHANNEES pw T 51 OPAT REV F 2 21 02 SB 190052 F Mechanical Description Of The System 1 1 MECHANICAL DESCRIPTION OF THE SYSTEM COMPONENTS Pressure Transducer The pressure transducer transforms hydraulic pressure into an electric analog voltage signal Two pressure transducers are connected one to the rod side and one to the piston side of the lift cylinder The pressure transducer is connected to the central unit with a four conductor double shielded cable The power supply voltage is2. Replace slip ring PE d Refer to Drawing 3 amp 5 in Section 3 Y Measure the A2B signal in the boom base 10 pin receptacle between terminal 5 and 6 with an ohmmeter Switch closed 4700 500Ohms Switch open gt 1 Megaohm Reconnected slip ring wires Refer to Drawing 5 Section 3 Fault in 7 conductor cable between cable reel and gt boom base box Refer to Drawing 5 in Section 3 NEXT PAGE 4 OPAT REV F 2 21 02 SB 190052 F 30 Service Manual PAT DS150C E PREVIOUS PAGE p Connect wire 5 back to the terminal X1 35 on the connection board Refer to Drawing 4 in Section 3 Turn system power off Check Anti Two Block signal central unit with ohmmeter measure between X1 34 and X1 35 Anti Two Block switch closed 4700 Ohms 50 OOhms Anti Two Block switch open gt 1 Megaohm Refer to Drawing 4 in Section 3 Faulty wiring between cable reel and central unit NO Check cable YES Y Disconnect X1 34 and X1 35 Check main board function by installing a temporary resistor 4700 Ohms between X1 34 and X1 35 in central unit With resistor connected alarm should be inactive Refer to Drawing 4 in Section 3 Replace connection board and reset pressure NO channel Refer to Drawing 1 amp 4 in Section and Replacement Procedure 4 in Section 4 Reconnect Wire 6
3. Set the override key switch in central unit into upper position to override Fixed YES Does console indicate Anti Two block warning bo gj 1 If console display is If Load Moment Limit Light Fault in crane electric blank fault is located in Fault in Anti Two displays fault it is located in or hydraulic system power supply wiring or Block system LMI cables wiring fuses or fuses console Read error code displayed on console and go to Section 6 Check lever lockout Go to Flow Chart 4 Go to Flow Chart 5 system in crane OPAT REV F 2 21 02 SB 190052 F Troubleshooting Flow Charts 25 7 3 Broken Length Cable PROBLEM Damaged or broken length cable Replace length cable using the following procedure 1 2 3 as Cut old cable at cable drum Disconnect damaged length cable from junction box at the boom nose Open cable reel cover and disconnect wiring from connection block Pull 7 conductor cable out of strain relief Remove cable reel from mounting brackets Remove damaged length cable which is mounted to the slip rings in the cable reel from slip ring connection Refer to Drawing 3 amp 5 in Section 4 Drawings On the backside of the cable reel open the strain relief attached to the axle in the center of the drum Pull existing length cable out of t
4. qQ31V SNI 109 QI3IHS SJ3NNI lt Q3193NNC GSLVINSNI QI3IHS YANNI lt 1445 45 OL Q3193NNOO 1 5 831 0 lt S dv Service Manual PAT DS150C DRAWING 4 Central Unit Electrical Diagram 12 4 3 190052 SALON E t A 74 lt o c 6 9 9 S v Z i Y Y Y y Y 5 i e TET Ah le z ie 1 it 19 19 Als gt 3105 02 9nd 13 205 01 4 55 y je je jz 1 lt 4 e b 2 E a a g 1 x T x J i zz ote eis voL va 414 Le lt j lt alb Hi gt SI n lt lt 226 c g p 6 19 k gt SI 5 r ie lee gi hg v 7 LL OL 6 2 9v les yiz y 2 6 zi
5. PAT America Inc Www patamerica com PAT PAT LOAD MOMENT INDICATOR DS150C SERVICE MANUAL P N 031 300 190 052 REV F 2 21 02 Service Manual PAT DS150C NOTICE PAT America Inc 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 PAT America Inc will not be liable for errors contained in this manual or for incidental or consequential damages in connection with the furnishing performance or use of this manual This document contains proprietary information which is protected by copyright and all rights are reserved No part of this document may be photocopied reproduced or translated to another language without the prior written consent of PAT America Inc PAT America Inc 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 PAT America Inc The drawings and or photos are subject to technical modification without prior notice All information in this document is subject to change without notice MANUAL REVISIONS DATE NAME DESCRIPTION 1 22 01 JRR Revised description of CPU module made correction to K8 K9 relays made corrections to 5 volt measuring references 03 02 01 GJO wiring in Theory 1 And formatted se
6. Check wiring Yes Y a NEXT PAGE p PAT REV F 2 21 02 SB 190052_F Troubleshooting Flow Charts 33 Continued from previous page PREVIOUS PAGE Measure length signal of amplified output on connection board between test point MP10 and test point MP13 5V NOTE Negative signal at terminal X1 11 will be converted into positive signa at MP13 i e input at terminal X1 11 0 5V and Refer to Drawing 4 Section 3 Drawings Replace connection board and reset pressure channel Correct No Referto Drawing 1 amp 4 in Section 3 and Replacement Procedure 4 in Section 4 Yes Y enn PAT REV F 2 21 02 SB 190052_F 34 Service Manual PAT DS150C 7 7 Load Reading Problem PROBLEM Load reading incorrect START Check selected operating mode code on operating mode switch Select operating mode switch to correct position see operating mode in load chart No Yes Y Check boom length reading on display Reset length potentiometer With fully retracted boom turn potentiometer No axle counter clockwise until it stops see Section 3 and 6 Refer to Procedure 3 Length amp Angle Adjustments Section 4 Yes 5 Measure radius check with the displayed radius Check mechanical adjustment of angle transducer i
7. If crane voltage is measured below 10V system will switch off Check crane power supply for faulty Correct No 4 crane electric or if supply is too low Yes Measure voltage on the connection board between 1 30 12 24V X1 33 ground This is an output voltage to the console Refer to Drawing 4 Central Unit Electric Section 3 Drawings Replace connection board and reset pressure No channel Refer to Drawing 1 amp 4 in Section and Replacement Procedure 4 in Section 4 Yes v S Next Page p PAT REV F 2 21 02 SB 190052_F Troubleshooting Flow Charts 27 PREVIOUS PAGE Measure voltage in the console between 1 1 12 24 and X1 2 ground Refer to Drawing 4 in Section 3 Check connections of the cable between NO p console and central unit Replace cable if necessary Refer to Drawing 4 in Section 3 YES Display is defective Refer to Drawing 2 in Section 3 YES C END PAT REV F 2 21 02 SB 190052 F 28 Service Manual PAT DS150C 7 5 Anti Two Block Problem PROBLEM Function of Anti Two Block System is faulty C START v Check to see whether or not crane is in two block condition Correct No gt Lower hook down into safe position Yes v Check if jumper dummy plug i
8. NEXT PAGE OPAT REV F 2 21 02 SB 190052 F 36 Service Manual PAT DS150C PREVIOUS PAGE Y Check transducer signals in central unit Connect pressure transducers to cable Disconnect wire No 4 of transducer cable from X1 21 signal piston side Measure transducer signals 0 1V between Pin 19 ground and wire No 4 of piston cable Disconnect wire No 4 of transducer cable from terminal block X1 Pin 16 single rod side Measure transducer signals 0 1V between Pin 19 ground and wire No 4 of rod cable Refer to Drawing 4 Section 3 Drawings Correct lt No Correct Yes Transducer defective replace transducer and reset pressure channel Yes Y Connect wire No 4 from transducer cables back to terminal X1 16 rod side and terminal X1 21 piston side Without pressure in pipes or hydraulic pipes disconnected from transducer check O point adjustment on connection board Measure between test point MP10 ground and test point MP11 Signal should be 0 50V piston side Measure between test point MP10 ground and test point MP12 Signal should be 0 50V rod side Measure voltage between test point MP10 ground and test point MP11 and reset with P1 to 0 50V piston side Measure voltage between test point MP10 ground and test point MP12 and reset with P2 to 0 50V rod side If not adjustable replace transduc
9. PROCEDURE 15 5 1 PPRCEDURE 1 EPROM REPLACEMENT CENTRAL UNIT 15 5 2 PROCEDURE 2 PISTON amp ROD PRESSURE CHANNEL ZERO POINT ADJUSTMENT 17 5 3 PROCEDURE LENGTH amp ANGLE 6 2 18 5 4 PROCEDURE 4 CONNECTION BOARD REPLACEMENT 19 6 THEORY 20 6 1 THEORY 1 ANTI TWO BLOCK amp SHUTOFF CIRCUIT 20 6 2 THEORY 2 LENGTH MEASURING 20 6 3 THEORY PISTON SIDE PRESSURE MEASURING CHANNEL 21 6 4 THEORY 4 ROD SIDE PRESSURE MEASURING CHANNEL iii 21 6 5 THEORY 5 MAIN BOOM ANGLE MEASURING 22 6 6 THEORY 6 SECOND ANGLE MEASURING 22 7 TROUBLESHOOTING FLOW CHARTS U 23 Fel GENERAL FLOWCHART 23 7 22 LEVER LOCKOUTACTIVATED entretien de dieta EI In abuse 24 1 3 BROKEN LENGTH u u 25 TA INOIDISPILAV
10. 1 Mei 1 Pressure 36 515725 3 Angle Main boom 8 o 4875 3425 MP 5626 4 AndeJb 8 24 185 3025 MP15 OPAT REV F 2 21 02 SB 190052 F
11. 500 on meter 7 Reconnect hydraulic hoses to pressure transducers and then bleed the air from hydraulic lines oR PAT REV F 2 21 02 SB 190052_F 18 Service Manual PAT DS150C 5 9 PROCEDURE 3 Length amp Angle Adjustments LL OPAT REV F 2 21 02 SB 190052 F Procedures 19 5 4 PROCEDURE 4 Connection Board Replacement Refer to Drawing 1 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 Be careful when lifting the CPU module board from the connection board because these boards have pins on the bottom side which insert into the connection board 3 Remove CPU module board by taking out the 4 small Philips screws holding it in place 4 Remove the relay from the connection board Item 4 on Drawing 1 5 Mark all connection wires before removing to identify location for reconnecting Disconnect all X1 terminal wires from the connection board 6 Remove the 9 large Philips screws holding the connection board in place 7 Note the orientation of the connection board in the central unit Remove connection board and place it in the same packing material that the replacement in which the connection board came 8 Carefully insert the new connection board in place Refer to Drawing 1 for location Insert the 9 Philips mounting screws 10 Inser
12. 9r er 9 clielee eloc y et gt Md gt gt amp S 2 gt 1 oe oup go x m gt A z 5 5 m u 29 on 2 5 lt 28 Se 2 7 5 gt o 600 490 09 0 REV F 2 21 02 SB Drawings 4 4 DRAWING 5 OPAT REV F 2 21 02 SB 13 Cable Reel Electrical Diagram TED 11 zx a 190052 Service Manual PAT DS150C 4 5 DRAWING 6 Central Unit Board Layout And Measuring Points DE1 DE2 DE3 42 41 40 39 58 37 56 55 54 55 32 51 30 25 24 25 22 21 Measuring Points MPO AGND MP2 9V MP3 9V MP4 5V MP5 AGND MP6 5V sensors supply MP7 5V sensors supply MP8 HES MP9 6V MP10 AGND MP11 PISTON PRESSURE SIGNAL OPAT REV F 2 21 02 SB K8 K9 H2 K10 uM K1 MP25 MP6 MP7 um um 5V 5V 20 19 18 17 16 15 14 13 12 11 10 9 8 7 8 5 4 3 2 1 9 48 47 46 45 44 X1 MP12 ROD PRESSURE SIGNAL MP13 LENGTH SIGNAL MP14 ANGLE SIGNAL 1 MP15 ANGLE SIGNAL 2 MP22 GND MP23 3 66V MP24 3 73V BATTERY MP25 MP26 GND MP27 AGND 29 5V 190052 Procedures 15 5 PROCEDURE 5 1 PPRCEDURE 1 EPROM replacement in Central Unit Follow this procedure when changing EPROM s in the DS150C central units 1 Remove cover from central u
13. CU X1 32 and console terminal 3 Refer to Drawing 4 Section 3 Drawings Replace connection board and reset pressure channel Correct No gt Refer to Drawing 1 amp 4 in Section 3 and Replacement Procedure 4 in Section 4 Yes END OPAT REV F 2 21 02 SB 190052 F Troubleshooting Flow Charts 39 7 9 Interference Problem PROBLEM Interference from crane 1 5 electric Error Code E93 E94 n intermittent Frozen console displays Refer to Section 8 Bad Data Transfer Between Console amp Central Unit Correct No Replace or repair part which is defective Y es Check if additional ground link between main board terminal X1 3 and central unit box mounting bracket is in place Install ground line single cable minimum of AWG14 2 0mm between terminal X1 3 and central unit box mounting bracket Refer to Drawing 4 Section 3 Yes Y Ensure that cable shields are connected correctly Refer to connection and wiring diagrams Drawings 4 amp 5 Section 3 Drawings Make correct shield connection gt Refer to connection and wiring diagrams Drawings 4 8 5 Section 3 Drawings 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
14. terminals of spiking component Diode type such as 1N4001 can be used C END b OPAT REV F 2 21 02 SB 190052 F 40 Service Manual PAT DS150C 7 10 Angle Problem PROBLEM Displayed Angle Incorrect Actual measured angle is different from displayed angle START Y Use a calibrated inclinometer to measure the actual main boom angle and compare with displayed angle on console Refer to Installation Manual Section 5 Mechanical Adjustments of Cable Reel Sensors 7 Check the supply voltage to angle sensor on connection board between X1 11 5VDC and X1 8 ground Refer to Installation Manual for system wiring diagram No Check system power supply voltage Refer to Section 7 4 No Display this manual Yes Check the voltage at angle sensor between connector pins AGND and C 5V Refer to Installation Manual for system wiring diagrams N Cable defective replace cable or cable assembly gt n Refer to Installation Manual for system wiring diagrams Yes v Check the voltage between X1 8 ground and X1 9 signal output voltage Voltage should be 3 125V 0 2 5V 45 1 875V 90 Refer to Theory 6 5 and 6 6 Angle Sensor Circuits Replace Angle Sensor Refer to Installation Manual Section 5 Procedure 3 Length and Angle Adjustments END 2 OPAT
15. 0 Service Manual PAT DS150C 4 2 DRAWING 3 Cable Reel 068 208 060 013 LWG208 Spare Parts List 17 EY REV F 2 21 02 SB 190052 F Drawings PART NO 006 7 10 006 002 068 000 110 038 067 000 050 065 064 103 060 002 002 050 206 012 000 207 010 064 002 050 206 100 000 208 040 083 068 000 100 064 068 000 110 029 068 000 100 152 068 000 1 10 011 000 673 020 002 006 800 005 058 000 205 031 230 006 800 005 057 005 682 000 001 068 000 1 10 031 000 208 020 006 021 441 131 013 000 214 030 703 PAT REV F 2 21 02 SB 11 QTY DESCRIPTION 1 1 1 1 2 3 1 1 1 1 1 1 SENSOR LENGTH TRANS LGE 100 KT200 LWG208 SENSOR ACCY GEAR WHEEL KT200 CABLE REEL SENSOR ACCY GEAR WHEEL 50 CENTER SHAFT SENSOR ANGLE WG103 SCREW 6M X 12 SOCKET CAP WASHER FLAT 6MM SCREW 6M x 100M SOCKET CAP WASHER LOCK 6MM SLIPRING 2 CONDUCTOR CONNECTION STRIP CABLE REEL KT200 HOUSING BKT CABLE DRUM amp NYLON CABLE COVER CABLE REEL ACCY CABLE DRUM KT 200 LWG208 CABLE LENGTH SENSOR 1 CORE W SHEILD per ft BRACKET MTG CABLE REEL ARM ONE SLOT SCREW 12mm x 30MM HEX HEAD BRACKET MTG CABLE REEL ARM TWO SLOTS COVER CABLE REEL KT200 CABLE REEL ACCY SCREW CABLE REEL COVER WASHER LOCK 6mm STRAIN RELIEF PG 13 5 8 12mm RED WHITE STRAIN RELIEF PG7 BLACK 190052 F 1104 28 384 TIVISNI dae 300 00 lt
16. 00 340 002 Central Unit Cover Installation and Tightening Procedure Rev A 031 300 340 003 Central Unit Gasket Recommendations Rev OPAT REV F 2 21 02 SB 190052 F Procedures 17 5 2 PROCEDURE 2 Piston amp Rod Pressure Channel Zero Point Adjustment s 1 36 82 To 91 MP9 MP26 4 24 25 9V AGND 9 P6 RN1 MP29 M rE RNE Nues 5 27 MP2 9 K 271 L L uw is 9V AGND 9V AGND 10 RA BR HES MP8 H3 H4 MP11 MP12 MP13 14 15 16 17 LA OAD A2B 1 CH2 CH3 CH4 CH5 CH 2 H5 H6 H7 D fom M K8 K9 SA OSA S DAV1 DAV2 161 WG1 WG2 42 DE1 DE2 DE3 Q 54 K1C UB1 K10 P25 ELAY MP28 T X46 X44 1 Q KGND 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 2120 19 18 17 16 15 14 13 12 1110 9 8 7 6 5 4 3 2 1 49 48 47 46 45 44 MP1 X1 1 Lower boom all the way down no rest pressure then disconnect hydraulic hose from the piston side pressure transducer 2 Connect a digital voltmeter to connection board A black lead to 10 B red lead to mp11 Adjust P1 to obtain a reading of 0 500 volts 500mv on meter Disconnect hydraulic hose from the rod side pressure transducer Connect a digital voltmeter to connection board A BLACK lead to MP10 B RED lead to MP12 6 Adjust P2 to obtain a reading of 0 500 volts
17. 024 150 300 050 1 Board Connection D8150 CU 02 024 351 300 004 1 Board Processor 03 4 351 300 011 1 Board Module 04 000 304 140 122 1 Relay Shut Off 12 V 05 024 150 110 002 1 Cover Central Unit 05150 06 024 350 100 135 1 Central Unit Accy Screw Set 05150 07 024 150 100 001 1 Housing Central Unit 05150 08 4 350 110 066 1 Central Unit Accy Gasket For C U Cover 09 4 350 100 661 1 Key Switch Central Unit 10 031 300 101 131 1 Key Central Unit Key Switch 11 000 314 022 006 1 Fuse Holder Central Unit 12 000 313 062 001 1 Fuse 2 Amp 1 4 X 1 1 4 250v Fast Acting 13 313 062 002 1 Fuse 10 Amp 1 4 X 1 1 4 250v Fast Acting 14 000 214 340 013 2 Strain Relief Accy PG13 5 Hole Plug 15 000 214 210 013 2 Nut PG13 5 16 050 350 110 116 1 Strain Relief Assy PG 13 5 Red Long W Nut Washer 17 024 350 100 312 2 Central Unit Accy Check Moisture Drainage 18 024 350 110 067 3 Strain Relief Assy PG 11 Grn Long W Nut Washer 19 000 214 340 011 4 Strain Relief Accy PG11 Hole Plug 20 214 210 011 4 Nut PG11 21 000 214 340 016 1 Strain Relief Accy PG16 Hole Plug 22 000 214 210 016 1 Nut PG16 23 024 350 100 139 1 Central Unit Accy Wall Mount Set 05150 350 24 024 150 100 002 1 Central Unit Accy Baseplate 05150 25 031 300 100 078 1 Chemical Moisture Pack 26 024 350 300 250 1 Board Battery Back Up for DS350 150C REV F 2 21 02 SB 190052_F 8 Service Manual PAT DS150C DRAWING 2 Co
18. 5V The output signal is 0 00V under 0 pressure to 1 00V at max pressure 4410psi The Length Angle Transducer The length angle sensor LWG is a combination of two transducers in one box fitted at the base section of the boom It measures the length and angle of the boom A reeling drum drives a potentiometer which is the length transducer Part of the length transducer is the length cable on the drum which is a two conductor cable screen and live It is connected to the anti two block switch at the boom head and to a slip ring body in the reel The angle transducer is fitted into a small box filled with oil A pendulum drives the axle of the angle potentiometer The power supply voltage for both is 5 00V The output signal for the length transducer is 0 500V up to 4 500V The output signal for the angle transducer is 1 875V up to 3 125V Anti Two Block Switch The anti two block switch monitors the load block and its relationship with the head of the boom In working condition the switch is closed When the hook block strikes the weight the circuit opens disengaging a relay output to the lockout solenoid valves where applicable To check the cable for damage short circuit to ground there is a 4 7k resistor between ground and the contact of the switch The weight at the anti two block switch keeps the switch closed until the hook block strikes it Console The console displays the geometrical information such as length and angle
19. I Replace buffer battery on the LMI main board Replace processor board Replace computer component 80C537 Replace CPU module Replace processor board with CPU module Load crane data EEPROM containing valid data Bridge memory module acc to memory type Replace crane data EPROM Bridge memory module acc to memory type Replace load chart EPROM 190052 F Error Codes 47 Error in crane data EEPROM Error in serial crane data EEPROM Error in the serial analog data EEPROM E85 Error in the serial analog data EEPROM Wrong rigging condition Error in the radius determination e Memory module wrongly bridged Crane data EEPROM defective Serial crane data EEPROM does not contain valid data Memory module defective No valid data in the serial analog data EEPROM LMI main board defective No valid data in the serial analog data EEPROM LMI main board defective The selected rigging condition is not contained in the data EPROM e The computed radius is too small negative deflection Error Code Error Cause Elimination Bridge memory module to memory type Replace crane data EEPROM Write data on the serial crane data EEPROM by means of test program or on line function then restart the LMI Replace memory module Write data on the serial analog data EEPROM by means of the test program then restart the LMI Replace LMI main bo
20. LMI main board Check sensors plugs and cable replace if need be Replace LMI main board Replace LMI main board Refer to E11 Refer to E12 Refer to E12 190052_F Error Codes 45 Error Code Error Case Elimintio Upper limit value in Refer to E15 Refer to E15 measuring channel main boom angle has been exceeded Upper limit value in e Refer to E16 e Refer to E16 measuring channel angle 2 has been exceeded Upper limit value in e Refer to E17 Referto E17 measuring channel length telescope 1 has been exceeded Reference and or e Refer to E19 e Refer to E19 supply voltage defective E31 Error in the system e The system program Replace system program program PROM is defective PROM PROM No 0 38 System program e The system program in Replace the system program and data EPROM the LMI does not match to PROM or the data EPROM do not match the programming in the PROM No 1 data EPROM System program e The system program in e Replace system program and TLK EPROM the LMI and the PROM or TLK EPROM do not match programming in the TLK PROM No 2 EPROM do not match Error in the internal e Computer component Replace computer write read memory 80C537 defective component 80C537 RAM of the computer CPU module defective e Replace CPU module component 80C537 Processor board e Replace processor board defective with CPU module Error in the extern
21. REV F 2 21 02 SB 190052 F Troubleshooting Flow Charts 41 8 ERROR CODE TABLE Fallen below e Fallen below the minimum e Luff down the boom to a radius radius range or radius or gone past the or angle specified in the load angle range maximum angle specified in chart exceeded the respective load chart due to luffing up the boom too far Radius range e Gone past the maximum e Luff up the boom to a radius or exceeded or fallen radius or fallen below the angle specified in the load below angle range minimum angle specified in chart the respective load chart due to luffing down the boom too far Non permitted e The slewing zone with load Slew to permitted area slewing zone no is not permitted load area Operating mode non existing operating e Set the correct operating mode not acknowledged mode has been selected for the operating state in or non permitted question slewing zone e The boom is in a non e Slew the boom to a permitted permitted slewing area Prohibited length Boom has been extended e Extend retract boom to the range either too far or not far correct length enough e g if it is prohibited to go beyond a certain maximum boom length or with load curves for jibs where the main boom has to be extended to a certain length e Length sensor adjustment Retract boom Check the pre has changed e g the cable stress of the cable reel cable slid off the length sensor must be taut O
22. Rod Piston 5V Mp VDC Mp 10 Ground Piston amp Rod Pressure 12V Mp25 VDC Mp 15 Ground Internal to Board 4 Boom Length MP10 Ground for Meter Fully Retracted Ft VDC X1 10 DC 13 Fully Extended Ft VDC X1 10 DC MP13 5 Volt Reference Voltage VDC X1 11 5 Boom Angle MP10 Ground for Meter Minimum Angle VDC X1 9 VDC Mp14 Maximum Angle VDC X1 9 VDC Mp14 5 Volt Reference Voltage VDC X1 11 6 Pressure Transducers MP10 Ground for Meter Piston Zero Point VDC X1 21 VDC 11 Rod Zero Point VDC X1 16 VDC Mp12 5 Volt Reference Voltage VDC X1 13 amp 18 5 Volt Reference Voltage VDC X1 15 amp 20 PAT REV F 2 20 02 SB 190052_FF Addendums 51 ADDENDUM B Reference Tables for measuring supply and signal voltages for sensor channels Use the table as a quick reference for measuring supply and signal voltages for the sensor channels that are specific to the error code listed Signal Voltage Wer Board Wer X1 Nominal Voltage Error Code Channel Pin Pin supply VDC 2 Tte j PE 8 8 5 512223 PesueRoisde 4 5 s ETS fs Angie Manboom 8 f 5 Signal Voltage Terminal Board Amplified Signal Terminal X1 on main board use MP10 GND Error i and MP supply Code Channel Voltage VDC voltage 0 5 4 5V CORAL we 50222 0 Pressure Pistonside 8 21 0
23. T REV F 2 21 02 SB 190052 F Troubleshooting Flow Charts 23 7 TROUBLESHOOTING FLOW CHARTS 7 1 General Flowchart This section explains how to handle a problem that may arise with the PAT Load Moment Indicator System PAT DS150C The procedures are easy to follow and are given in flowcharts on the following pages Start with the general flowchart below which will guide you to one of the detailed flowcharts shown in this section C START b Y What s Wrong I LZ Lever Lockout Activated Goto Flow Chart 2 gt Broken Length Cable gt Go to Flow Chart 3 gt No display e Go to Flow Chart 4 ww Anti Two Block Problem Go to Flow Chart 5 Length Reading Problem Goto Flow Chart 6 Load Reading Problem t Go to Flow Chart 7 Bad Data Transfer Between Go to Flow Chart 8 Console amp Central Unit Interference Problem m gt Go to Flow Chart 9 Angle Problem Go to Flow Chart 10 PAT REV F 2 20 02 SB 190052_FF 24 Service Manual PAT DS150C 7 2 Lever Lockout Activated g 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 p
24. al e Write read memory Replace processor board write read memory CMOS RAM or with CPU module 1st part RAM processor board defective E43 Error in the external e Refer to E42 e Refer to E42 write read memory 2nd part RAM OPAT REV F 2 21 02 SB 190052 F 46 Service Manual PAT DS150C ErrorCode Eror Cause Error in the A D converter uPD 7004 of the processor board E47 Error in the monitored write read memory The CRC verification of the monitored write read memory provides an incoherent result Cyclic RAM test error in the internal write read memory RAM of the computer component 80C537 Redundancy error in the A D conversion Error in load chart PROM Error in the crane data EPROM or EEPROM OPAT REV F 2 21 02 SB The A D converter on the processing board and the redundant A D converter in the CPU 80C537 provide different results No acknowledgment of the A D converter uPD 7004 The CRC sign of the monitored write read memory is wrong The buffer battery is decharged 2V at 1kOhm Processor board defective Computer component 80C537 defective CPU module defective Processor board defective No valid data in the crane data EEPROM Memory module wrongly bridged Crane data EPROM defective Memory module wrongly bridged Load chart EPROM defective e Replace processor board Replace processor board Restart the LM
25. angle Adjust the angle sensor to the same angle as the boom Check the angle at 20 degrees 45 degrees and 70 degrees Angle display should be less than 5 degrees of the value of the inclinometer See Procedure 3 Pressure Channel Rest the boom and disconnect hydraulic hoses from the pressure transducers Measure and record the zero points of both pressure transducers on the connection board Adjust P1 and P2 on the main board to 500mV at test points MP11 and MP12 Connect hydraulic hoses back to the pressure transducers See Procedure 2 Duty Selection Switches Digital Inputs Check the duty selection switches for correct operation Check the voltage on digital input connections Check the function of the hoist limit switch anti two block Check function of lever lockout Measure and record the power supply voltages See Addendum A PAT REV F 2 21 02 SB 190052 F 4 Service Manual PAT DS150C 3 DEFINITIONS BOOM LENGTH The straight line through the centerline of boom pivot pin to the centerline of the boom point load hoist sheave pin measured along the longitudinal axis of the boom Indicator 2 BOOM ANGLE The angle between the longitudinal centerline of the boom base section and the horizontal plane Indicator 65 to 90 boom angle 0 2 less than 65 boom angle 0 3 RADIUS OF LOAD The horizontal distance from a vertical projection of the crane s axis of rotation to the supporting surface before load
26. ard Write data on the serial analog data EEPROM by means of the test program then restart the LMI Replace LMI main board Select another rigging condition Check the programming in the data EPROM Check the programming in the data EPROM OPAT REV F 2 21 02 SB 190052 F 48 Service Manual PAT DS150C Error Code Error Cause Elimiation No data trans mission form the console to the central unit Error in the data transmission from console to central unit Error in the data transmission from the central unit to the console OPAT REV F 2 21 02 SB e 24 V supply of the console e Check 24 V at terminal X1 of is interrupted Interruption or accidental ground in the line between console electronics and central unit Transmitter receiver module is defective Loose connection in the line between console electronics and central unit Transmitter receiver module is defective Refer to E92 the console electronics Check the connection console electronics central unit In case of an accidental ground the transmitter module of the console electronics might be damaged Therefore replaces the console electronics Exchange console electronics or LMI main board Check the connection between console electronics and central unit Exchange console electronics or LMI main board Refer to E92 190052 F Error Codes 49 EL No data t
27. ctions 05 01 01 Chg channels in Section 6 Theory correction to wiring diagram Section 4 drawing 4 07 17 01 SB Refer to ECN 01 215 08 23 01 GJO Refer to ECN 01 246 n MO gt m lt 02 21 02 SB Refer to ECN 02 054 2001 PAT America Chambersburg PA 17201 USA PAT REV F 2 21 02 SB 190052_F Service Manual PAT DS150C TABLE OF CONTENTS 1 MECHANICAL DESCRIPTION OF THE SYSTEM COMPONENTS 1 2 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UNIT 2 2 1 BASIC ADJUSTMENT OF THE HARDWARE nnn n rrr rrr reni 2 3 DEFINITIONS rer Stanek ri ide esie end eed aga 4 4 DRAWINGS iicet aded 6 4 1 DRAWING 1 CENTRAL UNIT 024 150 061 005 SPARE PARTS LIST 6 42 DRAWING 2 CONSOLE 050 150 060 006 SPARE PARTS LIST 8 4 3 DRAWING CABLE REEL 068 208 060 013 LWG208 SPARE PARTS LIST 10 44 DRAWING 4 CENTRAL UNIT ELECTRICAL DIAGRAM 2220 12 4 5 DRAWING 5 CABLE REEL ELECTRICAL 13 4 6 DRAWING 6 CENTRAL UNIT BOARD LAYOUT AND MEASURING POINTS 14 3
28. d X1 11 5V Refer to Drawing 4 Section 3 Drawings Replace connection board and reset pressure No channel Refer to Drawing 1 8 4 in Section and Replacement Procedure 4 in Section 4 Yes Y 1 NEXT PAGE OPAT REV F 2 21 02 SB 190052 F 32 Service Manual PAT DS150C Continued from previous page PREVIOUS PAGE Measure supply to length transducer in cable reel at terminal between Pin 1 ground and Pin 5v Refer to Drawing 5 Section 3 Drawings Faulty wiring between central unit and length transducer Check wiring Correct No Yes Y between pin 2 signal and pin 1 ground Retract boom 0 Potentiometer turn 0 5v 10 Potentiometer turn 4 5v Replace length potentiometer assembly Remove slipring body from shaft and remove gear wheel from potentiometer axle Unscrew mounting plate and No remove potentiometer assembly frommounting plate Remove assembly wires form terminal block Connect new assembly to terminal block Reinstall mounting plate gear wheel and slip rings With boom fully retracted reset Yes i Measure singal from length transducer in central unit connection board between X1 8 ground and X1 10 signal 0 5 and 4 5v Refer to Drawing 4 Section 3 Drawings Correct No Faulty wiring between central unit and length transducer
29. el processor board defective OPAT REV F 2 21 02 SB 190052_F 44 Service Manual PAT DS150C ErrorCode Error Cause Elimintio Cable between the central e Check cable as well as Fallen below lower limit value in measuring channel Fallen below lower limit value length telescope 11 Reference and or supply voltage defective Upper limit value in measuring channel main boom length has been exceeded Upper limit value in measuring channel pressure piston side has been exceeded Upper limit value in measuring channel pressure rod side has been exceeded OPAT REV F 2 21 02 SB unit and the angle sensor defective or loose Water inside the plug of the angle sensor Angle potentiometer defective Electronic component in the measuring channel defective Cable between the central unit to the length sensor defective or loose Water inside the length sensor plug Length potentiometer defective Electronic component in the measuring channel defective The supply voltage is falsified by one of the sensors DAV LWG Electronic component is defective A D converter defective Refer to E11 Refer to E12 Refer to E12 plugs replace if need be Replace angle sensor Replace LMI main board or processor board Check cable as well as plugs replace if need be Replace length sensor Replace LMI main board or processor board Check the voltages on the
30. eplace processor board e Refer to E07 e Refer to E07 190052 F Error Codes 43 ErrorCode Eror Cause Elimintion Fallen below lower Cable between central e Check cable as well as limit value for unit and length sensor is plugs replace if need be measuring channel defective or disconnected length main boom Water inside the plug of the length angle sensor Length potentiometer is Replace length defective potentiometer Electronic component in Replace LMI main board or the measuring channel is processor board defective Fallen below the Cable between the central Check cable as well as lower limit value in unit and pressure plugs replace if need be the measuring transducers defective or channel pressure water inside the plugs piston side Pressure transducer is Replace pressure transducer defective Electronic component in Replace LMI main board or the measuring channel is processor board defective E13 Fallen below lower Refer to E12 Refer to E12 limit value in the So measuring channel pressure rod side E15 Fallen below lower e Cable between central e Check cable as well as limit value in unit and the length angle plugs replace if need be measuring channel sensor defective or loose angle main boom Water inside the plug of the length angle sensor Angle potentiometer Replace angle sensor defective Electronic componentin Replace LMI main board or the measuring chann
31. er No END OPAT REV F 2 21 02 SB 190052 F Troubleshooting Flow Charts 37 7 8 Bad Data Transfer Between Console amp Central Unit PROBLEM Error Code E93 E94 No data transfer to and from console Make sure that the eproms are plugged into the correct socket and orientated Refer to Procedure 1 Eprom replacement in Central Unit Section 4 Correct No Place EPROM in correct socket Yes Check crane supply voltage for console central unit at connection board X 33 ground X1 30 12V Make sure external and internal power supply is correct Refer to Section 4 Refer to Drawing 4 Section 3 Drawings Replace connection board and reset pressure channel Correct No gt Refer to Drawing 1 amp 4 in Section 3 and Replacement Procedure 4 in Section 4 Yes NEXT PAGE OPAT REV F 2 21 02 SB 190052 F 38 Service Manual PAT DS150C Continued from previous page PREVIOUS PAGE b Check power supply to console between console terminal 2 ground and terminal 1 12v Refer to Drawing 5 Console Board Section 11 Drawings Faulty wiring in cable from central unit to console Replace cable Correct Yes Ensure that wires are properly connected between CU X1 31 and console terminal 4 and between
32. he cable reel Pull new length cable through the hole pipe and strain relief and push it through the axle of the reeling drum Tighten strain relief to ensure sealing Reconnect the length cable to the slip ring Refer to Drawing 3 amp 5 in Section 4 Drawings Remount cable reel to the boom Turn reeling drum clockwise to spool the new cable neatly onto the drum Set preload on cable reel by turning the drum counter clockwise 5 to 8 turns Wrap the new 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 Connect the length cable into the boom tip junction box Refer to Drawing 5 in Section 4 Drawings Reset length potentiometer in length angle transducer screw is located 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 3 in Section 4 Procedure PAT REV F 2 21 02 SB 190052_F 26 Service Manual PAT DS150C 7 4 No Display PROBLEM Blank console display with no warning light shown All crane moments have been stopped E Start Y Check fuses on CPU box Correct No gt Replace fuses Yes Measure crane voltage on connection board between X1 2 12V and X1 4 ground Refer to Drawing 4 Central Unit Electric Section 3 Drawings NOTE
33. ing The central unit 05150 is a rugged waterproof sheet steel housing It is mounted on the left side of the turn table weldment or on the counterweight The cables are led into the central unit via strain reliefs and connected with fast ons An override switch is mounted on the housing which overrides the LMI function The system is protected by a 2 AMP fuse which is mounted on the lower right side The output signal is protected by a 10 AMP fuse mounted on the lower mid Description of the Boards Inside the central unit CU there is a connection CPU module and EPROM module board The connection board connects to the CU The CPU module is plugged into the connection board and fastened with four 4 screws The EPROM module slides into a receptacle on the main board The CPU module is the heart of the system and it contains the processor and the system EPROM The EPROM module holds the data crane and calibration information and TLK load chart information EPROM s The wires from the various components are connected with fast ons to the connection board The connection board holds the electronics necessary to receive evaluate and direct the continuous flow of data from the sensors to the processor Connection board components Power supply Provides all the necessary voltages for the transducers and the electronics on the main board Analog input part Receives and prepares all the signals from the transducers for further processing Ana
34. ing to the center of the vertical hoist line or tackle with rated load applied Indicator 100 to 110 RATED LOAD The load value shown on the applicable load rating chart of the crane for the particular crane configuration boom length boom angle or functions or these variables For radii outside those shown on the load rating chart the rated load is to be considered as zero ACTUAL LOAD The weight of the load being lifted and all additional equipment such as blocks slings sensors etc Also referred to as working load Indicator 10096 to 11096 CRANE CONFIGURATION The physical arrangement of the crane which is prepared for a particular operation in conformance with the manufacturer s operating instructions and load rating chart TWO BLOCKING Contact of the lower load block or hook with the upper load block boom point or boom point machinery ANALOG Electrical signals that vary in proportion to the quantities they represent Boom length angle and pressure transducer DIGITAL Electrical signals of an on and off state two different voltage levels to represent some quantity of operation A2B area definition switch OPAT REV F 2 21 02 SB 190052 F Service Manual PAT DS150C 5 BLANK PAGE PAT REV F 2 21 02 SB 190052 F 6 Service Manual PAT DS150C 4 DRAWINGS 4 1 DRAWING 1 Central Unit 024 150 061 005 Spare Parts List OPAT REV F 2 21 02 SB 190052 F Drawings 7 NO PART QTY DESCRIPTION 01
35. log digital converter part Converts all the processed analog signals into digital ones Relays an overload and anti two block relay Controls the Bosch relay for lever lockout Incoming Signals Signals from the transducers are connected to the connection board The signals vary depending on the sensor Angle transducer signal is between 1 875V and 3 125V Length transducer signal is between 0 500V and 4 500V Pressure transducer signals are between 0 00V and 1 00V measured between the negative and positive outputs Anti two block switch resistance is 4 7Kohms Digital inputs for the duty selection switches are on or off Outgoing Signal The outgoing signal of the connection board is the signal for lever lockout of connection 48 In normal working conditions there are 12 volts at this connection If there is an overload or anti two block condition the signal becomes 0 volts Furthermore all voltages for the transducers are going out through the connection board 2 1 Basic Adjustment Of The Hardware Length Ensure that the length cable tension is correct with fully retracted boom and no tension on the cable reel Turn the cable drum 5 to 8 turns counter clockwise Then remove cover from cable reel and adjust the potentiometer counter clockwise to end stop See Procedure 3 OPAT REV F 2 21 02 SB 190052 F Mechanical Description Of The System 3 Angle Set the boom between 0 and 5 degrees and set the inclinometer to the boom
36. n receptacle at boom nose is plugged in Refer to Drawing 5 Cable Reel Electrical Diagram Section 3 Drawings No Plug appropriate plug into socket of junction box Yes Y Turn power off or disconnect wire from connection board X1 35 in central unit Remove bypass plug and check function of Anti Two Block switches with ohmmeter between wires 2 and 3 of switches or between terminals 1 and 6 at boom nose box This checks the function of the Anti Two Block switch Install bypass plug Switch closed 0 Ohm weight installed Switch open gt 1 Megaohm weight removed Refer to Drawing 5 in Section 3 Correct No gt Replace Anti Two Block switch Yes v Next Page OPAT REV F 2 21 02 SB 190052 F Troubleshooting Flow Charts 29 PREVIOUS PAGE Measure the A2B signal the cable reel between X1 Brown and X2 Red wires on the slip ring with an ohmmeter Switch closed 4700 x500Ohms Switch open gt 1 Megaohm Reconnected slip ring wires Refer to Drawing 5 Section 3 for damaged length cable and wiring Refer to Drawing 5 Section 3 If broken length cable Refer to Section 3 r Measure the A2B signal in the cable reel between terminal 7 and 8 with an ohmmeter Switch closed 4700 x500Ohms Switch open gt 1 Megaohm Reconnected slip ring wires Refer to Drawing 5 Section 3
37. nit CAUTION Before handling the EPROM discharge any static electricity from your body by touching a ground source The EPROM could be damaged if this procedure is not followed PAT REV 2 20 02 SB 190052 FF 16 Service Manual PAT DS150C 2 Remove the old EPROM from the main board using an EPROM puller Be careful not to bend the legs of the EPROM when removing it H1 2230 9 2 Tio de 92 9 MP26 MP4 3 5 MP24 MP23 6V AGND 5 P6 RNI MP22 MP29 GND Bes 27 2 I 9V AGND 9V AGND MP10 HES MPS 3 4 MP11 MP12 MP13 MP14 MP15 MP16 MP17 gt 5 8 LOAD A2B CHO CH CH2 CH3 CH4 CHS CH6 p1 P2 5 Pa 5 H5 H6 H7 3 D V 4 DAVI DAV2 161 WG1 WG2 u2 DE1 DE2 14 K10 K10 p25 ds RELAY MP6 MP7 5V 5 KGND 2 4140 59 38 37 56 35 34 33 32 31 30 25 24 23 22 2120 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 69 48 47 46 45 44 xi 3 Installing the new EPROM Ensure the notch is in the correct direction The direction of the EPROM is determined by the notch on the e end of the EPROM e The DATA and EPROM S fill the bottom of the socket as shown by the arrows e Place EPROM in the correct EPROM socket as shown 4 Reinstall cover using the following procedures to prevent any moisture from entering the central unit Reference material 031 3
38. nsole 050 150 060 006 Spare Parts List OVERALL DIMENSIONS 18 J 6 7 14 CLOSED 6 7 13 15 1 8 X 5 1 2 X 6 lt 6 7 12 I n N COVER EE obs ull 16 14 X 1 1 4 X 5 1 4 s N 767240 REV F 2 21 02 SB 190052 Drawings 9 NO PART NO QTY DESCRIPTION 01 050 150 300 003 1 CONSOLE BOARD W ROTARY SWITCH DS150 02 050 350 110 292 1 LCD DISPLAY DS150 03 50 000 100 060 1 CONSOLE HOUSING W LID 04 050 350 110 116 1 STRAIN RELIEF LONG RED 05 000 305 045 141 2 LUMINOUS HOUSING 06 003 051 405 423 5 LUMINOUS PUSH BUTTON HOUSING 07 000 311 023 114 7 LIGHT BULB 12V 08 050 350 110 277 1 CAP A2B RED 09 050 350 110 278 1 CAP PREWARNING YELLOW 10 050 350 110 279 1 CAP STOP ALARM OFF RED 11 50 350 110 280 1 CAP LOAD ORANGE 12 050 350 110 281 1 CAP INFO ORANGE 13 050 350 110 282 1 CAP ANGLE ORANGE 14 50 350 110 283 1 CAP ENTER GREEN 15 003 051 903 364 1 KEY SWITCH 16 050 350 110 139 1 CONSOLE OVERRIDE KEY DS150 350 17 050 000 110 007 1 ALARM BUZZER 18 050 150 100 006 1 FRONT PANEL 19 000 209 022 095 850mm GASKET FOR FRONT PANEL 20 050 000 100 092 1 CONSOLE LID DS150 0006 21 050 150 110 005 1 GASKET FOR LID 22 050 000 110 014 3 LATCH ASSEMBLY 23 050 000 700 301 2 KNOB FOR ROTARY SWITCH 23 024 350 100 312 1 LABYRINTH MOISTURE ELEMENT REV F 2 21 02 SB 190052 F 1
39. of main boom working radius and head height of the boom It also displays the actual load and the maximum load permitted by load chart Furthermore it has an alarm horn and a warning light for overload and a pre warning light The analog instrument shows a percentage of the total permissible moment The console has a switch for the operating modes duty selection switch for crane configurations and a switch for the Reeving of the hook block It also has a warning light for anti two block conditions and an override switch for overload or anti two block condition Duty Selection Switches Digital Inputs The system has to be programmed for the lifting area configuration The crane is going to be worked in e g main boom on outriggers over front or rear or over the side for 360 degrees For obtaining this information from the crane micro switches are installed in the electrical swivel that tells the system the exact location of the boom Micro switches are also located on the counterweight which tells the system if the counterweight is installed or not where applicable OPAT REV F 2 21 02 SB 190052 F 2 Service Manual PAT DS150C 2 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UNIT All the data of the crane is stored inside the central unit in EPROM s The central unit receives all actual information of the crane This is computed against the reference data and the crane status is continuously monitored Description of the Hous
40. pen the length reel sensor and carefully turn the length sensor pot counter clockwise until loosened by using a screw driver OPAT REV F 2 20 02 SB 190052 FF 42 Service Manual PAT DS150C Nc eu Radius range exceeded or fallen below angle range with luffing jib operation Faulty acknowledgment of the overload relay on the connection board The relay should be energized the 2nd contact however is indicated to be off or the 2nd contact is indicated to be on while the relay should be de energized No acknowledge ment from the anti two block rela OPAT REV F 2 21 02 SB Clutch between length sensor pot and drive is defective Failure of 5V supply of analog part of analog board Cable between central unit and length sensor is defective or disconnected Defective length potentiometer Maximum radius as specified in the load chart exceeded or fallen below minimum angle due to luffing down the luffing jib too far Overload relay or connection board are defective Processor board defective Replace the complete clutch including drive wheel and adjust length sensor pot as described above Check 5 V supply Exchange main board in case of voltage failure or breakdown when loaded with 50 ohms approx Check cable and plugs replace if need be Replace length potentiometer Luff the jib to a radius or angle specified in the load chart Replace connection board R
41. rans mission from the central unit to the console Note e Interruption or accidental ground in the line central unit console 5 V supply of the computer in the central unit is missing 5 V supply is too low Transmitter receiver module is defective Computer module is defective Electro magnetic interferences e g when switching contacts or Check line to the console in case of accidental ground replace console electronics too Check connection to the power unit Exchange the LMI main board Replace console electronics or LMI main board Replace processor board Eliminate the source of interference by inverse diodes or varistors If an error message is displayed which is not contained in above list please contact PAT America Inc service department OPAT REV F 2 21 02 SB 190052 F 50 Service Manual PAT DS150C ADDENDUM A BASIC ADJUSTMENT AND VOLTAGE CHECKS MODEL S N PAT DS150C P N 024 150 061 005 central unit 024 150 300 050 connection board 1 Crane Supply Voltage X1 1 amp X1 4 GND VDC 2 Supply Voltage to Main Board X1 1 amp X1 3 GND VDC 3 Main Board Power Supply Reference Voltages 50 MV 5V Mp4 VDC Mp 10 Ground Internal to Board 6V Mp9 VDC Mp 10 Ground Internal to Board 9V Mp2 VDC Mp 10 Ground Internal to Board 9V Mp3 VDC Mp 10 Ground Internal to Board 5V Mp6 VDC Mp 10 Ground Jib Angle Length Angle
42. s correct Angle transducer box should be in line with boom and adjusted to actual boom angle should match displayed boom angle Refer to Procedure 3 Length amp Angle Adjustments Section 4 YES Check power supply to pressure transducer rodside Unplug transducer cable from transducer Measure connection board between X1 14 to X1 13 5 0v and X1 14 to X1 15 5 0 for rod side No Check power supply to pressure transducer piston side Unplug transducer cable from transducer Measure connection board between X1 19 to X1 20 5 0v and X1 19 to X1 18 5 0 Refer to Drawing 4 Section 3 Drawings OPAT REV F 2 21 02 SB 190052 F Troubleshooting Flow Charts 35 Pevious Page Correct No MP7 5 0v and between test point MP10 ground to MP6 5 0v Refer to Drawing 6 Board Layout Section 3 Drawings lt Yes Correct MP2 9 0v and between test point MP10 ground to MP3 9 0v Refer to Drawing 6 Board Layout Section 3 Drawings Yes lt Yes Correct Power supply on connection board faulty Replace connection board and reset Procedure 4 in Section 4 Y Check power supply at transducer plugs Measure between B ground 5V Measure between B ground and C 5V No gt Faulty wiring Check wiring of pressure transducer cable Yes Y
43. t CPU module board by lining up the pins into the sockets X11 and X12 and the 4 screw holes 11 Insert the 4 small Philips screws and washers 12 Insert the relay into the main board Item 4 on Drawing 1 13 Connect the X1 terminal wires to the main board Refer to Drawing 4 14 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 PAT REV F 2 21 02 SB 190052 F 20 Service Manual PAT DS150C 6 THEORY 6 1 THEORY 1 Anti Two Block amp Shutoff Circuit P e 4 pu aa 4 DANCE v y Re 6 2 THEORY 2 Length Measuring Channel OPAT REV F 2 20 02 SB 190052 FF 21 6 3 THEORY 3 Piston Side Pressure Measuring Channel l 2 5 2 5 JA 2 A X K L b e 10 MAX N N e E 2 e gt x e 6 4 THEORY 4 Rod Side Pressure Measuring Channel i 7 75 qa Z y z VA NS x ASE XI N N 23N i N N gt S Z DS A 9 e 9 NC LUNY PAT REV F 2 21 02 SB 190052_F 22 Service Manual PAT DS150C 6 5 THEORY 5 Main Boom Angle Measuring Channel 6 6 THEORY 6 Second Angle Measuring Channel 16 J 2 7 um j N N T4 1 8 C 4 w e e gt mm OPA
44. to X1 34 Wire 5 to X1 35 Refer to Drawing 3 in Section 3 2 21 02 5 190052 Troubleshooting Flow Charts 31 7 6 Length Reading Problem PROBLEM Length reading incorrect Crane is not in out of load chart condition starr Check mechanical adjustment of length potentiometer cable reel When main boom is fully retracted adjust length potentiometer counter clockwise until it stops Refer to Procedure 3 Length Angle Adjustments 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 form terminal block Connect new assembly to terminal block Reinstall mounting plate gear wheel and slip rings With boom fully retracted reset potentiometer by turning counter clockwise until it stops Yes Y Check out clutch in big gear wheel of length transducer Extend and retract boom to ensure that clutch is not sipping on potentiometer axle Replace the gear wheel clean potentiometer No axle Reset length potentiometer Refer to Drawing 6 Length Angle Transducer Section 11 Yes Y Check power supply to length transducer on connection board terminal X1 8 ground an
Download Pdf Manuals
Related Search