Service Manual
Contents
1. 17 5 13 PRESSURE TRANSDUCER CABLE ASSEMBLY sisi 17 5 14 JUMPER CABLE ASSEMBLY FOR EXTENSION 18 6 PROCEDURES 19 6 1 ANGLE SENSOR ADJUSTMENT eese eren a ease nenas nean 19 6 2 EPROM REPLACEMENT IN CENTRAL UNIT iii enne nnn sese sn sse snas 20 6 3 PISTON amp ROD PRESSURE CHANNEL ADJUSTMENT rese snnt rennen nnns 21 6 3 1 Adjust pressure piston ses 21 6 3 2 Adjust pressure uis eta 21 6 4 ANGLE TRANSDUCER REPLACEMENT AND ADJUSTMENT 22 6 5 LENGTH TRANSDUCER REPLACEMENT AND ADJUSTMENT 24 6 6 LENGTH CABLE REPLACEMENT 26 7 TROUBLESHOOTING FLOW CHARTS 27 T GENERAL FLOWCHAR D tette eror quota d davon incu a 27 7 2 LEVERLOCKOUT ACTIVATED heu o tnnt p sth oe Pha ig eoe duke Re roe Eg eai 28 7 37 BEANK DISPLAY rri eee RU RE REL LAPSI Mie ta o dup MR erc mated dete indes 29 1 4 ANIETWO BLOGCKPROBLEEM edet Rex inbh 31 4 91 LENGTH READING PROBLEM 20 34 1 07 ANGLE READING 35 8 ERROR CODES MIDI IM 36 8 1 OPERATOR ERROR CODE TABLE 36 92 SYSTEM ERROR CODE TABLE2. L CoS j A2B Switch 031 002 060 011 LEGEND NOTES BRN BROWN BLK BLACK WHT WHITE gt SHIELD CONNECTED TO STRAIN RELIEF INSERT GRA GRAY GRN GREEN BLU BLUE RED RED ENK aa gt Remove existing wire jumpers at terminal 5 amp 6 YEL YELLOW Swap jumper wires at terminal 5 amp 6 Refer to VIOLET wiring diagram CAD LED g diagram CREAM INNER EME PRS 145 w LWG 208 voltage amp KST P Transducers INGLE 55 Seven CHAMBERSBURG PA 17201 GENERALS 031 300 101 xxx DS REVI DESCRIPTION BY DATE DRAWN WB 09 29 2003 NOT EE REV PAT America Inc reserves proprietary rights to this drawing and to the data shown thereon The drawing and data are ECN confidential and are not to be used or reproduced without the written consent of PAT America Inc This drawing is subject to technical modification without prior notice C A G E 79760 gt SHIELD IS USED AS CONDUCTER FOR 2 SWITCH CIRCUIT EI so NS 7131 5 ss qans SS 12 VDC 24 GND Ref 3 8 VDC Ref 3 8 VDC GND Ref 1 0 VDC GND Ref 1 0 VDC GND RS232 TXD GND RS232 RXD RS232 CTS RS232 DTR BRN Piston 12v0c BRN Rod 12VDC jog Input 3 BRN S 1 12VDC og Input
3. 190162 a doc PAT Rev 09 15 03 SB Service Manual PRS145 5 2 CENTRAL PROCESSOR 12 24 VDC 1 0116440 00 Spare Parts List 2 1 ITEM DESCRIPTION QTY PART NUMBER 1 Housing 1 1 0103719 00 2 P C Board Central Processor 1 1 0116073 00 3 Module DC DC Converter 1 1 0028174 00 4 Key Switch 1 1 0103247 00 PAT Rev 09 15 03 SB 190162_a doc Drawings 5 3 ELECTRICAL DIAGRAM CONSOLE White Brown Green Yellow Grey Pink Blue Red Black Violet Grey Pink Red Blue 6 8 4 9 9 5 5 Jojonpuo PAT Rev 09 15 03 SB 190162_a doc 8 Service Manual PRS145 5 4 INDICATOR PANEL CONSOLE 1 0118417 00 Spare Parts List ITEM DESCRIPTION QTY PART NUMBER 1 0116046 00 1 0118389 00 1 0012135 00 1 0116059 00 1 010667800 1 0115673 00 6 1 LCD Matrix Display 1 1 0114234 00 PAT Rev 09 15 03 SB 190162_a doc Drawings 5 5 ELECTRICAL DIAGRAM CABLE REEL CABLE REEL 34 50 M TO CENTRAL UNIT 11213 4 5 1617 8 12 13 14 15 16 17 18 19 20 21 22 231 24 251 26 27 28 29 31 321 33 34 35 37 38 39 40 3
4. DE RS422 TXD RS422 TXD youms ssed g 82 21 94 52 re ec Console Heating GND 09262 dO VO VS OGA0E 07 65 82 ZE 92 SE v 5 o o 5 o Heating 24 12V sue19 Ho 26 101 005 150 2671 LIM 40 9 PRS 145 Sensors coozezeo 3ivo MN PRS 145 CENTRAL UNIT 12VDC 12VDC GND Analog Input 2 Analog Input 1 AB 4 Piston Pressure Rod Pressure Transducer 300bar Transducer 300bar 031 300 060 452 031 300 060 452 12 VDC 24 VDC 00 1 BRN Piston 1 BRN Rod _____ Crane Voltage refer to Crane DWG 3 BLK Piston Trans 3 BLK Rod Trans 2 BLU Piston Signal 2 BLU Rod Signal not used 12 VDC not used aa 0 55 O E E 455 Cable assembly 031 300 050 619 455 Cable assembly 031 300 050 619 LEGEND BROWN BLACK WHITE GRAY GREEN BLUE RED PINK ORANGE YELLOW VIOLET SHIELD PAT AMERICA Inc PRS 145 PRESSURE TRANSDUCER WIRING 1492 CREAM INNER 1665 ORCHARD DRIVE GENERAL SHIELD
5. J IKST Piston Pressure KST Rod Pressure Transducer 250bar Transducer 250bar p N 2 m o 5 N D 2 ra m 1 RS422 CLK gt RS422 CLK RS422 DATA gt 85422 DATA ol RS 422 LOAD lt BUTTON UP TARE BUTTON ANG LENG S BUTTON A2B BY PAS not used not used ue Er i Rollerswitch 1 031 006 100 043 12 a z 2 3 4 5 6 7 z Rad d n Fd PA E or Q gt 1 GND GND 12 VDC in Enclosure 12 VDC 2 5 V 7 5V Enclosure 12 VDC 12 VDC in 12 VDC in optional GRA PNK RED BLU BLK front rubber chart Rollerswitch S2 031 006 100 043 def arc chart on outriggers Rollerswitch S3 031 006 100 043 msn assembly 031 300 100 144 031 300 100 144 031 300 100 144 e 031 300 100 144 e 031 300 100 144 e mE 2 gt o w lt c E Color code reference table LEGEND RN BROWN LK BLACK H WHITE GRAY GREEN BLUE 006 100 043 031 optional optional D 12 VDC 12 VDC in l Rollerswitch 54 031 006 100 043 Rollerswitch 5 pa es m PINK R ORANGE E YELLOW VIOLET Notes SHIELD CREAM i gt gt Shield connected to strain relief insert RG PAT AMERICA Inc SHIELD 1665 ORCHARD DRIVE 5
6. VREF 5VDC ANALOG SH 50 e RS422 CLK 0 2 gt o 2 gt oz I m 22 2 o e RS422 CLK e RS422 DATA I gt lt 0 2 w c 2 e U gt N NOILdIH9S3Q Qo 3 3 gt o o eloe ez ez zz sz vz ez 5 2 e GND RED BLU Console le 12VDC e o 3 o o oy i efqns si Buymeup SIUL OUI 1 vd JO 1uesuoo pue UMOYS pue Bui e Shutoff 3 i imd o o o o o o le RS422 RXD e RS422 RXD Not used TVvH3N39 1 LSY 8 802 SUd k Not used By pass out S3ONVH3 10L r 5422 o o o ri M o o o o o 5422 TXD yoyms SSed g 2 84 22 94 52 ez zz Console Heating GND 09262 39 YO NO3 VS 85 ZE 9 se ce e o 3 o o e Heating 24 12V jueuoduio2 eue19 89118 Pos l1 01 005 150 19104 OL uojsid 1 4 OL 8L 8LL 9105405 OL l33HS 30 33HS To PRS 145 Sensors 5002 62 60 NM a8 PRS 145 Display Console 118418
7. a ping ied dote o 38 9 CONNECTION DESCRIPTION CONSOLE CENTRAL 40 PAT Rev 09 15 03 SB 190162_a doc Mechanical Description Of The Components 1 1 MECHANICAL DESCRIPTION OF THE COMPONENTS Pressure Transducer The pressure transducer transforms hydraulic pressure into an electric analogue 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 is 12V The output signal is 2 500V at 0 pressure to 7 500V at maximum pressure 250bar Cable Reel The cable reel houses the length angle transducer slip ring disc and slip ring pick up to feed and return A 2 B signal The PE cable goes through the drum and out to the tip where it is wired to the Anti Two Block switch The reel is driven by a tensioned spring and should be handled with caution The Length Angle Transducer The length angle sensor LWG is a combination of two transducers in cable reel fitted at the base section of the boom It measures the length and the 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 shield and core It is connected to the anti two block switch at the boom he
8. 3 8 VDC 1 0 VDC 1 0 RS 232 TxD RS 232 RxD RS 232 CTS RS 232 DTR 12 VDC 12 VDC 12 VDC 12 VDC 5 VDC Analog Ground Ground Ground Ground Ground Ground Ground Ground Ground Ground 1 2 3 Analog Input 4 Analog Input 5 Analog Input 6 Analog Input 7 Analog Input 8 Display RS 422 LOAD Display RS 422 LOAD 5 VDC Analog 5 VDC Analog 5 VDC Analog 5 VDC Analog Roller Switc h 1 Roller Switc Roller Switc h 2 h 3 Roller Switc h 4 Roller Switc h 5 5 VDC Analog Disp ay RS 422 CLK Disp ay RS 422 CLK Disp ay RS 422 DATA Disp ay RS 422 DATA Dis Disp ay Power 12 24 V ay Power GND Disp ay Power 12V Disp ay Shut Off ay RS 422 RxD Disp ay RS 422 RxD Disp ay RS 422 TXD ay RS 422 TxD Disp lay GND ay Heating PanelDown Button Panel Button Panel Up Button Roller Switch GND 1 8 N C A 2 B Return A 2 B 12V A 2 B By Pass A 2 B Bypass Shut Off By Pass Shut Off By Pass Shut Off 1 Shut Off 1 Shut Off 2 Shut Off 2
9. 61 62 63 64 65 65 67 68 69 70 71 72 73 74 75 76 77 78 79 80 o m e a lt 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 z a 7 Conductor Shielded Cable 7 1 1 2 2 3 3 5 5 6 6 7 7 SHIELD EH SHIELD 10 RECEPTACLE PLUG 7 12345 91011 spring Operated Cable 2 Conductor Olflex Inner Core Outer Shield A 2 B SWITCH A 2 B Wiring for one 1 winch amp NO Attachment 6 PIN BOOM POINT PLUG RECEPTACLE 190162 a doc PAT Rev 09 15 03 SB Service Manual PRS145 12 5 8 9 12 13114 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 311 321 33 341 35 36 37 38 39 40 3 ength ngle lt 41 42 43 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 1 2 5 6 7 7 Conductor Shielded Cable 7 T 1 2 Conductor Olflex 5 6 ELECTRICAL DIAGRAM CABLE REEL 24 30 M TO CENTRAL UNIT 10 2 3 2 SWITCH 5 6 7 A 2 B Wirin
10. Appendix Remove jumper dummy plug and check the function of the Two Block switch by using ohmmeter between terminals 2 and 4 of the receptacle Safe condition switch pulled down 0 ohm Two Blocked switch up open Plug appropriate plug into socket of the receptacle Remove cover from cable reel Check with ohmmeter between terminals 2 and 3 on the slip ring disc E Replace Anti Two Block switch with Two Block switch down 0 ohm NEXT PAGE PAT Rev 09 15 03 SB 190162 a doc 32 Service Manual PRS145 PREVIOUS PAGE el Replace length cable refer to Section Check with ohmmeter between terminals 2 and 3 on the terminal strip with Two Block switch down 0 ohm Clean or replace slip ring disc or terminal strip p c board with plungers Check with ohmmeter between terminals 6 and 7 in the receptacle a boom pivot point with Two Block switch down 0 ohm Replace defective cable from cable reel to receptacle Check with ohmmeter between terminals X1 71 and X1 72 in the electronic box with Two Block switch down 0 ohm Replace cable from plug at boom pivot point to electronic box Use a voltmeter with ground lead on X1 41 50 and positive lead on X1 72 check for 12 vdc NEXT PAGE PAT Rev 09 15 03 SB 190162 a doc Troubleshooting Flow Charts 33 PREVIOUS PAGE Electronic Box P C Board is defective Send to PAT America Inc for repair or repla
11. CHAMBERSBURG 17201 TOLERANCES P N 031 300 101 492 SHIELDED ECN DESCRIPTION BY APV DRAWN SB DATE 02 25 2005 DOUBLE APPROVED DATE SHIELD CONNECTED TO STRAIN SCALE SHEET 1of1 SHIELDED RELIEF INSERT SIZE DWG NO NOT PAT America Inc reserves proprietary rights to this drawing and to the data shown thereon The drawing and data are ECN CONNECTED confidential and are not to be used or reproduced without the written consent of PAT America Inc This drawing is subject to technical modification without prior notice C A G E 79760
12. HIRSCHMANN PAT LOAD MOMENT INDICATOR SYSTEM PRS145 SERVICE MANUAL P N 031 300 190 162 REV A 09 15 2003 Service Manual PRS145 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 REV DATE DESCRIPTION sd 07 25 02 Created service manual ECN 02 205 09 15 03 Add Console Central Unit Connections ECN 03 115 gt 2001 PAT America Chambersburg 17201 USA PAT Rev 09 15 03
13. 00 19 Thimble 1 0009988 00 20 Thimble Link 1 0009987 00 21 Screw 2 3 mm slotted flat head 1 0011819 00 22 Contact Socket 1 0110095 00 23 Contact Pin 1 0110094 00 PAT Rev 09 15 03 SB 190162 a doc 12 Service Manual PRS145 5 8 CABLE REEL 24 30 M 1 0115463 00 Spare parts List 16 15 14 6 2 9 oe abols tees S 3 4 5 ITEM DESCRIPTION QTY PART NUMBER 1 Cover Complete 1 1 0107886 00 2 Cable Reel Body 1 1 0107885 00 3 Angle Clamp 4 1 0010613 00 4 Slotted Flat Head Screw M5 x 14 4 1 0012350 00 5 Nylon Washer M5 4 1 0010581 00 6 Shielded Cable 1x1 30M 1 0102079 00 7 Receiver 1 1 0010615 00 8 Slip Ring Disk 1 1 0021448 00 9 Angle Bracket 1 1 0010175 00 10 Contact Holding Plate 1 1 0116041 00 11 Terminal Strip 1 1 0011684 00 12 Slotted Flat Head Screw M4 x 10 1 1 0010582 00 13 Angle Transducer Complete 1 1 0015264 00 Mounting Plate 1 1 0010626 00 Pot 1 1 0012157 00 Pendulum 1 1 0010628 00 14 Gear Drive Complete 1 1 0021212 00 Pot 1 1 0013697 00 15 Mounting Bracket 1 1 0027856 00 16 Hex Head Cap screw M10 x 45 1 1 0012207 00 17 Lock Washer M10 1 1 0010096 00 18 Shrink Tubing Alpha 1 4 x 2 1 1 0009986 00 19 Thimble 1 1 0009988 00 20 Thimble Link 1 1 0009987 00 21 Screw 2 3 mm slotted flat head 1 1 0011819 00 22 Contact Socket 3 1 0110095 00 23 Contact Pin 3 1
14. 0110094 00 PAT Rev 09 15 03 SB 190162 a doc Drawings 13 5 8 1 Length Sensor Assembly Part Number 1 0107887 00 Length Potentiometer PAT Rev 09 15 03 SB 190162 a doc 14 Service Manual PRS145 5 8 2 Angle Sensor Assembly Part Number 1 0015601 00 5 9 ANTI TWO BLOCK ELECTRICAL DIAGRAM To Cable Reel Inner Core Outer Shield 6 Pin Boom Point Receptacle Plug Dummy Plug Main Boom Point A 2 B Wiring for machine with two 2 winches To Cable Inner Core Reel BLUE BROWN Outer Shield Attachment Point 6 Pin Boom Point Receptacle Plug Main Boom Point A 2 B Wiring for machine with one 1 winch PAT Rev 09 15 03 SB 190162 a doc Drawings 15 5 10 ANTI TWO BLOCK SWITCH 1 0024849 00 Spare parts List ITEM DESCRIPTION QTY PART NUMBER 1 Center Housing 1 1 0112531 00 2 Cover Left 1 1 0010045 00 3 Cover Right 1 1 0010044 00 4 Slotted Flat Head Screw M5 x 8 2 1 0013391 00 5 Lever 1 1 0010041 00 6 Straight Pin 1 1 0010042 00 7 Bushing 1 1 0010104 00 8 Spring 1 1 0100326 00 9 Micro Switch 1 1 0010039 00 10 Cable Connector 1 1 0010037 00 11 Blind Plug 1 1 0010038 00 12 Shackle with Cotter Pin 1 1 0009999 00 Required for Mounting Order Separately DESCRIPTION QTY PART NUMBER Weld Plate 1 1 0010046 00 Hex Head Cap screw
15. 1 24 0 White X1 2 OVDC GND Brown X1 3 RS422 CLK Green X1 4 RS422 CLK Yellow X1 5 RS422 DATA Grey X1 6 RS422 DATA Pink X1 7 RS422 Load Blue X1 8 RS422 Load Red X1 9 Push button UP TARE Black X1 10 Push button PROGRAM BUZZER Violet X1 11 Push button DOWN ANGLE Grey pink LENGTH X1 12 Push button HOIST LIMIT SWITCH Red blue PAT Rev 09 15 03 SB 190162 a doc SST PE CTY TTI PRS 145 Display Console 118418 PASS IKST Piston Pressure KSTRod Pressure 1 Transducer 250bar Transducer 250bar ccs SQ 4 3 BUTTON ANG LENG GRA PNK RED BLU Rollerswitch 1 031 006 100 043 I BUTTON A2B N 2 m c a z gt a m Q gt le assembly 455 BUTTON UP TARE amp NS S Qn c dc 7 8 RS422 CLK gt RS422 CLK 9 RS422 DATA 45422 DATA not used not used a 2 12131415 212 Fed kA m Cable assembly 112843 11112 GND GND 12 VDC in Enclosure 12 VDC 2 5 V 7 5V Enclosure 12 VDC 12 VDC in 12 VDC in BLK front rubber chart Rollerswitch S2 031 006 100 043 def arc chart on outriggers Rollerswitch S3 031 006 100 043 optional TERNI rcm V 1255 Cable 031 300 100 144 031 300 100 144 le 031 300 100 144 031
16. 15 16 Adjust simulator to 7 500 vdc 18 19 20 21 22 17 Move positive lead of voltmeter to term 52 Push up or down button until PRESSURE ROD menu title is blinking then push P button Adjust simulator to 2 500 vdc Push up or down button until MINIMUM menu title is blinking then push P button Push P button until all digits have been verified with the proper value which will be 000 00 bar Push up or down button until MAXIMUM menu title is blinking then push P button Push P button until all digits have been verified with the proper value which will be 250 00 bar Push up or down button until ADJUST menu title is blinking then push P button Push down button until EXIT menu title is blinking then push P button Push down button to EXIT then P button until you get to the Program menu and enter the working display PAT Rev 09 15 03 SB 190162_a doc 22 Service Manual PRS145 6 4 ANGLE TRANSDUCER REPLACEMENT AND ADJUSTMENT Angle Transducer Replacement Tools required Soldering e 8mm Box wrench e Needle Nose Pliers e Digital Level Or Magnetic Base Angle Protractor e Small Flat Blade Screwdriver Procedure Fully retract the boom and lower to an degree angle to access the cable reel mounted on the boom base section 2 Turn off power to the Load Moment System 3 Remove cable reel cover Store the 4 screws washers and clamps in a safe place 4 Use the soldering iron and needl
17. 36 Service Manual PRS145 8 ERROR CODES 8 1 OPERATOR ERROR CODE TABLE Operation errors are measurement errors i e the actual radius is lower than in the load chart The information will be shown on the second line of the display with an error message or description The error will be automatically reset when user corrects error ERROR DISPLAYED ERROR CAUSE ACTION A2B CONDITION Anti 2 Block circuit has been activated The hoist limit switch has been activated or open in A 2 B circuit Lower the hook Check all cables and connection to hoist limit switch A2B BYPASS The hoist limit switch The hoist limit by pass Error occurs when bypass has been by passed button has been pushed or button on the panel is is defective pushed LOAD MAX The actual load is The crane is at maximum Lower load or move load into LOAD greater than the max lifting capacity safe working condition load SHUT OFF The shut off system is The shut off contact has Remove key from electronic BYPASS currently by passed been by passed by the user box with the aid of the key operated switch installed on the electronic box LENGTH CHART The length of the main boom is shorter than the lowest value in the Load Chart for the configuration selected The incorrect configuration has been selected The length indication is incorrect Select proper configuration Check length indication with boo
18. 5E CHAMBERSBURG PA 17201 SHIELDED 0 Co es Ix IG in PAT America Inc reserves propri ts to this drawing and to the data shown thereon The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT America Inc This drawing is subject to technical modification without prior notice 1 12VDC 1 NS 4 20mA BLK 1 4 20mA ls Pin Plug Extension A2B Switch 031 002 060 014 6 Pin Receptacal FE Dummy Plug tor Boom Tip 6 6 Main Boom only 1 C p 7 Cable 068 308 060 001 eos A2B Switch 031 002 060 011 LEGEND BRN BROWN L BLACK H WHITE RA GRAY EE SHIELD CONNECTED TO STRAIN RELIEF INSERT D 5 Lo o NOTES Le am a a a a 1 eee L le e OO gt SHIELD IS USED AS CONDUCTER 2 SWITCH CIRCUIT R ORANGE YELLOW VIOLET HD SHIELD CREAM Sieb PAT AMERICA Inc PRS 145 w LWG 308 amp KST P Transducers 1665 ORCHARD DRIVE 55 CHAMBERSBURG PA 17201 GENERAL 2 PIN 031 300 101 xxx ____________ 5 _ BY DATE DRawn ________ 09 29 2003 DS CONNECTED CETTE SIZE DWG NO REV PAT America Inc reserv
19. OL Q3123NNOO lt BLU Piston Signal BLU Rod Signal 2 C Reel Length Analog Input 1 Analog Input 2 Jeuondo GS 0 5 uoiMsie os uo ZS UO LS LINN IWYLNAD SVL Sud 4 C Reel Angle es es zs es se vc Les 26 os ev ev 27 ov vv zv 6 be Roller Switch 2 VREF 5VDC ANALOG Roller Switch 3 VREF 5VDC ANALOG jeojuuoer JE Roller Switch 4 VREF 5VDC ANALOG VREF 5VDC ANALOG VREF 5VDC ANALOG eree SH AV 13H HOSO8 Console 5422 CLK S991 LVd 5 o 2 Qo RB 1022 e S 8 2 S gt gt NOLLdIHOS3G Console RS422 DATA ESI Console Power 24 12V Console GND Console 12VDC 15105 62 8 15 gt 3 gt 5 8 3 8 2 5 8 8 3 5 3 8 5 5 2 3 5 3 a 5 5 8 a 8 5 8 5 5 5 8 5 8 2 3 5 3 amp 5 5 ce 8 5 g 8 8 8 8 8 5 8 8 5 8 amp 8 5 3 g 8 8 g 3 ES E gt 2 gt 3 3 3 8 5 8 a 5 5 T 8 5 e Shutoff 23 o o le RS422 RXD RS422 RXD TVH3Ni9
20. adjust or replace different system components Please read through the replacement or adjustment procedures before you perform the task defined in the procedures to ensure you have positioned the crane boom and have the necessary spare parts and tools If a component replacement is necessary order the component from PAT America Inc before removing the component Include Crane Model and Serial Number when ordering to allow PAT America technicians to test the potentiometer to ensure operation over the voltage range of the original system installation 6 1 ANGLE SENSOR ADJUSTMENT Part Number 1 0115294 00 The angle shown in drawing below 1 needs to be within 0 0 4 of the actual angle of the boom Check boom angle at base heel Section only After adjustment compare the actual boom angle with the displayed angle at about 0 30 60 and 70 30 90 angles are more critical than 0 30 To comply with the SAE J375 standards the displayed angle must be 0 0 to 2 0 of the actual angle Angle Transducer Pendulum Stop Set Angle Transducer Left Side of Boom Right Side Inside Set Screw Locking Bolt Te n Right Side of Boom Left Side inside PAT Rev 09 15 03 SB 190162_a doc 20 6 2 EPROM REPLACEMENT IN CENTRAL UNIT Service Manual PRS145 1 Loosen screws and remove electronic box cover 3 Replace with notch down and fla
21. shown on theangle protractor or digital level proceed to angle adjustment procedure 17 Lower boom and reinstall the cable reel cover 18 The Angle Transducer has been replaced and adjusted The machine can be put back into service PAT Rev 09 15 03 SB 190162 a doc Procedures 23 Angle Transducer Adjustment Tools required Small flat blade screwdriver e Digital Level or Magnetic base angle protractor Procedure 1 Fully retract the boom and lower to an angle 0 degrees or level 2 Push the DOWN ANGLE LENGTH 7 or UP TARE 9 button until NORM menu title is blinking then push the PROGRAM BUZZER 8 button 3 Push the DOWN ANGLE LENGTH 7 or UP TARE 9 button until ANGLE menu title is blinking then push the PROGRAM BUZZER 8 button 4 Verify boom is at 0 degrees using digital level 5 Push the DOWN ANGLE LENGTH 7 or UP TARE 9 button until MINIMUM menu title is blinking then push the PROGRAM BUZZER 8 button 6 Push the PROGRAM BUZZER 8 button until all digits have been verified with the proper value which will be 000 0 at 0 degrees 7 Hoist the boom all the way up and check angle using a digital level 8 Push the DOWN ANGLE LENGTH 7 or UP TARE 9 button until MAXIMUM menu title is blinking then push the PROGRAM BUZZER 8 button 9 Push the PROGRAM BUZZER 8 button to the first digit that has to be changed to the angle value found by using the digital level Change the di
22. terminal X1 2 If there is no voltage there is a problem with supply voltage from the crane Remove wires from terminals X1 11 X1 20 power to sensors and check for short circuit to ground Replace fuse with 2 amp fuse only If system returns to normal operation the crane is ready to be put back into service Defective electronic CPU Check for short on the wires removed X1 11 X1 20 when the short is found trace out short using wiring diagrams Refer to wiring diagram in Section 5 After short has been removed replace fuse with 2 amp fuse only board NEXT PAGE PAT Rev 09 15 03 SB 190162 a doc 30 Service Manual PRS145 PREVIOUS PAGE Then check output voltage to console using a If system returns to normal operation the voltmeter put positive lead at terminal X1 33 and crane is ready to be put back in service ground at terminal X1 2 Display working Voltage Replace console Replace or repair Electronic box CPU PAT Rev 09 15 03 SB 190162_a doc Troubleshooting Flow Charts 31 7 4 ANTI TWO BLOCK PROBLEM PROBLEM Function of the Anti Two Block System is faulty START Check to see whether the crane is in Anti Two Block condition Two Blocked Check if jumper or dummy plug if two Lower hook down into winch crane in receptacle at boom nose is safe position plugged in Refer to Drawing 2 Anti Two Block Junction In Section 11
23. 300 100 144 le 031 300 100 144 e c 2 10 lt o Color code reference table LEGEND BROWN BLACK WHITE GRAY GREEN LU BLUE RED N PINK RG ORANGE YELLOW VIOLET Notes HD SHIELD ris MER PAT AMERICA Inc PRS 145 w LWG 208 Voltage amp KST P Transducers IS 1665 ORCHARD DRIVE EIRE CHAMBERSBURG PA 17201 EEE P N 031 300 101 xxx ECN DESCRIPTON BY DATE WB 10 03 2003 DS PROVED TATE ae REV PAT America Inc reserves proprietary rights to this drawing and to the data shown thereon The drawing and data are ECN confidential and are not to be used or reproduced without the written consent of PAT America Inc This drawing is subject to technical modification without prior notice C A G E 79760 2 2 optional optional LK H 0 0 ele z n w 12 VDC in 12 VDC in Rollerswitch S4 031 006 100 043 Rellerswitch S5 031 006 100 043 D m 9 m eel lt lt To PRS 145 Central Uni as 0 5V 4 5V BLK 1 1 875V 3 125V 6 KE ls Pin Plug Extension eos j A2B Switch 031 002 060 014 BOTTOM 6 Pin Receptacal Dummy Plug for 6 Boom Tip 6 C Main Boom only 1 Cable Reel 068 208 060 013
24. 4 52 12VDC og Input 5 less 12VDC _____ ue Merso UU erns Evo BLU Console RS422 LOAD E 12VDC RED Console s RS422 LOAD 12VDC MOIS yz esn4 i LON GRN Piston Trans GRN Rod Trans 1 C reel GND By pass relay GND Q3193NNOO NMOSg obejJoA oue19 ___ E HS LOIA i ___ 980 qas 5535 NHO AVS LIHM OMA 9 0 ev zv T JON GND LYASNI 431134 NIVALS OL Q3193NNOO lt GND og Input 1 og Input 2 jeuondo GS 0 uo 25 UO S UOJIMSIS IOH LINN IWYLNAD SVL Sd VREF 5VDC ANALOG BRN 51 Signal 9 Roller Switch 1 BRN S2 Signal BRN 53 Optional zz iz oz Roller Switch 2 3 C Reel n 4VREF 5VDC ANALOG Roller Switch 3 VREF 5VDC ANALOG BRN 54 Optional BRN 55 Optional Roller Switch 5 GRA PNK Console VIO Console PROGR BUZZER YEL Cons GRA Cons PNK Cons e RS422 DATA x JA2B Switch Signal 2 Console Power 24 12 A2B Switch 12VDC BRN C ns A 2 B BYPASS WHT Cons A 2 B BYPASS To GND Roller Switch 4 VREF 5VDC ANALOG VREF 5VDC ANALOG
25. 6 100 043 def arc chart on outriggers optional Rollerswitch S3 12SS e assembly 031 300 050 619 435 assembly 031 300 050 619 2 Cable 031 300 100 144 e 031 300 100 144 e 031 300 100 144 e 031 300 100 144 e 031 300 100 144 e c o uw lt o E Color code reference table LEGEND BROWN BLACK WHITE GRAY GREEN BLUE RED N PINK R ORANGE EL YELLOW VIOLET HD SHIELD CRE CREAM _____ 5 INNER SHIELD SINGLE 55 SHIELDED DOUBLE SHIELDED DS NOT CONNECTED R K optional optional E iC 12 12 VDC 2 m ey Rollerswitch 54 031 006 100 043 Rollerswitch 55 031 006 100 043 E r S OIA Notes gt Shield connected to strain relief insert PAT AMERICA Inc PRS 145 w 4 20mA output sensors KIT 1492 1665 ORCHARD DRIVE CHAMBERSBURG PA 17201 SENERA 031 300 101 492 DESCRIPTION DATE oRAWN WB 0 ATE 09 28 2003 _______ LL one ______ E C A G E 79760 PAT America Inc reserves proprietary rights to this drawing and to the data shown thereon The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT America
26. 760 R lt lt ora MOTZA 19 EJ EI 12 VDC 24 VDC GND Ref 3 8 VDC Ref 3 8 VDC Ref 1 0 VDC Lo Ref 1 0 VDC RS232 TXD RS232 RxD RS232 CTS RS232 DTR BRN Piston 12VDC BRN Rod 12VDC Analog Input 3 S 1 12VDC Analog Input 4 BRN 1 52 12VDC Analog Input 5 fer 12VDC Analog Input 6 gt 12 Analog Input 7 ernn iso Fo 12VDC Analog Input 8 iss 12VDC BLU Console RS422 LOAD Musee ES 12VDC 7 7 RED Console 8 RS422 LOAD IL 12VDC BLU 2 51 Signal 5 Roller Switch 1 Ed VREF 5VDC ANALOG BLU 2 S2 Signal BRN 2 S3 Optional BRN 2 S4 Optional BRN 2 S5 Optional Roller Switch 5 GRA PNK Console ANGLE LENGTH VIO Console BLK Console YEL Cons GRA Cons PNK Cons El A2B Switch Signal A2B Switch 12VDC BRN Cons 2 BYPASS A 2 B BYPASS Not used MOIS yz esn4 c LON 7131 5 BLK Piston Trans BLK Rod Trans 3 C reel GND By pass relay GND Q3193NNOO algnod 1 1 5 I3IHS YANNI 380 IFO 12 PSHM LIHM 1 18 das 189 5535 NHO AVS VHO qiuHs OM 0 19491 lt LHISNI 4317134 NIVALS
27. ATED LOAD The load value shown on the applicable load ratings 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 ratings 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 100 to 110 CRANE CONFIGURATION The physical arrangement of the crane as 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 ANALOGUE 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 PAT Rev 09 15 03 SB 190162_a doc Drawings 5 DRAWINGS 5 1 WIRING DIAGRAM CENTRAL UNIT SHUT OFF 2 MAGNET OR SOLENOID VALVE SHUT OFF 4 o ec FO IN IN IN IN IN IN IN IN o FO IN 0o IN IR N e IIo 12V 24V Power Supply Ground 3 8 VDC
28. BUZZER 8 button Push the PROGRAM BUZZER 8 button until all digits have been verified with the proper value which will be minimum boom length of the load chart Telescope the boom all the way out Push DOWN ANGLE LENGTH 7 9 button until MAXIMUM menu title is blinking then push the PROGRAM BUZZER 8 button Push the PROGRAM BUZZER 8 button until all digits have been verified with the proper value which will be maximum boom length of the load chart Push the DOWN ANGLE LENGTH 7 or 9 button until ADJUST menu title is blinking then push the PROGRAM BUZZER 8 button Push DOWN ANGLE LENGTH 7 or 9 button until EXIT menu title is blinking then push the PROGRAM BUZZER 8 button Push the DOWN ANGLE LENGTH 7 button to EXIT then the PROGRAM BUZZER 8 button until you get to the Program menu and enter the working display Verify length values to load chart lengths The Length Transducer has been adjusted The machine can be put back in service PAT Rev 09 15 03 SB 190162_a doc 26 Service Manual PRS145 6 6 LENGTH CABLE REPLACEMENT PROBLEM Damaged or broken length cable Replace length cable using the following procedure OR GO Ne D 8 9 Turn drum counter clock wise until drum is fully tensioned Tighten locking nuts to drum to prevent recoil Refer to Drawing 1 in Section 11 Appendix Take reel cover of
29. IT All data of the crane are stored inside the central unit in ERPROMs The central unit gets all actual information of the crane This is computed against the reference data and the crane status continually monitored Description of the Housing The PRS145 central unit has a water proof aluminum housing It is mounted on the left side of the turntable 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 to override the LMI function The system is protected by a 2 AMP fuse that is mounted on the lower right side Description of the Boards Inside the central unit there is one board The main board that has terminal strips where power and various components are connected with fast ons to the terminal strip The main board is the heart of the system It contains the main computer and the necessary electronics to receive evaluate process and direct the continuous data There are overload and anti two block relays which control the Bosch relay for lever lockout also mounted on this board A 24 12 volt converter for 24 volt cranes which converts 24 volts to 12 volts on the main board An analogue input part which receives and prepares all the signals from the transducers for further processing An analogue digital converter part which converts all the processed analogue signals into digital ones A digital part which conta
30. Inc This drawing is subject to technical modification without prior notice gt cot M 1 1 12VDC 1 4 20mA BLK 1 4 20mA 6 Pin Plug Extension A2B Switch 031 002 060 014 6 Pin Receptacal 77 Dummy Plug for Boom Tip 6 C 6 Main Boom only 1 C E Uo Cable Reel 068 308 060 001 L gt A2B Switch 031 002 060 011 LEGEND BROWN BLACK di is WHITE NOTES a GRAY SRPEN gt SHIELD CONNECTED STRAIN RELIEF INSERT R L H To PRS 145 Central Uni Bg r o 85 0 0 53 55 85 ROZ ES ORANGE YELLOW VIOLET HD SHIELD CREAM is SUEDE PAT AMERICA Inc PRS 145 w 4 20mA output sensors KIT 1492 SINGLE 1665 ORCHARD DRIVE 55 Sheen CHAMBERSBURG 17201 ERR P N 031 300 101 492 EN DESCRIPTION DATE RAW Jours 0972972003 DS NOT NC CONNECTED L LL 2 DWO NO FEV PAT America Inc reserves proprietary rights to this drawing and to the data shown thereon The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT America Inc This drawing is subject to technical modification without prior notice C A G E 79
31. M8 x 50 2 1 0010083 00 Lock Washer M8 2 1 0010097 00 PAT Rev 09 15 03 SB 190162 a doc Service Manual PRS145 5 11 ELECTRICAL DIAGRAM PRESSURE TRANSDUCER TO CENTRAL UNIT 16 Pressure Transducer Piston Side Pressure Transducer Rod Side Quick Disconnect 1112 3 4 5 7 8 Lo 42 13 14 15 16 17 20 21 22 231 24 25 26 27 28 29 31 32 33 35 37 39 40 190162 a doc PAT Rev 09 15 03 SB Drawings 17 5 12 PRESSURE TRANSDUCER 250 BAR 1 0108060 00 5 13 PRESSURE TRANSDUCER CABLE ASSEMBLY Part Number is depends cable length Connector Cable Straight x 7M 1 0114293 00 Connector Cable Straight x 10M 1 0114294 00 Connector Cable 90 Connector 1 0101758 00 Rev 09 15 03 SB 190162_a doc 18 Service Manual PRS145 5 14 JUMPER CABLE ASSEMBLY FOR EXTENSION PAT Rev 09 15 03 SB 4 3 9 3 pecsm szo cosmos muo 2 pu asi ors onr CONNECTOR SOCKET EMA 1 00m 5 061 CONNECTOR MEER CFM EEA ES 00 214 251 3511 STRAIN RELIEF ACT 8 5 1 HEDULER 6 21 441 118 811 STRAH RELIEF P011 6mm m 190162 a doc Procedures 19 6 PROCEDURES This section will provide the user with step by step procedures to
32. SB 190162_a doc Service Manual PRS145 TABLE OF CONTENTS 1 MECHANICAL DESCRIPTION OF THE 1 2 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UNIT 2 3 BASIC ADJUSTMENT OF THE HARDWARE nnn nnn nnn 3 4 DEFINIT 4 5 5 1 WIRING DIAGRAM CENTRAL UNIT SHUT iii 5 5 4 CENTRAL PROCESSOR 12 24 VDO nn den tq a nd sue reas 6 5 37 ELECTRICAL DIAGRAM CONSOLE i ras retiennent nan 7 5 4 INDICATOR PANEL CONSOLE meia ee i a oc a 8 5 5 ELECTRICAL DIAGRAM CABLE REEL TO CENTRAL UNIT 9 5 6 ELECTRICAL DIAGRAM CABLE REEL TO CENTRAL UNIT nnnm nennen nnns 10 b CABLE REEL rend aere mte 11 D 8 CABLE REEL 24 30 M terree Debo tr t ed REOR E sete IN RR uen eue 12 5 8 1 Length Sensor Assembly ettet tie e Pob esae tentat 13 5 8 2 Angle Sensor Assembly iles 14 5 9 ANTI TWO BLOCK ELECTRICAL DIAGRAM sisi 14 5 10 ANT TWO BEOGK SWITCH 52d tte dita he tite rro reat be a pla ds da Fa 15 5 11 ELECTRICAL DIAGRAM PRESSURE TRANSDUCER TO CENTRAL 16 5 12 PRESSURE TRANSDUCER 250 BAR 1 0108060 00
33. SISIION EB bed S4 a 12 BRN 1 1 C Reel EE S 12voc a 12 0 02 6 VREF 5VDC ANALOG ec VREF 5VDC ANALOG VREF 5VDC ANALOG VREF 5VDC ANALOG VREF 5VDC ANALOG 9c VREF 5VDC ANALOG Console RS422 CLK 5 o o 2 Qo R N N 2 T e RS422 DATA o 2 o o o le RS422 DATA Console Power 24 12V ez ez 2z BRN Cons Console GND Console 12VDC Console Shutoff le RS422 RXD 5 RS422 RXD le RS422 TXD RS422 TXD Heating GND ov ec ec se vc ee ze e o P n e o 5 a o e Heating 24 12V Il Il YEL Cons PRS 145 Display Console 118418 Piston Pressure 1 Transducer 300bar 031 300 060 452 r Rod Pressure 7 Transducer 300bar 031 300 060 452 04 BUTTON A2B BY PASS 100 RS 422 LOAD lt BUTTON UP TARE BUTTON PROG BUZ BUTTON ANG LENG a lt o a o a 2 RS422 CLK gt RS422 CLK RS422 DATA RS422 DATA 12 VDC not used 12 VDC not used a z 2 3 4 5 7 22 x a acy acp uu 2 KO gt a Cable assembly 112843 12 VDC in 006 12 VDC in 12 VDC in 031 BLK VIO GRA PNK RED BLU Rollerswitch S1 031 006 100 043 front rubber chart Rollerswitch 2 031 00
34. acts Then remove cover from cable reel and adjust arm mounted on the potentiometer till length indication is correct Angle Set the boom to 0 degrees and set a digital level on the boom Adjust the angle sensor to the same angle as the boom Check the angle at 20 degrees 45 degrees 70 degrees Angle display should be less than 5 degrees of the value of the inclinometer Pressure Channel Rest the boom and disconnect the pressure transducers Measure the voltage of both pressure transducers on the terminal board The output voltage of the pressure transducers should be 2 500vdc 025vdc Check the function of the hoist limit switch anti two block Check function of lever lockout Measure and record the power supply voltages PAT Rev 09 15 03 SB 190162_a doc 4 Service Manual PRS145 4 DEFINITIONS BOOM LENGTH The straight line thru 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 loading to the center of the vertical hoist line or tackle with rated load applied Indicator 100 to 110 R
35. ad and to a slip ring body in the LWG The angle transducer is fitted in the cable reel 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 1 000V up to 5 000V The output signal for the angle transducer is 1 000V up to 5 000V 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 lock out solenoid valves where applicable The weight at the anti two block switch keeps the switch closed until the hook block strikes it Console The console displays all geometrical information such as length and angle of main boom and working radius 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 LED s instrument shows a percentage of the total permissible moment The console has pushbuttons to switch the operating modes for selection of crane configurations and reeving of the block It also has a warning light for overload anti two block conditions and an override push button for anti two block condition PAT Rev 09 15 03 SB 190162_a doc 2 Service Manual PRS145 2 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UN
36. cement With 12vdc on terminal X1 72 and all checks have been completed you should have 12 vdc on terminal X1 71 If you have the correct voltages the Electronic Box P C Board is defective Send to PAT America Inc for repair or replacement PAT Rev 09 15 03 SB 190162_a doc 34 Service Manual PRS145 7 5 LENGTH READING PROBLEM PROBLEM Length reading is incorrect Crane Is not out of load chart condition START Check mechanical adjustment of the length Potentiometer with boom fully retracted If indication is correct at short boom and If indication is off by approximately 3 ft 1m has bad indication the problem my be a add or remove 1 rap from cable reel If this defective length potentiometer Refer to does not repair problem refer to Length Section Adjustment Procedure section PAT Rev 09 15 03 SB 190162_a doc Troubleshooting Flow Charts 35 7 6 ANGLE READING PROBLEM PROBLEM Angle reading incorrect Crane is not out of load chart condition START Check mechanical adjustment of the angle Potentiometer with boom at 0 degrees Indication should match load chart Indication should match load chart If indication is correct at 0 degrees and If indication is off check the mechanical has bad indication the problem my be adjustment of the angle bracket defective length potentiometer Refer to Section 7 Refer to Section 7 PAT Rev 09 15 03 SB 190162_a doc
37. d F040 FE43 Hardware Error The system has a hardware Contact PAT America Inc failure or replace electronic box P C board PAT Rev 09 15 03 SB 190162 a doc 40 Service Manual PRS145 9 CONNECTION DESCRIPTION CONSOLE CENTRAL UNIT The tables below show the connection terminal wire color and terminal description for the 7m long supplied cable between the console and central unit Connections to the central unit Terminal Function Lead Color x1 1 Supply voltage 12VDC opt 24VDC X1 2 Input GND OV X1 3 Output Uref 3 8VDC for slewing angle sensor X1 4 Output Uref 3 8VDC for slewing angle sensor X1 5 Output Uref 1 0VDC for slewing angle sensor X1 6 Output Uref 1 0VDC for slewing angle sensor X1 7 Interface RS232 TxD X1 8 Interface RS232 RxD X1 9 Interface RSRS232 CTS X1 10 Interface RS232 X1 11 20 12VDC X1 21 26 5VDC Vref X1 27 Interface RS422 CLK Green from indicator panel X1 28 Interface RS422 CLK Yellow from indicator panel X1 29 Interface RS422 Data Grey from indicator panel X1 30 Interface RS422 Data Pink from indicator panel X1 31 Supply voltage indicator panel 24 12VDC X1 32 Supply voltage indicator panel OVDC GND Brown from indicator panel X1 33 Indicator panel 12VDC White from indica
38. d and pc board has replace pc board with real no real time clock or time clock defective real time clock E 1080 1080 Range Check Errors Errors occur from improper If problem reoccurs contact programming of data 1 PAT America Inc C s E 10C0 10CE Data Programming Programming errors in If problem recurs contact Errors EPROM 1 EPROM 1 PAT America Inc PAT Rev 09 15 03 SB 190162 a doc Error Codes 39 ERROR ERROR CAUSE ACTION DISPLAYED E 1100 Invalid EEPROM Incorrect EEPROM inserted Replace the EEPROM with identification in EEPROM 2 slot valid programming E 1101 Incorrect Information has been With error message CHECKSUM changed in EPROM 2 and displayed push down EEPROM 2 not checksum before button Enter ACCESS turning power off to system code and CHECKSUM EEP then RESET 1102 110E Data Programming Invalid programming of If problem reoccurs contact Errors EPROM 2 PAT America Inc F000 Error in shut off Fault on electronic box P C Replace electronic box P C circuit board board E F001 12 Volt DC fault The 12 Volt DC power If crane is 12 volt check supply voltage has dropped supply voltage of crane If below 12 Volt DC 20 crane is 24 volt check for fault of 12 24 volt converter on electronic box P C board E 2002 ADC timeout Malfunction of A D Replace electronic box P C converter boar
39. ducer or cable transducer or cable voltage to low CH 2 OPEN Rod Pressure Defective pressure Replace pressure Transducer output transducer or cable transducer or cable voltage to high CH 3 SHORT Length Transducer Defective length transducer Replace length transducer output voltage to low or cable or cable CH 3 OPEN Length Transducer Defective length transducer Replace length transducer output voltage to high or cable or cable CH 6 SHORT Angle Transducer Defective angle transducer Replace angle transducer output voltage to low or cable or cable CH 6 OPEN Angle Transducer Defective angle transducer Replace angle transducer output voltage to high or cable or cable E 0001 0042 LMB Error Codes Errors occur from improper If problem recurs contact programming of data 8 PAT America Inc E 1040 Error of division The system has tried to Reset system by turning divide by zero power off then on If problem recurs contact PAT America Inc E 1041 Invalid interrupt The system has attempted Reset system by turning vector to execute an interrupt that power off then If is in valid problem recurs contact PAT America Inc E 1042 Incorrect CHECKSUM Loss of data or invalid Install new EPROM 1 with of EPROM 1 modification of EPROM 1 valid control program E 1043 No real time clock A EPROM 1 program for Replace EPROM 1 with using data logger has been proper programming or installe
40. e nose pliers to remove the three 3 wires from the angle potentiometer WARNING Before removing wires make a diagram of their location 5 With box end wrench loosen the nut and remove the pendulum from the angle potentiometer 6 Remove the three new angle potentiometer clamps and install the new angle potentiometer 7 Use the soldering iron to connect the wires to the angle potentiometer using the diagram made in Step 4 8 Supply power to the Load Moment System 9 Adjust stem of the potentiometer to indicate 0 degrees then put pendulum on and tighten nut using 8mm wrench 10 After putting pendulum on recheck for 0 degree indication If panel agrees tighten all nuts and screws 11 If the angle displayed on the panel does NOT AGREE with the actual angle shown on the angle protractor proceed as follows 12 Loosen but DO NOT remove the three 3 screws holding the angle potentiometer clamps SLOWLY rotate the Potentiometer until the angle indication on the panel is the same as the actual angle 0 degrees with boom level 13 Tighten the 3 screws that hold the angle potentiometer clamps 14 Boom up to the maximum angle possible Be sure to verify the actual boom angle using the Magnetic base angle protractor or digital level 15 If the angle displayed on the panel AGREES with the actual angle shown on the angle protractor or digital level go to step 15 16 If the Angle displayed on the panel DOES NOT agree with the actual angle
41. e reel cover Store the 4 screws washers and clamps in a safe place 5 Rotate the arm attached to the length potentiometer until the setscrew is accessible Loosen but DO NOT remove the setscrew 6 Rotate the arm until the second setscrew is accessible Loosen but DO NOT remove the setscrew 7 Remove the arm from the Length potentiometer and store in a safe location 8 Remove the nylon gear from the length potentiometer shaft 9 Use the 13mm wrench to remove the length potentiometer from the mounting bracket 10 Use the soldering iron and needle nose pliers to remove the three 3 wires from the angle potentiometer WARNING Before removing wires make a diagram of their location 11 Install the new length potentiometer in the mounting bracket Tighten using 13 mm wrench 12 Install the large nylon gear on the potentiometer shaft Be sure that the brass spacer is facing toward the boom 13 Install the lever arm on the potentiometer shaft and tighten both setscrews 14 Use the soldering iron to connect the wires to the angle potentiometer using the diagram made in step 4 15 Set VOLT OHM meter to read OHMS Place one probe on terminal 1 of the terminal strip and the other probe on terminal 2 Turn the lever arm until the meter indicates approximately 95 OHMS Remove the meter from the circuit 16 Supply power to the Load Moment System 17 Follow system start up procedure to put the display panel in the normal operating m
42. ection 7 2 Blank Display Go to Section 7 3 Anti Two Block Problem Go to Section 7 4 Length Reading Problem Go to Section 7 5 Angle Reading Problem Go to Section 7 6 PAT Rev 09 15 03 SB 190162_a doc 28 Service Manual PRS145 7 2 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 Set override key switch in electronic box into upper position to override LMI Refer to Drawing 8 If console display is blank fault is Does light 6 located in power supply wiring or indicate 195 Anti Two Block warning If Load Moment Limit Light 5 displays Fault in Anti Two Check lever lockout system in fault is located in LMI cables wiring Block system Chane fuses or console Read error code Refer to Section 7 4 displayed on console display Refer to Section 8 PAT Rev 09 15 03 SB 190162_a doc Troubleshooting Flow Charts 29 7 3 BLANK DISPLAY PROBLEM Blank display No warning lights shown Crane movements stopped Se E Check input voltage using If fuse is open check for direct short to ground by using voltmeter put positive lead at voltmeter checking for continuity between terminal X1 2 and terminal X1 1 and ground at X1 11 20
43. es proprietary rights to this drawing and to the data shown thereon The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT America Inc This drawing is subject to technical modification without prior notice C A G E 79760 zo Q3103NNOO LON Gad TaIHS A 9NIS Q I3IHS lt 5 431134 NIVULS OL Q3193NNOO Q T3IHS 3 0 jou pue jeguepyuoo OU LYd eogou ioefqns si Bumesp siu 1 Vd Jo 1uesuoo eu 10 LOZLL Vd pue Bujweup eu eu pue Sy 0 TVH3N39 LSM 9 80 OMI 544 S3ONVH3 10L 09 627 A39 VO 1 ERE REI ON SA 101 005 150 5002 62 60 aiva MN 104 YANNI INV3HOD 97315 GH GHVHOHO 699 VOIMANV LVd LFIOIA MOTISA gAs Q 13 20 0 SONVYO O2 _____ 5008 19 555 NHO TWYHLNAD SVL 4 SH AV144 50 CHR ce 0 24 Queu
44. f and remove screw and cable clamp Remove wire from slip ring disc cut wire ends off and remove all old length cable from reel Feed new length cable through drum Strip wire separate inner core from shield insulate shield by using heat shrink or electrical tape put spade lugs on and wire to slip ring disc terminals 2 and 3 Put cable clamp on and tighten screw to drum Put silicone around hole where the new length cable is fed through the drum While holding cable or drum Warning To prevent recoil loosen locking nuts and jam the nuts together Slowly allow cable to spool onto the drum keeping the cable tight together and layering properly spool until all tension is off the cable reel Re string cable through the roller guides and reconnect at the boom tip 10 After cable replacement refer to length adjustment procedure to reset length 11 Put cover on reel Crane is ready to put back into service PAT Rev 09 15 03 SB 190162_a doc Troubleshooting Flow Charts 27 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 Kruger Mark 4E 2 System The procedures are easy to follow and are given in flowcharts on the following pages Start with the general flowchart below that will guide you to one of the other detailed flowcharts shown in this section START What s Wrong Lever Lockout Activated Go to S
45. g for one 1 winch amp NO Attachment 6 PIN BOOM POINT PLUG RECEPTACLE SHIELD Spring Operated 10 PIN BOOM PIVOT N Cable Reel PA RECEPTACLE PLUG S 190162 a doc PAT Rev 09 15 03 SB Drawings 11 5 7 CABLE REEL 34 50 M 1 0115468 00 Spare Parts List 1 6 15 m10 11 12 14 184 19 204 END 16 17 3 4 5 21 8 13 9 ITEM DESCRIPTION PART NUMBER 1 Cover Complete 1 0016897 00 Cover 1 0010159 00 Rubber Seal 1 0010631 00 2 Cable Reel Body 1 0010653 00 3 Angle Clamp 1 0010613 00 4 Slotted Flat Head Screw M5 x 14 1 0012350 00 5 Nylon Washer M5 1 0010581 00 6 Shielded Cable 1x1 45M 1 0102079 00 7 1 0010615 00 8 Slip Ring Disk 1 0021448 00 9 Angle Bracket 1 0010175 00 10 Contact Holding Plate 1 0116041 00 11 Terminal Strip 1 0011684 00 12 Slotted Flat Head Screw M4 x 10 1 0010582 00 13 Angle Transducer Complete 1 0015264 00 Mount ing Plate 1 0010626 00 OS LOS ES gt 5 5 5 5 5 5 5 5 5 SO AA 5 x Pot 1 0012157 00 Pendulum 1 0010628 00 14 Gear Drive Complete 1 0021212 00 Pot 1 0013697 00 15 Mounting Bracket 1 0027856 00 16 Hex Head Cap screw M10 x 45 1 0012207 00 17 Lock Washer M10 1 0010096 00 18 Shrink Tubing Alpha 1 4 x 2 1 0009986
46. git value by pushing the DOWN ANGLE LENGTH 7 or 9 button until you get the proper number for that digit Continue this process until at digit values have been corrected For Example if the angle given by digital level was 76 5 degrees then the display should read 076 5 before the PROGRAM BUZZER 8 button is pushed for the last time 10 Push the DOWN ANGLE LENGTH 7 or UP TARE 9 button until ADJUST menu title is blinking then push the PROGRAM BUZZER 8 button 11 Push the DOWN ANGLE LENGTH 7 or 9 button until EXIT menu title is blinking then push the PROGRAM BUZZER 8 button 12 Boom down to 60 degrees using crane angle indicator and verify angle with magnetic base protractor or digital level The Angle Transducer has been replaced and adjusted The machine can be put back into service PAT Rev 09 15 03 SB 190162 a doc 24 Service Manual PRS145 6 5 LENGTH TRANSDUCER REPLACEMENT AND ADJUSTMENT Tools required e 1 5mm Allen Wrench e 13mm Open End Wrench e Medium Flat Blade Screwdriver e Needle Nose Pliers e Digital Volt Ohm Meter Procedure Locate machine in an area that will allow you to safely extend the boom to its full extension Powered sections plus manual section 2 Fully retract the boom and lower to an angle that will provide you with access to the cable reel mounted on the boom base section 3 Turn off power to the Load Moment System 4 Remove cabl
47. he boom to return to a working angle in the load chart ANGLE gt CHART The Angle of the main boom is higher than the highest value in the Load Chart for the configuration selected The crane has exceeded the highest angle for the configuration that has been selected Lower the boom to return to a working angle in the load chart SWING AREA The crane has swung into a non working area unacceptable to the Load Chart for the configuration selected The crane has swung into the wrong working range May have defective roller switch or open wire to the roller switch Swing to return to a working rang Replace defective roller switch Replace wire from electronic box to roller switch PAT Rev 09 15 03 SB 190162 a doc 38 Service Manual PRS145 8 2 SYSTEM ERROR CODE TABLE System errors will occur if a system component has failed or been damaged and must be corrected The system has to be reset after error has been corrected ERROR ERROR CAUSE ACTION DISPLAYED CH 1 SHORT Piston Pressure Defective pressure Replace pressure Transducer output transducer or cable transducer or cable voltage to low CH 1 OPEN Piston Pressure Defective pressure Replace pressure Transducer output transducer or cable transducer or cable voltage to high CH 2 SHORT Rod Pressure Defective pressure Replace pressure Transducer output trans
48. ins the main computer and the ancillary electronics Incoming Signals The signals from the transducers are connected to the terminal board The signals of the angle length transducer are connected to terminal 56 angle and terminal 53 length The signal on terminal 56 angle is between approximately 1 000V and 4 500V The signal on terminal 53 length is between 1 000V and 4 500V The signals from the pressure transducers are connected to terminal 52 rod side and terminal 51 piston side The signals on terminals 51 and 52 range between 2 500V and 2 500V The signal from the force transducer is connected to the terminals 51 and 52 range between 2 500V and 7 500 The supply voltage 12vdc for the anti two block switch is terminal 72 and return signal on terminal 71 Outgoing Signal The outgoing signal of the terminal board is the signal for lever lockout of terminal 87 on the Bosch relay In normal working conditions there are 12 or 24 volts at this terminal When there is an overload or anti two block condition the signal becomes 0 volts Furthermore all voltages for the transducers and console are going out via the terminal strip PAT Rev 09 15 03 SB 190162 a doc Basic Adjustment of Hardware 3 3 BASIC ADJUSTMENT OF THE HARDWARE Length Ensure that the length cable tension is correct with fully retracted boom by turning the cable reel 2 to 3 turns counterclockwise and check that reel fully retr
49. m fully retracted if incorrect length is indicated Refer to Section 7 5 LENGTH CHART The length of the main boom is longer than the highest value in the Load Chart for the configuration selected The incorrect configuration has been selected The length indication is incorrect Select proper configuration Check length indication with boom fully extended if incorrect length is indicated Refer to Section 7 5 RADIUS CHART The Radius is shorter than the lowest value in the Load Chart for the configuration selected The crane has exceeded the shortest radius for the configuration that has been selected Lower or extend boom to return to a working radius in the load chart Check radius indication to actual radius RADIUS CHART The Radius is longer than the highest value in the Load Chart for the configuration selected The crane has exceeded the longest radius for the configuration that has been selected Raise or retract boom to return to a working radius in the load chart Check radius indication to actual radius PAT Rev 09 15 03 SB 190162 a doc Error Codes 37 ERROR DISPLAYED ERROR CAUSE ACTION ANGLE lt CHART The Angle of the main boom is lower than the lowest value in he Load Chart for the configuration selected The crane has exceeded the lowest angle for the configuration that has been selected Raise t
50. ode 18 With all boom sections FULLY RETRACTED rotate lever arm on the length potentiometer until the length displayed on the panel indicates the shortest boom length shown on the crane capacity chart 19 FULLY EXTEND boom sections Panel should display the maximum extended boom length of the load chart 20 If the length displayed on the panel AGREES the machine can be put back in service 21 If the length displayed DOES NOT AGREE go to LENGTH TRANSDUCER ADJUSTMENT PAT Rev 09 15 03 SB 190162_a doc Procedures 25 Length Transducer Adjustment Tools required Medium screw driver Procedure 1 2 10 11 12 13 Locate machine in an area that will allow you to safely extend the boom to its full extension Fully retract the boom and lower to an angle that will provide you with access to the cable reel mounted on the boom base section Open reel and adjust length voltage to 1 000 vdc measuring from terminal 1 to terminal 2 on the terminal strip in the cable reel Push DOWN ANGLE LENGTH 7 9 button until NORM menu title is blinking then push the PROGRAM BUZZER 8 button Push DOWN ANGLE LENGTH 7 9 button until LENGTH menu title is blinking then push the PROGRAM BUZZER 8 button Verify boom is at fully retracted Push DOWN ANGLE LENGTH 7 9 button until MINIMUM menu title is blinking then push the PROGRAM
51. oduo9 PRS 145 Sensors GRN Piston Trans GRN Rod Trans 3 C reel GND By pass relay GND YEL Rod Signal 2 C Reel Length es zs es 99 vs es zs is os RED Console E BLU 2 1 Signal BLU 2 52 Signal BLU 2 S3 Signal BLU 2 54 Signal BLU 2 S5 Signal VIO Console BLK Console GND nput 1 nput 2 nput 3 nput 4 nput 5 nput 6 nput 7 nput 8 RS422 LOAD RS422 LOAD Roller Switch 1 Roller Switch 2 Roller Switch 3 Roller Switch 4 Roller Switch 5 ANGLE LENGTH PROG BUZZER UP TARE x A2B Switch Signal 5 C Reel A2B 12V RED BLU Console 8 11 92 92 v4 e 22 62 82 youms Sseq g G OMS OL piil 2 OL pill YOM OL 1991 91429 OL A2B Switch 12VDC A 2 B BYPASS A 2 B BYPASS Not used Not used By pass VS uojsid psueil d OL 817811 210SU09 OL OM JULI 0 13431 GS 0 5 uo ZS oue19 MOIS vz esn4 cpu N Ref 1 0 VDC o Ref 1 0 VDC RS232 TXD RS232 RS232 CTS RS232 DTR BRN Piston 5 2 1 12VDC BRN 1 2 BRN 1 3 Hove B S5 S UOJIM
52. t side to the top as shown diagram WARNING If I C is placed wron the will be destroyed and a new will have to be ordered Calculation Program Rev 09 15 03 SB 190162 a doc Procedures 21 6 3 PISTON amp ROD PRESSURE CHANNEL ADJUSTMENT 6 3 1 Adjust pressure piston 1 rc D Rope 9 10 11 power off to the system and wire simulator to the piston pressure channel blue to term 12 brown to term 45 green yellow to term 51 Put voltmeter ground on term 45 and positive to term 51 Go to the Calibration menu by pushing the up then P button while in the Program menu screen Push up or down button until NORM menu title is blinking then push P button Push up or down button until PRESSURE PIS menu title is blinking then push P button Adjust simulator to 2 500 vdc Push up or down button until MINIMUM menu title is blinking then push P button Push P button until all digits have been verified with the proper value which will be 000 00 bar Adjust simulator to 7 500 vdc Push up or down button until MAXIMUM menu title is blinking then push P button Push P button until all digits have been verified with the proper value which will be 250 00 bar Push up or down button until ADJUST menu title is blinking then push P button Push down button until EXIT menu title is blinking then push P button 6 3 2 Adjust pressure Rod 12 13 14
53. tor panel X1 34 Indicator panel shut off Jumper to X1 41 X1 35 Indicator panel RxD X1 36 Indicator panel RxD X1 37 Indicator panel TxD X1 38 Indicator panel TxD X1 39 Indicator panel heating GND X1 40 Indicator panel heating 24 12VDC X1 41 50 GND X1 51 Analog input 1 Pressure transducer piston side X1 52 Analog input 2 Pressure transducer rod side X1 53 Analog input 3 length transducer X1 54 Analog input 4 X1 55 Analog input 5 X1 56 Analog input 6 angle transducer X1 57 Analog input 7 X1 58 Analog input 8 X1 59 Interface RS422 Load Blue from indicator panel X1 60 Interface RS422 Load Red from indicator panel X1 61 Roller switch 1 Front rubber X1 62 Roller switch 2 Front Rear outrigger X1 63 Roller switch 3 X1 64 Roller switch 4 X1 65 Roller switch 5 X1 66 Down button Grey pink from indicator panel X1 67 Prog button Violet from indicator panel X1 68 Up button Black from indicator panel X1 69 Roller switch GND 1 8 PAT Rev 09 15 03 SB 190162 a doc Error Codes 41 X1 70 n c X1 71 Hoist limit switch X1 72 Hoist limit switch 12VDC X1 73 Bypass hoist limit switch Red blue from indicator panel X1 74 Bypass hoist limit switch X1 75 Bypass LMI X1 76 Bypass LMI X1 77 78 Shutoff 1 X1 79 80 Shutoff 2 Console Table 1 Console connection Terminal Description Lead Color X1
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