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PAT America, Inc. LOAD MOMENT INDICATOR SERVICE MANUAL

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2. QQ ADJUST LENGTH POTE TURN THE CENTER SC AT REV E 8 23 01 GJ O 190052_E doc 5 4 Procedures 19 PROCEDURE 4 Connection Board Replacement Refer to Drawing 1 central unit parts list for board location 1 Turn svstem power off 2 Remove the central unit lid NOTE Take care not to damage the boards with the screw driver when removing and inserting screws NOTE Be careful when lifting the CPU module board from the connection board because these 3 4 5 11 12 boards have pins on the bottom side which insert into the connection board Remove CPU module board by taking out the 4 small Philips screws holding it in place Remove the relay from the connection board Item 4 on Drawing 1 Mark all connection wires before removing to identify location for reconnecting Disconnect all X1 terminal wires from the connection board Remove the 9 large Philips screws holding the connection board in place 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 Carefully insert the new connection board in place Refer to Drawing 1 for location Insert the 9 Philips mounting screws Insert CPU module board by lining up the pins into the sockets X11 and X12 and the 4 screw holes Insert the 4 sm
3. gt D CLOSED OVERALL 5 1 8 X 5 1 2 COVER 14 xq X 5 44 190052_E doc AT REV E 8 23 01 GJ O 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 03 050 000 100 060 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 11 050 350 110 280 1 CAP LOAD ORANGE 12 050 350 110 281 1 CAP INFO ORANGE 13 050 350 110 282 1 CAP ANGLE ORANGE 14 050 350 110 283 1 CAP ENTER GREEN 15 003 051 903 364 1 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 850mmGASKET 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 1 024 350 100 312 AT REV E 8 23 01 GJ O LABYRINTH MOISTURE ELEM ENT 190052 E doc 10 Service Manual PAT ps150C 4 3 DRAWING 3 Cable Reel 068 208 060 013 LWG208 Spare Parts List REV E 8 23 01 GJ O 190052 E doc
4. TPUT SIGNAL SSURE C OV D5 gt AAA 20 MV THEORY 3 Piston Side Pressure Measuring Channel RANGE X PSI 6 4 X1 CENTRAL UNIT TERMINAL BC f NUMBER iden qg TEST POINT ON MAIN BOARD PRESSURE TRANSDUCER ROD SIDE ROU DAVS z TAY 300 BAR MAX 4410 P1 ZERO POIN ADJUSTMEN N THEORY 4 Rod Side Pressure Measuring Channel X1 RAY SP 20V AT REV E 8 23 01 GJ O 4 Vez l P2 ZERO POIN ADJUSTMENT P Aa E 2 2 2 UV 2 14 0 0V GND MI e i O MP11 P1 LATEST POINT CODE gt TERMIN ON MAN BOARD AN RROR PENAS A D CONVERTER Ao MP12 V TEST POIN 21 BOV JUV MAX OV MIN 4 50V MAX AI GND TERMINAL X1 14 ON MAIN BOARD MEASURED WITH OR MP 10 190052 E doc 22 6 5 BOOM ANG PENDULUM ANGLE SENSOR O CABLE REEL TERMINA E CENTRAL UNIT TERMINAL BOARD RE NUMBER A Q TEST POINT ON OARD MAIN BO 6 6 BOARD CENTRAL UN ERMINAL WIRE NUMBER DO TEST POINT ON MAIN BO AT REV E 8 23 01 GJ O E SENSOR X EN 4 5 8 ji ii FIXED lt RESISTOR PART OF THE ANGLE OTENTIOMETER ma 5
5. gt Broken Length Cable Goto Flow Chart 3 gt No display c Goto Flow Chart 4 mE LZ Anti Two Block Problem Goto Flow Chart 5 gt Length Reading Problem Goto Flow Chart 6 Load Reading Problem Go to Flow Chart 7 Bad Data Transfer Between i p Console Central Unit Go to Flow Chart 8 c p Interference Problem gt Go to Flow Chart 9 NM P Angle Problem Goto Flow Chart 10 AT REV E 8 23 01 GJ O 190052 E doc 24 7 2 Lever Lockout Activated Service Manual PAT DS150C 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 i Set the override key switch in central unit into upper position to override LMI Refer to Operator s Handbook for LMI override instructions Fixed YES Does console indicate Anti Two block warning Yes l v Fault in crane electric or hydraulic system If console display is blank fault is located in power supply wiring or fuses Fault in Anti Two Block system If Load Moment Limit Light displavs fault it is located in LMI cab
6. PAT America Inc Www patamerica co PAT PAT LOAD MOMENT INDICATOR DS150C SERVICE MANUAL P N 031 300 190 052 REV E 8 23 01 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 REV DATE NAME DESCRIPTION A 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 Change wiring in Theory 1 And formatted
7. HReferto connection and wiring diagrams Drawings 4 amp 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 terminals of spiking component Diode type such as 1N4001 can be used however ensure the correct plus and minus connections for diode C END AT REV E 8 23 01 GJ O 190052 E doc 40 Service Manual PAT DS150C 7 10 Angle Problem PROBLEM Displayed Angle Incorrect Actual measured angle is different from displayed angle C START 2 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 Check the supplv voltage to angle sensor on connection board between X1 11 5VDC and X1 8 ground Refer to Installation Manual for svstem wiring diagram Check system power supply voltage Refer to Section 7 4 No Display this manual Yes l Check the voltage at angle sensor between connector pins A AGND and C 5V Refer to Installation Manual for svstem wiring diagrams Cable defective replace cable or cable assembiv Refer to Installation Manual for svstem wiring diagrams Ves Check the voltage be
8. 4 6 DRAWING 6 Central Unit Board Lavout And Measuring Points MP24 MP23 o9 H5 H6 H7 A 8 Q Ww W W DE1 DE2 DES H1 O W ET MP9 MP26 MP4 6V AGND 5 vV v4 N I J Ken Pe w N A RNI Sa MP22 IN GND Ju MP5 a NO MP3 MP27MP2 O 9V AGND 9V AGND 5 MP10 co BRA BRI HES 5 4 MP11 MP12 MP13 MP14 MP15 MP16 MP17 wen Ww W us NES NS AM LOAD A2B CHO CHI CH2 CH3 CH4 CHS CH6 ka IA P1 P2 P3 P4 P5 E A N N rN N Ne 9j e ej Q ANS oe DAVI DAV2 LGI WGI WG2 vnm Kg g 555 K10 UB1 K10 MP25 RELAY J h MP6 MP7 EH Ld 45V 5V T T FTI eal O ie ND KGND 18 17 16 15 14 13 12 11109 8 7 6 5 4 3 1 49 48 47 46 45 44 BIA BIB BIB BUE 43 42 41 40 39 38 37 56 35 34 33 32 31 30 25 24 23 22 21 20 19 Measuring Points MPO MP2 MP3 MP4 MP5 MP6 MP7 MP8 MP9 AT AGND 9V 9V 5V AGND 5V sensors supply 5V sensors supply HES 6V REV E 8 23 01 GJ O MP10 MP11 MP12 MP13 MP14 MP15 MP22 MP25 MP2
9. 000 0000000 UB1 K10 RELAY b b b b MP6 MP7 E um L L 5V 5V B TT T T N VY O KGND 43 42 41 40 39 38 37 36 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 49 48 47 46 45 44 X1 3 Installing the new EPROM e Ensure the notch is in the correct direction The direction of the EPROM is determined by the notch on the end of the EPROM e The DATA and TLK 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 follow ing procedures to prevent any moisture from entering the central unit Reference material 031 300 340 002 Central Unit Cover Installation and Tightening Procedure Rev A 031 300 340 003 Central Unit Gasket Recommendations Rev REV E 8 23 01 GJ O 190052 E doc Procedures 5 2 PROCEDURE 2 Piston amp Rod Pressure Channel Zero Point Adjustment MP11 MP12 MP13 MP14 MP15 MP16 MP17 LI LI E CHO lt 41 CH2 CH3 CH4 CH5 CH6 AN w P2 P3 P4 P5 O S O C DAVI DAV2 LGI Wei we2 O na pa O 2 Mtr 3 x re oo2 e J10 do o1 MP9 MP26 MP4 MP24 MP23 9V AGND 9V WV NV 29000000000000000 I c bi SN SYSTEM NON 00000000000000
10. 2 EPROM do not match Error in the internal e Computer component e Replace computer write read memory 80C537 defective component 80C537 RAM of the computer CPU module defective Replace CPU module component 80C537 e Processor board e Replace processor board defective with CPU module Error in the external e Write read memory e Replace processor board write read memory CMOS RAM or with CPU module 1st part RAM processor board defective Error in the external e Refer to E42 e Refer to E42 write read memory 2nd part RAM REV E 8 23 01 GJ O 190052 E doc 46 ErrorCode Error Case 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 AT REV E 8 23 01 GJ O Service Manual PAT DS150C 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 lt 2V at 1kOhm Processor board defective Computer component
11. AD Ps M 4 MINIMUM SIGNAL 1 875V 90 ANGLE PEN 4 4 9 NA 1 UM SIGNAL E ANGLE OF THE ANGLE OTENTIOMETER 3 3 THEORY 6 Second Angle Measuring Channel A XI FIXED RESISTOR PART OF THE ANGLE POTENTIOMETER THEORY 5 Main Boom Angle Measuring Channel Service Manual PAT DS150C 4 50V MAX B 25 5 0V OV Z UM 16 900V MIN MAXIMUM SIGNAL 3 125V ANGLE FIXED RESISTOR PART OF THE ANGI POTENTIOM R ALL VOLIA RENC N 4 50V MAX vu F 26 i A i 5 0V TO A D CONVERTER P i NW TEST POINT MP15 MP15 VOLTAGES OMV 500V ANGLE MIN SIGNAL ANGLE 4 50V O ANGLE MAX SIGNA GES ARE MEASURED TO GND TERMINAL X1 23 ON MAIN BOARD 190052 E doc Troubleshooting Flow Charts 23 7 TROUBLESHOOTING FLOW CHARTS 7 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 flow chart below which will guide you to one of the detailed flow charts shown in this section Cm v What s Wrong AN Lever Lockout Activated I gt Go to Flow Chart 2
12. JA TX e ioo M Z 5 il E Q o 5 p S SITE meee pe Le co hd Ceo QNOv eo ne pn A a a a d RI a a8 fa gt x 0 H 2 A ea lt c EE EE t a LA Yo lt jak a 8 7 wa 0 lt z a Ie m LU O Li Li a E a 2 o o EE o lt Z a e m N SE A z A A E bio wi A A fA JA E amp JA SA Je TA lt LN FN f SN LO ano ia a Ot i E ZE ano z ia g Tas ond 11 5 ano 8 A A pe JA LA 3 8 l SS x E Vu QNO OND Es q q zZz 59 NU 39 E ES By x aS lt Co AT REV E 8 23 01 GJ O 190052_E doc Draw ings 4 5 NOTES TAPE AN 1 gt P z 3 gt 4 5 Se 5 es o DRAWING 5 Cable Reel Electrical Diagram ALL WIRES NOT CONNECTED JTER SHIELD CONNECTED TO STRAIN RELIEF INSERT ER SHIELD INSULATED AND CONNECTED AS 5 13 NER SHIELD CUT AND INSULATED z ODE ASSY IS NSTALL AI cH POTTED ams N e Co ti lt bel A ht JE SHIELD y ton 2 2 2 5 5 5 LENG 4 4 4 gt 5 5 5 c gi CORE BYPASS PLUG 5 2 AT REV E 8 23 01 GJ O CABLE 190052_E doc 14 Service Manual PAT DS150C
13. X1 Nominal Voltage Error Code Channel Pin E Pin supply Peer iT und enar fe qe E1 Piston side vll 3 23 s Rod side E SEE Am eManbom 8 1 s Angle Ji Signal Voltage Terminal Board Amplified Signal Terminal X1 on main board use MP10 GND Error i i and MP supply Code Channel Voltage VDC voltage 0 5 4 5V FEE rpm LE 3 L 35 48 a E1222 0 Pressure Piston side 8 2i 0 4 MP i Presse Rodsa f e ie 0 riz E1525 3 Angle Main boom 8 9 8675 3425 MPi4 E1626 4 Andedb 8 24 18753125 MPI5 AT REV E 8 23 01 GJ O 190052 E doc
14. and adjust length sensor pot as described above Check 4 5 V supply Exchange main board in case of voltage failure or breakdow n 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 Replace processor board e Refer to E07 190052 E doc Error Codes 43 Fallen below lower limit value for measuring channel length main boom Fallen below the lower limit value in the measuring channel pressure piston side E15 Fallen below lower limit value in the measuring channel pressure rod side Fallen below lower limit value in measuring channel angle main boom e Cable between central unit and length sensor is defective or disconnected Water inside the plug of the length angle sensor Length potentiometer is defective Electronic component in the measuring channel is defective Cable between the central unit and pressure transducers defective or water inside the plugs Pressure transducer is defective Electronic component in the measuring channel is defective Refer to E12 Cable between central unit and the length angle sensor defective or loose Water inside the plug of the length angle sensor Angle potentiometer defective Electronic component in the measuring channel defective ErrorCode Error Case Elimination am
15. cceecceeeceeecececececeeecececeeeceeeceeeceeeseeeneeenees 13 4 6 DRAWING 6 CENTRAL UNIT BOARD LAYOUT AND 5 14 PROCEDURE i i coke eua A a kk pa Z UE X ook rco v CIC Y EUR S peduni fa ODER DER n 15 5 1 PPRCEDURE 1 EPROM REPLACEMENT IN 15 5 2 PROCEDURE 2 PISTON ROD PRESSURE CHANNEL ZERO POINT ADJUSTMENT 17 5 3 PROCEDURE 3 LENGTH ANGLE eee mee re nre rn re rer rennen 18 5 4 PROCEDURE 4 CONNECTION BOARD REPLACEMENT enm rrr rens 19 6 THEORY uu 20 6 1 THEORY 1 ANTI TWO BLOCK SHUTOFF CIRCUIT rara 20 6 2 THEORY 2 LENGTH MEASURING CHANNEL ll mee emen nen rent rete rete rettet renun 20 6 3 THEORY 3 PISTON SIDE PRESSURE MEASURING CHANNEL errem ren 21 6 4 THEORY 4 ROD SIDE PRESSURE MEASURING CHANNEL een emere nennen 21 6 5 THEORY 5 MAIN BOOM ANGLE MEASURING CHANNEL cene eene rnm 22 6 6 THEORY 6 SECOND ANGLE MEASURING CHANNEL 22 7 TROUBLESHOOTING FLOW CHARTS nhne ranura nena mesh cesar 23 ft SGENERAL EEOWG AB Ti i l a Duo A a UU et o de ER 23 7 2 LEVER LOCKOUT ACTIVATED t ee S ka usasapa ANKE
16. rre trie tree tree tree 24 73 BROKEN LENGTHICABIE Ma A niae aciei 25 T4 INQ DISPLAW Zw L U A i A A AI a A euim m enu 26 7 5 ANTI TWO BLOCK PROBLEM u enne kaya aaa 28 16 2 LENGTH READING PROBLEM 252 i u dO wa dooms oh data de qua u asas s ZY 31 foro OAD READING PROBLEM uuu a A A a tM RII A A A 34 7 8 BAD DATA TRANSFER BETWEEN CONSOLE CENTRAL UNIT mmn 37 7 9 INTERFERENCE PROBLEM usei ro Ab asia asas doi o ea ti 39 Z LD ANGEE PROBLEM stato eds seda da oett eoe da ed taa u a ERES 40 8 ERROR CODE TABLE nir rrr i Dean cada aba a 41 ADDENDUM A BASIC ADJUSTMENT AND VOLTAGE CHECKS 50 ADDENDUM B REFERENCE TABLES FOR MEASURING SUPPLY AND SIGNAL VOLTAGES FOR SENSOR GHANNELS a dda 51 AT REV E 8 23 01 GJ O 190052 E doc Mechanical Description Of The Svstem 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 is 5V The output signal is 0 00V under 0 pressure t
17. 00 N wa WT ON O X fi RN1 SS e AN N MP29 MP22 e L a I IO oo 7 MES MP3 MP27MP2 L 1 Es Key A DD 1 Em a ao D2 TLK I O 9V AGND 9V A 0000000000000000 bx O AGND oN MP10 o ooo BRA BRI o H3 H4 Wo S W N LOAD A2B S E m A K8 H2 O W O 96996 9999 UB1 K10 RELAV _ X46 X44 x T O TTI p D N z e X EX KGND 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 Tm 10 49 8 77 6 797 4 j 2 1 49 48 47 46 45 44 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 mp10 B red 4 lead to mp11 U Ae w 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 500mv on meter Reconnect hydraulic hoses to pressure transducers and then bleed the air from hydraulic lines N AT REV E 8 23 01 GJ O Adjust P1 to obtain a reading of 0 500 volts 500mv on meter Disconnect hydraulic hose from the rod side pressure transducer 17 190052_E doc 18 Service Manual PAT DS150C 5 3 PROCEDURE 3 Length amp Angle Adjustments
18. 011 000 304 140 122 024 150 110 002 024 350 100 135 024 150 100 001 024 350 110 066 024 350 100 661 031 300 101 131 000 314 022 006 000 313 062 001 000 313 062 002 000 214 340 013 000 214 210 013 050 350 110 116 024 350 100 312 024 350 110 067 000 214 340 011 000 214 210 011 000 214 340 016 000 214 210 016 024 350 100 139 024 150 100 002 031 300 100 078 AT REV E 8 23 01 GJ O QTY r3 BRWNHPINNBP mp PIP RP m mp DESCRIPTION Board Connection DS150 CU Board Processor Board EPROM Module Relay Shut Off 12 V Cover Central Unit DS150 Central Unit Accy Screw Set DS150 Housing Central Unit DS150 Central Unit Accy Gasket For C U Cover Key Switch Central Unit Key Central Unit Key Switch Fuse Holder Central Unit Fuse 2 Amp 1 4 X 1 1 4 250v Fast Acting Fuse 10 Amp 1 4 X 1 1 4 250v Fast Acting Strain Relief Accy PG13 5 Hole Plug Nut PG13 5 Strain Relief Assy PG 13 5 Red Long W Nut Washer Central Unit Accy Check Moisture Drainage Strain Relief Assy PG 11 Grn Long W Nut Washer Strain Relief Accy PG11 Hole Plug Nut PG11 Strain Relief Accy PG16 Hole Plug Nut PG16 Central Unit Accy Wall Mount Set DS150 350 Central Unit Accy Baseplate DS150 Chemical Moisture Pack 190052 E doc Service Manual PAT ps150C DRAWING 2 Console 050 150 060 006 Spare Parts List 4 2 VYJ 7 ji f 35 ONS
19. 11 Draw ings DESCRIPTION PART NO 006 710 006 002 QTY 1 SENSOR LENGTH TRANS LGE 100 KT200 LWG208 068 000 110 038 067 000 050 065 064 103 060 002 SENSOR ACCV GEAR WHEEL KT200 CABLE REEL SENSOR ACCV GEAR WHEEL T 50 CENTER SHAFT SENSOR ANGLE WG103 SCREW 6M X 12 SOCKET CAP 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 lrrhrrhwnhmh h WASHER FLAT 6 SCREW 6M x 100M SOCKET CAP WASHER LOCK 6MM SLIPRING 2 CONDUCTOR CONNECTION STRIP CABLE REEL KT200 HOUSING BKT CABLE DRUM amp NYLON 068 000 110 011 000 673 020 002 006 800 005 058 000 205 031 230 006 800 005 057 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 005 682 000 001 068 000 110 031 000 208 020 006 021 441 131 013 nm roo Hre eS COVER CABLE REEL KT200 CABLE REEL ACCY SCREW CABLE REEL COVER WASHER LOCK 6mm STRAIN RELIEF PG 13 5 8 12mm RED WHITE 000 214 030 703 AT REV E 8 23 01 GJ O 1 STRAIN RELIEF PG7 BLACK 190052 E doc 12 Service Manual PAT ps150C 4 4 DRAWING 4 Central Unit Electrical Diagram
20. 6 X1 AGND PISTON PRESSURE SIGNAL ROD PRESSURE SIGNAL LENGTH SIGNAL ANGLE SIGNAL 1 ANGLE SIGNAL 2 GND UB GND MP27 AGND 190052 E doc 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 unit SI Bt 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 follow ed AT REV E 8 23 01 GJ O 190052 E doc 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 2 vein l i 59 MP9 MP26 MP4 MP24 MP23 oc 46V AGND 5V 38 E W oo 0000000000000000 c c AN all SYSTEM P6 W a O I J RN1 k EZ MP22 GND g MP5 END MP3 MP27MP2 9V AGND 9V AGND MP10 S SI HES MP8 H H4 Q MP11 MP12 MP13 MP14 MP15 MP16 MP17 WT VU RE HEH Wi j LOAD 28 CHO CH1 CH2 CH3 CH4 CH5 CH6 NP Pi P2 P3 P4 P5 CN H5 H6 H7 olololo bo 2 O O 6 olojololo N ks K VY S DAVI DAV2 LG1 WG1 WG2 o H2 DE1 DE2 DES FR wW 5000 9656665669 K10
21. 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 Y Replace Anti Two Block switch Yes v q Next Page D AT REV E 8 23 01 GJ O 190052_E doc Troubleshooting Flow Charts 29 OUS PAGE PREV PA Es Measure the A2B signal in the cable reel between X1 Brown and X2 Red wires on the slip ring with an ohmmeter Switch closed 4700 5000hms Switch open gt 1 Megaohm Reconnected slip ring wires Refer to Drawing 5 Section 3 Fault in wiring between boom nose box and cable reel Check for damaged length cable and wiring Refer to Drawing 5 Section 3 If broken length cable Refer to Section 3 l y Measure the A2B signal in the cable reel between terminal 7 and 8 with an ohmmeter Switch closed 4700 5000hms Switch open gt 1 Megaohm Reconnected slip ring wires Refer to Drawing 5 Section 3 Replace slip ring NEC Refer to Drawing 3 amp 5 in Section 3 t v Measure the A2B signal in the boom base 10 pin receptacle between terminal 5 and 6 with an ohmmeter Switch closed 24700 5000hms Switch open gt 1 Megaohm Reconnected slip ring wires Refer to Drawing 5 Section 3 Fault in 7 conductor cable
22. 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 LMI 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 E doc Error Codes 47 Error Code Error Cause Error in crane data Memory module wrongly e Bridge memory module acc Error in serial crane data EEPROM Error in the serial analog data EEPROM Error in the serial analog data EEPROM Wrong rigging condition E85 Error in the radius determination 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 to memory type
23. 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 transducer Refer to Drawing 6 in Section 3 and Procedure 2 in Section 4 No END REV E 8 23 01 GJ O 190052 E doc 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 C sme 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 gt Place EPROM in correct socket Yes l Check crane supply voltage for console in central unit at connection board X 33 ground and 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 Refer to Drawing 1 amp 4 in Section 3 and Replacement Procedure 4 in Section 4 Y Correct No Yes NEXT PAGE AT REV E 8 23 01 GJ O 190052 E doc 38 Service Manual PAT DS150C Continued from previous page 4 PREVIOUS PAGE p Check power supply to console between console terminal 2 ground and terminal 1 12v Refer to Drawing 5 Console Board Sec
24. REVIOUS 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 signal at MP13 i e input at terminal X1 11 0 5V and gnd 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 C END AT REV E 8 23 01 GJ O 190052 E doc 34 Service Manual PAT DS150C 7 7 Load Reading Problem PROBLEM Load reading incorrect C START I Check selected operating mode code on operating mode switch Select operating mode switch to correct position see operating mode in load chart 4 Yes v Check boom length reading on display Reset length potentiometer With fully retracted boom turn potentiometer axle counter clockwise until it stops see Section 3 and 6 Refer to Procedure 3 Length amp Angle Adjustments Section 4 D z o Y Y Measure radius and check with the displayed radius Check mechanical adjustment of angle transducer is 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 Le
25. 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 board 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 REV E 8 23 01 GJ O 190052 E doc 48 Service Manual PAT DS150C Error Code Error Cause Elimination 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 REV E 8 23 01 GJ O 24 V supply of the console 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 c
26. all Philips screws and washers Insert the relav into the main board Item 4 on Drawing 1 13 14 Connect the X1 terminal wires to the main board Refer to Drawing 4 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 AT REV E 8 23 01 GJ O 190052_E doc 20 Service Manual PAT DS150C 6 THEORY 6 1 THEORY 1 Anti Two Block amp Shutoff Circuit 46 1 C X K9 ke aN ON 7 44 e o A 8 Ns N K8 LMI N 7 A OVERLOAD JB n E eo A i 54 0 5 b ous 4 a d FROM CRANE p 6 P N SUPPLY 12V ic 3 X1 CENTRAL UNI ERMINAL BOARD O CRANE MANUFACTURER S B i WIRE NUMBER AN 6 2 THEORY 2 Length Measuring Channel a 1 FTIT WORKING RANGE PA 1 ERROR 2 A CODE 5 a q UN ji U PRELOAD 27 ux MP13 T M TEST POIN P3 ZERO POINT ADJUSTMENT CABLE REEL TERMINAL CENTRAL UNIT TERMINAL BOARD 4 WIRE NUMBER C 51 J TEST POINT ON MAIN BOARD xi AT REV E 8 23 01 GJ O 190052 E doc Theorv 6 3 CENTRAL UNIT WIRE NUMBER TEST POINT ON MAIN BOARD PRESSURE TRANSDUCER PISTON SIE ERMINAL BOARD OU 18 5 0V
27. between cable reel and No boom base box Refer to Drawing 5 in Section 3 ib Y NEXT PAGE p AT REV E 8 23 01 GJ O 190052_E doc 30 Service Manual PAT DS150C PREVIOUS PAGE l 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 in central unit with onmmeter measure between X1 34 and X1 35 Anti Two Block switch closed 4700 Ohms 50 0Ohms Anti Two Block switch open gt 1 Megaohm Refer to Drawing 4 in Section 3 Faultv 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 3 and Replacement Procedure 4 in Section 4 Y Reconnect Wire 46 to X1 34 and Wire 5 to X1 35 Refer to Drawing 3 in Section 3 Com AT REV E 8 23 01 GJ O 190052_E doc Troubleshooting Flow Charts 31 7 6 Length Reading Problem PROBLEM Length reading incorrect Crane is not in out of load chart condition q START Check mechanical adjustment o
28. ce Voltages 50 MV 5V Mp4 VDC Mp 10 Ground Internal to Board 6V O 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 ib Angle Length Angle Rod Piston 5V Mps __ O VDC Mp 10 Ground Piston amp Rod Pressure 12V O Mp25 VDC Mp 15 Ground Internal to Board 4 Boom Length MP10 Ground for Meter Fully Retracted Ft nose VDC O X1 10 DC MP13 Fully Extended Ft entra teenie es VDC O X1 10 DC MP13 5 Volt Reference Voltage VDC Q X1 11 5 Boom Angle MP10 Ground for Meter Minimum Angle O a q VDC O X1 9 VDC Mp14 Maximum Angle VDC O XII _ VDC Mp14 5 Volt Reference Voltage VDC X1 11 6 Pressure Transducers MP10 Ground for Meter Piston Zero Point VDC O X1 21 VDC 11 Rod Zero Point VDC X1 16 VDC Mp12 5 Volt Reference Voltage VDC O X1 13 amp 18 5 Volt Reference Voltage _ _ _ ___ VDC X1 15 amp 20 AT REV E 8 23 01 GJ O 190052_E doc Addendums B1 ADDENDUM B Reference Tables for measuring supplv and signal voltages for sensor channels Use the table as a quick reference for measuring supplv and signal voltages for the sensor channels that are specific to the error code listed Signal Voltage one Board one
29. e 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 AT REV E 8 23 01 GJ O 190052_E doc 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 07 27 less than 65 boom angle 03 93 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
30. f length potentiometer in 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 bv turning counter clockwise until it stops Refer to Drawing 3 Cable Reel Parts List Section 3 Drawings Ves 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 and X1 11 5V Refer to Drawing 4 Section 3 Drawings Replace connection board and reset pressure No channel Refer to Drawing 1 amp 4 in Section 3 and Replacement Procedure 4 in Section 4 Yes Y NEXT PAGE AT REV E 8 23 01 GJ O 190052 E doc 32 Service Manua
31. he 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 AT REV E 8 23 01 GJ O 190052_E doc 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 unitin 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 Housing The central unit DS150C is a rugged wate
32. l PAT DS150C Continued from previous page PREVIOUS PAGE Measure supply to length transducer in cable reel at terminal between Pin 1 ground and Pin 3 5v Refer to Drawing 5 Section 3 Drawings Faulty wiring between central unit and length transducer Check wiring Correct7 No Ves v Measure singal from length transducer in cable reel at terminal 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 Cones mi remove potentiometer assembly frommounting plate Remove assembly wires form terminal block Connect new assembiv to terminal block Reinstall mounting plate gear wheel and slip rings With boom fullv retracted reset potentiometer bv turning counter clockwise until it stops Ves 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 Check wiring Yes Y C NEXT PAGE REV E 8 23 01 GJ O 190052 E doc Troubleshooting Flow Charts 33 Continued from previous page P
33. les wiring fuses or console Check lever lockout svstem in crane REV E 8 23 01 GJ O Go to Flow Chart 4 Go to Flow Chart 5 Read error code displaved on console and go to Section 6 190052 E doc Troubleshooting Flow Charts 25 7 3 N 7 8 9 Broken Length Cable PROBLEM Damaged or broken length cable Replace length cable using the following procedure 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 the cable reel Pull new length cable through the hole pipe and strain relief and push it through the axle of the reeling drum Tighten 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 10 Turn reeling drum clockwise to spool the new cable neatly onto the drum 11 12 13 14 Set preload on cable reel by turning the drum counter clock
34. 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 100 to 110 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 AT REV E 8 23 01 GJ O 190052 E doc Service Manual PAT DS150C 5 BLANK PAGE AT REV E 8 23 01 GJ O 190052_E doc 6 Service Manual PAT ps150C 4 DRAWINGS 4 1 DRAWING 1 Central Unit 024 150 061 005 Spare Parts List AT REV E 8 23 01 GJ O 190052_E doc Draw ings PART NO 024 150 300 050 024 351 300 004 024 351 300
35. ngth 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 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 C NEXT PAGE p AT REV E 8 23 01 GJ O 190052_E doc Troubleshooting Flow Charts 35 C Pevious Page Check power supply and measure between test point MP10 ground to Correct No MP7 5 0v and between test point MP10 ground to MP6 5 0v Refer to Drawing 6 Board Layout Section 3 Drawings la Yes Correct Check power supply and measure between test point MP10 ground to 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 pressure channel Refer to Drawing 1 amp 4 in Section 3 and Replacement Procedure 4 in Section 4 Y Check power supply at transducer plugs Measure between B ground and A 5V Measure between B ground and C 5V No Faulty wiring Check wiring
36. o 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 of main boom working radius and head height of t
37. ocessed 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 O 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 AT REV E 8 23 01 GJ O 190052 E doc Mechanical Description Of The Svstem 3 Angle Set the boom between 0 and 5 degrees and set the inclinometer to the boom angle Adjust the angle sensor to the sam
38. of pressure transducer cable Yes v q NEXT PAGE b AT REV E 8 23 01 GJ O 190052 E doc 36 Service Manual PAT DS150C PREVIOUS PAGE p 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 No Check wiring in pressure transducer cable Continuity Good 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 Refer to Drawing 6 in Section 3 and Procedure 2 in Section 4 Measure voltage between test point MP10 ground and test point MP1 1 and reset with
39. onsole 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 E doc Error Codes 49 acc mms No data trans 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 valves 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 AT REV E 8 23 01 GJ O 190052 E doc 50 Service Manual PAT DS150C ADDENDUM A BASIC ADJUSTMENT AND VOLTAGE CHECKS MODEL SIN PAT DS150C P N 024 150 061 005 central unit 024 150 300 050 connection board 1 Crane Supply Voltage O 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 Referen
40. p e Check cable as well as plugs replace if need be Replace length potentiometer Replace LMI main board or processor board Check cable as well as plugs replace if need be Replace pressure transducer Replace LMI main board or processor board Refer to E12 Check cable as well as plugs replace if need be Replace angle sensor Replace LMI main board or processor board REV E 8 23 01 GJ O 190052 E doc 44 Service Manual PAT DS150C Error Code Error Cause sd Elimination Cable between the central e Check cable as well as Fallen below lower limit value in measuring channel angle 2 Fallen below lower limit value length telescope Il 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 AT REV E 8 23 01 GJ O 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 defecti
41. rd and reset pressure No channel Refer to Drawing 1 amp 4 in Section 3 and Replacement Procedure 4 in Section 4 Yes Next Page D REV E 8 23 01 GJ O 190052 E doc Troubleshooting Flow Charts 27 PREVIOUS PAGE D l Measure voltage in the console between X1 1 12 24V 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 d END D AT REV E 8 23 01 GJ O 190052 E doc 28 Service Manual PAT DS150C 7 5 Anti Two Block Problem PROBLEM Function of Anti Two Block System is faulty q START b v Check to see whether or not crane is in two block condition Correct No Lower hook down into safe position Yes Y Check if jumper dummy plug in 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
42. rohibited 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 e 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 Open the length reel sensor and carefully turn the length sensor pot counter clockwise until loosened by using a screw driver REV E 8 23 01 GJ O 190052 E doc 42 Radius range exceeded or fallen below angle range with luffing jib operation E07 Faulty acknow ledgment of the overload relay on the connection board The relay should be energized the 2nd contact how ever is indicated to be off or the 2nd contact is indicated to be on while the relay should be de energized No acknow ledge ment from the anti tw o block relay REV E 8 23 01 GJ O Service Manual PAT DS150C e Clutch between length sensor pot and drive is defective Failure of 4 5V supply of analog part of analog board Cable betw een central unit and length sensor is defective or disconnected Defective length potentiometer M aximum 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 e Refer to E07 e Replace the complete clutch including drive w heel
43. rproof 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 Analog digital converter part Converts all the pr
44. sections 05 01 01 CSH Chg channels in Section 6 Theory correction to wiring diagram Section 4 drawing 4 07 17 01 SB Refer to ECN 01 215 mio O D 08 23 01 GJO Refer to ECN 01 246 2001 PAT America Chambersburg PA 17201 USA AT REV E 8 23 01 GJ O 190052_E doc Service Manual PAT DS150C TABLE OF CONTENTS 1 MECHANICAL DESCRIPTION OF THE 9 1 2 MECHANICAL AND ELECTRICAL DESCRIPTION THE CENTRAL UNIT 2 2 1 BASIC ADJUSTMENT OF THE HARDWARE 2 3 DEFINITIONS u lU UU 4 LE 6 4 1 DRAWING 1 CENTRAL UNIT 024 150 061 005 SPARE PARTS 9 6 4 2 DRAWING 2 CONSOLE 050 150 060 006 SPARE PARTS LIST 8 4 3 DRAWING 3 CABLE REEL 068 208 060 013 LWG208 SPARE PARTS 5 10 44 DRAWING 4 CENTRAL UNIT ELECTRICAL DIAGRAM hne rr renis 12 4 5 DRAWING 5 CABLE REEL ELECTRICAL DIAGRAM 0
45. tion 11 Drawings 2 Correct No P Replace cable Faulty wiring in cable from central unit to console Yes i Ensure that wires are properly connected between CU X1 31 and console terminal 4 and between CU X1 32 and console terminal 3 Refer to Drawing 4 Section 3 Drawings Correct No Refer to Drawing 1 8 4 in Section 3 and Replacement Procedure 4 in Section 4 Replace connection board and reset pressure channel Ves AT REV E 8 23 01 GJ O 190052_E doc Troubleshooting Flow Charts 39 7 9 Interference Problem PROBLEM Interference from crane C START B 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 Yes l 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 No 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 No
46. tween X1 8 ground and X1 9 signal output voltage Voltage should be 3 125V 03 2 5V 459 1 875V 909 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 AT REV E 8 23 01 GJ O 190052_E doc 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 Gone past the maximum 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 je Slew to permitted area slewing zone no is not permitted load area Operating mode je Anon existing operating e Setthe 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 e 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 p
47. ve 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 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 E doc Error Codes 45 Error Code Error Case I Upper limit value in e Refer to E15 e EM 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 e Refer to E17 measuring channel length telescope 1 18 has been exceeded Reference and or e Refer to E19 e Refer to E19 defective program PROM is defective PROM PROM No 0 System program The system program in the svstem 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 Svstem 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
48. wise 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 clockw ise until it stops Recheck length and angle display Refer to Procedure 3 in Section 4 Procedure AT REV E 8 23 01 GJ O 190052 E doc 26 Service Manual PAT DS150C 7 4 No Display PROBLEM Blank console display with no warning light shown All crane moments have been stopped Start p Check fuses on CPU box Correct No b 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 If crane voltage is measured below 10V svstem will switch off Check crane power supply for faultv Correct No crane electric or if supply is too low Yes Measure voltage on the connection board between X1 30 12 24V and X1 33 ground This is an output voltage to the console Refer to Drawing 4 Central Unit Electric Section 3 Drawings Replace connection boa

PAT America, Inc. LOAD MOMENT INDICATOR SERVICE MANUAL

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