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DS-350 GW Service Manual

1. www skyazul com 301 371 6126 DS350GW Service 8 SERVICE MANUAL IPART vs350c cw DRAWING 4 Angle Sensor WG103 Assembly 064 103 060 002 N ITEM PART NUMBER DESCRIPTION QTY N 1 031 300 100 358 SCREW 6mm X 1 X 110 1 2 000 208 040 084 WASHER LOCK 8mm 1 3 000 207 010 064 WASHER FLAT 6mm 3 4 002 050 206 012 SCREW 6 X 12 HEX CAP 2 OVERALL DIMENSIONS 6 5 16 X 4 7 8 X 3 7 16 www skyazul com 301 371 6126 DS350GW Service Drawings DRAWING 5 Angle Sensor WG203 Adjustment 006 420 306 001 The angle shown in drawing below 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 and 60 To comply with the SAE J375 standards the displayed angle must be 0 0 to 2 0 of the actual angle www skyazul com 301 371 6126 DS350GW Service servic MANUAL PAT _ DRAWING 6 Anti Two Block Switch 031 002 060 011 157 c 149 2 5 oTt id www skyazul com 301 371 6126 INTERNAL SWITCH AND WIRING ARE INACCESSABLE DS350GW Service Drawings DRAWING 7 Pressure Transducer 044 213 060 001 5 02
2. DRAWING 8 Pressure Transducer Cable Assembly Part Number is depends cable length ITEM PART NUMBER QTY DESCRIPTION 1 051 300 100 197 1 CONNECTOR CANNON 4 50 PLUG 2 005 101 013 001 1 CONNECTOR ACCY HOUSING 16 PG 11 3 020 903 200 200 1 HARDWARE O RING CONNECTOR HOUSING 16 4 125 429 900 400 1 CONNECTOR ACCY DUST COVER PLUG END 16 5 021 441 090 711 1 STRAIN RELIEF PG11 BLACK GROMMET 6 031 300 100 447 1 SCREW 5mm x 5mm SLOTTED MACHINE 7 051 300 100 145 ft CABLE 4 0 5 D S ft LENGTH IS SPECIFIC TO MACHINE NOTE 5 www skyazul com 301 371 6126 DS350GW Service 11 22 SERVICE MANUAL PAT _ DRAWING 9 Jumper Cable Assembly for Extension 031 300 103 541 ITEM PART NUMBER DESCRIPTION QTY 1 051 300 100 145 CABLE 4 X 0 5 DS PER FOOT 000 501 022 060 CONNECTOR PLUG 6 PIN CONTACT 000 301 025 062 CONNECTOR ACCY INSERT 6 SOCKET FEMALE 000 301 025 061 CONNECTOR INSERT 6 PIN MALE 000 214 261 511 STRAIN RELIEF ACCY PG13 5 11 REDUCER 021 441 110 811 STRAIN RELIEF PG11 6mm GRN WHT OA N a Ll www skyazul com 301 371 6126 DS350GW Service Drawings 13 DRAWING 10 EPROM replacement in Central Unit 1 Remove cover from central unit CAUTION Before handling the
3. ai o ina 40 7 LOAD READING PROBLEM uuu uu u ono a e iu in E 43 8 BAD DATA TRANSFER BETWEEN CONSOLE 8 CENTRAL UNIT 46 9 INTERFERENCE PROBLEM lo O E 48 10 LIGHTBAR MALFUNCTION erret edi rne 49 ERROR CODE DISPLAY ee ee ei 51 REFERENCE GUIDE ener ere nt reece re ee eer k edes 58 www skyazul com 301 371 6126 DS350GW Service Mechanical Description 1 SECTION 1 MECHANICAL DESCRIPTION OF THE SYSTEM 1 0 MECHANICAL DESCRIPTION OF THE COMPONENTS 1 1 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 5V The output signal is 0 00 under 0 pressure to 1 00V at max pressure 4410psi 12 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 the angle of the boom A reeling drum drives a potentiometer which is the length transducer Part of the length transducer circuit is the length cable on the drum which is a two conductor cable screen and live It is co
4. 2 7 1 BB r o EB MP 21 EB ur EB vr 1s EB v 16 EB 1 mE X6 A pou T E 5 11 22 Si 11121011 12 VOLT SYSTEM BR 7 8 amp 9 INSTALLED 24 VOLT SYSTEM BR 7 8 9 REMOVED BR 00 BR 8 00 x2 U M q X3 BR 9 00 P10 MP_TEST POINTS 1 5V 11 GROUND 2 5V 12 5V 3 ANALOG MEASURING CHANNEL REFERENCE SOFTWARE 13 DIGITAL GROUND 4 ANALOG MEASURING CHANNEL REFERENCE SOFTWARE 14 9V 5 ANALOG MEASURING CHANNEL REFERENCE SOFTWARE 15 ANALOG GROUND AP 6 ANALOG MEASURING CHANNEL REFERENCE SOFTWARE 16 9 7 ANALOG MEASURING CHANNEL REFERENCE SOFTWARE 17 5V AP 8 ANALOG MEASURING CHANNEL REFERENCE SOFTWARE 18 5V 9 ANALOG MEASURING CHANNEL REFERENCE SOFTWARE 19 5V 9 1 COMPUTER GND 20 OPERATING VOLTAGE 9 2 CRANE GND 21 INPUT VOLTAGE 10 3V REFERENCE VOLTAGE www skyazul com 301 371 6126 DS350GW Service Theory 31 MODEL SN o o PAT DS350G PART 024 350 300 081 and 024 350 300 068 1 Crane Supply Voltage X1 1 8 1 4 GND V
5. EQUIPMENT SOLUTIONS qA DS350G GW SERVICE MANUAL SkyAzul 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 SkyAzul 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 SkyAzul SkyAzul reserves proprietary rights to all drawings photos and the data contained therein The drawings photos and data are confidential and cannot be used or reproduced without the written consent of SkyAzul The drawings and or photos are subject to technical modification without prior notice All information in this document is subject to change without notice r SkyAzul Inc gai 200 W Main Street Suite 2A Middletown MD 21769 EQUIPMENT SOLUTIONS Fax 301 371 0029 info skyazul com SkyAzul Equipment Solutions www skyazul com 301 371 6126 SkyAz l Equipment Solutions SERVICE MANUAL ps3soc cw TABLE OF CONTENTS SECTION 1 MECHANICAL DESCRIPTION OF THE SYSTEM 1 1 0 MECHANICAL DESCRIPTION OF THE C
6. AVNSIS TVLENPHS3HIG 1 Zv WAL 6 81 OF 1 230 168 8 WHIL 130 WVXYOSVIC SNIHIM OL 44424 7I3GOW 3NV312 NO SaNadaa 39vsn SLNANI TVLIOIG SLNANI 1YLI9IG 234 4 r ONNECTION BOARDI A101 24 350 30 0073 S M90SESd 1 NON 7 1i3H139O1 HUV 6 LL NOLLO3NNOO 5 YANNI GND I I I 1 vzl TH l EH O HOLIMS SSVdA8 SNOLLOINNOO 1d O OL TIOSNO MD OSE SA ATOSNOD M9 L OL VLVG NO WO t e AM SSVd Ad 4 10SNOD L S3ATVA HO 3ATVA QION31OS 190X001 414411 DS350GW Service 301 371 6126 www skyazul com SERVICE MANUAL PAT psssoc cw DRAWING 19 Electrical Diagram Cable Reel to Central Uni 22 M E an 0 JALLISOd 14406 ANVUD ar g 6X ang an lt Soa o NOLLO3NNO2 13 6 YANNI GND AS vt 934 0 WNOSIS 3 19NV 9x oz 10d 01 EM 1 8 os lt sis Sm lt ZAP za ER WOOG S HD m A aw aais 310N
7. 9 92 745 21 zal ud od 9 1 5 amo Q oe LUE IE 6 gt 905650 LINN 1WYLNAD o 5 a DS350GW Service 301 371 6126 www skyazul com 21 Drawings DRAWING 18 Electrical Diagram Console to Central Uni A100 MAIN BOARD 124 3 1HV2 310N 336 A00S 0 Q312 VH LIH IWNSIS H19N31WWOO8 viva LLINSNVAL ano I VHIN32 OL Shh ee AS E 9340 5 X 9 MEASURE PINS viva 3A 233 3NV32 0 ADVLIOA 3ALLISOd AlddNS 3NV32 I 9 10d N m OL AS y 100604 NIN TWNOISHIONST__ 7y 9 dN AS y aN 0 ov MEMORY EXTENSION 24 350 30 0001 TAGOW YVINDILYVd NOILOANNOD QN9 SL dW ASN S LY A0090 Sd 15 Y d Lv A0090 vd 15 2 NO T4nss24d AS 0 OL LIS S 4 dN NOLSId ANSWLSNrdv 33055339 42 AS OL 00570 TVNOIS 3H SSd3Hd S3ONV3 TVNDIS TANNYHO Z TONY WOO8 NIVW OL 24343234 dN AS p OL 00570 5 LNALNO MaldridWv 5 39304 AW sz MO Tag 38 32304 ON LNIOd OAZ 62 8 80 AS Z OL A0 0
8. I I d aiHs 4 4OLO3NNOO 1434 414V2 ISON W009 q lt S1IOA ci ix t3MOd DG O 2 eo S3ATVA HO AATWA GIONS 10S 1 Y43441 HOLSIS3H DS350GW Service 301 371 6126 www skyazul com 23 Drawings DRAWING 20 Electrical Diagram Pressure Transducer to Central Uni ano viva LLINSNVUL VLVG 3AI3233 OXY YULNI QN9 3NV32 an 0 39VL10A JAILISOd 3NV32 an oF 2 X Men t4 6X ano an lt z o x 2 0060 29120 06 _ ASz 93qSr AS v 930 0 IVN IS 319NV EX LEN S N 11 2 N 2 2 ATI OL NADAGSNFUI 10d Ninu 01 17 80 0 wm du 11 ON Y NOLSId zy Io xS 93058 rg 4 7m 8 TWNOIS 3H9NV lt 05 MD D OSE SE 4104 6 aunssaud 4 009 0 OALOVALIU J 2 Xe 4 H2 341 dod WE YJDNGSNVYL r aYuNssaud 8 don QNO 404 SL ISN S dN LY A00S 0 Sd Lsnrav l dN Lv 00570 td 15 IJDNOSNVYALNO 34 ON HLIM AS 0 OL 135 S QOY
9. a diode or resistor across terminals of spiking component Diode type such as 1N4001 can be used watch and connection for diode END p www skyazul com 301 371 6126 DS350GW Service 49 10 LIGHTBAR MALFUNCTION PROBLEM Lightbar is Malfunctioning START Remove console face from the enclosure carefully and connect the voltmeter with the positive probe to terminal X 8 1 and with negative problem to terminal X 8 2 The indicated voltage shall equal the crane voltage e g 12V 24 V CONSOLE Check crane electric fuse and wiring from crane electric supply Refer to Crane Manufacturer s Service Document Correct NO Y YES Y Connect a voltmeter with probe to console terminal X 7 1 and with probe to X7 2 The indicated voltage shall equal crane voltage e g 12 V or 24V Either LMI is not operational not switched on or defective No component on console board Check if LMI is powered and operational If not corrected replace console terminal board YES 1 Switch power off Disconnect lightbar connector and measure crane voltage between connector terminal A and B Wiring Defective or wiring is incorrect between terminal strip X7 and lightbar connector Check wiring or rewire connections Inspect and clean connector contacts Wiring Defective
10. 1V 1101G an Bc an C 198 zv Wual1 9 B 65 9 Ov WH3L 3 12 8 8 NYAL 130 15692 YVINDILYVd NOILOANNOD HOS WVYAOVIG Lvd OL 444434 lt 5 8 14GOW ANVYD NO I9YSN ne z TNT ZN got Nolo 6 an o gt o MO0S SG LINN 1V31N3O PI b 101 0 DR E 06 a x x if 9 9 2 ap S IAS e 1 17 0 EM e LN e i cw gt 672 q SLIOA 21 QN9 o N o lI SANTA HO SATWA GION3 OS 1000201 4144141 SNOLLOHINNOO 1d O OL JTJAASNVAL y ATONV dir 41 5 VSE SQ dAT1DNGSNVAL 319NV air dAT1PNGSNVAYAL 490404 DS350GW Service 301 371 6126 www skyazul com Theory SECTION 4 THEORY THEORY 1 Anti Two Block amp Shutoff Circuit z G 520 SHIELD s 2 C7 KON CABLE TERMINA CENTRAL UNIT RMINAL BOARD E NUMBER 4 TEST POINT ON MAIN BOARD www skyazul com 1 BRN e e BRN 3 LEVER LOCK
11. 208548 www skyazul com 301 371 6126 DS350GW Service SkyAz l Inc 200 W Main Street Suite 2A En Middletown MD 21769 Phone 301 371 6126 EQUIPMENT SOLUTIONS Fax 301 371 0029 www skyazul com info skyazul com
12. Disconnect the Black 1 and the Brown 11 wires from the slipring in the cable reel Measure the the resistance between the two wires with an ohmmeter Switch closed 4700 5000hms Switch open gt 1 slipring wires Refer to Drawing 1 Slip Ring Unit Section 11 Drawings Fault in wiring between junction box and cable reel Check for No damaged length cable and wiring Refer to Section 3 Length Cable Problem www skyazul com 301 371 6126 DS350GW Service Troubleshooting 39 5 ANTI TWO BLOCK PROBLEM continued Continued from previous page PREVIOUS PAGE Check Anti Two Block signal in central unit With ohmmeter measure between wire disconnected from terminal block X1 Pin 35 and Pin 34 Anti Two Block switch closed 4700 Ohms 50 Ohms Anti Two Block switch open gt 1 Megohm Refer to Drawing 3 Terminal Board Section 11 Drawings Faulty wiring between cable reel and central unit gt Check cable Yes Check main board function by installing a temporary resistor 4700 Ohms at terminal between X1 35 and X1 34 in central unit With resistor connected alarm should be inactive Defect on main board Replace main board and No reset pressure channel Refer to Section 7 Yes Y End www skyazul com 301 371 6126 DS350GW Service 40 SERVICE MANUA
13. E71 for Analogous to E71 for the Analogous to E71 for the E77 the relays 2 7 relays 2 7 relays 2 7 RAM www skyazul com 301 371 6126 DS350GW Service 56 E91 E92 93 code during lifting a load No data transmission from console to central unit See Section 8 and 9 Error in the data transmission from console to central unit See also Section 8 and 9 Error in the data transmission from central unit to console See also Section 8 and 9 www skyazul com SERVICE MANUAL PAT lt 5 ERROR ERROR CAUSE ACTION CODE Change of the operating The operating mode switch in the console was used during lifting a load a This causes no display b Interruption or accidental ground in the line from console electronics to central unit c Transmitter receiver module defective a Temporary interruption of the data line from console electronics to central unit b Transmitter receiver module defective a Temporary interruption of the data line from console electronics to central unit b Transmitter receiver module defective 301 371 6126 Lower the load and set the operating mode switch correctly to the code assigned to the actual operating mode of the crane a Check the connection between console electronics and central unit b If you find an accidental ground the transmitter module in the console electronics can be damaged You should therefore replac
14. EB EB DN v 2 ANNEL ZERO E ALL FORCES FORCE 1 REMOV CH 2 CONNECT DIGITAL A BLACK LEAD B RED LEAD 3 ADJUST P3 TO OBTAIN 500MV ON METER www skyazul com VOLTMETER TO M POINT ADJUSTMENT APPLIED TO THE FORCE AIN P C BOARD TO MP15 TO MP3 A READING OF 0 500 VOLTS 301 371 6126 DS350GW Service Theory THEORY 6 Main Boom Angle Measuring Channel 5 CENTRAL AJ TES CABLE REEL POINT CENTRAL TERMINAL AN ON MA UNIT TERMINAL 2 O BOARD gt 29 1 a MAXIMUM SIGNA 3 125V J ANGLE A Q ANGLE MIN SIGNAL TH 3 OR 15 CA POTENTIOMETER UNIT NUMB www skyazul com ON MAIN BOARD TERMINAL 500MV ANGLE MAX ANGLE SOTENTIOM R OTENTIOMETER ALL VO MEASUR 301 371 6126 DS350GW Service 30 THEORY 8 BASIC ADJUSTMENT AND VOLTAGE CHECKS SERVICE MANUAL lt 5 MEMORY EXT RAM SYSTEM EPROM Ws EB
15. EPROM discharge any static electricity from your body by touching a grounded point The EPROM could be damaged by static electricity 2 Remove the old DATA EPROM from the main board Be careful to pull the EPROM out without bending the legs Refer to drawing above NOTE The notch on the EPROM and in the socket determines the correct orientation of the EPROM Refer to the drawing below for correct EPROM locations 3 Carefully align the new EPROM legs with the socket and push the EPROM into place Be careful not to bend any of the legs 4 Install the cover and tighten screws 2 d making sure the rubber gasket is positioned correctly to prevent any moisture from entering the k SZA central unit x Tm d New u X y ON Iw CI CI CI CI CI CI CI CI CI CI CI www skyazul com 301 371 6126 DS350GW Service 14 SERVICE MANUAL PAT lt 5 DRAWING 11 Main Board Piston amp Rod Pressure Channel Zero Point Adjustment oR c M NO MEMORY EXT KO 5 RA
16. Swingaway Extension Electrical Diagram RECEPTACLE CONNEC EXT BASE SECTION CAB Ps www skyazul com 301 371 6126 DS350GW Service Drawings 19 DRAWING 16 Tele Swingaway Extension Electrical Diagram ELE RECEPTACLE www skyazul com GROL ND MAIN EXTENSION BOOM NOSE AY EXTENS ON J i RED 301 371 6126 CONN AND C TOR DS350GW Service SERVICE MANUAL PAT lt 5 20 e ano UNS an 0 JAILISOd 3NV32 7 6X Rud UE anc 43HLA901 JAV 3 LL p gm d cams H3NNI i x p g 9 06 1 t 1VNOIS 319NV 8 woog r m 1 C 2 e NN SNOLLOsNNOO 9X7 e9 dW lt b ions 0 E 104 NHN 01 HLONAT e e e gt SE 28 87 8 TYN IS STONY gt E e 3 88 4 s n ois 6 6 aw aais K 134 318V2 31ON 33S L 24 918 OL x gr AS faynssgud 4 L Z AS A008 0 Q312VH13H gt eo VN IS HL9N31WOO8 y QNO ZL 11 ax HI i R1 BOVRAL
17. System is faulty START Check to see whether 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 2 Anti Two Block Junction Section 11 Drawings No Plug appropriate plug into socket of junction box Yes v Remove jumper dummy plug and check function of Anti Two Block switches with ohmmeter between wires 1 and 2 of switches Safe condition 0 Ohm Block to block gt 1 Megohm Correct No Replace Anti Two Block switch Yes v Next Page www skyazul com 301 371 6126 DS350GW Service 38 SERVICE MANUAL PAT psssoc cw 5 ANTI TWO BLOCK PROBLEM continued Continued from previous page PREVIOUS PAGE Disconnect wire from terminal block 1 35 in Central unit At boom nose junction box measure between terminals 1 and 13 with ohmmeter Check switch condition and campair Switch closed 0 ohm Switch open gt 1 Megohm Refer to Drawing 3 Terminal Board Section 11 Drawings Reconnect wire from terminal block X1 35 in Central unit Some No Fault in wiring between switch and junction box Check wiring Yes Next measure the A2B signal in the cable reel Connect jumper cable dummy plug
18. a Cable leading from the a Check cable as well as value for the measuring central unit to the sensor of connectors and replace if channel 7 channel 7 defective loose or necessary water in the connectors b Replace sensor of channel 7 b Sensor of channel 7 and reset adjustment defective c Replace main board and reset c Electronic component in pressure channels the measuring channel 7 defective m eee oo a voltage main board defective pressure channels No analog voltages a The crane supply voltage is a Check crane voltage too low b The voltage converter is b Check supply voltages defective or short circuit in the wiring Upper limiting value for a Cable from central unit to a Check cable Replace if the measuring channel the length angle sensor necessary See Section 6 length exceeded defective or loose b Replace and reset length b Length potentiometer potentiometer defective c Replace main board and reset c Electronic component in pressure channels the measuring channel defective on main board Upper limiting value for a Cable from central unit to a Check cable as well as plug the measuring channel the pressure transducer Replace if necessary pressure piston side defective loose or water in b Replace pressure transducer exceeded the plug and reset pressure channels b Pressure transducer on c Replace main board and reset piston side defective pressure channels c Electronic co
19. aas aos ASY 5 4 008 0 319 1VN9IS HLONST WOOS cal eN 7 MEMORY QNO SL dW3sn S dN LV 009 0 Sd v dN LV 1006570 vd 15 H3OnGSNVHI NO 155484 ON HLIM AS 0 OL 135 S V dW NOLSId 404 lt 333nSS33d ONJZ _ AS Y OL 00670 39NVY TVNOIS 81155484 EN 33nSS33d 0133334 dN 6 OL A00S 0 J0NVA TVN IS LNdLNOo MWalaridWv YSONGSNVAL 32403 HL9N31 5 d OL TIONV y HDD OSE SQ 3NIHOVIN T4GOM 214123645 AHL WV39VIG 9NIHIM 33S NOILO3NNOO Wood 7 62 8 8c AGZ OL 00 AW InoHs GRO ON 1004 2 5 4 1 I SLNdNI u a o 5 o aa zz sh o ue x A101 TA4GOW NO 5 24 350 30 0073 CONNECTION BOARD a S1 NI an 0 MDOSESG LINN 1V3 1N32 TVNOIS t Nid IVNSIS HL9N371 Z Nid AS 298 QN9 7 S 91 ASSV LHSISM 1 1 M evans 1
20. block between Pin 1 12V and Pin 2 crane ground Fault in wiring between terminal block X1 and NO console board Check wiring Yes Y Replace console board C End 2 www skyazul com 301 371 6126 DS350GW Service SERVICE MANUAL PAT psssoc cw 36 4 NO DISPLAY continued Continued from previous page Previous pace Disconnect ribbon cables from X2 and X3 of main board Measure voltage out of power supply between MP15 ground analog and MP1 5V MP15 ground analog and MP2 5V MP 13 ground digital and MP12 5V MP 15 ground analog and MP 18 5V MP15 ground analog and MP19 5V MP are test points on main board Refer to Drawing 4 Main Board Section 11 Drawings Short circuit in external wiring Check external wiring of system for defects No pi Yes Y Measure voltage at console terminal block between Pin 1 12V and Pin 2 crane ground Refer to Drawing 5 Console Board Section 11 D ratings Fault in wiring between terminal block X1 and console board Check wiring Refer to Drawing 5 Console Board Section11 Drawings No Yes v Replace console board i C end DS350GW Service 301 371 6126 www skyazul com Troubleshooting 5 TWO BLOCK PROBLEM PROBLEM Function of Anti Two Block
21. by disconnecting hydraulic pipes from transducer Measure between test point MP15 ground and test point MP4 Signal should be 0 50V piston side Measure between test point MP15 ground and test point MP5 Signal should be 0 50V rod side Refer to Drawing 4 Main Board in Section 11 Drawings Measure voltage between test point MP15 ground and test point MP4 and reset with P4 to 0 50V piston side Measure voltage between test No point MP15 ground and test point MP5 and reset with P5 to 0 50V rod side If not adjustable replace transducer Refer to Drawing 4 Main Board in Section 11 Drawings Yes Y Check hydraulic input vs transducer outputs No Check hydraulic system Yes END p www skyazul com 301 371 6126 DS350GW Service 46 SERVICE MANUAL IPART npss50c cw 8 BAD DATA TRANSFER BETWEEN CONSOLE amp CENTRAL UNIT PROBLEM Error Code E93 E94 No data transfer to and from console C START Make sure that Data EPROM is plugged into main board socket D5 and System EPROM is plugged into main board socket D4 Check that EPROM s are inserted with notch on EPROM to matching notch on socket Refer to Drawing 4 Main Board Section 11 Drawings Correct No gt Place EPROM in correct socket Yes v Check power supply to console between console terminal 2 g
22. radius or above the angle angle given in the load chart exceeded given in the load chart due to raising the boom to far Maximum radius or The maximum radius or Raise boom back to a radius or minimum angle range minimum angle given in the angle given in the load chart exceeded load chart was exceeded due to lowering the boom too far Prohibited slewing Slewing range prohibited with Slew back into admissible range range no load area load Operating mode not Operating mode switch in the Set operating mode switch available console set incorrectly correctly to the code assigned to Operating mode is not the operating mode of the crane permissible with actual crane configuration Length range not Boom has been extended too Retract or extend boom to correct permitted far or not far enough Length length given in the load chart sensor adjustment changed i e length sensor cable slid off the cable drum range with luffing jib angle specified n the specified in the load chart operation respective load chart due to luffing out the jib too far No acknowledgment Overload relay is stuck Replace relay signal from overload defective or not being relay K1 selected No acknowledgment Anti Two Block switch relay is Replace relay signal from Anti Two defective or not being Block switch relay K2 selected Fallen below limit for a Cable between length a Check cable and connector as the measuring channel sensor and c
23. to Drawing 1 in Section 11 Drawings Remount cable reel to the boom Turn reeling drum clockwise to spool the new cable neatly onto the drum Set preload on cable reel by turning the drum counter clockwise 5 to 8 turns Wrap the new length cable around the boom tip anchor pin 4 or 5 wraps and secure with tie wraps Leave enough length cable to connect into the boom tip junction box Connect the length cable into the boom tip junction box Refer to Drawing 1 in Section 11 Drawings Reset length potentiometer in length angle transducer screw is located in center of white gear with boom fully retracted turn potentiometer carefully counter clockwise until it stops Recheck length and angle display Refer to Drawing 6 in Section 11 Drawings www skyazul com 301 371 6126 DS350GW Service Troubleshooting t 35 4 NO DISPLAY PROBLEM Blank console display with no warning light shown All crane moments have been stopped C Start v Check fuses on CPU box Correct Replace fuses Yes Measure crane voltage on connection board between X1 2 UB and X1 4 ground Refer to Drawing 3 Terminal Board Section 11 Drawings NOTE If crane voltage is measured below 10V system will switch off Check crane power supply for faulty crane Correct No electric or if supply is too low Measure voltage at console terminal
24. 0 volts 500 on meter Rod Pressure Channel Zero Point Adjustment Disconnect hydraulic hose from the rod side pressure transducer Connect a digital voltmeter to main p c board black lead to MP15 red lead to MP5 Adjust P5 to obtain a reading of 0 500 volts 500 on meter Reconnect hydraulic hoses to pressure transducers then bleed the air from hydraulic lines www skyazul com 301 371 6126 DS350GW Service Theory THEORY 4 Rod Side Pressure Measuring Channel 3 CENTRAL UNIT TERMINAL BOARD 1 5 0 OINT TEST SIDE 27 v V REFERENCE x1 X1 y CENTRAL UNIT TERMINAL BOARD 1 28 9 0V 20 OV 2 2 26 2 WIRE NUMBER MIN TEST POINT ON MAIN BOARD ORCE TRANSDUCER 5 2 22 AL 7 DOIN ZERO OIN r 2 SHOULD BE BELOW k ES 29 5 a e gt 3 par SIG gt 3 2 KU TEST POINT KMD ZERO 3 V AGES ADJUSTMENT Al VOLTAGES ARE M REFERENCE TO TERMINAL 15 EXC JIFFERENTIAL OUTPUT NAL AT X1 28 29 2 ON TERMINAL BOARD www skyazul com 301 371 6126 DS350GW Service 28 RAM DATA EPROM SYSTEM EPROM SERVICE MANUAL PAT psssoc cw 15 KT A X9 2 m e i v o
25. 1516171 8 TRUS T PISTON ROD mi 94 1 PRESSURE PRESSURE ae lt 1 2 2172 N FN 5 gt X8 1 12 TRANS TRANS a o 2345678910 TO CABLE REEL TN NOTES CRANE SYSTEM D Be DOUTER SHIELD GROUNDED AT STRAI TL RELIEF CONNECTOR ah Z gt INSULATED WIRE SOLDERED TO INNER 4 31 2 SHIELD AND CONNECTED AS SHOWN BINNER SHIELD CUT OFF AND TAPED i E gt OUTER SHIELD CUT OFF AND TAPED 5 gt GW CONSOLE IS WIRED AS SHOWN AREA_ DEFINITION DIODE IS CONNECTED WITH FASTONS SWITCH AND WIRES 8 amp 9 POWER THE LIGHTBAR CONSOLE WILL USE ONLY WIRES 1 7 WIRES 1 4 6 ARE THE SAME AS THE GW WIRE 5 TO X1 45 AND WIRE 7 1 44 www skyazul com 301 371 6126 DS350GW Service 8 sevice MANUAL PAT psssociow _ DRAWING 13 Cable Reel Electrical Diagram E 57 N ENTRA O CENTRAL U X a P 10 SOCKET PLUG 5 a P RESISTOR OUTER SHIELD GROUNDED AT STRAIN RELIEF CONNECTOR NSULATED AND CONNECTED NSULATED AND CONNECTED SED AND POTTED www skyazul com 301 371 6126 DS350GW Service DT DRAWING 14 A Frame or Swingaway Extension Electrical Diagram ROOSTER SHEAVE JIB OR EXTENSIOI GROUNDED Al CONNECTOR WIRED AND POTTED www skyazul com 301 371 6126 DS350GW Service 8 SERVICE MANUAL PAT psssociow _ DRAWING 15 Offset
26. 9 angle is between 1 875V 90 and 3 125V 0 The signal on terminal 10 length is between 0 500V retracted M B and 4 500V The signals from the pressure transducers are connected to terminal 16 rod side and terminal 21 piston side The signals on terminals 16 and 21 are between 0 00V OPSI and 1 00V max PSI www skyazul com 301 371 6126 DS350GW Service 2 4 3 0 3 1 3 2 3 3 3 4 3 5 3 6 3 7 Mechanical Description The signal from the force transducer is connected to the terminals 28 and 29 The signal between 29 negative output and 28 positive output is between 0 00V 0 force and 2 500V max force The inputs for the duty selection switches are the terminals 38 40 42 for positive signals or 37 39 41 for negative signals The input for the anti two block switch is terminal 35 Outgoing Signal The outgoing signal of the terminal board is the signal for lever lockout of terminal 48 In normal working conditions there are 12 volts at this terminal If there is an overload or anti two block condition the signal becomes 0 volts Furthermore all supply voltages for the transducers are going out via the terminal board BASIC ADJUSTMENT OF THE HARDWARE Length Ensure that the length cable tension is correct with fully retracted boom by turning the cable reel 5 to 8 turns counterclockwise Then remove cover form LWG and adjust counterclockwise the potentiometer to end stop A
27. CRIPTION SCREW 6M X 12 SOCKET CAP BRACKET MTG CABLE REEL ARM TWO SLOTS 6 NO PART NO 01 006 710 006 002 02 068 000 110 038 03 067 000 050 065 04 064 103 060 002 05 002 050 206 012 06 000 207 010 064 07 002 050 206 100 08 000 208 040 083 09 068 000 100 064 10 068 000 110 029 11 068 000 110 010 12 068 000 110 011 13 000 673 020 002 14 006 800 005 058 15 000 205 031 230 16 006 800 005 057 17 005 682 000 001 18 068 000 110 031 19 021 441 131 013 STRAIN RELIEF PG 13 5 8 12mm RED WHITE zx 1 A QO gla 1 co aa SERVICE MANUAL PAT psssoc cw SENSOR LENGTH TRANS LGE 100 KT200 LWG208 SENSOR ACCY GEAR WHEEL KT200 CABLE REEL SENSOR ACCY GEAR WHEEL T 50 CENTER SHAFT SENSOR ANGLE WG103 WASHER FLAT 6MM SCREW 6M x 100M SOCKET CAP WASHER LOCK 6MM SLIPRING 2 CONDUCTOR TERMINAL STRIP SPRING PACK W HOUSING KT200 LWG208 LWG221 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 COVER CABLE REEL KT200 CABLE REEL ACCY SCREW CABLE REEL COVER DRAWING 2 Cable Reel LWG208 www skyazul com 301 371 6126 DS350GW Service Drawings DRAWING 3 Length Sensor Assembly 006 710 006 002 A 068 000 110 058 SENSOR ACCY GEAR WHEEL OD 3 031 068 000 110 037 SENSOR LENGTH POT PRINTED CIRCUIT 27 BOARD POTENTIOMETER N 2
28. Check power supply and measure between test point Mp 15 ground to MP18 5 0v and between test point Mp 15 ground to MP2 5 0v If incorrect No power supply on main board defective replace main board and reset pressure channels Refer to Drawing 4 Main Board Section 11 Drawings Yes 1 Check power supply at transducer plugs Measure between B ground and A 5V Measure between B ground and C 5V gt Faulty wiring Check wiring of pressure transducer cable Yes 1 Check transducer signals in central unit Disconnect wire 4 of transducer cable from terminal block X1 Pin 21 signal piston side Disconnect wire No 4 of transducer cable from terminal block X1 Pin 16 single rod side Measure transducer signals 0 V between Pin 19 ground and wire No 4 piston and rod side transducer cable Refer to Drawing 3 Terminal Board Section 11 Drawings Faulty wiring Check wiring pressure transducer cable gt Transducer defective replace transducer and reset pressure channel Yes Y NEXT PAGE p www skyazul com 301 371 6126 DS350GW Service Troubleshooting 45 7 LOAD READING PROBLEM continued C PREVIOUS PAGE Reconnect wire No 4 from transducer cables back to terminal X1 Pin 16 rod side and terminal X1 Pin 21 piston side Without pressure in pipes check O point adjustment on main board
29. DC 2 Supply Voltage to Main Board X1 1 8 X1 3 GND VDC 3 Main Board Power Supply Reference Voltages 50 MV 9V Mp 14 VDC Mp 15 Ground Force Transducer 9 Mp 16 VDC Mp 15 Ground Force Transducer 5 Mp 17 VDC Mp 15 Ground Internal to Board Mp 19 VDC Mp 15 Ground Internal to Board 5V Mp 1 VDC Mp 15 Ground Internal to Board 5V 2 VDC Mp 15 Ground Jib Angle Length Angle Rod Piston Supply 5V 18 f VDCMp 15 Ground Piston 8 Rod Supply 5 12 SW VDC Mp 13 Ground Internal to Board 12V Mp21 7 VDC Mp 15 Ground Internal to Board 6 20 7 VDC Mp 15 Ground Internal to Board 4 Boom Length Mp 15 Ground for Meter Fully Retracted Ft VDC X1 10 DC Mp6 Fully Extended Ft VDC X1 10 DC Mp 6 5 Volt Reference Voltage VDC 1 11 5 Boom Angle MP 15 Ground for Meter Minimum Angle x VDC X1 9 VDC Mp8 Maximum Angle VDC 1 9 VDC Mp8 5 Volt Reference Voltage VDC 1 11 6 Pressure Transducers Mp 15 Ground for Meter Piston Zero Point VDC 1 21 VDC Mp 4 Rod Zero Point VDC 1 16 VDC Mp 5 5 Volt Reference Voltage VDC X1 13 amp 18 5 Volt Reference Voltage VDC X1 15 amp 20 www skyazul com 301 371 6126 DS350GW Service 32 SERVICE MANUAL PAT 5 TROUBLESHOOTING FLOW CHARTS 1 GENERAL FLOWCHART This section explains how to handle a problem that may arise with the PAT Load Moment
30. Indicator System PAT DS350G The procedures are easy to follow and are given in flowcharts on the following pages Start with the general flowchart below which will guide you to one of the more detailed flowcharts shown in this section START Y What s Wrong Rn Lever Lockout Activated Go to Section 2 EE ZZ Length Cable Problem di Go to Section 3 d No display Fi Go to Section 4 Function Anti Two Block o Go to Section 5 gt Wrong Length Displayed Go to Section 6 s Wrong Load Displayed gt Go Error Code Displayed Go to Section 8 9 10 Light Bar Malfunction IM M M LCS G Go to Section 12 Console 05350 is not Go to Section 13 Functioning www skyazul com 301 371 6126 DS350GW Service Troubleshooting 33 2 LEVER LOCKOUT ACIVATED 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
31. L psssoc cw 6 LENGTH READING PROBLEM PROBLEM Length reading incorrect Crane is not in out of load chart condition C START p Check mechanical adjustment of length potentiometer in cable reel When main boom is fully retracted adjust length potentiometer counter clockwise until it stops Refer to Drawing 6 Length Angle Transducer Section 11 Drawings Replace length potentiometer assembly Remove slip ring body from shaft remove gear wheel from potentiometer axle Unscrew mounting plate and remove potentiometer assembly from mounting plate Remove assembly wires form terminal block Connect new assembly to terminal block Reinstall mounting plate gear wheel and slip rings With boom fully retracted reset potentiometer by turning counter clockwise until it stops Refer to Drawing 6 Length Angle Transducer Section 11 Drawings Yes Y Check out clutch in big gear wheel of length transducer Extend and retract boom to ensure that clutch is not slipping on potentiometer axle Refer to Drawing 6 Length Angle Transducer Section 11 Drawings Replace the gear wheel clean potentiometer No axle Reset length potentiometer Refer to Drawing 6 Length Angle Transducer Section 11 Check power supply to length transducer on connection board terminal X1 Pin 8 ground and Pin 11 5V Refer to Dra
32. LMI a EPROM with system program defective b Electronic component on the main board defective a EPROM with system program defective b Electronic component on the main board defective The system program in the LMI does not correspond to a Replace system program EPROM b Replace main board and reset pressure channels a Replace system program EPROM b Replace main board and reset pressure channels Replace system program EPROM the programming in the data EPROM 0 RAM pressure channels Section7 Error in the external Internal defect in digital part Exchange write read memory write read memory of CPU CMOS RAM Replace main board and reset pressure channels See Section 7 rt mmm mmc Saga mms communications component pressure channels Section 7 Malfunction in the Internal defect in digital part Replace main board and reset monitored write read of CPU pressure channels memory Error in data memory Data EPROM on the main Replace Data EPROM Make board defective sure BR3 on the main board is installed Incorrect a Anti Two block relay is a Replace 1 relay acknowledgment of the stuck or defective b Check terminal board 1 Relay on the terminal b Anti Two Block relay is not A101 main board and ribbon board A101 being selected due to a break cables as well as replace on the terminal board A101 defective part if necessary main board or ribbon cables E72 Analogous to
33. M er 3 E EE BR 4 DATA EPROM E 6 B SYSTEM EPROM LOWER BOOM ALL THE WAY DOWN NO REST PRESSURE THEN DISCONNECT HYDRAULIC HOSE FROM THE PISTON SIDE PRESSURE TRANSDUCER CONNECT A DIGITAL VOLTMETER TO MAIN P C BOARD A BLACK LEAD TO MP15 B RED LEAD TO MP4 ADJUST P4 TO OBTAIN A READING OF 0 500 VOLTS 500 ON METER DISCONNECT HYDRAULIC HOSE FROM THE ROD SIDE PRESSURE TRANSDUCER CONNECT A DIGITAL VOLTMETER TO MAIN P C BOARD A BLACK LEAD TO 15 B RED LEAD TO MP5 ADJUST P5 TO OBTAIN A READING OF 0 500 VOLTS 500 ON METER RECONNECT HYDRAULIC HOSES TO PRESSURE TRANSDUCERS THEN BLEED THE AIR FROM HYDRAULIC LINES www skyazul com 301 371 6126 DS350GW Service Drawings 15 DRAWING 12 Central Unit Electrical Diagram Refer to Drawings 17 to 21 for individual component wiring CONNECTING BOARD 024 4350 300 073 a 09 a
34. NI tp XZ 1 X sx x 7 IA adhi b san iv O dol SE C t AP ZNIE r ranivaucosoaraienray MER NSsI4d ON HLIM AS0 OL 13S B9NVH TIVNSIS 7 S f NOLSId 20 SNVUL 5634 6L 1NAWLSNFGV J4NSSIAd ONJZ gt 02 OL A00S 0 1514 3 1611 ma 39NVMW TVNOIS 55344 31OSNOO x i B Sa fy OL I E SAAIVA HO JA IVA GION31OS 1N0M001 41 411 o 22 I 2 ONES L o po 01434534 4 Tana 2 5 Tm a a Ss ee 332nasNV li 398401 uw T 1 T i a MM E v r gt n 9 INO vivd an 0 mi 7 a MOlVNVdWOO mi AW SZ a9 azy 915 04 7 x INT 32304 ON LNIOd O33Z AF SIS lt gp woe sm ae j u m 1 h BIM zaa lt lt 6 8 dev 2 1 AHOLIMS AGM 1224 I 4 5 1 2 o i a AM C zr NYAL 98 si Zo E
35. OANNOO gt Aa ak es GT IHS GND g Mo090 93006 P fe 319 8 woog mi U EX Rex SN 0 9x q f gt 104 01 HON an AS Y L A00S 0 NIN TG 9 IVNSIS HLON31 5 8 8 ex 8 e 318 2 1 33S dog 6 fayunssaud 4 AD0S 0 991993134 7TIVNSIS HL9N31I NOO8 L 2 v b TWRES xz 0 x _ lt lt o t uve 00 A00 0 AN9 SL dN ISN LY 009 0 Sd Lsnrav LY A00S 0 td Lsnrav MSAINGSNVYL NO IONV IVNOISA S dN Y NOLSId P SNVUL 6544 ANAWLSNrdv 553 4 2 aais AS Y OL 005 0 ON HLIM AS 0 OL 13S NOLSId FONVA IVNOIS 553 558 6 s_al 319NV SHONVY TVN IS 7 TANNYHO I 5 NIVW OL d3733d pee OL A00S 0 AQUOS TVN IS LNALNO 2 I3II1dNV 32404 22 d 2 WOIVNVdWO2S AW SZ 38 azv 5 32804 ON LNIOd O33Z 62 82 ASZ OL I an o IVNSIS LNANI TVILLNISSH IG SLNdNI
36. OMPONENTS 1 2 0 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UNIT 2 3 0 BASIC ADJUSTMENT OF THE HARDWARE esses 3 SECTION 2 DEFINITIONS etree eet 4 SECTION 3 DRAWINGS u gins sa Slan ai or IDA 5 DRAWING 1 Cable Reel 068 208 060 013 LWG208 Spare Parts List 5 DRAWING 2 Cable Reel 206 6 DRAWING 3 Length Sensor Assembly 006 710 006 002 7 DRAWING 4 Angle Sensor WG103 Assembly 064 103 060 002 8 DRAWING 5 Angle Sensor WG203 Adjustment 006 420 306 001 9 DRAWING 6 Anti Two Block Switch 031 002 060 011 10 DRAWING 7 Pressure Transducer 044 213 060 001 11 DRAWING 8 Pressure Transducer Cable 2 11 DRAWING 9 Jumper Cable Assembly for Extension 031 300 103 541 12 DRAWING 10 Eprom replacement in Central Unit 13 DRAWING 12 Central Unit Electrical nenne 15 DRAWING 13 Cable Reel Electrical Diagram 2 2 16 DRAWING 14 A Frame or Swingaway Extension Electrical Diagram 17 DRAWING 15 Offset Swingaway Extension Electr
37. OU SOLENOID VALVE PONN A X1 49 25 L 5 2 S X MINIMUM RETRACTED gt 2 UNIT TERMINA 301 371 6126 BOARD OV UV 5 REFERENCE A OUTPUT ANE MANUFACTURER S CUMENTATION FOR OF LOCKOUT SIC 6 VOLTAGES DS350GW Service 26 SERVICE MANUAL vs350c cw THEORY 3 Piston Side Pressure Measuring Channel 2 CENTRAL UNI ERMINA o 0 4 WIRE NUMBER J TEST POINT ON MAIN BOARD N SIDE 2 LIFT CYLINDER Em gt gt DOSTA EPROM EPROM SYSTEM EPROM DP SYSTEM EPROM 4 aR 2 oy NJ 5 22 mm 000000 000000 8 2 BR 7 00 293 330000 BR 9 00 BR 9 00 Piston Pressure Channel Zero Point Adjustment 1 NOOO Lower boom all the way down no rest pressure then disconnect hydraulic hose from the piston side pressure transducer Connect a digital voltmeter to main p c board black lead to 15 red lead to MP4 Adjust to obtain a reading of 0 50
38. The horizontal distance from a vertical projection of the crane s center of rotation to the center of the vertical hoist line or tackle with rated load applied Indicator 100 to 110 RATED LOAD The load value shown on the applicable load rating chart of the crane for the particular crane configuration boom length boom angle or functions or these variables For radii outside those shown on the load rating chart the rated load is to be considered as zero ACTUAL LOAD The weight of the load being lifted and all additional equipment such as blocks slings sensors etc Also referred to as working load Indicator 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 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 www skyazul com 301 371 6126 DS350GW Service Drawings SECTION 3 DRAWINGS DRAWING 1 Cable Reel 068 208 060 013 LWG208 Spare Parts List S www skyazul com 301 371 6126 DS350GW Service QTY DES
39. V NO 1519 303 z 006 A100 0 6 OL 0050 39NV3 TVNIIS 2465538 DAVS SHONV3 IVNOIS WOO NIVW 2413334 JONVA IVNOIS LANdLNO YADNGSNVUYL 39401 dN ASY OL A00S 0 AW sz lt LNIOd ON3Z 62 9 820 2 OL 1VN9OIS LNANI TVILNRI3441G 51 4 TYLIOIG DAVS CONNECTION BOARD AdIS NOLSId YAONGSNVaL 455444 t Ws Zv NHL x i N TAGOW YVINDILYVd NOLLO3NNOO 401 WVYDVIC Lyd OL 33333 TAGOW 3NV32 NO 39vsn A101 24 350 30 0073 SLON 21 oa an 0 x ENNI MD 21 1 SAANTWA 3NTVA CIONA10OS 1N0x001 414 411 DS350GW Service 301 371 6126 www skyazul com SERVICE MANUAL psssoc cw DRAWING 21 Electrical Diagram Jib Angle and Force Transducer to Central Uni 24 Vivd LLINSNVA L I Vivd 3AI3233 IV81N39 3NY32 an 0 39V1 10A JAILISOd AlddNS 3NV49 O See PX 4 4 He A gt 4 t vt L an 6X auo an 04 z mi HLA OS O x 2 IX NOIL
40. Yes _ If Load Moment Limit Light If console display is Fault in crane electric blank fault is located in Fault in Anti Two 10 displays fault is located or hydraulic system power supply wiring or Block system in LMI cables wiring fuses fuses or console Check lever lockout Go to Section 4 Go to Section 5 Read po system in crane on iis bn go to ection 10 DS350GW Service www skyazul com 301 371 6126 34 SERVICE MANUAL PAT psssoc cw 3 BROKEN LENGTH CABLE PROBLEM Damaged or broken length cable Replace length cable using the following procedure 1 2 3 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 slipring connection Refer to Drawing 1 in Section 11 Drawings On the back side of the cable reel open the strain relief attached to the axle in the center of the drum Pull existing length cable out of the cable reel Pull new length cable through the hole pipe and strain relief and push it through the axle of the reeling drum Tighten strain relief to ensure sealing Reconnect the length cable to the slipring Refer
41. al 0 5 and 4 5v Refer to Drawing 3 Terminal Board Section 11 Drawings Correct No q Faulty wiring between central unit and length transducer Check wiring Yes Y 4 NEXT PAGE www skyazul com 301 371 6126 DS350GW Service 42 SERVICE MANUAL PAT lt 5 6 LENGTH READING PROBLEM continued Continued from previous page PREVIOUS PAGE Measure length signal of amplified output on main board between test point MP15 and test point MP6 NOTE Negative signal at terminal X1 Pin 15 will be converted into positive signal at MP6 i e input at terminal X1 Pin 15 0 5V output test between MP15 and MP6 0 5v Refer to Drawing 4 Main Board Section 11 Drawings Main board defective Replace Main board Reset 2 we pressure channel Refer to Section 7 Yes END 2 www skyazul com 301 371 6126 DS350GW Service Troubleshooting 7 LOAD READING PROBLEM PROBLEM Load reading incorrect START p Y Check selected operating mode code on operating mode switch Select operating mode switch to correct position No gt see operating mode in load chart 4 Yes v Check boom length reading on display Reset length potentiometer With fully retracted boom turn potentiometer No axle counter clockwise until it stops see S
42. d with fast ons On the housing is mounted an override switch to override 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 which is mounted on the lower mid Description of the Boards Inside the central unit there is one board The main board and the terminal board are two separate boards connected by a pair of ribbon cables Power and are also connected from the terminal board to the main board The wires from the various components are connected with fast ons to the terminal board 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 mounted on this board that control the lever lockout s A power supply prepares all the necessary voltages for the transducers and the electronics on the main board An analoque input part which receives and prepares all the signals from the transducers for further processing An analoque digital converter converts all the processed analogue signals into digital ones A digital circuit contains 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 9 angle and terminal 10 length The signal on terminal
43. e the console electronics Replace console electronics or main board respectively a Check the connection between console electronics and central unit a Check the connection between console electronics and central unit b Replace console electronics or main board respectively DS350GW Service Error Code 57 ERROR ERROR CAUSE ACTION CODE E94 No data transmission a Interruption or accidental a Check the connection from central unit to ground in the line from between console electronics console console electronics to central and central unit If you find an unit accidental ground the b Transmitter receiver transmitter module in the module defective console electronics can be c Data EPROM defective damaged Replace the console d CPU defective electronics e Electromagnetic b Replace console electronics interference when switching or main board respectively contractors or valves c Check data EPROM d Replace main board e Eliminate interference source by inverse diodes or varistors Error in the crane data a Data EPROM defective a Replace data EPROM b EPROM b Position of jumper for the Check the jumper position c selection of the type of Replace main board and reset EPROM is wrong pressure channels c Electronics component on the main board defective Error in the internal CPU or main board of the Replace console main board amp RAM of the CPU of the console de
44. ection 3 and 6 Refer to Drawing 6 Length Angle Transducer Section 11 Drawings T Yes v Measure radius and check with the displayed radius Check if mechanical adjustment of angle transducer is correct Angle transducer No box should be in line with boom and adjusted to actual boom angle Refer to Drawing 6 Length Angle Transducer Section 11 Drawings YES 1 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 Refer to Drawing 3 Terminal Board Section 11 Drawings b Check power supply and measure between test point Mp 15 ground to MP18 5 0v and between test point Mp 15 ground to 21 5 0 If incorrect power supply on main board defective replace main board and reset pressure channels Refer to Drawing 4 Main Board Section 11 Drawings Yes Y NEXT PAGE Fs www skyazul com 301 371 6126 DS350GW Service 44 SERVICE MANUAL IPAE lt 5 7 LOAD READING PROBLEM continued Pervious Page Y 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 45 0 Refer to Drawing 3 Terminal Board Section 11 Drawings
45. entral unit well and replace if necessary length defective not connected or Section 6 water in the connectors b Replace and reset length b Length sensor sensor Potentiometer See Potentiometer defective Section 6 c Electronic board in the c Replace main board and reset measuring channel defective pressure channels Fallen below angle Fallen below the minimum jib Luff in the jib to a radius or angle www skyazul com 301 371 6126 DS350GW Service 52 Fallen below lower limit value for the measuring channel pressure transducer piston side Fallen below lower limit value for the measuring channel pressure transducer rod side Fallen below lower limit value for the measuring channel force Fallen below lower limit value for the measuring channel angle main boom Fallen below lower limit value for measuring channel Luffing Jib Angle www skyazul com SERVICE MANUAL PAT psssoc cw ERROR ERROR CAUSE CODE a Cable leading from the central unit to the pressure transducer defective loose or water in the connector b Pressure transducer on piston side defective c Electronic component in the measuring channel defective a Cable leading from the central unit to the pressure transducer defective loose or water in the connector b Pressure transducer on rod side defective c Electronic component in the measuring channel defective a Cable leading from the cen
46. ents on main board Replace main board and reset pressure channel See Appendix A Or Defect in connection board Replace connection board Correct No Yes END www skyazul com 301 371 6126 DS350GW Service 8 service MANUAL PAT psssociow _ 9 INTERFERENCE PROBLEM PROBLEM Interference from crane START 2 electric Error Code E93 E94 1 intermittent Frozen console displays Check system out refer to Section 8 Bad Data Transfer Between Console amp Central Unit Correct No Y Replace or repair part which is defective Yes 1 Check if additional ground link between main board terminal X9 and central unit box mounting bracket is in place Refer to Drawing 4 Main Board in Section 11 Drawings Install ground line single cable minimum of AWG14 2 0mm between No gt terminal X9 1 and central unit box mounting bracket Refer to Drawing 4 Main Board in Section 11 Drawings Yes Y Ensure that cable shields are connected correctly Refer to connection and wiring diagrams Drawings 9A B C Section 11 Drawings Make correct shield connection Refer to connection and wiring diagrams Drawings B C Section 11 Drawings Yes Y Find out which component of the crane electric is spiking out e g dump valve outrigger relay Install
47. fective Appendix A console Error in the external a External RAM of the a Replace console main RAM of the CPU of the console defective board b Replace console console b Electronic component main board the main board defective Wrong jumper position a The jumper position BR a Check the jumper position in the console 9 BR 10 in the console does b Replace console main not correspond to the actual board type of central unit b Electronic component on the main board defective www skyazul com 301 371 6126 DS350GW Service SB servic MANUAL PAT nsssoc ow REFERENCE GUIDE Use the table as a quick reference for measuring supply and signal voltages for the sensor channels that are specific to the error code listed Signal Voltage Terminal 1 Error Code Channel Pin ground Pin supply __ 8 n 11 21 11 j Lengh 12 22 a Pressure Piston side E13 23 Pressure Rod side 15 25 5 AngeManbom 8 26 6 Angle Jib Signal Voltage Terminal Board Amplified Signal Terminal 1 on main board use MP15 GND Error i i and MP supply Code Channel I Voltage VDC voltage 0 5 4 5V E11 21 1 Length 8 10 05 45 6 12 22 2 Pressure Piston side 8 21 0 7 MB E13 23 3 Pressure Rodside 8 16 0 7 15 25 5 Angle Mainboom 8 9 1875 3 125 8 E16 20 6 Angle Jib 8 24 18 5 34125 9 Ear t 1 7 j
48. hz o m S gt a nw gt _ N 22 gt gt o Z o Z gt a 0 a 9 gt gt 7 NNmaz zoo AL gt Z O gt Z Z BED 04 04 gt cu U ZZ I CN ONE amp N Z gt s C 1D 5 iO z O O OO IO Z Z Z F cT lt O 5 9 Ch 15608 Cy JS m cx od c0 09 TV 1l oe IPC lt 1 1 X11 fm A Ff S IO o s GN 45 21 EE pare ares dd J T T T TT I ue D JUMPER lt ms sr m c Ma M CN ala a O E a S SIE LI 2 2 UD gt I ue 00 v E 2 E 7 A 43 l t r Z 15 14 1 Lu L LI gt 11112 gt D 2 gt gt 2 KENE 11 gt gt I c 2 y JL IS 10AMP Ne Ne gt FUSE LMI 55 SWITCH TIN s Natl bara Ms EL H 5 1 AB CD ABCD CLO m 111213 4
49. ical Diagram 18 DRAWING 16 Tele Swingaway Extension Electrical Diagram 19 DRAWING 17 Electrical Diagram Console to Central Unit 20 DRAWING 18 Electrical Diagram Cable Reel to Central Unit 21 DRAWING 19 Electrical Diagram Pressure Transducer to Central Unit 23 SECTION 4 THEORY cs chee ee 25 THEORY 1 Anti Two Block amp Shutoff 25 THEORY 2 Length Measuring Channel 31 444 011 25 THEORY Piston Side Pressure Measuring Channel 2 26 THEORY 4 Rod Side Pressure Measuring Channel 3 27 THEORY 5 Force Transducer Measuring Channel 4 27 THEORY 6 Main Boom Angle Measuring Channel 5 29 THEORY 7 Jib Angle Measuring Channel 86 29 THEORY 8 BASIC ADJUSTMENT AND VOLTAGE CHECKS 30 5 TROUBLESHOOTING FLOW CHARTS 11 32 1 GENERAL LOV 2 iene 32 a NODISPLAY S Su E 35 5 ANTI TWO BLOCK PROBLEM eee cee 37 6 LENGTH READING PROBLEM
50. ing of the hook block It also has a warning light for anti two block conditions and an override switch for overload or anti block condition The console also has a toggle switch that engages digital inputs to identify various hoist options www skyazul com 301 371 6126 DS350GW Service 1 5 2 0 SERVICE MANUAL lt 5 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 this information from the crane we use micro switches that are installed in the electrical swivel and tells the system the location of the boom We also use micro switches on the counterweight that informs the system if the counterweight is installed or not where applicable MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UNIT All the data of the crane are stored inside the central unit in E Proms The central unit gets all actual information of the crane This is computed against the reference data and the crane status continually monitored 2 1 2 2 2 3 Description of the Housing The central unit DS350 has a rugged waterproof sheet steel 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 On the housing is mounted an override connecte
51. l unit to the jib angle sensor defective loose or water in the connectors b Jib angle sensor defective c Electronic component in the measuring channel defective a Cable leading from the central unit to the sensor of channel 7 defective loose or water in the connectors b Sensor of channel 7 defective c Electronic component in the measuring channel 7 defective a The total of the supply and the reference voltages on MP10 is more than 3 3V b A D converter defective 301 371 6126 a Check cable and connectors as well and replace if necessary b Replace force transducer c Replace main board and reset pressure channels a Check cable as well as connectors and replace if necessary Section No 6 b Replace angle sensor and reset adjustment c Replace main board and reset pressure channels a Check cable as well as connectors and replace if necessary b Replace jib angle sensor and reset adjustment c Replace main board and reset pressure channels a Check cable as well as connectors and replace if necessary b Replace sensor of channel 7 and reset adjustment c Replace main board and reset pressure channels a Check supply voltages b Replace main board and reset pressure channels DS350GW Service Error Code 55 ERROR ERROR CAUSE ACTION CODE E31 Error in the system program Error in the program run Wrong system program in the
52. mponent in the measuring channel defective on main board Upper limit value for the a Cable from the central unit a Check cable and connectors measuring channel to press trans defective not as well and replace if pressure transducer connected or water in the necessary rod side exceeded connectors b Replace pressure transducer b Pressure transducer on Replace main board and rod side defective reset pressure channels c Electronic component in the measuring channel defective www skyazul com 301 371 6126 DS350GW Service 54 24 Upper limit value for the measuring channel force exceeded Upper limit value for the measuring channel angle main boom exceeded Upper limit value for the measuring channel 7 exceeded Upper limit value for the measuring channel Luffing Jib Angle exceeded E25 E26 E27 29 E Reference voltage defective www skyazul com SERVICE MANUAL PAT lt 5 ERROR ERROR CAUSE ACTION CODE a Cable leading from the central unit to the force transducer defective not connected or water in the connectors b Force transducer defective c Electric component in the measuring channel defective a Cable leading from the central unit to the length angle sensor defective loose or water I the connectors b Angle sensor defective c Electronic component in the measuring channel defective a Cable leading from the centra
53. ngle Set the boom between 0 and 5 degrees and set the inclinometer to the boom angle 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 hydraulic hoses from the pressure transducers Measure and record the zero points of both pressure transducers on the terminal board X1 16 rod X1 21 piston Adjust P4 and P5 on the main board to 500 at test points MP4 and MP5 Connect hydraulic hoses back to the pressure transducers Bleed the air Duty Selection Switches Digital Inputs Check the duty selection switches for correct operation Check the voltage on digital input terminals Check the function of the hoist limit switch anti two block Check function of lever lockout Measure and record the power supply voltages www skyazul com 301 371 6126 DS350GW Service 4 SERVICE MANUAL lt 5 SECTION 2 DEFINITIONS N 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
54. nnected to the anti two block switch at the boom head and to a slip ring body in the LWG The angle transducer is fitted in 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 1 3 Anti Two Block Switch The anti two block switch monitors the load block and it s 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 To check the cable for damage short circuit to ground there is a 4 7k resistor between ground and the contact of the switch to give a signal back to the central unit The weight at the anti two block switch keeps the switch closed until the hook block strikes it 1 4 Console The console displays all geometrical information such as length and angle of main boom working radius and head height of the boom It also displays the actual load and the maximum load permitted by load chart Furthermore it has an alarm horn 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 reev
55. or wiring is incorrect between terminal strip X7 and lightbar connector Check wiring Correct No or rewire connections Inspect and clean connector contacts Yes v Continued on next page www skyazul com 301 371 6126 DS350GW Service 50 SERVICE MANUAL PAT lt 5 10 LIGHTBAR MALFUNCTION continued Previous Page 2 Measure voltage on console terminal X 7 3 and 7 4 Voltage will increase with increasing load moment and decrease with decreasing load moment NOTE voltage varies in relation to beam position therefore a voltage value cannot be given Ensure crane power is switched on Defective electronic components on console terminal board Replace console terminal board Correct No YES Y Measure voltage on lightbar connector between C and D Voltage should vary in relation to load moment as described previously Defect in wiring or incorrect wiring between Correct No console terminal 7 and lightbar connector Correct wiring YES Defect in lightbar electronic Contact factory service department for repair www skyazul com 301 371 6126 DS350GW Service Error Code 51 6 ERROR CODE DISPLAY PROBLEM Error code displayed Lever lockout activated Warning lights on CODE E01 Minimum radius or Fallen below the minimum Lower boom back to a radius or maximum angle range
56. round and terminal 1 12v Refer to Drawing 5 Console Board Section 11 Drawings Faulty wiring in cable from central unit to console gt Correct No Replace cable Yes Y Ensure that wires are properly connected between CU X1 31 and console pin 4 and between CU X1 32 and console pin 3 Refer to Drawing 3 Terminal Board Section 11 Drawings Refer to Drawing 5 Console Board Section 11 Drawings Defective electrical components on main board Replace main board and reset pressure channel See Appendix A Or Defect in connection board Replace connection board Correct No Yes Y p jJ www skyazul com 301 371 6126 DS350GW Service Troubleshooting 47 8 BAD DATA TRANSFER BETWEEN CONSOLE amp CU continued Continued from previous page PREVIOUS PAGE 2 Check power supply to console between console terminal 2 ground and terminal 1 12v Refer to Drawing 5 Console Board Section 11 Drawings Faulty wiring in cable from central unit to console Replace cable Correct No Yes 1 Ensure that wires are properly connected between CU X1 31 and console 4 and between CU X1 32 and console pin 3 Refer to Drawing 3 Terminal Board Section 11 Drawings Refer to Drawing 5 Console Board Section 11 Drawings Defective electrical compon
57. tral unit to the pressure transducer defective loose or water in the connector b Force transducer defective c Electronic component in the measuring channel defective a Cable from central unit to the length angle sensor defective or loose b Angle sensor defective c Electronic component in the measuring channel defective a Cable from central unit to angle sensor defective or disconnected or water inside the plug b Angle sensor defective c Electronic component in the measuring channel defective 301 371 6126 ACTION a Check cable and connector as well and replace if necessary b Replace pressure transducer and reset pressure channel c Replace main board and reset pressure channels a Check cable and connectors as well and replace if necessary b Replace pressure transducer and reset pressure channel c Replace main board and reset pressure channels a Check cable and connectors as well and replace if necessary b Replace force transducer c Replace main board and reset pressure channels a Check cable Replace if necessary See Section 6 b Replace angle sensor and reset adjustment c Replace main board and reset pressure channels a Check cable as well as plug replace if need be b Replace angle sensor c Replace Main board and reset pressure channels DS350GW Service Error Code 53 ERROR CAUSE ACTION CODE E17 Le NNNM below lower limit
58. wing 3 Terminal Board Section 11 Drawings Main board defective Replace main board and No reset pressure channel Refer to Section 7 Yes 4 NEXT PAGE www skyazul com 301 371 6126 DS350GW Service Troubleshooting 41 6 LENGTH READING PROBLEM continued Continued from previous page C PREVIOUS PAGE Measure supply to length transducer in cable reel at terminal between Pin 1 ground and Pin 3 5v Refer to Drawing 6 Length Angle Transducer Section 11 Drawings Faulty wiring between central unit and length transducer Check wiring Correct Yes Y Measure signal 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 remove potentiometer assembly from mounting plate Remove assembly wires form terminal block Connect new assembly to terminal block Reinstall mounting plate gear wheel and slip rings With boom fully retracted reset potentiometer by turning counter clockwise until it stops Yes 1 Measure signal from length transducer in central unit connection board between 1 8 ground and 1 10 sign

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