ds350mlatlmi - crane lmi systems
Contents
1. J5L0022 031 300 060 192 F9L0029 zi X1 BRN BRN A 5 A 1 1 A gt A 1 55 24v e eNO BLK 1 gLk 8 5 8 2 2 B gt B 2 16 gt DI 1 24V OVER DRIVE END o e NC WHT WHT 3 3 c gt d 3 18 gt DI 2 BLU BLU D gt gt D 4 4 D D 4 035 GND 5 da A 1 e 3 lt E 24V B 2 A GND gt c 3 5 TXD D 4 sp RXD gt E 5 7 A2B RELAY OUT F 6 8 A2B RELAY IN WG203 ANGLE SENSOR ae A diis d 064 203 060 007 F9L0021 190 X3 4 LA 1 1 a gt a 1 26 12V B 5 8 2 28 gt gt bB 2 29 gt SIG gt ANGLE Lito Se 3 c gt c 3 e28 lt GND NC 4 4 NC cz ov cubo Sy ANGLE CABLE ASSEMBLY 20 4X0 5 DS 031 300 060 177 F9L0025 X4 gt A 1 1 A ae 1 e 23 12V 2B I 2 B gt B 2 36 FORCE 1 SIGNAL gt C 3 3 c gt gt c 3 e 25 GND gt p 44 e 4 D gt gt bD 4 NOT CONNECTED E 5 5 E gt gt E 5 e 32 A2B GND gt F 6 4 L 6 EF gt gt F 6 e 31 gt A2B SIGNAL gt 6 7 7 G gt gt G 7 NOT CONNECTED e 24 FORCE 2 SIGNAL gt 8 L 8 H gt H 8 76 12V gt J 3 9 dl 9 30 SIG gt LUFF ANGLE E 10 K gt gt K 10 77 GND gt L NC NC gt 11 NOT CONNECTED gt M NC NC M gt2. Check connections and replace cable assembly from central unit to console Refer to Drawing 1 NEXT PAGE O PAT Rev 12 18 00 CSH 190118 DOC 22 Service Manual F 44T DS 350 Modular PREVIOUS PAGE Check if additional ground link between main board MP1 and central unit box mounting bracket is in place Refer to Drawing 4 Install ground line single cable minimum of AWG14 2 0mm NO between terminal MP1 and central unit box mounting bracket Refer to Drawing 2 and 4 YES Ensure that cable shields are connected correctly Check continuity in shielded cable assemblies Refer to connection and wiring diagrams Drawings 1 Make correct shield connection NO a 9 Refer to connection and wiring diagrams Drawings 1 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 1N4003 can be used watch and connection for diode Refer to Crane Electrical Diagrams F C END O PAT Rev 12 18 00 CSH 190118 DOC Drawings 13 DRAWINGS 13 1 PROXIMITY SENSOR ASSEMBLY 031 300 060 249 Electrical Wiring Drawing 1 Part 1 CABLE ASSEMBLY 14 4X0 5 DS CENTRAL UNIT 03 23 500 060 225 J5L0004
3. Check cable assembly between cable reel and CU for damaged cable Replace cable assembly Refer to Drawing 1 Yes O PAT Rev 12 18 00 CSH 190118 DOC 16 Service Manual F 44T DS 350 Modular 9 ANGLE SENSORS PROBLEM Angle displayed incorrect Crane is not in out of load chart condition Ne START Check the angle sensor for damages or movement of mounting bracket Refer to Drawing 1 and Adjustment Procedure 3 Replace angle sensor if damaged or adjustments can not be made YES Measure the crain power supply voltage in the central unit between terminals X1 1 12 24v and X1 2 ground Refer to Drawing 1 Check wiring between crane battery and central unit YES Y Measure the angle sensor supply voltage in the central unit between terminals X1 26 12 24v and X1 28 ground Refer to Drawing 1 NO Fuse blown or main board defective Replace main board Refer to Drawing 2 and Replacement Procedure 4 YES C NEXT PAGE O PAT Rev 12 18 00 CSH 190118 DOC Angle Sensor a pore Y Follow signal flow from angle sensor to central unit Refer to drawing 1 or 2 Measure sensor input voltage between wires X1 28 as Ground X1 29 has to be between 1 1V or 4mA 2909 and 5 5V or 20mA 02 Refer to Angle Sensor Theory 1
4. v Relay defective on the main Check lever lockout The fault is located in LMI cables board Replace main board system in crane wiring fuses or console Refer to Sect 14 Procedure 2 service manual Read error code displayed on Main board replacement console and go to Section 5 O PAT Rev 12 18 00 CSH 190118 DOC Anti Two Block 7 NO DISPLAY PROBLEM Blank console display with no warning light shown All crane moments have been stopped START D v Check fuses in central unit Corrected NO Replace fuses YES Y Measure voltage on the main board terminal strip between X1 1 12 24V and X1 2 ground This is an input voltage from the crane Refer to Drawing 1 Check crane power supply for faulty wiring in crane electric Corrected NO YES y Measure voltage on the main board between X1 3 12 24V and X1 4 ground This is an output voltage to the console Refer to Drawing 1 Replace the main board in central unit Corrected NO Refer to Drawing 2 and Replacement Procedure 2 YES y E NEXT PAGE O PAT Rev 12 18 00 CSH 190118 DOC 11 12 Service Manual F 44T DS 350 Modular a PREVIOUS PAGE Measure voltage in the console between X1 1 12 24V and X1 2 ground Refer to Drawing 1 3 8 6
5. Check connections of the cable between NO gt console and central unit Replace cable if necessary Refer to Drawing 1 in Section 13 YES v Console Display is defective Replace the console Refer to Drawing 1 and 3 C END D PAT Rev 12 18 00 CSH 190118_ DOC Anti Two Block 8 ANTI TWO BLOCK PROBLEM PROBLEM Function of Anti Two Block System is faulty C START Y Check to see whether or not crane is in two block condition Correct NO gt Lower hook down into safe position YES y Check by pass plugs installed and system cables connected Refer to Drawing 1 and 2 Plug appropriate bypass plug or system cable NO gt connectors into socket Refer to Drawing 1 and 2 YES Check anti two block weight and or flags whether installed correctly Refer to Operator s Manual Pre Operational Inspection and Calibration Install A2B weight or flag if not correctly NO installed YES nexmaes O PAT Rev 12 18 00 CSH 190118_ DOG 13 Service Manual F 44T DS 350 Modular PREVIOUS PAGE The A2B circuit supplies 9 volts to the circuit and a 4 7K resistor in the circuit modifies the return signal to 4 5 volts The computer continuously monitors this signal to ensure the signal is between for a 3 to 6 volt if
6. YES Y measure voltage between X1 36 and X1 25 or amperage at X1 36 voltage should be between 1 1 5 5 volt or amperage between 4 20mA Zero force on load cell equals 1 1V or 4mA Referto Drawing 1 Measure signals for main force transducer in the central unit Correct NO junction box and or force transducer Fault in cable assemblies cable reel boom tip go to next page YES Y Measure signal from the force transducer on analog input board measure voltage between X1 7 and MPO voltage should be between 0 5 4 5 volts Zero force on load cell equals 0 5V Referto Drawing 2 and 5 NO gt Analog Input board defective Replace analog input board Refer to Drawing 2 and Procedure 2 steps 1 2 4 11 12 PAT Rev 12 18 00 CSH lt NEXT PAGE 190118_ DOC Load Reading PREVIOUS PAGE D Check power supply to force transducer by unplugging the cable assembly from the force transducer Measure voltage at the cable connection between A 12 24v and C ground at the connector Refer to Drawing 1 in Section 12 Check linerider for any visual damages and check continuity in force transducer cable assembly A to A B to C C to B note the wiring of the connector junction box 5 socket to 14 pin A to D B to C and C to A e cable reel and cable assembly 14 pass connector
7. NS V NO PART NO QTY DESCRIPTION 01 050 150 300 050 1 BOARD 02 050 150 300 051 03 050 150 300 052 04 003 051 905 235 05 050 350 110 139 06 050 350 300 076 TERMINAL BOARD BOARD PUSHBUTTON SET KEYBOARDS SWITCH KEY KEY SPARE BOARD TERMINAL INTERFACE FOR LIGHTBAR O PAT Rev 12 18 00 CSH 190118_ DOG 28 Service Manual F 44T DS 350 Modular 13 4 Central Unit Main Board Layout Drawing 4 BOARD P N 024 352 300 001 ON MP26 MP4 MP9 MP8 XQ DI1 lt SIHRU e 9 DI6 Q Qv Y O PAT Rev 12 18 00 CSH MP1 KGND MP4 5V MP8 9V MP9 6V MP23 VBAT MP24 BATT MP25 UBS console sensors DI s MP26 GND LED S HO8 LOAD HO9 A2B H10 LOCKOUT on when K10 is lit H11 POWER H12 TxD FUSES F1 4A F2 10A DI 1 not used D1 2 rigging mode UB on DI 3 not used DI 4 not used DI 5 not used DI 6 not used 190118_ DOC Drawings 29 13 5 Central Unit Analog Input Module Drawing 5 BOARD P N 024 352 300 020 O PAT Rev 12 18 00 CSH X1 1 7 ADC INPUT 0 5V 4 5V Note If channel adjustments are made through the software and graphic console DO NOT adjust offset with P1 P7 X1 8 TEMP 0 5V 10mV C X1 9 VREFA 5 000V reference X1 10 AGND reference GND X1 11 VREF 5 0V power ADC X1 12 15 CH01 04 DIN1 4 10 X1
8. 20 TON 4 20mA gt MAIN A2B 127 047 020 060 044 ape due 031 300 100 507 J5L0001 B5L0023 B5L0023 PAT Rev 12 18 00 CSH 190118_ DOC Drawings 25 13 2 Central Unit Breakdown Parts List Drawing 2 The central unit is located in the cabin behind el the operator s seat shown with the lid removed The electronics consist of the mainboard with the following modules Mainboard Analog Input Module CPU Module w Data Module O PAT Rev 12 18 00 CSH 190118 DOC 26 PART NO 031 300 060 225 A Je Se Nue PART NO 024 352 300 001 024 352 300 020 024 351 300 007 024 351 300 016 000 304 140 112 000 304 140 241 031 300 050 170 031 300 050 171 024 350 100 661 031 300 101 131 024 000 100 095 24 350 050 292A 024 350 100 135 024 350 110 067 O PAT Rev 12 18 00 CSH QTY Ny aa sch sch LL X Service Manual F 44T DS 350 Modular DESCRIPTION MAIN BOARD ANALOG INPUT MODULE CPU MODULE EPROM MODULE RELAY 12V RELAY 24V FUSE 4amp auto F1 FUSE 10amp auto F2 KEYSWITCH SPARE KEY MEMBRANE ELEMENT BREATHER CENTRAL UNIT COVER SCREW SET FOR COVER GASKET 190118 DOC Drawings 13 3 Console Ds350 1334 Parts List Drawing 3 GRAPHIC CONSOLE PARTS LIST PART NO 031 300 060 170 amp et 2 OBS
9. EEPROM Faulty acknowledgment of relay K1 on the connection board O PAT Rev 12 18 00 CSH The CRC sign of the monitored write read memory is wrong The buffer battery is discharged lt 2V at 1kOhm Processor board defective Computer component 80C537 defective CPU module defective Processor board defective No valid data in the data EEPROM Memory module wrongly bridged Crane data EPROM defective Memory module wrongly bridged Crane data EEPROM defective Serial crane data EEPROM does not contain valid data Memory module defective No valid data in the serial analog data EEPROM LMI module s defective Load chart EPROM defective Base number not programmed Load chart EPROM wrongly programmed Relay K1 or main board defective 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 data EEPROM containing valid data Bridge memory module acc to memory type Replace crane data EPROM Bridge memory module acc to memory type Replace crane data EEPROM Write data on the serial crane data EEPROM by means of test program or on line function then restart the LMI Replace memory module Write data on the serial analog data EEPROM by means of the test program then restart the LMI Replace LMI module s Replace load chart EPROM Program
10. 0r3 OO NU SS 8 Fig 1 Components of the LMI system PAT DS 350 Modular O PAT Rev 12 18 00 CSH 190118_ DOG General Flow Charis 4 GENERAL FLOW CHARTS This section explains how to handle a problem that may arise with the PAT DS 350 Modular System The procedures are given in flowchart format for the following sections Start with the general flowchart below that will guide you to one of the detailed flowcharts shown in Sections 5 through 12 The drawings and procedures that are referenced in these sections can be found in Section 13 and 14 What s Wrong gt Error Code Displayed o b Go to Section 5 Lever Lockout Activated Go to Section 6 No display Go to Section 7 Anti Two Block Problem gt Go to Section 8 gt Angle Reading Problem gt Go to Section 9 Load Reading Problem gt Goto Section 10 gt Area Definition Indication Problem Goto Section 11 lte Soto Seaton 12 O PAT Rev 12 18 00 CSH 190118_ DOG 5 ERROR CODES Service Manual F 44T DS 350 Modular 5 1 Operating Errors E01 through E06 These errors are usually caused by operating in a way that is not allowed per the load charts Error Code E
11. 16 CHO5 UBS 10 X1 17 CH06 HESIN A2B 4 X1 18 CHO7 9V 4 X1 19 CHO8 VREFA 2 2 500V X1 20 UKLEMM app VREFA limits ADC input to 5 0V MP1 AGND MP8 5V MP1 7 Input channels 1 7 0 5V 4mA 2 5V 20mA MP14 13V REF02 MP16 HESIN input voltage MP17 app 5 4V clamp for inputs The analog input module converts the sensor signals on channels 1 7 to signals that will be processed at the CPU and software The incoming signal measured at the measuring points MP will be 0 5V 4mA 2 5V 20mA The analog input module then converts the channel signals to 0 5V 4 5V which can be measured on X1 1 through X1 7 The signal voltage can be measured at either point using ground and the signal input 190118_ DOC 30 Service Manual F 44T DS 350 Modular 13 6 Console Connection Board Drawing 6 MP2 Al IN Ur MPO on NG GND SCH _ NIDO ten OO NN gt lt O PAT Rev 12 18 00 CSH 190118_ DOC Drawings 13 7 Force Transducer Drawing 7 There are no spare parts associated with the force transducer 31 16 54 e 11 81 i Aj gt 1 S i MT UI 19 de 13 8 Area Definition Switch Drawing 8 PROXIMITY SENSOR ASSEMBLY 031 300 060 249 J5L0022 BRN e eNO BLK e e NC WHT BLU A BROWN 10 30VDC B BLACK NO UB LED ON C WHITE N
12. 2 0 of the actual angle PAT Rev 12 18 00 CSH 190118 _ DOC Procedures 37 14 4 Troubleshooting Moisture The PAT DS 350 LMI contains electronic components in various locations such as central unit sensors junction boxes etc These internal components cannot be designed to withstand exposure to moisture over a longer period of time For this reason the housings of the components are water protected according to IP 65 If you find water or moisture inside any of the housings the source for the water ingress has to be detected and corrected to ensure proper operation There are two major possibilities for the occurrence of excessive moisture inside an enclosure 1 Water ingress 2 Condensation This outline gives instructions for detecting the cause for excessive moisture by using simple troubleshooting methods and how to prevent the moisture ingress from happening again 14 4 1 Water Ingress There are 6 possibilities for water to enter an enclosure 1 Spray Cleaning 2 Missing Loose Screws 3 Bent Lid 4 Defective Gasket 5 Loose Strain Relieves 6 Water Entry Through External Cabling It is possible to find out the source of water ingress by going through the following steps and ruling out one possibility after the other until the cause is identified 1 Spray Cleaning The enclosures used for the PAT DS 350 system are water protected to IP 65 This means protection against the environment such as rain
13. 44 LA pD lt lt D 4 GND 2 e 2 5 E E 54 5 e lt Ce 5 CONNECTION TO i Ss S ON Pa SP 8a Leer 6 OR DRIVER FOR me WE lt SY We E EXTERNAL LIGHTBAR A2B OUT 6 e E FAO DE NOTE CONSOLE CABLE ASSEMBLIES LMI on 7 el ele 2 INCLUDED IN CONSOLE ASSEMBLY Dom 8 ej c c 3 2 LOCKWIRED TO CONSOLE 1 X8 a ene CABLE ASSEMBLY E Hed a ES ES S 10 7X0 5 SS SES 1 F F GND 20 YEL GRN e G gt gt G 7 er qu E E 7 6 MAIN BOOM TIP JUNCTION BOX 031 300 060 228 J5L0006 A 1 CONNECTOR gt e mE USED FOR TESTING Le 1 NOT USE IN NORMAL q OPERATION 2 3 l pis e gt A 1 1 A CABLE ASSEMBLY 4740 4 Zeal te 2 50 2X0 5 SS AA AA AMAN 5 zeae 5 Er 31 300 060 245 e 293250 4 4 p J5L0011 g gt gt E 5 5 E gt rae 7 AE 6 6 FO 1 a lt D 8 9 3 22 6 7 7 6 ec e a gt H 8 8 H ngi l q gt J 9 9 J EE Wu 2 K 10 10 K gt 11 nej AL L gt 12 M gt M M gt a 13 N gt N N gt t2 14 pi AP Pr A B L vL J if FEE CABLE REEL Ar LR 6 150 10X0 5 DS 3 ale alel co 031 300 060 227 DEW J5L0005 EN E vv JL YY el TAMAN I EE Hit a 2 123 iL ASE a BYPASS PLUG 15 4X0 5 SS 031 300 100 532 031 300 060 242 C4L0066 J5L0024 A SN me ma Me E 1 A X A 1 Es 2c Ce 2 0 lt g 5 c c s x Oo x Sek 7 IN FORCE TRANSDUCER
14. However through the use of spray cleaner at short distances it is possible to force water through the gasket or strain relieves For this reason avoid spraying any components from short distances with spray cleaners Convey this fact to any member of a maintenance crew 2 Missing Loose Screws All screws have to be present and to be equally tight to ensure water protection of the enclosure If there are screws missing replace them If no screw is missing check the tightness If any were loose then open all screws and then re tighten them equally 3 Bent Lid An enclosure will only seal correctly if the lid is not bent To check this loosen all screws of the lid take the lid off the box and visually inspect it for deflection If the lid is bent or damaged it needs to be replaced Try to determine what has caused the lid to be bent and eliminate the reason for that Order a new lid through your Link Belt or PAT representative 4 Defective Gasket PAT Rev 12 18 00 CSH 190118 _ DOC 38 Service Manual F 44T DS 350 Modular The gasket underneath the lid seals the unit The gasket needs to be in good condition in order to seal correctly If the gasket is torn brittle or severely bent it needs to be replaced Order a new gasket through your Link Belt or PAT representative 5 Loose Strain Relieves The strain relieves allow cabling to enter the box without allowing water to enter it The strain relieves have to be correctly ti
15. accepted safe crane operating procedures The responsibility for the safe crane operation shall remain with the crane operator who shall ensure that all warnings and instructions supplied are fully understood and observed Prior to operating the crane the operator must carefully and thoroughly read and understand the information in this manual to ensure that he knows the operation and limitations of indicator and crane Proper functioning depends upon proper daily inspection and observance of the operating instructions set forth in this manual Refer to Section Pre Operation Inspection and Calibration Verification of the operator s manual The LMI can only work correctly if all adjustments have been properly set For correct adjustment the operator has to answer thoroughly and correctly all questions asked during the setup procedure in accordance with the real rigging state of the crane To prevent material damage and serious or even fatal accidents the correct adjustment of the LMI has to be ensured before starting the crane Operation PAT Rev 12 18 00 CSH 190118 _ DOC 2 Service Manual F 44T DS 350 Modular 3 SYSTEM DESCRIPTION The PAT Load Moment Indicator DS 350 consists of a central microprocessor unit operating console angle sensor force transducer and anti two block switches The system operates on the principle of reference real comparison The real value resulting from the load measurement is compared wi
16. gt M 12 NOT CONNECTED gt N NC NC N N 13 NOT CONNECTED P NC NC P E 14 NOT CONNECTED CABLE ASSEMBLY 22 Ni4 60 aaa 24 10X0 5 DS 031 300 060 241 Aa e GER A2B RELAY IN J5L0008 59 gt LOAD RELAY IN KEY SWITCH d DI 2 X5 12V POWER 1 CABLE ASSEMBLY 1 a lt 1 e 1 lt 24V GROUND 2 14 7X0 5 SS 2 B 2 e 2 GND NOT CONNECTED 3 031 300 060 223 30 lt lt 3 3 NOT CONNECTED NOT CONNECTED 4 C4L0085 4 D 4 4 NOT CONNECTED 013 lt LB 4520 5 5 LE 4 amp E 5 12 P LockoUT RELAY GROUND 6 6 F 4 amp F 6 211 gt AR DEENERGIZED NOT CONNECTED 7 7 6 4 lt c 7 NOT CONNECTED K10 X1 NOTE ALL OUTER SHIELDS GROUNED AT STRAIN RELIEF INSERT WIRING DIAGRAM 031 PAT Rev 12 18 00 CSH 300 31 1281 REV C NOTE LOCKOUT RELAY ENERGIZED DURING NORMAL OPERATION 190118_ DOC 24 Service Manual F 44T DS 350 Modular Electrical Wiring Drawing 1 Part 2 CONSOLE 031 300 060 170 X7 TS i A des F9L0007 Dime mc uev cec AE s INTERNAL LIGHTBAR 2 8 lt lt s 2 2 BKC B 2 050 000 060 042 x1 pace es 031 300 060 180 e 68 F9L0040 F9L0018 C 12V 1 1 4 e D lt lt D
17. gt e 10 M Enge Le Se TO BOOM TIP JUNCTION BOX ITEM PART NUMBER 031 300 060 027 031 300 100 667 031 300 050 231 DESCRIPTION WY 6 606060 o inimlolo w 3100 uo lula a n wate ra KARA RA AA AN TO JUNCTIO BOK ON CABLE REEL JUNCTION BOX ASSY 80X70 LATTICE REEL SCREW 8 32X3 4 SOCKET HEAD CABLE REEL LATTICE MAIN BOOM QTY 10 00 33 1 40 397 1 2 3 4 031 300 110 095 CABLE ASSY 170 10 COND W 14 SOCKET PLUG GN PEN NOTES T gt OUTER SHIELD GROUNDED AT s RAIN RELIEF INSER All boom tip signals go from the central unit through this cable reel to the boom tip sensors and switches Refer to drawing 3 for schematics O PAT Rev 12 18 00 CSH 190118 DOC 34 Service Manual F 44T DS 350 Modular 14 PROCEDURES 14 1 Procedure 1 EPROM Location and Installation SS e Ensure the notch is in the correct direction e The DATA EPROM fills the bottom of the socket as shown by the arrows e Place EPROM s in the correct EPROM socket as shown O PAT Rev 12 18 00 CSH 190118_ DOC NSR Procedures 35 14 2 Procedure 2 Main Board Replacement Refer to Drawing 4 central unit parts list for board location 1 Turn system power off 2 Remove the central unit lid NOTE Take care not to damage the boards with the sc
18. module of the console electronics might be damaged Therefore replaces the console electronics Exchange console electronics or LMI main board resp Check the connection between console electronics and central unit Exchange console electronics or LMI main board resp refer to E92 e Check wiring to the console in case of accidental ground replace console electronics too e Check connection to the power unit e Exchange the LMI main board 190118 DOC Error Codes 9 ErrorCodelError Cause Elimination e Transmitter receiver module is e Replace console defective electronics or LMI main board e Computer module is defective e Replace processor board e Electro magnetic interferences e Eliminate the source of e g when switching contactors interferences by inverse or valves diodes or varistors Error in the console e The console EPROM is e Replace the console EPROM defective EPROM Error in the internal The CPU of the console is Replace the CPU of the RAM of the console defective console The console main board is Replace the console main defective board defective board Short circuit in the Short circuit in the A2B switch Replace A2B switch A2B switch circuit Short circuit in the cable to the A2B switch Replace cable to the A2B switch Error in the external The external RAM of the Replace the external RAM of the console console is defective RAM of the console The console main board i
19. the correct base number 1 for base 1 2 for base 2 Check base programming in the load chart EPROM Replace main board 190118 DOC Relay should be energized but the 2nd contact is signaled to be off or the 2nd contact is signaled to be on whereas the relay acknowledgment of relays K2 K7 on the connection board E72 E77 No data trans mission form the console to the central unit E94 Error in the data transmission from console to central unit Error in the data transmission from the central unit to the console No data trans mission from the central unit to the console O PAT Rev 12 18 00 CSH Service Manual PAT DS 350 Modular Main board is defective refer to E71 24 V supply of the console 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 Interruption or accidental ground in the cable between central unit and console 5 V supply of the computer in the central unit is missing 5 V supply is too low ErrorCodelError Cause Elimination e Replace main board refer to E71 Check 24 V at terminal X1 of the console electronics Check the connection console electronics central unit In case of an accidental ground the transmitter
20. 07 AND 08 2 5 5 3 ANALOG INPUT CHANNEL ERRORS 5 5 4 JERRORS 31 AND REENEN 6 6 FUNGTIONTOGISOD T RE 10 E NODISPLA EE 11 8 ANTI TWO BLOCK PRODEEM enee IA eai Ge eta era A 13 9 ANGLE SENSOR Sana 16 OEROAD READING EE 18 11 AREA DEFINITION INDICATION PROBLEM nee eee e nenen e nean e nenen ene nean 20 12 DATA TRANSFER CENTRAL UNIT lt gt CONSOLE aaa e eaaa eee eaaa eaaa nee e eee e eee 21 Ee NEE 23 13 1 ELECTRICAL WIRING DRAWING 1 PART EE 23 13 2 CENTRAL UNIT BREAKDOWN PARTS LIST DRAWING 2 25 13 3 CONSOLE DS350 1334 PARTS LIST DRAWING A 27 13 4 CENTRAL UNIT MAIN BOARD LAYOUT DRAWING 4 coccccoooooocccccccccccnnnnnnnnnonnnncnnnnnnnnncncnnnncnnnnnnns 28 13 5 CENTRAL UNIT ANALOG INPUT MODULE DRAWING D 29 13 6 CONSOLE CONNECTION BOARD DRAWING 6 30 19 7 FORCE TRANSDUCER DRAWING 7 rete t ree ELI ek ed ee ede UR exer ERAN EE Ra cer ud an 31 13 8 AREA DEFINITION SWITCH DRAWING HI 31 19 9 BOOM JUNCTION BOX DRAWING Tios 32 13100 CABLE REEL DRAWING Leger and 33 t4 PROCEDURES EA A A A A A A E A a a 34 14 1 PROCEDURE 1 EPROM LOCATION AND INSTALLATION em emen rne tenerse rre 34 14 2 PROCEDURE 2 MAIN BOARD REPLACEMENT eaaa eaaa eaaa mene ese rre rre rne pret rre rre re 35 14 3 PROCEDURE 3 ANGLE SENSOR ADJUSTMENT REPLACEMENT emeret rne tenere
21. 36 14 4 TROUBLESHOOTING MOISTURE ida 37 14 5 THEORY 1 OPERATION OF ANGLE GENSOR cere aee aee eee emere rne ree ese ree ree rre trre pneri 39 PAT Rev 12 18 00 CSH 190118 DOC General Information 1 1 GENERAL INFORMATION The PAT Load Moment Indicator LMI DS 350 has been designed to provide the crane operator with the essential information required to operate the machine within its design parameters Using different sensing devices the Load Moment Indicator monitors various crane functions and provides the operator with a continuous reading of the crane s capacity The readings continuously change as the crane moves through the motions needed to make the lift The LMI provides the operator with information regarding the angle of the boom working radius rated load and the total calculated weight being lifted by the crane If non permitted conditions are approached the DS 350 Load Moment Indicator will warn the operator by sounding an audible alarm lighting a warning light and locking out those functions that may aggravate the crane s condition Refer to operator s manual 031 300 190 089 for console operating instructions 2 WARNINGS The LMI is an operational aid that warns a crane operator of approaching overload conditions and of over hoist conditions that could cause damage to equipment and personnel The device is not and shall not be a substitute for good operator judgment experience and use of
22. C UB LED OFF D BLUE GND LED ON WHEN STEEL IS PASSED IN FRONT OF SWITCH O PAT Rev 12 18 00 CSH CABLE ASSEMBLY 14 4X0 5 DS CENTRAL UNIT 051 300 060 192 F9L0029 x1 1 1 1 BRN A gt 1 1 AT A 1 033 lt 4 24v BLK B gt gt B 2 2 B 5 B 2 16 gt DI 1 24V OVER DRIVE END WHT gt 3 3 o c 3 18 DI 2 BLU D 5 D 4 4 D gt gt D 4 35 GND t 190118 DOC 32 13 9 Boom Junction Box Drawing 9 E D C AD QW 4 QD A_1 SIL II CONNECTOR NOT USED gt Be2 1 TO 1 OF IN NORMAL OPERATION oS 5 1 2 Do L H S E S 3 Ka fi 5 1 4 7KQ 4 28 gt e ol Ad 5 eC gt LS 7 6 4D gt p 8 H 5 WE gt LS a Ser amp mo H Geo 8 7 eG gt LS hot A2B Ba 9 Sen gt gt gt i Seil 3 T 10 10 eK gt 11 11 eL gt s 12 eM 13 eh 14 ep 5 112 123 e o A el AB CD NENG L ANAN A2B FORCE TRANSDUCER You can use the terminal strip to easily measure voltages in one central point PAT Rev 12 18 00 CSH 190118_ DOC Service Manual F 44T DS 350 Modular CABLE REEL Drawings 13 10 Cable Reel Drawing 10 eL IET P E 5 F 6 Dram gt J 9
23. EPROM Luff the jib to a radius or angle specified in the load chart 190118 DOC Error Codes 5 5 2 Lockout Function Errors 07 and 08 These errors are caused by defects around the function lockouts Faulty acknowledgment e Overload relay or main e Replace main board of the overload relay on board are defective the connection board The relay should be e Processor board e Replace processor board energized the 2nd defective contact however is indicated to be off or the 2nd contact is indicated to be on while the relay should be de energized No acknowledgment from e refer to E07 e refer to E07 the anti two block relay 5 3 Analog Input Channel Errors These errors occur if the input signal of an analog input channel falls below E1x the minimum 4 mA or exceeds E2x the maximum 20 mA The analog channels are used as follows Senso PinsTerminalX1 Upper Limit Main Force Transducer Angle Sensor Main Boom Each channel is constantly being monitored to be within 4 mA 1 1V resp and 20 mA 5 5V resp If it exceeds these limits the following errors are triggered ErrorCode Error Cause Elimination Fallen below the Cable between the central e Check cable as well as lower limit value in unit and force transducer plugs replace if need be the main force defective or water inside the channel plugs Force transducer is Replace force transducer defective Electronic component in the Re
24. PAT America Inc patamerica com PAT PAT LOAD MOMENT INDICATOR DS 350 MODULAR GRAPHIC for Lattice Boom Cranes Set OP JOI SERVICE MANUAL P N 031 300 190 118 REV 12 18 2000 Service Manual F 44T DS 350 Modular NOTICE The information in this document is subject to change without notice PAT makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose PAT shall 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 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 MANUAL REVISIONS DATE NAME DESCRIPTION 12 18 00 Troubleshooting Manual created O 2000 PAT America Chambersburg PA 17201 USA PAT Rev 12 18 00 CSH 190118 DOC Service Manual PAT DS 350 Modular TABLE OF CONTENTS Td GENERALINEORMA TION n 1 PA n IN UIN IE fe EEE Es 1 3 SYS TEM DESCRIPTION EE 2 4 GENERAL E Ee a da sun Ci ane ns 3 ERROR OO 4 5 1 OPERATING ERRORS E01 THROUGH EO6 0ccccecceeeceeeceeeceeeceeeceeeceeeceeecaeecenecaeecaeeceeeseeeseeesaeeees 4 5 2 LOCKOUT FUNCTION ERRORS
25. US PAGE Disconnect switch es from boom tip junction box and measure the resistance between A and B to check the function of the anti two block switch Check all connected switches main and extension This checks the function of the Anti Two Block switch Switch closed 0Ohms weight or flag installed Switch open gt 1 Megaohm weight or flag removed Connect switches to the correct position Refer to Drawing 1 and 9 Replace faulty anti two block switch assembly Refer to Drawing 1 Correct No Yes Y Turn off system power Check the the signal in the main boom tip junction box measure the resistance between terminals 5 and 6 the junction box must be connected as follows e aSwitch or by pass plug connected to the two 2 pin receptacles Switch closed 4 7KOhms weight or flag installed Switch open gt 1 Megaohm weight or flag removed Refer to Drawing 1 and 9 Check wire connections in boom nose box Correct No gt Replace junction box Refer to Drawing 1 Yes y Turn off system power Check the the signal in the 14 pin receptacle on the cable reel measure the resistance between terminals E and F Switch closed 4 7KOhms weight or flag installed Switch open gt 1 Megaohm weight or flag removed Refer to Drawing 1 Check cable reel for damaged cable Correct No Replace cable reel Refer to Drawing 1and 10
26. do not match programming in the data data EPROM PROM No EPROM 1 Error in the internal e Computer component 80C537 e Replace computer write read memory defective component 80C537 RAM of the e CPU module defective e Replace CPU module computer component 80C537 e Processor board defective e Replace processor board with CPU module Error in the external e Write read memory CMOS e Replace processor board write read memory RAM or processor board with CPU module 1st part RAM defective Error in the external refer to E42 refer to E42 write read memory 2nd part RAM Redundancy error e The A D converter on the e Replace processor board in the A D processing board and the conversion redundant A D converter in the CPU 80C537 provide different results Error in the A D No acknowledgment of the A D e Replace processor board converter uPD 7004 converter uPD 7004 of the processor board PAT Rev 12 18 00 CSH 190118 _ DOC Error Codes ES A AS A 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 Error in the data EPROM or EEPROM Error in serial crane data EEPROM Error in the serial analog data EEPROM The number of the selected EPROM base and the programmed value are not identical Error in the data
27. for information on the difference between voltage and amperage measurements Three conductor wires are X1 26 A Ub X1 29 B signal 4 20mA X1 28 C GND Check analog input board voltage between X1 4 on analog input board and MPO GND 0 5V to 4 5V is correct If otherwise main or analog board defective Replace main board YES and or analog board Refer to Drawings 2 4 and 5 Main board or Analog Input Module Somewhere between angle sensor and central unit the signal is lost Check wiring and replace Replace angle sensor Refer to Adjustment Procedure 3 C w PAT Rev 12 18 00 CSH 190118_ DOC 18 Service Manual F 44T DS 350 Modular 10 LOAD READING PROBLEM Load reading incorrect C START Y Measure radius and check with the displayed radius NO Check if mechanical adjustment of angle transducer is correct Angle transducer box should be in line with boom and adjusted to actual boom angle Refer to Procedure 2 Angle Sensor Adjustment YES Y Measure the force transducer sensor supply voltage in the central unit between terminals X1 23 12 24v and X1 25 ground Refer to Drawing 1 Main board defective Replace main board NO Refer to Drawing 2 in Section 12 and Replacement Procedure 3 in Section 13
28. ghtened in order to do this Check the tightness by taking the external cable into one hand and carefully trying to turn it If the internal wires turn with the outer cable the strain relief is loose Get a new grommet insert through your Link Belt or PAT representative and replace the existing one with the new one Tighten the strain relief correctly Note Whenever a strain relief is opened i e to replace a cable a new grommet needs to be used Never re use any grommet or the strain relief will not seal properly 6 Water Entry Through Extemal Cabling Even with a tight strain relief water may still enter the box through the inside of the cable In this case you have to find out why and where water enters the cable Look for damages to the cable itself and inspect the opposite side of the cable In example if the cable comes from a connector that is full of water the water will run through the inside of the cable and fill up the central unit too 14 4 2 Condensation In a climate with high humidity and rapidly changing temperatures condensation can happen inside any enclosure usually the larger the volume of the box the more likely In this case water drops build up on the inner components when humid air is trapped inside the box With condensation water tightness is not a problem the box is sealed just fine which is what prevents the trapped air from exiting the box There are two ways to deal with condensation 1 Ifthe volume i
29. h and the LED in the switch is on voltage should be between 24 volts and the DI3 LED should be on Refer to Drawing 1 4 and 8 Proximity switch defective Replace switch nor Refer to Drawing 1 and 8 YES p END m O PAT Rev 12 18 00 CSH 190118 DOC Data Transfer Central Unit lt gt Console 21 12 DATA TRANSFER CENTRAL UNIT lt gt CONSOLE PROBLEM Error Code E93 E94 No data transfer to and from console interference from crane electric or console display frozen START D y Check the H12 TxD LED on the main board ON OFF Refer to Drawing 3 ON y Make sure that the EPROM s are correct and plugged into the EPROM Module on the main board Refer to Procedure 1 Correct NO Place EPROM in correct socket Refer to Procedure 1 YES OFF Measure process voltage on the Main Board in the central unit between MP25 UB and MPO ground Refer to Drawing 2 and 4 EH NO Make sure external and internal power supplies are correct Refer to No Display Section YES y Check the continuity of the receive RXD and transfer TXD wires central unit main board X1 5 and console X1 3 central unit main board X1 6 and console X1 4 Turn off system power Check continuity between Refer to Drawing 1 NO
30. place LMI module s measuring channel is defective Upper limit value in refer to E14 refer to E14 main force transducer measuring channel has been exceeded E15 Fallen below lower e Cable between central unit e Check cable as well as limit value in and the angle sensor plugs replace if need be measuring channel defective or loose Water angle main boom inside the plugs e Angle sensor defective e Replace angle sensor O PAT Rev 12 18 00 CSH 190118 DOC 6 Service Manual F 44T DS 350 Modular A A AAA Electronic component in the Elimination a LMI module s measuring channel defective Upper limit value in refer to E15 refer to E15 measuring channel main boom angle has been exceeded Reference and or e The supply voltage is being e Check the voltages on the supply voltage dragged down by one of the LMI main board AGND defective sensors MPO Check sensors plugs and cable replace if need be e Electronic component is e Replace LMI main board defective e A D converter defective e Replace analog board Reference and or e refer to E19 e refer to E19 supply voltage defective Errors 31 and up GE Errors most of them caused by electronics E AE A A Error in the system e The system program PROM is e Replace system program program defective PROM PROM No 0 System program e The system program in the LMI Je Replace the system and data EPROM does not match to the program PROM or the
31. rewdriver when removing and inserting screws NOTE Use care when lifting the CPU module board and analog input module from the main board due to the fact that these boards have pins on the bottom side which insert into the main board Remove CPU module board by taking out the 4 small Philips screws holding it in place Remove analog input module board by taking out the 6 small Philips screws holding it in place Remove the relay and fuses from the main board items 5 6 and 7 on Drawing 4 Mark all connection wires before removing to identify location for reconnecting Disconnect all X1 terminal wires from the main board 7 Remove the 14 large Philips screws holding the main board in place 8 Take notice of the orientation of the main board in the central unit Remove main board and place in the packing material that the replacement main board came in 9 Carefully insert the new main board in place Refer to Drawing 4 for location 10 Insert the 14 Philips mounting screws be sure to attach the ground wire to the KGND screw in the lower left corner Refer to Drawing 4 11 Insert analog input module board by lining up the pins into the sockets X16 and X17 and the 6 screw holes 12 Insert the 6 small Philips screws and washers 13 Insert CPU module board by lining up the pins into the sockets X11 and X12 and the 4 screw holes 14 Insert the 4 small Philips screws and washers 15 Insert the relay on to the main board i
32. rror Cause Elimination Fallen below radius range or angle range exceeded Radius range exceeded or fallen below angle range Operating mode not existing or non permitted slewing zone Boom length not existing Radius range exceeded or fallen below angle range with luffing jib operation O PAT Rev 12 18 00 CSH Fallen below the minimum radius or gone past the maximum angle specified in the respective load chart due to hoisting up the boom too far Gone past the maximum radius or fallen below the minimum angle specified in the respective load chart due to hoisting down the boom too far A non existing operating mode has been selected The selected operating mode is not available in the data EPROM or blocked The boom is in a non permitted slewing A non existing boom length has been selected The selected boom length is not available in the data EPROM Maximum radius as specified in the load chart exceeded or fallen below minimum angle due to luffing down the luffing jib too far Hoist the boom down to a radius or angle specified in the load chart Hoist the boom up to a radius or angle specified in the load chart Set the correct operating mode for the crane configuration in question Check programming of the data EPROM Slew the crane into a permitted area Correctly enter the boom length according to the attribution of the operating state Check programming of the data
33. s B to B C to C and D to D Refer to Drawing 1 Correct gt NO_ No Fault in cable or wiring YES v Check force transducer for any visual damages Complete the force transducer calibration in operator s and calibration manual If force transducer can not be adjusted replace force transducer Refer to Procedure 5 and Drawing 1 or 7 C PAT Rev 12 18 00 CSH 190118_ DOC 19 20 Service Manual F 44T DS 350 Modular 11 AREA DEFINITION INDICATION PROBLEM START Y Check proximity switch or activation stump or rail for physical damage Repair as necessary check Link Belt load chart for correct switching point YES y Measure the proximity sensor supply voltage in the central unit between terminals X1 33 24v and X1 35 ground Refer to Drawing 1 Main board defective Replace main board NO Refer to Drawing 4 in Section 12 and Replacement Procedure 3 in Section 13 YES y Measure the proximity sensor supply voltage at cable assembly 031 300 060 192 4 socket plug between A 24v and B return Refer to Drawing 1 and 8 Cable assembly defective Replace cable No Refer to Drawing 1 and 8 YES Y Measure signal from the proximity switch in the central unit between X1 16 and X1 35 with the stricker in front of the switc
34. s Replace the console main Note If an error message is displayed which is not contained in above list please contact the PAT service department O PAT Rev 12 18 00 CSH 190118 DOC Service Manual F 44T DS 350 Modular 6 FUNCTION LOCKOUT PROBLEM The lever lockout system of the crane is activated Crane movements hoist up and optional boom down are stopped Only if the crane is not in overload or two block condition continue with flow chart WARNING If overload or A2B condition exists use extreme caution and move the crane out of the condition If Error Code is displayed goto Section 5 1 Start Use the console key switch and the LMI by pass button or the central unit key switch to override the overload When by passing the system the following instructions must be obeyed The by pass function shall be used with discretion as unwarranted use of it to override the control lever lockout system can result in harm to the crane and danger to property and persons Never use the by pass function to either overload or operate the crane in a non permissible range The LMI by pass warning light and or anti two block warning light is lit on the console Corrected Wes LED s H8 H9 and H10 are lit on the main terminal board Refer to Drawing 4 in Section 13 NO Y Fault in crane electric hydraulic system or electronic board
35. s very small a desiccant bag might be able to soak up the air s humidity 2 If the effect is more severe the only way to get rid of this effect is then to give the box the ability to breath without sacrificing its water tightness Contact your Link Belt or PAT representative for breathing elements to than can be added to the box and will help to reduce the effects of humid climates PAT Rev 12 18 00 CSH 190118 _ DOC 14 5 Theory 1 Operation of Angle Sensor 14 5 1 Measuring current The ammeter A is used to measure current at the angle input signal Remove the wire from X1 29 terminal in the central unit and measure the current with the ammeter in series The measurement should be between 4 20mA 14 5 2 Measuring voltage The voltmeter is used to measure voltage between pins X1 29 angle signal and X1 28 GND on the main board 024 352 300 001 The resistors are there to show that at 4mA the voltage is 1 1V because current multiplied with resistance equals voltage therefore 4mA x 275 ohms total resistance 1 1V OPERATING WINDOW ERROR YY CODE WORKING RANGE RRO J E CODE O PAT Rev 12 18 00 CSH nA 1 20mA 5 5V CENTRAL UNIT SOZAN DS350 50 MODULAR 250 ohms 150 250 ohms ohms 190118_ DOC
36. tem 7 on Drawing 4 16 Connect the X1 terminal wires to the main board Refer to Drawings 1 2 and 3 17 Turn power on and test system 18 Inspect the gasket for nicks cuts or damages before installing and tightening the cover oon O PAT Rev 12 18 00 CSH 190118 DOC 36 Service Manual F 44T DS 350 Modular 14 3 Procedure 3 Angle Sensor Adjustment Replacement The angle 4 shown in the figure below needs to be within 0 0 5 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 Angle Sensor Adjustment Note that accuracy is more important at higher boom angles To compare indicated angle with actual angle make sure you use a high precision inclinometer to determine actual boom angle right at the angle sensor Due to boom deflection etc an angle measured at another part of the boom can differ from the indicated angle To adjust the angle sensor carefully loosen screws that hold it to the boom adjust the sensor very carefully and re tighten the screws Double check your indicated angle When you have found the correct position make sure all screws are tight The angle sensor provides an output signal of 20 mA at 0 degrees boom angle and 4 mA at 90 degrees Refer to Theory 1 To comply with the SAE J375 standards the displayed angle must be 0 0 to
37. th the reference data stored in the central processor memory and evaluated in the microprocessor When limits are reached an overload warning signal is generated at the operator s console At the same time the aggravating crane movements such as hoist up and boom down will be stopped The fixed data regarding the crane such as capacity charts boom weights centers of gravity and dimensions are stored in memory chips in the central processor unit This data is the reference information used to calculate the operating conditions The boom angle is measured by the angle sensor mounted in the boom base The cable reel cable serves as an electrical conductor for the anti two block switches and force transducer signals The load on the boom is measured by force transducer mounted on top of the boom close to the tip The interactive user guidance considerably simplifies the input of operating modes as well as the setting of geometry limit values Please refer to the PAT DS350 operator s manual for the operation of the system The System consists of the following main components Central Unit Cable for crane power Cable to cable reel Cable Reel Junction box A2B switch with weight A2B bypass plug Cable to force transducer Force transducer 10 Cable to main boom angle sensor 11 Main boom angle sensor 12 Operator s console with cable assembly 13 Cable for area definition sensor 14 Area definition sensor O O NO
38. the signal is less than 3 open A2B alarm and light Check wiring for open circuit switch not connected bypass plugs not installed or sensor cables not connected greater than 6 short then EAB error is given to the system The signal is returned to the CU unmodified for example a jumper wire connected between X1 31 and X1 32 in CU If the signal is within 3 to 6 volts or the A2B circuit is by passed LED H9 on the main board will be lit Refer to Drawing 3 Measure voltage on the main board terminal strip between X1 31 9V 0 5 and X1 2 ground This is an input voltage from the system Refer to Drawing 1 and 4 NO Replace the main board in central unit Refer to Drawing 2 and Replacement Procedure 2 Measure voltage on the main board terminal strip between X1 31 9V 0 5 and X1 32 A2B GND This is the voltage in the A2B circuit lt 3 open and gt 6 short in system Refer to Drawing 1 and 4 aii Look for damaged cable between central unit and boom tip junction box YES e Check 4 7K resistor in boom tip junction box Turn system power NEXT PAGE off and measure resistance between terminal 5 in junction box and pin A of 7 socket receptacle measurement reading 4 7K check for short between terminals 5 and 6 in boom tip junction box or between X1 31 and X1 32 in CU O PAT Rev 12 18 00 CSH 190118_ DOG Anti Two Block 15 PREVIO
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