Service Manual - RW Sales & Services Ltd.
Contents
1. Disconnect X1 34 and X1 35 Check main board function by installing a temporary resistor 4700 Ohms between X1 34 and X1 35 in central unit With resistor connected alarm should be inactive Refer to system wiring diagram Replace main board and reset pressure channel NO Refer to main board replacement procedure Y Reconnect Wire 6 to X1 34 and Wire 5 to X1 35 Refer to system wiring diagram End Hirschmann REV C 08 22 03 100753_C doc S00 Manual PAT Deen 7 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 cable reel When main boom is fully retracted adjust length potentiometer counter clockwise until it stops Refer to length angle adjustments procedure Replace length potentiometer assembly Remove slip ring body from shaft and remove gear wheel from potentiometer axle Unscrew mounting plate and remove potentiometer assembly from mounting plate Remove assembly wires No form terminal block Connect new assembly to terminal block Reinstall mounting plate gear wheel and slip rings With boom fully retracted reset potentiometer by turning counter clockwise until it stops Refer to Cable Reel Parts List Yes Y Check out clutch in big2. Error the internal Computer component Replace computer write read memory 80C537 defective component 80C537 RAM of the computer e CPU module defective e Replace CPU module component 80C537 Processor board e Replace processor board defective with CPU module Error in the external e Write read memory e Replace processor board write read memory CMOS RAM or with CPU module 1st part RAM processor board defective Error in the external e Refer to E42 e Refer to E42 write read memory 2nd part RAM 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 e No acknowledgment of e Replace processor board converter uPD the A D converter uPD 7004 of the 7004 processor board Error in the crane e No valid data in the crane Load crane data EEPROM data EPROM or data EEPROM containing valid data EEPROM e Memory module wrongly e Bridge memory module acc bridged to memory type e Crane data EPROM e Replace crane data EPROM defective Short circuit in the e Short circuit in the A2B e Replace A2B switch Anti two Block switch A2B switch e Short circuit in the cable to e Replace cable to the A2B the A2B switch switch Cyclic RAM test e Computer component e Replace computer error in the internal 80C537 defective component 80C537 w
3. Fault in wiring between boom nose box and cable reel No Check for damaged length cable and wiring Refer to system wiring diagram If broken length cable Refer to length cable replacement Measure the A2B signal in cable reel between terminal 7 and 8 with ohmmeter Switch closed 4700 5000hms Switch open gt 1 Megaohm Reconnected slip ring wires Refer to system wiring diagram Replace slip ring ze d Refer to cable reel parts list Y Measure the A2B signal in the boom base 10 pin receptacle between terminal 5 and 6 with an ohmmeter Switch closed 4700 500Ohms Switch open gt 1 Megaohm Reconnected slip ring wires Refer to system wiring diagram Fault in 7 conductor cable between cable reel and No boom base box Refer to system wiring diagram T NEXT PAGE p Hirschmann REV C 08 22 03 100753_C doc Troubleshooting Flow Charts 29 PREVIOUS PAGE 2 Connect wire 5 back to terminal 1 35 on the connection board Refer to system wiring diagram i Turn system power off Check Anti Two Block signal in central unit with ohmmeter measure between X1 34 and X1 35 Anti Two Block switch closed 4700 Ohms 50 OOhms Anti Two Block switch open gt 1 Megaohm Refer to system wiring diagram Faulty wiring between cable reel and central unit NO Check cable YES Y
4. on meter 4 Disconnect hydraulic hose from the rod side pressure transducer 5 Connect a digital voltmeter to main board A BLACK lead to MP10 B RED lead to MP12 6 Adjust P2 to obtain a reading of 0 500 volts 500mv on meter 7 Reconnect hydraulic hoses to pressure transducers and then bleed the air from hydraulic lines REV B 03 08 02 100753 C doc Procedures 17 5 3 Length 8 Angle Adjustments mJ y Z ADJUST LENGTH POTENTIOMETER WITH BOO TURN THE CENTER SCREW COUNTER CLOCK FULLY SE SOFT STOP Hirschmann REV C 08 22 03 100753_C doc 8 Service Manual PAT DS150 5 4 Main Board Replacement Refer to Drawing 1 central unit parts list for board location 1 Turn system power off 2 Remove the central unit lid NOTE Take care not to damage the boards with the screwdriver when removing and inserting Screws 3 Remove the system and data software from the main board 4 Remove the relay from the main board 5 Mark all connection wires before removing to identify location for reconnecting Disconnect all X1 terminal wires from the main 6 Remove the 9 large Philips screws holding the main board in place 7 Note the orientation of the main board in the centra
5. 33 ground and X1 30 12V Make sure external and internal power supply is correct Refer to Section 4 Refer to system wiring diagram Replace main board and reset pressure channel Refer to Correct No gt system wiring diagram and transducer replacement procedure Yes C NEXT PAGE Hirschmann REV 08 22 03 100753_C doc Troubleshooting Flow Charts 37 Continued from previous page C PREVIOUS PAGE Check power supply to console between console terminal 2 ground and terminal 1 12 Refer to system wiring diagram Faulty wiring in cable from central unit to console Replace cable Correct No Yes Ensure that wires are properly connected between CU X1 31 and console terminal 4 and between CU X1 32 and console terminal 3 Refer to system wiring diagram Replace main board and reset pressure channel Correct No gt Refer to system wiring diagram and transducer replacement procedure Yes m Hirschmann 08 22 03 100753_C doc SBS vice Manual PAT Deen 7 9 Interference Problem PROBLEM Interference from crane electric Error Code E93 E94 intermittent Frozen console displays Refer to Section 8 Bad Data Transfer Between Console amp Central Unit Correct No gt Replace
6. 1 Remove cover from central unit CAUTION Before handling the EPROM discharge any static electricity from your body by touching a ground source The EPROM could be damaged if this procedure is not followed Use the central unit main board layout and measuring point drawing to locate the system and data EPROM s 2 Remove the old EPROM from the main board using an EPROM puller Be careful not to bend the legs of the EPROM when removing it Installing the new EPROM Ensure the notch is in the correct direction The direction of the EPROM is determined by the notch on the end of the EPROM The DATA and EPROM s fill the bottom of the socket as shown by the arrows Place EPROM in the correct EPROM socket as shown 4 Inspect gasket and install cover using the following procedures to prevent any moisture from entering the central unit Reference material 031 300 340 002 Central Unit Cover Installation and Tightening Procedure Rev A 031 300 340 003 Central Unit Gasket Recommendations Rev 5 2 Piston Rod Pressure Channel Zero Point Adjustment Use the central unit main board layout and measuring point drawing to make the following adjustments 1 Lower boom all the way down no rest pressure then disconnect hydraulic hose from the piston side pressure transducer 2 Connect a digital voltmeter to main board A black lead to mp10 B red lead to mp11 3 Adjust P1 to obtain a reading of 0 500 volts 500
7. Hirschmann REV C 08 22 03 100753_C doc Troubleshooting Flow Charts 27 7 5 Anti Two Block Problem PROBLEM Function of Anti Two Block System is faulty C START v Check to see whether or not crane is in two block condition Correct No gt Lower hook down into safe position Yes Y Check if jumper dummy plug in receptacle at boom nose is plugged in Refer to system wiring diagram No Plug appropriate plug into socket of junction box Yes Y Turn power off or disconnect wire from connection board X1 35 in central unit Remove bypass plug and check function of Anti Two Block switches with ohmmeter between wires 2 and 3 of switches or between terminals 1 and 6 at boom nose box This checks the function of the Anti Two Block switch Install bypass plug Switch closed 0 Ohm weight installed Switch open gt 1 Megaohm weight removed Refer to system wiring diagram Correct No gt Replace Anti Two Block switch Yes v Next p Hirschmann REV C 08 22 03 100753_C doc Bo Service Manual PAT DS150 PREVIOUS dpt Measure A2B signal in the cable reel between X1 Brown and X2 Red wires on the slip ring with an ohmmeter Switch closed 24700 x500Ohms Switch open gt 1 Megaohm Reconnected slip ring wires Refer to system wiring diagram
8. See Procedure 3 Angle 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 and 70 degrees Angle display should be less than 5 degrees of the value of the inclinometer See Procedure 3 Pressure Channel Rest the boom and disconnect hydraulic hoses from the pressure transducers Measure and record the zero points of both pressure transducers on the main board Adjust P1 and P2 on the main board to 500mV at test points 11 and MP12 Connect hydraulic hoses back to the pressure transducers See Procedure 2 Duty Selection Switches Digital Inputs Check the duty selection switches for correct operation Check the voltage on digital input connections Check the function of the hoist limit switch anti two block Check function of lever lockout Measure and record the power supply voltages See Addendum A Hirschmann REV C 08 22 03 100753 C doc Definitions 5 3 DEFINITIONS BOOM LENGTH The straight line through the centerline of boom pivot pin to the centerline of the boom point load hoist sheave pin measured along the longitudinal axis of the boom Indicator 2 BOOM ANGLE The angle between the longitudinal centerline of the boom base section and the horizontal plane Indicator 65 to 90 boom angle 0 2 less than 65 boom angle 0 3 RADIUS OF LOAD The horizontal distance from a
9. either too far or not far enough e g if it is prohibited to go beyond a certain maximum boom length or with load curves for jibs where the main boom has to be extended to a certain length Prohibited length range e Length sensor adjustment has changed e g the cable slid off the length sensor reel radius or angle specified in the load chart e Luff up the boom to a radius or angle specified in the load chart e The slewing zone with e Slew to permitted area load is not permitted e Set the correct operating mode for the operating state in question e Slew the boom to a permitted area e Extend retract boom to the correct length e Retract boom Check the pre stress of the cable reel cable must be taut Open the length sensor and carefully turn the length sensor pot counter clockwise until loosened by using a screw driver REV 03 08 02 100753_C doc Error Codes 41 eg n OO Clutch between length e Replace the complete clutch sensor pot and drive is including drive wheel and defective adjust length sensor pot as described above Failure of 5V supply of e Check 5 V supply analog part of analog Exchange main board in board case of voltage failure or breakdown when loaded with 50 ohms approx Cable between central e Check cable and plugs unit and length sensor is replace if need be defective or disconnected Defective length e Replace length potentiometer potenti
10. electronics or LMI main board Check the connection between console electronics and central unit Exchange console electronics or LMI main board Refer to E92 Check line to the console in case of accidental ground replace console electronics too Check connection to the power unit Exchange the LMI main board Replace console electronics or LMI main board Replace processor board Eliminate the source of interference by inverse diodes or varistors Note If an error message is displayed which is not contained in above list please contact PAT America Inc service department Hirschmann REV C 08 22 03 100753 46 Service Manual PAT DS150 ADDENDUM A BASIC ADJUSTMENT AND VOLTAGE CHECKS MODEL S N PAT DS150 P N 024 150 060 002 central unit 024 150 300 001 main board 1 Crane Supply Voltage X1 1 amp X1 4 GND VDC 2 Main Board Power Supply Reference Voltages 50 MV 9 Mp2 VDC Mp 10 Ground Piston amp Rod Pressure 9V Mp3 VDC Mp 10 Ground Piston amp Rod Pressure 5V Mp4 VDC Mp 10 Ground TTL on Board 5V Mp5 VDC Mp 10 Ground Reference on Board 5V Mp6 VDC Mp 10 Ground Internal on Board 5V Mp Mp 10 Ground Length and Main Jib Angle 4 Boom Length MP10 Ground for Meter Fully Retracted Ft VDC 1 10 DC 13 Fully Extended Ft VDC X1 10 DC 13 5 Volt Reference Voltage VDC X1 11 5 Boom Angle MP10 Ground for
11. i Check selected operating mode code on operating mode switch Select operating mode switch to correct position see operating mode in load chart No gt Yes Y Check boom length reading on display Reset length potentiometer With fully retracted boom turn potentiometer No axle counter clockwise until it stops see Section 3 and 6 Refer to length amp angle adjustments procedure Measure radius and check with the displayed radius Check mechanical adjustment of angle transducer is correct Angle transducer box should be in line with boom and adjusted to actual boom angle should match displayed boom angle Refer to length amp angle adjustments procedure YES Check power supply to pressure transducer rodside Unplug transducer cable from transducer Measure connection board between X1 14 to X1 13 5 0v and X1 14 to X1 15 5 0 for rod side No Check power supply to pressure transducer piston side Unplug transducer cable from transducer Measure connection board between X1 19 to X1 20 5 0v and X1 19 to X1 18 5 0 Refer to system wiring diagram Hirschmann REV C 08 22 03 100753 C doc BS vice Manual PAT 08150 d Pervious Page Check power supply and measure between test point MP10 ground to Correct No 7 5 0 and b
12. Meter Minimum Angle i VDC X1 9 VDC Mp14 Maximum Angle VDC X1 9 VDC Mp14 5 Volt Reference Voltage VDC X1 11 6 Pressure Transducers MP10 Ground for Meter Piston Zero Point VDC X1 21 VDC 11 Rod Zero Point VDC X1 16 VDC Mp12 5 Volt Reference Voltage VDC X1 13 amp 18 5 Volt Reference Voltage VDC 1 15 20 REV 03 08 02 100753_C doc Addendums 47 ADDENDUM B Reference Tables for measuring supply and signal voltages for sensor channels Use the table as a quick reference for measuring supply and signal voltages for the sensor channels that are specific to the error code listed Signal Voltage Terminal Board Terminal X1 Nominal Voltage Error Code Channel Pin ground Pin supply VDC Lengih 12 22 1 Pressure Piston side 19 mer 5 13 23 Pressure Rod side 14 15 15 25 Angle Main boom 11 E16 26 Angle Signal Voltage Terminal Board Amplified Signal Terminal X1 on main board use 10 GND Error i i and MP supply Code Channel voltage 0 5 4 5V E11 21 E12 22 MP11 E13 23 MP12 E15 25 Angle Main boom 8 9 1 875 3 125 MP14 E16 26 Angle Jib 8 24 1 875 3 125 MP15 Hirschmann REV C 08 22 03 100753_C doc
13. i PI aa E a ai 29 gt al puru 6 1 gl A101 2 3 lag d Yi 213 48 6 6 9 20 21 2 3 4 2 3 4 IS d 1 1 8 o d m gt i Ee S S LL n x x E E NOTES TAPE AND 5 gt gt OUTER 2 INNER SHIELD gt gt INNER w 4 DIODE ASSY gt gt REFER SE SHIELD SHIELD CTED TO INSULATED S PRE RED Hirschmann REV B 03 08 02 PRES TRANS ROD ED AND CONNECTED AS INSULATED INSTA SH TRANS ON STRAIN RELIEF INSERT Service Manual PAT DS150 BE DS 0 SOCKET PLUG EES ee dr e 9 345 7 8 345 6 7 4 5 v IS 3 10 PIN RECEPTACLE BYPASS PLUG 100753_C doc Drawings 7 4 2 Central Unit 024 150 060 002 Spare Parts List Hirschmann REV C 08 22 03 100753 C doc Service Manual PAT DS150 PART NO 024 150 060 002 CENTRAL UNIT DS150 0002 STANDARD PARTS LIST NO PART NO QTY DESCRIPTION 01 024 1
14. or repair part which is defective Yes Y Check if additional ground link between main board terminal X1 3 and central unit box mounting bracket is in place Install ground line single cable minimum of AWG14 2 0mm between No terminal X1 3 and central unit box mounting bracket Refer to system wiring diagram Yes Ensure that cable shields are connected correctly Refer to connection and wiring diagrams Refer to system wiring diagram Make correct shield connection Refer to system wiring diagram Yes Find out which component of the crane electric is spiking out e g dump valve outrigger relay Install a diode or resistor across terminals of spiking component Diode type such as 1N4001 can be used however ensure the correct plus and minus connections for diode 6 2 Hirschmann REV C 08 22 03 100753 C doc Troubleshooting Flow Charts 39 7 10 Angle Problem PROBLEM Displayed Angle Incorrect Actual measured angle is different from displayed angle Y Use a calibrated inclinometer to measure the actual main boom angle and compare with displayed angle on console Refer to length angle adjustments procedure v Check the supply voltage to angle sensor on connection board between X1 11 5VDC and X1 8 ground Refer to system wiring diagram No Check system power supply volt
15. vertical projection of the crane s axis of rotation to the supporting surface before loading to the center of the vertical hoist line or tackle with rated load applied Indicator 100 to 110 RATED LOAD The load value shown on the applicable load rating chart of the crane for the particular crane configuration boom length boom angle or functions or these variables For radii outside those shown on the load rating chart the rated load is to be considered as zero ACTUAL LOAD The weight of the load being lifted and all additional equipment such as blocks slings sensors etc Also referred to as working load Indicator 100 to 110 CRANE CONFIGURATION The physical arrangement of the crane which is prepared for a particular operation in conformance with the manufacturer s operating instructions and load rating chart TWO BLOCKING Contact of the lower load block or hook with the upper load block boom point or boom point machinery ANALOG Electrical signals that vary in proportion to the quantities they represent Boom length angle and pressure transducer DIGITAL Electrical signals of an on and off state two different voltage levels to represent some quantity of operation A2B area definition switch Hirschmann REV B 03 08 02 100753_C doc 4 DRAWINGS 41 SYSTEM Electrical Diagram LM E z 5
16. 0 6 4 ROD SIDE PRESSURE MEASURING CHANNEL diode U 20 6 5 MAIN BOOM ANGLE MEASURING CHANNEL ith bee gee i re En 21 6 6 SECOND ANGLE MEASURING CHANNEL un ER ei n 21 7 TROUBLESHOOTING FLOW CHARTS I mn taeda Dek de uuu 22 YT GENERAL ee E 22 7 2 LEVER LOCKOUT ACTIVATED see a Se ER ee 23 1 3 BROKEN LENGTH CABLE riiinig EE 24 e NO DISPLAY en ne er re EE 25 7 9 ANTI TWO BEOCKPROBDEM EE 27 1 6 LENGTH READING PROBLEM reese 30 Tit LOAD READING PROBLEM Ee Re es ee se 33 7 8 DATA TRANSFER BETWEEN CONSOLE CENTRAL UN 36 7 9 INTERFERENCE PROBLEM u ete eto tpi ted IS ee ge ER EN De 38 1 10 ANGLE PROBLEM EE 39 8 ERROR GODE ee De awas eg el ee ee ee Ge Pra d dee 40 ADDENDUM A BASIC ADJUSTMENT AND VOLTAGE CHECKS 46 ADDENDUM B REFERENCE TABLES FOR MEASURING SUPPLY AND SIGNAL VOLTAGES FOR SENSOR CHANNEES se ed eke ke De Be ee ea N ae ie Se Re ee ke ee ie ee PUR dU end 47 Hirschmann REV 03 08 02 100753_C doc Mechanical Description Of The System 1 1 MECHANICAL DESCRIPTION OF THE SYSTEM COMPONENTS Pressure Transducer The pressure transducer transforms hydraulic pressure into an electric analog voltage signal Two pressure transducers are connected one to the rod side and one to the piston side of the lift cyli
17. 0 060 008 Spare Parts List To change DS150 0008 12V to DS150 0012 24V a jumer wire must be soldered on main board J3 added and the ligth bulbs changed When ordering spare part please specify 12 or 24 volt machine Hirschmann REV C 08 22 03 100753 C doc 12 Service Manual PAT DS150 050 150 300 003 050 350 110 292 050 000 100 048 050 150 110 001 050 350 110 183 050 350 110 116 000 312 043 141 003 051 403 423 000 311 023 114 000 311 023 128 050 350 110 074 050 350 110 073 050 350 110 075 050 350 110 076 050 350 110 077 050 350 110 078 050 350 110 079 003 051 903 364 050 350 100 001 050 150 110 002 050 350 110 140 050 350 110 049 050 150 100 008 050 000 050 309 002 053 703 101 QTY DESCRIPTION AA AA om sch ch AA Ss oo ON SIN AA EA Hirschmann REV C 08 22 03 BOARD MAIN DS150 CONSOLE 12V FOR 4x20mm DISPLAY INDICATOR DISPLAY LCD DS150 CONSOLE HOUSING DS150 CONSOLE COMPLETE BRACKET CONSOLE DS150 COMPLETE KNOB MOUNTING KNOB STRAIN RELIEF ASSY PG 13 5 RED WHITE W NUT WASHER LAMP ACCY PILOT BASIC HOUSING SWITCH PUSHBUTTON w o LENS amp BULB LAMP SPARE LIGHT BULB 12V LAMP SPARE LIGHT BULB 28V SWITCH ACCY LENS CAP RED A2B SWITCH ACCY LENS CAP YELLOW PREWARNING SWITCH ACCY LENS CAP RED STOP BUZZER OFF SWITCH ACCY LENS CAP ORANGE LOAD SWITCH ACCY LENS CAP ORANGE INFO SWITCH ACCY LENS CAP ORANGE ANGLE SWITCH ACCY LE
18. 2V to DS150 0036 24V a jumer wire must be soldered on main board J3 added and the ligth bulbs changed When ordering spare part please specify 12 or 24 volt machine Hirschmann REV C 08 22 03 100753 C doc 10 Service Manual PAT 05150 QTY DESCRIPTION 01 050 150 300 003 1 CONSOLE BOARD W ROTARY SWITCH 05150 02 050 350 110 292 1 LCD DISPLAY DS150 03 050 000 100 060 1 CONSOLE HOUSING W LID 04 050 350 110 116 1 STRAIN RELIEF LONG RED 05 000 305 045 141 2 LUMINOUS HOUSING 06 003 051 405 423 5 LUMINOUS PUSH BUTTON HOUSING 07 000 311 023 114 7 LIGHT BULB 12V 07 000 311 023 128 7 LAMP SPARE LIGHT BULB 28V 08 050 350 110 277 1 CAP A2B RED 09 050 350 110 278 1 CAP PREWARNING YELLOW 10 050 350 110 279 1 CAP STOP ALARM OFF RED 11 050 350 110 280 1 CAP LOAD ORANGE 12 050 350 110 281 1 CAP INFO ORANGE 13 050 350 110 282 1 CAP ANGLE ORANGE 14 050 350 110 283 1 CAP ENTER GREEN 15 003 051 903 364 1 KEY SWITCH 16 050 350 110 139 1 CONSOLE OVERRIDE KEY DS150 350 17 050 000 110 007 1 ALARM BUZZER 18 050 150 100 006 1 FRONT PANEL 19 000 209 022 095 850mm GASKET FOR FRONT PANEL 20 050 000 100 092 1 CONSOLE DS150 0006 21 050 150 110 005 1 GASKET FOR LID 22 050 000 110 014 3 LATCH ASSEMBLY 23 050 000 700 301 2 KNOB FOR ROTARY SWITCH 23 024 350 100 312 1 LABYRINTH MOISTURE ELEMENT Hirschmann REV C 08 22 03 100753 C doc Drawings 11 4 4 Console 050 15
19. 50 300 001 1 BOARD MAIN DS150 CU 12V 02 024 350 100 135 1 CENTRAL UNIT ACCY SCREW SET DS150 03 024 000 100 041 1 CENTRAL UNIT ACCY GROUNDING KIT FOR COVER 04 024 350 100 139 1 CENTRAL UNIT ACCY WALL MOUNT SET DS150 350 05 024 150 100 001 1 HOUSING CENTRAL UNIT DS150 06 024 350 100 661 1 KEYSWITCH CENTRAL UNIT NEW STATIONARY 07 031 300 101 131 1 KEY ASSY ONE OLD STYLE KEY ONE NEW STYLE KEY 08 024 350 110 067 2 STRAIN RELIEF ASSY PG 11 GRN W NUT WASHER 09 000 314 022 006 2 FUSE HOLDER CENTRAL UNIT MAIN BOARD 10 000 313 062 001 1 FUSE 2 AMP 1 4 x 1 1 4 250V FAST ACTING 11 000 313 062 002 1 FUSE 10 AMP 1 4 x 1 1 4 250V FAST ACTING 12 000 304 140 122 1 RELAY SHUT OFF 12 V BOSCH 13 024 350 110 066 1 CENTRAL UNIT ACCY GASKET FOR C U COVER 14 021 441 161 213 1 STRAIN RELIEF PG 13 5 12 15mm GRY WHT INSERT 15 050 350 110 116 1 STRAIN RELIEF ASSY PG 13 5 RED W NUT WASHER 16 000 214 340 011 4 STRAIN RELIEF PG11 HOLE PLUG 17 000 214 210 011 4 NUT PG11 18 000 214 340 013 1 STRAIN RELIEF ACCY PG13 5 HOLE PLUG 19 000 214 210 013 1 NUT PG13 5 20 000 214 340 016 1 STRAIN RELIEF ACCY PG16 HOLE PLUG 21 000 214 210 016 1 NUT PG16 22 024 150 100 002 1 CENTRAL UNIT ACCY BASEPLATE DS150 23 031 300 100 078 1 CHEMICAL MOISTURE PACK 24 024 150 110 002 1 COVER CENTRAL UNIT DS150 Hirschmann REV C 08 22 03 100753_C doc Drawings 9 43 Console 050 150 060 006 Spare Parts List To change DS150 0006 1
20. CKET MTG CABLE REEL ARM TWO SLOTS COVER CABLE REEL KT200 CABLE REEL ACCY SCREW CABLE REEL COVER WASHER LOCK 6mm STRAIN RELIEF PG 13 5 8 12mm RED WHITE STRAIN RELIEF PG7 BLACK 100753_C doc Drawings 15 4 6 43 42 Central Unit Board Layout And Measuring Points 024 150 300 001 MP4 d 4 5V TT MEMORY EXT AC X4 MPS 5V REF mpe LPS MP7 Pd USP 5V USP 5V 5 2 5 9V 9V N 7 Q 10 GND 5 MP8 9V HES 1 12 DAV1 DAV2 DAV K1 MP15 c K8 RELAY LOAD wG2 A D PS P 4 3 A MP14 5 4 9 K9 w WG2 DAV2 161 2 7 MP13 LGI KGND NE GND 41 40 39 38 37 36 35 34 33 32 31 30 25 24 23 22 21 16 15 14 13 12 11109 87 6 554 32 X1 Measuring Points 1 MP2 MP3 MP4 MP5 MP6 MP7 MP8 MP10 MP11 MP12 MP13 MP14 MP15 LED s AGND 9V 9V 5V TTL 5V REF 5V UPS sensors supply 5V UPS sensors supply 9 HES AGND DAV1 piston pressure signal DAV2 rod pressure signal LW1 length signal WG1 angle signal 1 WG2 angle signal 2 LOAD Overload relay ON energized normal conditions OFF de energized A2B A2B relay ON energized normal conditions OFF de energized Hirsc hmann REV C 08 22 03 100753 C doc 16 Service Manual PAT DS150 5 PROCEDURE 5 1 EPROM replacement in Central Unit Follow this procedure when changing EPROM s in the DS150 central units
21. HIRSCHMANN PAT LOAD MOMENT INDICATOR DS150 SERVICE MANUAL P N 031 300 100 753 REV C 08 22 03 Service Manual PAT DS150 NOTICE Hirschmann Inc makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and or its fitness for a particular purpose Hirschmann Inc will not be liable for errors contained in this manual or for incidental or consequential damages in connection with the furnishing performance or use of this manual This document contains proprietary information which is protected by copyright and all rights are reserved No part of this document may be photocopied reproduced or translated to another language without the prior written consent of Hirschmann Inc Hirschmann Inc reserves proprietary rights to all drawings photos and the data contained therein The drawings photos and data are confidential and cannot be used or reproduced without the written consent of Hirschamnn Inc The drawings and or photos are subject to technical modification without prior notice All information in this document is subject to change without notice MANUAL REVISIONS DATE NAME DESCRIPTION 10 16 01 ECN 01 283 03 08 02 CLC ECN 02 087 Oo m lt 08 22 032 CSH 03 097 2001 Hirschmann Chambersburg PA 17201 USA Hirschmann REV B 03 08 02 100753_C doc Serv
22. NS CAP GREEN ENTER KEYSWITCH W KEYS CONSOLE DS150 KEY CONSOLE KEYSWITCH SWITCH ACCY KNOB WITH SCALE DISK 1 63 SWITCH ACCY KNOB WITH SCALE DISK 1 16 ALARM BUZZER DS150 amp DS350C CONSOLE FACEPLATE DS150 CONSOLE LARGE DISPLAY STD GASKET HOUSING SCREW 3mm x 10mm PANHEAD PHILLIPS FACEPLATE 100753_C doc Drawings 13 45 Cable Reel 068 208 060 013 LWG208 Spare Parts List Hirschmann REV C 08 22 03 100753 C doc 14 Service Manual F 44 DS150 Hirschmann REV C 08 22 03 PART NO 006 7 10 006 002 068 000 110 038 067 000 050 065 064 103 060 002 002 050 206 012 000 207 010 064 002 050 206 100 000 208 040 083 068 000 100 064 068 000 110 029 068 000 100 152 068 000 110 011 000 673 020 002 006 800 005 058 000 205 031 230 006 800 005 057 005 682 000 001 068 000 1 10 031 000 208 020 006 021 441 131 013 000 214 030 703 QTY DESCRIPTION 1 1 1 1 2 3 1 1 1 1 1 1 SENSOR LENGTH TRANS LGE 100 KT200 LWG208 SENSOR ACCY GEAR WHEEL KT200 CABLE REEL SENSOR ACCY GEAR WHEEL T 50 CENTER SHAFT SENSOR ANGLE WG103 SCREW 6M X 12 SOCKET CAP WASHER FLAT 6MM SCREW 6M x 100M SOCKET CAP WASHER LOCK 6MM SLIPRING 2 CONDUCTOR CONNECTION STRIP CABLE REEL KT200 HOUSING BKT CABLE DRUM amp NYLON CABLE COVER CABLE REEL ACCY CABLE DRUM KT 200 LWG208 CABLE LENGTH SENSOR 1 CORE W SHEILD per ft BRACKET MTG CABLE REEL ARM ONE SLOT SCREW 12mm x 30MM HEX HEAD BRA
23. age Refer to Section 7 4 No Display this manual Yes i Check the voltage at angle sensor between connector pins A AGND and C 5V Refer to system wiring diagram Cable defective replace cable or cable assembly No gt ns Refer to system wiring diagram Yes v Check the voltage between X1 8 ground and X1 9 signal output voltage Voltage should be 3 125V 0 2 5V 45 1 875V 90 Refer to angle sensor theory Replace Angle Sensor Refer to length angle adjustments procedure Hirschmann REV C 08 22 03 100753 C doc 40 Service Manual 05150 8 ERROR CODE TABLE Error Code Error Cause Elimination Fallen below radius e Fallen below the minimum e Luff down the boom to a range or angle radius or gone past the range exceeded maximum angle specified in the respective load chart due to luffing up the boom too far e Gone past the maximum radius or fallen below the minimum angle specified in the respective load chart due to luffing down the boom too far Radius range exceeded or fallen below angle range E03 Non permitted slewing zone no load area Operating mode not acknowledged or non permitted slewing zone e Anon existing operating mode has been selected e The boom is in a non permitted slewing zone e Boom has been extended
24. asuring Channel gt ra i C JAN e kas SCH N 554 N e x lt TR 6 S 64 Rod Side Pressure Measuring Channel Es WA 5 A E x S REZIN 5 e po wu s Hirschmann REV C 08 22 03 100753_C doc 21 65 Main Boom Angle Measuring Channel 6 6 Second Angle Measuring Channel NORKIN N SAN x S NUN N RK N N EN ZON N N N x N Hirschmann REV C 08 22 03 100753 C doc 22 Service Manual PAT 05150 7 TROUBLESHOOTING FLOW CHARTS 7 1 General Flowchart This section explains how to handle a problem that may arise with the PAT Load Moment Indicator System PAT DS150 The procedures are easy to follow and are given in flowcharts on the following pages Start with the general flowchart below which will guide you to one of the detailed flowcharts shown in this section START Y What s Wrong KM Lever Lockout Activated Go to Flow Chart 2 ER Broken Length Cable Go to Flow Chart No display m Go to Flow Chart 4 DM Anti Two Block Problem Go to Flow Chart 5 Length Reading Problem to Flow Chart 6 gt Load Reading Problem m to Flow Chart 7 Bad Data Transfer Between Console amp Central Unit lo Flow Char
25. ctual information of the crane This is computed against the reference data and the crane status is continuously monitored Description of the Housing The central unit DS150 is a rugged waterproof sheet steel housing It is mounted on the left side of the turn table weldment or on the counterweight The cables are led into the central unit via strain reliefs and connected with fast ons An override switch is mounted on the housing which overrides the LMI function The system is protected by a 2 AMP fuse which is mounted on the lower right side The output signal is protected by a 10 AMP fuse mounted on the lower mid Description of the Boards Inside the central unit CU there is a main board The main board and CPU is the heart of the system and it contains the processor and the system and data The system EPROM holds the operating system and data EPROM hold the crane and calibration information The wires from the various components are connected with fast ons to the main board The main board holds the electronics necessary to receive evaluate and direct the continuous flow of data from the sensors to the processor Main board components Power supply Provides all the necessary voltages for the transducers and the electronics on the main board Analog input part Receives and prepares all the signals from the transducers for further processing Relays an overload and anti two block relay Controls the Bosch relay for lever l
26. ed Upper limit value in measuring channel pressure piston side has been exceeded Upper limit value in measuring channel pressure rod side has been exceeded Upper limit value in measuring channel main boom angle has been exceeded Upper limit value in measuring channel angle 2 has been exceeded Reference and or supply voltage defective Error in the ET ndi ET ndi System program and data EPROM do not match E31 Hirschmann 08 22 03 e The supply voltage is falsified by one of the sensors DAV LWG e Check the voltages on the LMI main board Check sensors plugs and cable replace if need be e Electronic component is e Replace LMI main board defective e The analog voltage is falsified by one of the sensors e Check the voltages on the LMI main board Check sensors plugs and cable replace if need be e Electronic component is e Replace LMI main board defective e Refer to E11 e Refer to E11 e Refer to E12 e Refer to E12 e Refer to E12 e Refer to E12 Refer to E15 e Refer to E15 e Refer to E16 e Refer to E16 e Refer to E19 e Refer to E19 e The system program e Replace system program PROM is defective PROM PROM No 0 e The system program in e Replace the system program the LMI does not match to PROM or the data EPROM the programming in the PROM No 1 data EPROM 100753_C doc Service Manual PAT Dean Error Code JError Case
27. etween test point MP10 ground to MP6 5 0v Refer to main board layout 4 Yes Correct Check power supply and measure between test point MP10 ground to 2 9 0 and between test point MP10 ground to MP3 9 0v Refer to main board layout Yes lt Yes Correct Power supply on connection board faulty Replace connection board and reset pressure channel Refer to system wiring diagram and main board replacement procedure Y Check power supply at transducer plugs Measure between B ground and 5V Measure between B ground and C 5V No Faulty wiring Check wiring of pressure transducer cable Yes Y C NEXT PAGE Hirschmann REV C 08 22 03 100753 C doc Troubleshooting Flow Charts 35 C PREVIOUS PAGE p Check transducer signals in central unit Connect pressure transducers to cable Disconnect wire No 4 of transducer cable from X1 21 signal piston side Measure transducer signals 0 1V between Pin 19 ground and wire No 4 of piston cable Disconnect wire No 4 of transducer cable from terminal block X1 Pin 16 single rod side Measure transducer signals 0 1V between Pin 19 ground and wire No 4 of rod cable Refer to system wiring diagram Correct Check wiring in pressure transducer cable Continuity Good No Correct Yes i Tra
28. gear wheel of length transducer Extend and retract boom to ensure that clutch is not sipping on potentiometer axle Replace the gear wheel clean potentiometer No axle Reset length potentiometer Refer to length angle adjustments procedure Ye um Check power supply to length transducer on connection board terminal X1 8 ground and X1 11 5V Refer to system wiring diagram Replace connection board and reset pressure No p channel Refer to system wiring diagram and main board replacement procedure Yes Y d 2 Hirschmann REV C 08 22 03 100753 C doc Troubleshooting Flow Charts 31 Continued from previous page wenn PAGE Measure supply to length transducer in cable reel at terminal between Pin 1 ground and Pin 3 5 Refer to system wiring diagram Faulty wiring between central unit and length transducer Check wiring Correct No Yes Y Measure signal from length transducer in cable reel between pin 2 signal and pin 1 ground Retracted boom with no turns on the potentiometer signal is 0 500v At 10 turns on the potentiometer the signal measurement would be 4 500v Therefore the voltage of an extended boom will be between 0 500 to 4 500 volts Replace length potentiometer assembly Remove slip ring body from shaft and remove gear wheel fro
29. ic component in the measuring channel is defective Refer to E12 Cable between central unit and the length angle sensor defective or loose Water inside the plug of the length angle sensor Angle potentiometer defective Electronic component in the measuring channel defective e Check cable as well as plugs replace if need be Replace length potentiometer Replace LMI main board or processor board Check cable as well as plugs replace if need be Replace pressure transducer Replace LMI main board or processor board Refer to E12 Check cable as well as plugs replace if need be Replace angle sensor Replace LMI main board or processor board Fallen below lower limit value in measuring channel angle 2 E13 Fallen below lower limit value in the measuring channel pressure rod side Hirschmann REV C 08 22 03 Cable between the central unit and the angle sensor defective or loose Water inside the plug of the angle sensor Angle potentiometer defective Electronic component in the measuring channel defective Check cable as well as plugs replace if need be Replace angle sensor Replace LMI main board or processor board 100753_C doc Error Codes 43 Error Code Error Cause Eliminton 0 Reference and or supply voltage defective Analog and or supply voltage defective Upper limit value in measuring channel main boom length has been exceed
30. ice Manual FAT DS150 TABLE OF CONTENTS 1 MECHANICAL DESCRIPTION OF THE SYSTEM COMPONENTS 1 2 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL 2 2 1 BASIC SYSTEM COMPONENT LAYOUT redet Re espe EB beate 3 2 2 BASIC ADJUSIMENT OF THE COMPONENIS nee 4 3 DEFINITIONS EE ER EE LE RE EIS 5 SE 6 AA SYSTEM ELECTRICAL DIAGR M ege EE 6 4 2 CENTRAL UNIT 024 150 060 002 SPARE PARTS LIST 7 4 3 CONSOLE 050 150 060 006 SPARE PARTS LIST u un ke er aa 9 4 4 CONSOLE 050 150 060 008 SPARE PARTS 11 4 5 CABLE REEL 068 208 060 013 LWG208 SPARE PARTS 13 4 6 CENTRAL UNIT BOARD LAYOUT AND MEASURING POINTS 024 150 300 001 15 9 PROCEDURE tnu iate ae Pao pda 16 5 1 EPROM REPLACEMENT IN CENTRAL UNIT ticae tti abre u 16 5 2 PISTON amp ROD PRESSURE CHANNEL ZERO POINT ADJUSTMENT l een 16 5 3 LENGTH amp ANGLE ADJUSTMENTS bee de ee nee 17 9 4 MAINBOARD REPLACEMENT is Ee eis nd 18 6 THEORY J actrees qayakuy nennen 19 6 1 ANTI IWO BLOCK amp SHUTOFF CIRCUIT en 19 6 2 LENGTH MEASURING CHANNEL eisen 19 63 PISTON SIDE PRESSURE MEASURING CHANNEL ah a Ge ewe ee gesek ek See 2
31. keeps the switch closed until the hook block strikes it Console The console displays the geometrical information such as length and angle of main boom working radius and head height of the boom It also displays the actual load and the maximum load permitted by load chart Furthermore it has an alarm horn and a warning light for overload and a pre warning light The analog instrument shows a percentage of the total permissible moment The console has a switch for the operating modes duty selection switch for crane configurations and a switch for the Reeving of the hook block It also has a warning light for anti two block conditions and an override switch for overload or anti two block condition Duty Selection Switches Digital Inputs The system has to be programmed for the lifting area configuration The crane is going to be worked in e g main boom on outriggers over front or rear or over the side for 360 degrees For obtaining this information from the crane micro switches are installed in the electrical swivel that tells the system the exact location of the boom Micro switches are also located on the counterweight which tells the system if the counterweight is installed or not where applicable Hirschmann REV B 03 08 02 100753_C doc 2 Service Manual PAT DS150 2 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UNIT All the data of the crane is stored inside the central unit in EPROM s The central unit receives all a
32. l unit Remove main board and place it in the same packing material that the replacement in which the main board came 8 Carefully insert the new main board in place 9 Insert the 9 Philips mounting screws 10 Insert the relay into the main board 11 Insert the system and data software into the main board 12 Connect the X1 terminal wires to the main board Refer to Wiring Diagram 13 Zero pressure transducers using the zeroing procedure in this section 14 Inspect the gasket for nicks cuts or damages Refer to 031 300 340 003 DS 350 Central Unit Gasket Recommendations Revision and 031 300 340 002 Central Unit Cover Installation and Tightening Procedure Revision A Hirschmann REV C 08 22 03 100753 C doc 19 6 6 1 Anti Two Block amp Shutoff Circuit BLOCK amp CIRCUIT SOLENOID 4 7KOhm RESISTOR 1 FROM CRANE gt SUPPLY 12V ACTURER S D ON FO ON OF LOCKOUT SIGNAL CENTRAL UNIT TERMINAL BOARD WIRE NUMBER MIN MAX LENGTH SENSOR 10 K TURNS CABLE REEL TERMINAL CENTRAL UNI ERMINAL BOARD WIRE NUMBER D TEST POINT ON MAIN BOARD REV B 03 08 02 100753 C doc 9 Service Manual PAT DS150 6 3 Piston Side Pressure Me
33. leshooting Flow Charts 25 74 No Display PROBLEM Blank console display with no warning light shown All crane moments have been stopped C Start i Check fuses on CPU box Correct No gt v Measure crane voltage on connection board between X1 2 12V and X1 4 ground Refer to system wiring diagram NOTE If crane voltage is measured below 10V system will switch off Check crane power supply for faulty Correct No crane electric or if supply is too low Yes Measure voltage the connection board between 1 30 12 24V X1 33 ground This is an output voltage to the console Refer to system wiring diagram Replace connection board and reset pressure No channel Refer to system wiring diagram and main board replacement procedure Yes _ v d Next Page E Hirschmann REV C 08 22 03 100753 C doc 26 Service Manual DS150 4 PREVIOUS PAGE Measure voltage in the console between X1 1 12 24V and X1 2 ground Refer to system wiring diagram NO Check connections of the cable between console and central unit Replace cable if necessary Refer to system wiring diagram YES Display is defective Refer to console parts list YES C END
34. m potentiometer axle Unscrew mounting plate and Coes Me F 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 i Measure signal from length transducer in central unit main board between X1 8 ground and 1 10 signal 0 5 and 4 5v Refer to system wiring diagram Correct No Faulty wiring between central unit and length transducer Check wiring Yes Y d NEXT PAGE D Hirschmann REV C 08 22 03 100753_C doc MB Manual PAT Deen Continued from previous page C PREVIOUS PAGE Measure length signal of amplified output on connection board between test point MP10 and test point MP13 5 NOTE Negative signal at terminal X1 11 will be converted into positive signa at MP13 i e input at terminal X1 11 0 5V and Refer to system wiring diagram Replace connection board and reset pressure channel Correct No gt Refer to system wiring diagram and main board replacement Procedure Yes Hirschmann REV 08 22 03 100753_C doc Troubleshooting Flow Charts 33 77 Load Reading Problem PROBLEM Load reading incorrect d START gt
35. nder The pressure transducer is connected to the central unit with a four conductor double shielded cable The power supply voltage is 5V The output signal is 0 00V under 0 pressure to 1 00V at max pressure 441 Opsi The Length Angle Transducer The length angle sensor LWG is a combination of two transducers in one box fitted at the base section of the boom It measures the length and angle of the boom A reeling drum drives a potentiometer which is the length transducer Part of the length transducer is the length cable on the drum which is a two conductor cable screen and live It is connected to the anti two block switch at the boom head and to a slip ring body in the reel The angle transducer is fitted into a small box filled with oil A pendulum drives the axle of the angle potentiometer The power supply voltage for both is 5 00V The output signal for the length transducer is 0 500V up to 4 500V The output signal for the angle transducer is 1 875V up to 3 125V Anti Two Block Switch The anti two block switch monitors the load block and its relationship with the head of the boom In working condition the switch is closed When the hook block strikes the weight the circuit opens disengaging a relay output to the lockout solenoid valves where applicable To check the cable for damage short circuit to ground there is a 4 7k resistor between ground and the contact of the switch The weight at the anti two block switch
36. nsducer defective replace transducer and reset pressure channel Yes Connect wire No 4 from transducer cables back to terminal X1 16 rod side and terminal X1 21 piston side Without pressure in pipes or hydraulic pipes disconnected from transducer check O point Measure between test point MP10 ground and test point MP11 Signal should be 0 50V piston side Measure between test point MP10 ground and test point MP12 Signal should be 0 50V rod side adjustment on connection board Refer to system wiring diagram No Measure voltage between test point MP10 ground and test point 11 and reset with P1 to 0 50V piston side Measure voltage between test point MP10 ground and test point MP12 and reset with P2 to 0 50V rod side If not adjustable replace transducer Refer to system wiring diagram and zeroing transducer procedure ad END E Hirschmann REV 08 22 03 100753_C doc BS vice Manual PAT Ds150 7 8 Bad Data Transfer Between Console amp Central Unit PROBLEM Error Code E93 E94 No data transfer to and from console Make sure that the eproms are plugged into the correct socket and orientated Refer to EPROM replacement procedure Correct No gt Place EPROM in correct socket Yes Check crane supply voltage for console in central unit at connection board
37. ockout Incoming Signals Signals from the transducers are connected to the main board The signals vary depending on the sensor Angle transducer signal is between 1 875V and 3 125V Length transducer signal is between 0 500V and 4 500V Pressure transducer signals are between 0 00V and 1 00V measured between the negative and positive outputs Anti two block switch resistance is 4 7Kohms Digital inputs for the duty selection switches are on or off Outgoing Signal The outgoing signal of the main board is the signal for lever lockout of connection 48 In normal working conditions there are 12 volts at this connection If there is an overload or anti two block condition the signal becomes 0 volts Furthermore all voltages for the transducers are going out through the main board Hirschmann REV B 03 08 02 100753 C doc Mechanical Description Of The System 3 2 1 Basic System Component Layout NS P JUNCTION BOX ANTI TWO BLOCK SWITCH A2B WEIGHT CABLE REE W LENGTH AND ANGLE SENSORS CENTRAL UN CONSOLE PRESSURE TRANSDUCERS Hirschmann REV C 08 22 03 100753 C doc 4 Service Manual PAT DS150 2 2 Basic Adjustment Of The Components Length Ensure that the length cable tension is correct with fully retracted boom and no tension on the cable reel Turn the cable drum 5 to 8 turns counter clockwise Then remove cover from cable reel and adjust the potentiometer counter clockwise to end stop
38. ometer Radius range Maximum radius as e Luff the jib to a radius or exceeded or fallen specified in the load chart angle specified in the load below angle range exceeded or fallen below chart with luffing jib minimum angle due to operation luffing down the luffing jib too far Faulty Overload relay or main e Replace main board acknowledgment of board are defective the overload relay on the main board Processor board defective The relay should be e Replace processor board energized the 2nd contact however is indicated to be off or the 2nd contact is indicated to be on while the relay should be de energized No acknowledge e Refer to E07 Refer to E07 ment from the anti two block relay Hirschmann REV C 08 22 03 100753_C doc 42 Service Manual F 44 DS150 Error Code Error Cause Fallen below lower limit value for measuring channel length main boom Fallen below the lower limit value in the measuring channel pressure piston side Fallen below lower limit value in measuring channel angle main boom Cable between central unit and length sensor is defective or disconnected Water inside the plug of the length angle sensor Length potentiometer is defective Electronic component in the measuring channel is defective Cable between the central unit and pressure transducers defective or water inside the plugs Pressure transducer is defective Electron
39. rite read memory RAM of the e CPU module defective e Replace CPU module computer component 800537 Processor board e Replace processor board defective with CPU module Hirschmann REV C 08 22 03 100753_C doc Error Codes 45 Error Code Error Cause e 24 V supply of the console Check 24 V at terminal X1 of No data trans mission form the console to the 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 Error in the data transmission from console to central unit 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 line central unit console 5 V supply of the computer in the central unit is missing 5 V supply is too low Transmitter receiver module is defective Computer module is defective Electro magnetic interferences e g when switching contacts or valves Elimination the console electronics Check the main console electronics central unit In case of an accidental ground the transmitter module of the console electronics might be damaged Therefore replaces the console electronics Exchange console
40. the following procedure 1 Cut old cable at cable drum 2 Disconnect damaged length cable from junction box at the boom nose 3 Open cable reel cover and disconnect wiring from connection block Pull 7 conductor cable out of strain relief Remove cable reel from mounting brackets Remove damaged length cable which is mounted to the slip rings in the cable reel from slip ring connection 6 backside of the cable reel open the strain relief attached to the axle in the center of the drum Pull existing length cable out of the cable reel 7 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 8 Reconnect the length cable to the slip ring 9 Remount cable reel to the boom 10 Turn reeling drum clockwise to spool the new cable neatly onto the drum 11 Set preload on cable reel by turning the drum counter clockwise 5 to 8 turns 12 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 13 Connect the length cable into the boom tip junction box 14 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 as Hirschmann REV C 08 22 03 100753_C doc Troub
41. ts IE Interference Problem GO to Flow Chart 9 Angle Problem gt Goto Flow Chart 10 REV 03 08 02 100753_C doc Troubleshooting Flow Charts 23 7 2 Lever Lockout Activated P o PROBLEM The lever lockout system of the crane is activated Crane movements hoist up telescope out and boom down are stopped Crane is not in overload or two block condition Start Set 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 i If console display is If Load Moment Limit Light Fault in crane electric blank fault is located in Fault in Anti Two displays fault it is located in or hydraulic system power supply wiring or Block system LMI cables wiring fuses or fuses console Read error code displayed on console and go to Section 6 Check lever lockout Go to Flow Chart 4 Go to Flow Chart 5 system in crane Hirschmann REV C 08 22 03 100753 C doc BA Service Manuel PAT DS150 _ 7 3 Broken Length Cable PROBLEM Damaged or broken length cable Refer to cabel reel parts list and system wiring diagram Replace length cable using
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