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DS-160 LMI Service Manual

1. Defect on main board Replace main board NO p Refer to system wiring diagram and main board replacement Procedure Y Reconnect Wire 5 to X1 9 and Wire 6 to X1 10 Refer to system wiring diagram C End SkyAzul Equipment Solutions www skyazul com 301 371 6126 Length Reading Problem 17 9 LENGTH READING PROBLEM PROBLEM Length displayed incorrect Crane is not in out of load chart condition START Y Check mechanical adjustment of length potentiometer in cable reel With boom fully retracted reset potentiometer by turning it slowly counter clockwise until it reaches a soft stop Check the length Refer to system wiring diagram and sensor adjustment procedure Replace length potentiometer assembly Refer to Drawing 6 in Section 4 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 form terminal block Connect new NO a i assembly to terminal block Reinstall mounting plate gear wheel and slip rings With boom fully retracted reset potentiometer by turning it slowly counter clockwise until it reaches a soft stop Refer to system wiring diagram and sensor adjustment procedure YES i Check out clutch in big gear wheel of length transducer Extend and retract boom to ensu
2. 3 EE 4 5 1 OPERATING ERRORS E01 THROUGH E05 surra 4 5 2 LOCKOUT FUNCTION ERRORS 07 AND 08 aaa 5 5 3 ANALOG INPUT CHANNEL ERRORS a 5 5 3 1 TROUBLESHOOTING A SENSOR PROBLEM USING THE DISPLAY rss 5 5 3 2 ERROR CODES FOR THE ANALOG INPUTS nennen nn nnne 6 54 ERRORS STAND UP sde clase Da beet bera ser br eege DEENEN 8 E FUNCTION LOOKOUT EE 11 E RRE 12 8 ANTI TWO BLOCK PROBLEM ara egn 14 9 LENGTH READING PROBLEM 17 10 ANGLE READING PROBLEM 19 LOAD READING PROBLEM 21 12 DATA TRANSFER CENTRAL UNIT lt gt CONSOLE 5 23 ci 59 25 13 1 SYSTEM WIRING DIAGRAM ss 25 13 2 SYSTEM WIRING DIAGERAN ss 26 13 3 SYSTEM WIRING DIAGRAM rss 27 13 4 CENTRAL UNIT MAIN BOARD TERMINATION AND BREAKDOWN PARTS LIST eee 28 13 5 CENTRAL UNIT MAIN BOARD LAYOUT nennen nennen nnn sene nn sese 29 13 6 CONSOLE DS 100 0005 J PARTS TEEN 30 13 7 PRESSURE TRANSDUCER IDANEGTIAI rss 31 13 8 PRESSURE TRANSDUCER DAVS300 3401 tte 31 EEE NINE 32 EE ae e 33 14 1 EPROM LOCATION AND INSTALLATION PROCEDURE aaa 33 14 2 MAIN BOARD REPLACEMENT PROCEDURE aaa 34 14 3 CALIBRATION OF SENSORS PROCEDURE aaa 35 14 3 1 PRESSURE TRANSDUCER CALIBRATIO
3. Correct NO Place EPROM in correct socket Refer to EPROM installation procedure YES OFF Measure process voltage on the Main Board in the central unit between X1 1 UB and X1 3 ground Refer to system wiring diagram NO Make sure external and internal power supplies are correct Refer to No Display Section YES Y Turn off system power Check the continuity of the receive RXD and transfer TXD wires Check continuity between central unit main board X1 8 and console X1 3 central unit main board X1 7 and console X1 4 Refer to system wiring diagram Check connections and replace cable assembly from central NO p ka unit to console Refer to system wiring diagram NEXT PAGE SkyAzul Equipment Solutions www skyazul com 301 371 6126 23 24 Service Manual ESAT Ds 160 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 co
4. gt Error Code Displayed hu gt Go to Section 5 m Function Lockout HO Go to Section 6 a No display Go to Section 7 H Anti Two Block Problem HO Go to Section 8 KE A Length Reading Problem a Go to Section 9 gt Angle Reading Problem m gt Goto Section 10 BA Load Reading Problem gt gt Goto Section 11 aa paa Goto Seaton 12 SkyAz l Equipment Solutions www skyazul com 301 371 6126 A Service Manual ESAT Ds 160 5 ERROR CODES 5 1 Operating Errors E01 through E05 These errors are usually caused by operating in a way that is not allowed per the load charts Note If an error message is displayed which is not contained in the following list please contact the PAT service department Error Code Error Cause Elimination a Fallen below Fallen below the minimum e Hoist the boom down to a radius range or radius or gone past the radius or angle specified angle range maximum angle specified in the in the load chart exceeded respective load chart due to hoisting up the boom too far Radius range Gone past the maximum radius Hoist the boom up to a exceeded or or fallen below the minimum radius or angle specified fallen below angle specified in the respective in the load chart angle range load chart due to hoisting down the boom too far Operating mode Anon existing operating mode Set the correct operating not existing or has been selected mode for the crane non permitted configuration in q
5. Correct NO Y Replace fuses YES Y Measure voltage on the main board terminal strip between X1 1 10 30V and X1 3 ground This is an input voltage from the crane Refer to system wiring diagram Check crane power supply for faulty Correct NO 6 wiring in crane electric YES Y Measure voltage on the main board between X1 5 UB and X1 6 ground This is an output voltage to the console Refer to system wiring diagram Replace the main board in central unit NO Refer to system wiring diagram and main board replacement Procedure YES v C NEXT PAGE n SkyAzul Equipment Solutions www skyazul com 301 371 6126 No Display C PREVIOUS PAGE Measure voltage in the console between X1 1 10 30V and X1 2 ground Refer to system wiring diagram Check connections of the cable between NO gt console and central unit Replace cable if necessary Refer to system wiring diagram YES E Console Display is defective Replace the console Refer to system wiring diagram C END SkyAzul Equipment Solutions www skyazul com 301 371 6126 13 14 Service Manual ESAT Ds 160 8 ANTI TWO BLOCK PROBLEM Refer to the crane owner s manual for a complete description of the anti two block system PROBLEM Function of Anti Two Block System is fa
6. LA EQUIPMENT SOLUTIONS Late e 58 KEE SERVICE MANUAL NOTICE SkyAzul makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and or its fitness for a particular purpose SkyAzul will not be liable for errors contained in this manual or for incidental or consequential damages in connection with the furnishing performance or use of this manual This document contains proprietary information which is protected by copyright and all rights are reserved No part of this document may be photocopied reproduced or translated to another language without the prior written consent of SkyAzul SkyAzul reserves proprietary rights to all drawings photos and the data contained therein The drawings photos and data are confidential and cannot be used or reproduced without the written consent of SkyAzul The drawings and or photos are subject to technical modification without prior notice All information in this document is subject to change without notice r SkyAz l Inc 91 200 W Main Street Suite 2A Middletown MD 21769 EQUIPMENT SOLUTIONS Fax 301 371 0029 info skyazul com SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual ESAT Ds 160 TABLE OF CONTENTS SEENEN d See d 3 SYSTEM DESCRIPTION eege ee 2 4 GENERAL TROUBLESHOOTING INFORMATION a 3 4i GENERAL LOW CHART maa
7. 1 0 1 0 6 0 6 0 6 0 2 0 2 0 2 0 1 0 1 0 1 0 1 0 DESCRIPTION CENTRAL UNIT ASSY DS160 0003RETRO W 90 CONSL CBL amp H DAVS CONSOLE ASSY DS160 W RAMMOUNT CONSOLE ACCY PCS30 5 MOUNTING1 BALL W 2 437 DIA PLATE SCREW 10 24 X 5 8 PH PH SSMACHINE SCREW NUT 10 24 LOCK NYLON INSERT WASHER FLAT 10 SENSOR ACCY CUTTING RING DKA16 PRESSURE TRANSDUCERS SENSOR PRES TRAN DAVS300 34014 20mA 300 bar M12 9 16 18 HYDR ADAPTER 9 16 18 UNF 2B M16 X 1 5 STRAIN RELIEF PG11 6mm GREEN WHITE INSERT STRAIN RELIEF PG11 GREEN EMI RFI 8 10 5mm MANUAL OPER DS160 MANUAL SERV DS160 www skyazul com 301 371 6126 DS160 Upgrade Installation 47 17 1 Console Mounting The console has a mount that allows the console to be swiveled into any direction and to be mounted in a variety of locations and on nearly any surface Choose a location that is in line of site of the sensor and within reach of the operator Securely attach the two RAM mount bases onto a solid surface for the left and right side operation The console cable may not fit through goose neck conduit as existing wiring therefore run the console cable to the outside of the conduit and insure there no interference Refer to 13 6 Console DS160 0005 Parts List 7 17 2 Central Unit Mounting Mount the central unit in covered but accessible location You will need to remove the cover and access the EPROM s and main board The central is supplied with 4 m
8. 13 Connect the X1 terminal blocks wires to the main board Refer to the system wiring diagram in this manual or in the central unit lid for wiring connections 14 Turn power on and test system 15 Inspect the gasket for nicks cuts or damages before installing and tightening the cover NONA SkyAz l Equipment Solutions www skyazul com 301 371 6126 Procedures 35 14 3 Calibration of Sensors Procedure To access the calibration sensors screen use the following procedure OK 1 From the operating screen simultaneously press and hold t and for approximately 5 seconds 2 The screen show the following selections CALIBRATE SENSORS EXIT 3 Use the UP and DOWN arrows to high light text flashes calibrate sensors and then press OK to display a similar screen as shown below Note the displayed length indication is noted by XX X in following step PIS 0 500V 000 PSI ROD 0 500V 000 PSI LEN 0 500V XX X FT ANG 0 500V 90 DEG Go to the following selection for the pressure transducer length or angle procedure below to complete sensor calibration after confirming the following step 4 Acknowledge the sensor selection by selecting yes or no CALIBRATE SENSOR YES NO Proceed to the following sections for pressure transducer length and angle calibration procedures 14 3 1 Pressure Transducer Calibration Procedure After selecting PIS or ROD in steps 1 thro
9. Adapter 9 16 18 UNF 2B M16 X 1 5 SkyAzul Equipment Solutions www skyazul com 301 371 6126 32 Service Manual ESAT Ds 160 13 9 Cable Reel Part Number 031 300 060 401 Refer to system wiring diagram in central unit for assembly part DESCRIPTION BOARD TERMINAL W EMC FILTERS numbers NO PART NO 01 068 000 300 060 02 064 143 060 005 03 068 000 300 018 04 002 050 206 012 05 000 207 010 064 06 068 000 100 152 07 000 214 340 013 08 000 673 020 002 09 031 300 050 255 10 031 300 100 206 11 068 000 100 064 12 031 300 060 414 13 068 000 110 038 14 006 800 005 001 15 092 000 060 202 16 000 214 261 311 SkyAzul Equipment Solutions QTY ek ek eek SNN O ANGLE SENSOR WG 103 0007 SENSOR LENGTH POT LPE0018 CURRENT 4 20mA SCREW M6 X 12 HEX SOCKET CAP WASHER M6 FLAT HOUSING KT200 PG13 5 HOLE PLUG CABLE LENGTH SINGLE CORE STRAIN RELIEF PG11 GREEN CHEMICAL CORROSION INHIBITOR SLIP RING ASSEMBLY 2 POLE CABLE ASSEMBLY 17 GEAR 75 TOOTH FOR LWG208 GEAR 25 TOOTH FOR LWG208 CABLE MODULAR LENGTH amp ANGLE SENSOR 3p 32cm STRAIN RELIEF ACCY PG13 5 11 REDUCER www skyazul com 301 371 6126 Procedures 33 14 14 1 PROCEDURES EPROM Location and Installation Procedure Ba coco 13 Ensure the notch is in the correct direction The DATA TLK and SYSTEM EPROM s fill the bottom of the socket as shown by the arrows Place EPROM s in the correct EP
10. Refer to system wiring diagram and sensor adjustment procedure YES Check power supply to pressure transducers piston and rod side Check each transducer by unplugging the transducer cable from transducer Measure voltage at the cable connection between A 12 24v and C ground at each connector Refer to system wiring diagram Check power supply in the central unit between X1 37 UBV and X1 36 ground for piston side and rod side pressure transducers Refer to system wiring diagram Fault in pressure transducer cable YES e Refer to system wiring diagram Y C NEXT PAGE NO Main board defective Replace main board Refer to system wiring diagram and main board replacement procedure Correct NO p SkyAzul Equipment Solutions www skyazul com 301 371 6126 22 Service Manual ESAT Ds 160 C PREVIOUS PAGE Measure signal from pressure transducers in central unit The return signal is a current output and must be measured in series Set Voltmeter to measure amps Piston Side remove Wire 2 from X1 32 in the central unit and connect one ammeter lead to wire 2 and the other lead to X1 32 The measurement should be between 4 20ma 4ma when there is no pressure in the hydraulic lines O psi Rod Side remove Wire 2 from X1 33 in the central unit and connect one voltmeter lead to wire 2 and the other lead to X1 33 The me
11. X X Note the displayed length indication is noted by XX X in OK following steps EXIT 2 Verify the boom retracted boom length is correct If incorrect adjust length pot in cable reel define in the Cable Reel LWG308 0001 Adjustment Procedure Note The retracted main boom length may not be indicating correctly until after the calibration procedure step 2 The display length is not the load chart length The correct display length can be found in the LMI section of the crane operator s manual If the indication is more than 0 2 feet incorrect recheck step 1 3 Press the OK button FULLY EXTEND MAINBOOM XX X ft EXIT 4 Fully extend the main boom Press the OK button After OK the system request the length sensor calibration is saved SkyAzul Equipment Solutions www skyazul com 301 371 6126 Procedures 37 14 3 3 Angle Sensor Calibration Procedure After completing steps 1 through 4 at the beginning of this section boom down to a flat angle and mechanically adjust the angle sensor The angle should be set to be 0 0 of the measured angle Material calibrated inclinometer Displayed angle indication BOOM ANGLE Q 0 MECH 0 CALIBRATION Note the displayed angle indication is noted by XX X in following OK steps EXIT Press OK when the sensor is mechanically set Pressing OK confirm the mechanical adjustment BOOM TO 40 0 DEG XX X DEG EXIT Boom up to the next correction angle
12. by touching a grounded surface WARNING Do not re use the DS50 EPROM module in the cable reel as damage may occur to the DS160 system 6 Remove the two screws that secure the gear wheel guardrail SkyAz l Equipment Solutions www skyazul com 301 371 6126 DS160 Upgrade Installation 49 7 Remove the 4 screws holding the slip ring length sensor mounting plates and remove the slip ring and length sensor assemblies Mounting plate screws 8 Replace the length sensor potentiometer 068 000 300 018 with the pot board and JST wire assembly provided The length pot is keyed not to turn as shown below and should be installed in the plastic mounting plate ET uA patera E rr RT KETA SkyAzul Equipment Solutions www skyazul com 301 371 6126 50 Service Manual ESAT Ds 160 9 Locate the 8 Philips screws that secure the main board to the cable reel housing and carefully remove the screws e SkyAzul Equipment Solutions www skyazul com 301 371 6126 DS160 Upgrade Installation 51 11 Remove 2 screws in the bottom of the cable reel as shown and install 2 M3 x 25mm standoffs as seen in the two photographs below 12 Reinstall the slip ring length sensor and mounting plates previously removed in step 7 into the cable reel and tighten the 4 screws 13 Install angle sensor 064 143 060 005 into the cable reel using the 3 M6x16mm screws and washers provide
13. 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 SkyAzul Equipment Solutions www skyazul com 301 371 6126 2 Service Manual ESAT Ds 160 3 SYSTEM DESCRIPTION The PAT Load Moment Indicator DS 160 consists of a central microprocessor unit operating console length angle sensor pressure transducers 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 with 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 crane functions 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 calcul
14. 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 If the volume is very small a desiccant bag might be able to soak up the airs 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 PAT representative for breathing elements to than can be added to the box and will help to reduce the effects of humid climates SkyAzul Equipment Solutions www skyazul com 301 371 6126 42 Service Manual ESAT Ds 160 16 SENSOR THEORY The system sensors provide a 4 to 20mA output however due to a fixed resistor circuit in the central unit the input signal can be measured using ammeter current or voltmeter voltage The input signal operating window is 4 to 20mA measured in series at the analog input terminal OR 1 0 to 4 9V measured in parallel between the analog input and ground GND terminals At 4mA the voltage is 1 0V and at 20mA the voltage is 4 9V When troubleshooting this system a current or voltage needs to be measured to determine the status or condition of the sensor 16 1 THEORY 1 OPERATION OF PISTON SIDE LOAD SENSOR Measuring current The ammeter A is used to me
15. out of load chart condition E START Check the cable reel for damages or movement of mounting bracket Refer to system wiring diagram and sensor adjustment procedure Repair or replace cable reel if damaged or NOS adjustments can not be made YES Place the boom at 0 Measure the angle sensor supply voltage in the central unit between terminals X1 31 UBV and X1 39 ground Refer to system wiring diagram Main board defective Replace main board NO Refer to system wiring diagram and main board replacement procedure Open cable reel cover Measure the angle sensor supply voltage in the cable reel between terminals X1 1 UBV and X1 3 ground Refer to system wiring diagram Faulty wiring between central unit and cable reel NOS Check wiring Refer to system wiring diagram Yes NEXT PAGE SkyAzul Equipment Solutions www skyazul com 301 371 6126 Service Manual IP 4XTF Ds 160 PREVIOUS PAGE Measure signal from angle transducer in cable reel The return signal is a current output and must be measured in series Set Voltmeter to measure amps Remove Wire 4 from X1 4 in the cable reel and connect one voltmeter lead to wire 4 and the other lead to X1 4 The measurement should be between 4 20ma 20ma with the boom at 0 or 4ma with the boom a 90 Refer to system wir
16. 26 10 Service Manual ESAT Ds 160 Error Code Error 1 Cause 73 Elimination No data trans e Interruption or accidental ground e Check wiring to the mission from the in the cable between central unit console in case of central unit to the and console accidental ground console replace console electronics too 5 V supply of the computer in Check connection to the the central unit is missing power unit 5 V supply is too low Exchange the LMI main board Transmitter receiver module is Replace console defective electronics or LMI main board Computer module is defective Replace processor board Electro magnetic interferences 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 e The CPU of the console is e Replace the CPU of the RAM of the defective console console e The console main board is e Replace the console defective main board SkyAzul Equipment Solutions www skyazul com 301 371 6126 Error Codes 6 FUNCTION LOCKOUT 11 PROBLEM The lever lockout system of the crane is activated Crane movements hoist up boom extended and 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
17. 40 DEG range 35 45 Note When the boom angle is within the calibration range the screen will add the CHANGE and OK text to the screen similar to the screen below Measure the boom angle with the inclinometer and when the boom is positioned in the calibration range compare the measured angle to the displayed angle BOOM ANGLE 40 0 DEG CHANGE XX X DEG OK EXIT Use the UP and DOAN arrow buttons to select CHANGE then press OK The displayed angle should now be flashing Use the UP and DOAN arrow buttons to adjust the indicated angle to match the measured angle After the display shows the correct angle press OK Complete the above procedure to set the correction factor at 60 and 70 boom angle After OK is selected the system defines a high boom correction angle 60 DEG range 55 65 After OK is selected the system defines a high boom correction angle 70 DEG range 65 75 After OK the system request the angle sensor calibration is saved SAVE CALIBRATION YES NO Use the UP and DOAN arrow buttons to select YES which should be flashing then press OK to confirm calibration Press EXIT to leave calibration or select the CALIBRATE SENSORS to calibrate another sensor SkyAzul Equipment Solutions www skyazul com 301 371 6126 38 Service Manual ESAT Ds 160 14 4 Cable Reel LWG308 0001 Adjustment Procedure de d
18. 5 000 205 020 616 000 207 020 064 068 000 300 018 092 000 060 202 068 000 300 060 000 205 370 306 000 212 010 325 002 060 100 301 000 208 030 030 031 300 060 414 123 429 907 910 123 429 907 890 031 300 050 255 000 214 261 311 000 214 340 013 031 300 101 579 ITE O OO NOD ABA ON AS SkyAzul Equipment Solutions PART NUMBER 031 300 060 645 031 300 060 362 031 300 050 589 031 300 050 485 031 300 050 489 000 207 010 053 000 209 140 016 031 300 060 452 031 300 050 689 021 441 110 811 031 300 050 255 031 300 190 139 031 300 190 142 KIT DS160 BOOM UPGRADE DS50 TO LWG308 QT Y 1 0 3 0 3 0 1 0 1 0 1 0 2 0 4 0 4 0 4 0 1 0 5 0 3 0 1 0 1 0 1 0 DESCRIPTION SENSOR ANGLE WG143 5 90 DEG W MTG FOR LWG308 1 2 4 20mA SCREW 6mm X 16mm SOCKET CAP WASHER FLAT 6mm S SDIN 9021 ST A2 SENSOR LENGTH POT LPE0018CURRENT AMP OUTPUT 4 20mA CABLE MODULAR LENGTH amp ANGLESENSOR 3p 32cm BOARD TERMINAL W EMC FILTERSFOR LG LWG308 W CURR LOOP OUT SCREW 3mm x 6mm PH PH HARDWARE STANDOFF 3mm x 25 MF5mm HEX NUT 3MM HEX WASHER 3mm CONCAVE BELLVILLEFOR ELECTRONIC BOARDS CABLE ASSY 7COND 18 7 PINPLUG FOR CABLE REEL ASSEMBLY WIRING ACCY CRIMP FERRULE 20AWG INSULATED WHITE WIRING ACCY CRIMP FERRULE 14AWG INSULATED BLUE STRAIN RELIEF PG11 GREEN EMI RFI 8 10 5mm STRAIN RELIEF PG13 5 PG11REDUCER STRAIN RELIEF PG13 5 HOLEPLUG KIT DS160 CU CONSOLE PT amp SOFTWARE US BASE KIT QT Y 1 0
19. 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 160 system are water protected to IP 65 This means protection against the environment such as rain 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 PAT representative SkyAzul Equipment Solutions www skyazul com 301 371 6126 Troubleshooting Moisture 41 4 Defective Gasket The gasket underneath the lid seals the unit The gasket needs to
20. F BODY MOUNTED IN REEL STRAIN RELIEF INSERT CABLE INNER JACKET 65 CABLE OUTER SHIELD CABLE OUTER SHIELD a GROMMET a CABLE OUTER JACKET STRAIN RELIEF NUT SkyAzul Equipment Solutions www skyazul com 301 371 6126 54 Service Manual ESAT Ds 160 18 Install the PG 13 5 hole plug in the other cable entry hole in the cable reel 19 Adjust length and angle sensor a 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 b Check the angle Use a calibrated inclinometer to measure the main boom angle and compare with displayed angle on console Adjust the angle sensor if necessary Loosen the mounting screws holding the angle sensor in the reel The plate is slotted which will allow the sensor to be adjusted in the reel until the displayed angle is equal to or 2 degrees less than the actual measured boom angle c Verify A2B operation Refer to Operators Manual 031 300 190 139 Sese 20 Replace cable reel cover and tight the cover bolt in a crossing pattern to 5 5N m or 7ft Ibs 21 Proceed to Section 14 3 page 35 for the Calibration of Sensors Procedure SkyAzul Equipment Solutions www skyazul com 301 371 6126 DS160 Upgrade Installation 55 17 6 LMI SYSTEM TEST PROCEDURE WARNING Do not operate the crane out side the permissible operating range for the
21. LAY DS160 0005 04 050 050 300 030 MAIN BOARD D160 0005 05 031 300 050 223 FUSE 2 AMP AUTO 06 050 050 300 036 KEYBOARD DS160 CONSOLE 0005 07 031 300 100 391 CONNECTOR 7 PIN RECEPTACLE 08 024 350 100 312 MOISTURE DRAINAGE PLUG 09 050 000 100 274 ALARM DS160 CONSOLE 0005 IP65 W CABLE 10 050 160 100 005 HOUSING COMPLETE DS160 0005 W DECAL ek ek ek ek ek A ek ek ek esk KEISER B nun a 9 10 10 SkyAz l Equipment Solutions www skyazul com 301 371 6126 Procedures 31 13 7 Pressure Transducer DAVS314 Part Number 044 314 060 003 obsolete replaced by 031 300 060 452 Lo 4 N a There are no spare parts associated with the pressure transducer the following parts are used to make a hydraulic connection to a 9 16 18 JIC fitting 000 209 140 016 Pressure Transducer Cutting Ring Seal 000 214 600 093 Pressure Transducer Adapter 9 16 18 JIC 37 X 16M X 1 5 Replacement DAVS314 pressure transducers are no longer available Pressure transducer replacement kit 031 300 101 515 contains all necessary items required to change to the updated DAVS300 3401 pressure transducer 13 8 Pressure Transducer DAVS300 3401 Part Number 031 300 060 452 4 20mA 300 bar M12 9 16 18 ba There are no spare parts associated with the pressure transducer the following parts are use to make a hydraulic connection to a 9 16 18 JIC fitting 000 209 140 016 Pressure Transducer Cutting Ring Seal 031 300 050 689 Pressure Transducer
22. Measuring voltage The voltmeter OO is used to measure voltage between pins X1 34 length signal and X1 39 gnd on the main board 024 050 300 030 The conversion of 4mA to the voltage of 1 0V is due to the resistor circuit on the main board SkyAzul Equipment Solutions www skyazul com 301 371 6126 Theory 45 16 4 THEORY 4 OPERATION OF ANGLE SENSOR Measuring current The ammeter A is used to measure current at the length input signal Remove the wire from X1 35 terminal in the central unit and measure the current with the ammeter in series The measurement should be between 4 20mA Measuring voltage The voltmeter OO is used to measure voltage between pins X1 35 angle signal and X1 39 gnd on the main board 024 050 300 030 The conversion of 4mA to the voltage of 1 0V is due to the resistor circuit on the main board SkyAzul Equipment Solutions www skyazul com 301 371 6126 46 Service Manual F 44 TF Ds 160 17 DS50C TO DS160 UPGRADE INSTALLATION The following procedure is an installation guide for the DS 160 system when upgrading from a DS50C system The console and central unit are new installations The cable reel internal components will be replaced with 4 20mA length and angle sensors The new 4 20mA pressure transducer and adaptors will replace the existing passive pressure transducers 031 300 101 552 ITE OO JO Om P ON HAS 10 11 12 13 14 15 16 PART NUMBER 064 143 060 00
23. N PROCEDURE enne nnne 35 14 3 2LENGTH SENSOR CALIBRATION PROCEDURE nnnm 36 14 3 3 ANGLE SENSOR CALIBRATION PROCEDURE 37 14 4 CABLE REEL LWG308 0001 ADJUSTMENT PROCEDURE er 36 14 5 CABLE REEL LENGTH CABLE REPLACEMENT PROCEDURE rss 39 15 TROUBLESHOOTING MOISTURE umaasam 40 15 1 WATER INGRESS maa aa ee enee as 40 1 6 1 2 CONDENSATION EE 41 16 SENSOR EE 42 16 1 THEORY 1 OPERATION OF PISTON SIDE LOAD SENSOR a 42 16 2 THEORY 2 OPERATION OF ROD SIDE LOAD SENSOR 43 16 3 THEORY 3 OPERATION OF BOOM LENGTH SENSOR a 44 SkyAzul Equipment Solutions www skyazul com 301 371 6126 16 4 THEORY 4 OPERATION OF ANGLE SENSOR AAA 45 17 DS50C TO DS160 UPGRADE INSTALLATION ua mma 46 17 1 CONSOLE AA AA 47 17 2 CENTRAL UNIT MOUNTING 0 47 17 3 EE 47 17 4 PRESSURE TRANSDUCER REPLACEMENT eegene 47 17 5 DS160 COMPONENT INSTALLATION PROCEDURE 11 aaa 48 Ke RIEGERT 55 SkyAzul Equipment Solutions www skyazul com 301 371 6126 General Information 1 1 GENERAL INFORMATION The PAT Load Moment Indicator LMI DS 160 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 vario
24. NER SHIELD CUT AND INSULATED SkyAzul Equipment Solutions www skyazul com 301 371 6126 25 26 Service Manual ESAT Ds 160 13 2 System Wiring Diagram 031 300 060 690 Central Unit NTERFACE 5S o9 og 5 S 2 x1 1 2 3la b i 2 4 9 a He 8 Bt Hee ce Lap D lt 4 I LEE APP KEY BOARD E o z 3 gt gt E CH Lt uus D D UNIT HUB N p gt gt OUTER SHIELD CONNECTED TO S ITION ON CABLE IES ARE SAIN RELIEF TO STRAIN RELIEF SHIELD CUT AND JLATED gt b NER 1 2 3 4 6 4 4 1 2 3 p Sl us gt ed amp 8 1 A OVERRIDE es KEY SWITC gt 9 UB GND LOAD A28 LOCKOUT x3 PLUG E i I d ey m Lai Era 2T mit lt in 2 11 lt SkyAz l Equipment Solutions www skyazul com 301 371 6126 Procedures 13 3 System Wiring Diagram 031 300 060 645 Central Unit 27 NOTES API AND WIRES
25. NO SHIELD CONNECTED TO S N RELIEF INSERT gt LABELS FO TIFICATION AS FOLL 8 TO INTERFACE TO TO 5 HO NO LABEL REQUI 5 P 5 AIN NO LABEL R 3 X XE 2 3 6 O LABEL C Saga d a m SS t 8 TEE b Gm x 2 eB Pa POSITION NUMBER ERENCE POSITION 3 3 x1 1 4 UNIT lt p pe 44 4 BLE AS RELIEF TO 5 5 f ka E NNER SHIELD CUT AND INSULATED e e 3 EGE m ee E T 5 SHIELD INSULATED AND CONNECTED AS SHOWN A 8 m M 3 amp m m 2 SR Sg ES E 5 725 FR 6 x 6 8 E 1 3 2 29 3C 7 18 19 20 21 26 31 34 39 35 9 10 37 3 33 36 XI V 2 4 6 7 BLUE BLACI 2 3 4 5 6 7 1 2 3 2 8 ul 5 Z d 4 D 5 8 5 GRN YEL BOOM TIP MAIN SkyAzul Equipment Solutions www skyazul com 301 371 6126 28 Service Manual ESAT Ds 160 13 4 Central Unit Main Board Termination and Breakdown Parts List Refer to system electrical wiring and central unit parts break down diagram inside central unit lid for a complete list of system components and assemblies For area def
26. ROM socket as shown SkyAzul Equipment Solutions www skyazul com 301 371 6126 34 Service Manual ESAT Ds 160 14 2 Main Board Replacement Procedure Refer to Drawing 13 2 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 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 3 Disconnect the wiring by unplugging terminal blocks ensure all blocks and wires are marked to simplify installation If disconnecting wires from terminal blocks refer to the system wiring diagram in this manual or in the central unit lid for wiring connections Remove the EPROM module board by taking out the 2 small Philips screws holding it in place Remove the system EPROM Remove the main board by taking out the 4 Philips screws holding it in place 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 8 Carefully insert the new main board in place 9 Insert the 4 Philips mounting screws 10 Insert system EPROM 11 Insert EPROM module board by lining up the pins into the sockets X14 and the 2 screw holes 12 Insert the 2 small Philips screws and washers
27. SkyAzul Equipment Solutions www skyazul com 301 371 6126 Procedures 39 14 5 Cable Reel Length Cable Replacement Procedure Replace length cable using the following procedure Refer to system electrical wiring diagram and cable reel parts list 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 terminal block Pull 7 conductor cable out of strain relief Note Mark wires to make connection simpler after cable installation 4 Remove cable reel from mounting brackets 5 Remove damaged length cable which is mounted to the slip rings in the cable reel from slip ring terminal 6 Onthe 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 new 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 pre load on cable reel by turning the drum counter clockwise 5 to 8 turns 12 Run the new length cable through the cable guides and wrap the 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 ti
28. annel is or processor board defective Upper limit value refer to E12 refer to E12 in measuring channel pressure piston side has been exceeded SkyAz l Equipment Solutions www skyazul com 301 371 6126 Error Code Error Cause Elimination Fallen below lower e refer to E12 e refer to E12 limit value in the measuring channel pressure rod side Upper limit value e referto E12 refer to E12 in measuring channel pressure rod side has been exceeded Fallen below lower e Angle sensor defective e Replace angle sensor limit value for the measuring Electronic part in the channel angle measuring channel main boom defective Upper limit value e referto E15 in measuring channel angle main boom exceeded E19 Error Codes 7 e e Replace LMI board e refer to E15 e Replace angle sensor Fallen below lower e Angle sensor defective limit value for the measuring Electronic part in the Replace LMI board channel middle measuring channel section defective Upper limit value in measuring channel middle section exceeded Fallen below lower e Angle sensor defective e Replace angle sensor limit value for the measuring Electronic part in the channel measuring channel telescopic jib defective Upper limit value e refer to E17 in measuring channel telescopic jib exceeded Reference and or supply voltage defective e Rep
29. ashes sensor outputs and then press OK to display a similar screen as shown below 4 Press the OK button to exit back to operating screen All Analog input voltages shown in millivolts received from the sensors will be displayed here as described below The minimum values are show in the screen pictured SkyAzul Equipment Solutions www skyazul com 301 371 6126 6 Service Manual ESAT Ds 160 PAT DS 160 see 5 3 2 Error Codes for the Analog Inputs If it exceeds these limits the following errors are triggered NOTE the upper limit follows the lower limit error i e 11 and 21 12 and 22 13 and 23 Error Code Error Fallen below limit e Length sensor e Replace length sensor for the measuring potentiometer defective potentiometer channel Length telescopic boom Replace LMI board Electronic board in the measuring channel defective Upper limit value for Length sensor Replace length sensor measuring channel potentiometer defective potentiometer length telescopic Replace LMI board boom exceeded Electronic part in the measuring channel defective Fallen below the Cable between the Check cable as well as lower limit value in central unit and pressure plugs replace if need the measuring transducers defective or be channel pressure water inside the plugs piston side Pressure transducer is Replace pressure defective transducer Electronic component in Replace LMI main board the measuring ch
30. asure current at the piston side input signal Remove the wire from X1 32 terminal in the central unit and measure the current with the ammeter in series The measurement should be between 4 20mA Measuring voltage The voltmeter V is used to measure voltage between pins X1 32 piston side signal and X1 36 gnd on the main board 024 050 300 030 The conversion of 4mA to the voltage of 1 0V is due to the resistor circuit on the main board SkyAz l Equipment Solutions www skyazul com 301 371 6126 Theory 43 16 2 THEORY 2 OPERATION OF ROD SIDE LOAD SENSOR Measuring current The ammeter A is used to measure current at the piston side input signal Remove the wire from X1 33 terminal in the central unit and measure the current with the ammeter in series The measurement should be between 4 20mA Measuring voltage The voltmeter Vv is used to measure voltage between pins X1 33 rod side signal and X1 36 gnd on the main board 024 050 300 030 The conversion of 4mA to the voltage of 1 0V is due to the resistor circuit on the main board SkyAzul Equipment Solutions www skyazul com 301 371 6126 44 Service Manual ESAT Ds 160 16 3 THEORY 3 OPERATION OF BOOM LENGTH SENSOR Measuring current The ammeter A is used to measure current at the length input signal Remove the wire from X1 34 terminal in the central unit and measure the current with the ammeter in series The measurement should be between 4 20mA
31. asurement should be between 4 20ma 4ma when there is no pressure in the hydraulic lines O psi Refer to system wiring diagram Check continuity of wire 2 and pin B in pressure transducer cable by first unplugging the transducer cable from transducer and second moving wire 2 to Correct NO the ground terminal X1 36 Measure voltage at the cable connection between A UBV and B ground for each connector Re connect the wiring a shown on the system wiring diagram v No Fault in cable v Adjust zero point on pressure transducers Pressure transducer zero point adjustment Procedure If transducer s are not adjustable Replace pressure transducer s and adjust zero point Refer to system wiring diagram and pressure transducer zero point adjustment Procedure YES YES Y C END SkyAzul Equipment Solutions www skyazul com 301 371 6126 Data Transfer Central Unit lt gt Console 12 DATA TRANSFER CENTRAL UNIT CONSOLE PROBLEM Error Code E93 E94 No data transfer to and from console interference from crane electric or console display frozen START Y Check the H1 TxD LED on the main board ON OFF Refer to main board drawing ON Y Make sure that the EPROM s are correct and plugged into the EPROM Module on the main board Refer to EPROM installation procedure
32. ate the operating conditions The length angle sensors inside the cable reel which is mounted on the boom measure the boom length and angle The boom length is measured by the cable reel cable that also serves as an electrical conductor for the anti two block switches The crane load is measured by pressure transducers attached to the piston and rod sides of the hoist cylinders 1 A2B Switch es 2 Pressure Transducers 3 Cable Reel 4 Console 5 Central Unit in cab or outside PAT ns 160 Fig 1 Components of the LMI System PAT DS 160 SkyAzul Equipment Solutions www skyazul com 301 371 6126 General Flow Charts 4 GENERAL TROUBLESHOOTING INFORMATION This section explains how to handle a problem that may arise with the PAT DS 160 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 noted detailed sections Use the Table of Contents to find the drawings and procedures that are referenced in these sections The system wiring diagram and central unit spare parts list are machine specific and can be found in the central unit lid The system wiring diagram in the central unit lists component part numbers 4 1 GENERAL FLOW CHARTS What s Wrong
33. 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 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 tightened 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 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 External 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 15 1 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
34. ctive 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 acknowledgment from the e refer to E07 e refer to E07 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 500V or exceeds E2x the maximum 4500V as measured on the troubleshooting display The analog channels are as follows Use theory section to define voltage or current at terminal strip Sensor Pins Terminal X1 Upper Limit Piston Pressure Transducer Rod Pressure Transducer Length Sensor Angle Sensor 5 3 1 Troubleshooting a Sensor Problem using the Display For a sensor error or problem with a sensor look at the output voltage of the pressure transducer length and angle sensors on the display screen and compare the reading with the following Pressure transducers piston and rod 500mV Opsi Length sensor 500mV retracted boom length Angle sensor 4500mV at 0 2500mV at 45 or 500mV at 90 Note The sensor output voltages displayed will not be the same as measured in the central unit To access the analog output screen use the following procedure 1 From the operating screen press and hold the information button for 5 seconds 2 The screen show the following selections e sensor outputs e exit 3 Use the UP and DOWN arrows to high light text fl
35. d in the kit Pr L e SkyAzul Equipment Solutions www skyazul com 301 371 6126 52 Service Manual ESAT Ds 160 14 Install the gear wheel and guard rail Tie wrap the wires as shown to prevent wires from getting wrapped in the gear wheels or slip ring 15 Install 2 M3 x 25mm standoffs in the 068 000 300 060 labeled on board as 68 000 30 0060 using 2 3mm hex nuts and 2 3mm washers as shown below These 2 standoffs serve as legs to support the board and are not attached to the reel SkyAz l Equipment Solutions www skyazul com 301 371 6126 DS160 Upgrade Installation 53 16 Install the board into the cable reel using 2 3mm x 6mm screws and 2 3mm washers Connect the length JST connector to X3 and the angle sensor connector to X4 Strip the red and brown wires and connect red to X2 7 and brown to X2 8 17 Connect cable assembly 03 1 300 060 414 7 conductor x 18 long to the cable assembly extending from the central unit Route the cable up the boom to the cable reel Allow a minimum 12 length to extend into the cable reel then cutoff the excess cable Strip the outer cable jacket cut the outer shield and install the cable into the reel through the PG11 green colored strain relief per the diagram below For the wiring diagram to the board shown above refer to the system wiring diagram on page 27 in this manual a WIRES BOTTOM OF CABLE REEL a N Ee EN 4 STRAIN RELIE
36. d shall be determined by linear interpolation unless otherwise specified by the crane manufacturer The system accuracy is to be determined from the following formula TEST LOAD x 100 OF RATED LOAD RATED LOAD at cut off radius angle 7 The actual load which activates the overload lock out is not less than 90 of the rated load nor more than 100 of the rated load for the corresponding actual load radius or boom angle Note This is a general standard and variations may exist if in doubt contact the crane manufacturer CALIBRATION TEST CRANE S N Op Parts of Main B Main B Jib Ext Jib Actual Indicated Actual Indicated Cutoff Mode Line Length Angle Length Offset Load Load Radius Radius Yo SkyAzul Equipment Solutions www skyazul com 301 371 6126 SkyAz l Inc 200 W Main Street Suite 2A dr Middletown MD 21769 Phone 301 371 6126 EQUIPMENT SOLUTIONS Fax 301 371 0029 www skyazul com info skyazul com
37. el between terminal 7 and 6 with an ohmmeter Switch closed 24700 5000hms Switch open gt 1 Megaohm Refer to system wiring diagram TEE Replace slip ring Refer to system wiring and cable reel diagram Y Disconnect boom base connector measure the A2B signal in the boom base connector on cable reel cable assembly between terminals 5 and 6 with an ohmmeter Switch closed 24700 5000hms Switch open gt 1 Megaohm Refer to system wiring diagram Fault in 7 conductor cable between cable reel and boom base connector Check connections and No B replace cable if necessary Refer to system wiring diagram C NEXT PAGE SkyAzul Equipment Solutions www skyazul com 301 371 6126 15 16 Service Manual ESAT Ds 160 C PREVIOUS PAGE Connect the boom base connector Check Anti Two Block signal between disconnected wires 5 and 6 in central unit with ohmmeter measure Anti Two Block switch closed 4700 Ohms x50 OOhms Anti Two Block switch open gt 1 Megaohm Refer to system wiring diagram Faulty wiring between boom base connector and central NO unit Check connections and replace cable if necessary YES Disconnect X1 9 and X1 10 Check main board function by installing a temporary resistor 4700 Ohms between X1 9 and X1 10 in central unit With resistor connected alarm should be inactive Refer to system wiring diagram
38. ing diagram 20 Replace angle sensor Refer to system wiring diagram and sensor adjustment procedure YES Measure signal from angle transducer in central unit The return signal is a current output and must be measured in series Set Voltmeter to measure amps Remove Wire 4 from X1 35 in the central unit and connect one voltmeter lead to wire 4 and the other lead to X1 35 The measurement should be between 4 20ma 20ma with the boom at O or 4ma with the boom at 90 Connect wire 4 to terminal X1 35 Refer to system wiring diagram Correct NO Faulty wiring between central unit and cable reel Check wiring NO Refer to system wiring diagram YES SkyAzul Equipment Solutions www skyazul com 301 371 6126 Load Reading Problem 21 11 LOAD READING PROBLEM PROBLEM Load reading incorrect C START LA Check boom length reading on display Reset length potentiometer With fully retracted boom turn potentiometer axle NO counter clockwise until it stops Refer to system wiring diagram and sensor adjustment procedure YES v Measure radius and check with the displayed radius Check if mechanical adjustment of angle transducer is correct Angle transducer NO box should be in line with boom and adjusted to actual boom angle
39. inition switches and ranges refer to specific documentation provided by crane manufacture ITEM NO 021 441 060 409 000 214 340 009 031 300 050 255 000 214 340 011 021 441 090 711 000 214 261 109 SkyAzul Equipment Solutions STRAIN RELIEF DESCRIPTION PG 9 4 6mm YELLOW WHITE PG 9 HOLEPLUG PG11 GREEN EMI RFI 8 10 5mm PG11 HOLE PLUG PG11 5 5mm 9mmBLACK WHITE PG11 PG 9 REDUCER ITEM NO 000 214 340 013 000 214 261 309 000 214 261 311 000 214 210 009 000 214 210 011 000 214 210 013 www skyazul com DESCRIPTION PG13 5 HOLEPLUG PG13 5 PG 9REDUCER PG13 5 PG11REDUCER NUT PG9 NUT PG11 NUT PG13 5 301 371 6126 Procedures 29 13 5 Central Unit Main Board Layout BOARD P N 024 050 300 030 eee MP1 DGND MP2 AGND LED S H1 TxD on when transferring and receiving data form console H2 A2B on when A2B relay energized H3 LOAD on when LOAD relay energized Two Digit Indication normal two zeros or will show an error code if error condition occurs Fuse 2AMP SkyAzul Equipment Solutions www skyazul com 301 371 6126 30 Service Manual ESAT Ds 160 13 6 Console DS160 0005 Parts List Part Number 031 300 060 362 Refer to system wiring diagram for 050 160 060 005 console wiring connections to central unit NO PART NO QTY DESCRIPTION 01 050 160 120 005 DECAL DS160 5 FRONT FOIL 02 031 300 060 382 MOUNTING ARM RAM MOUNT B 101 W 1 BALL 03 050 000 100 267 INDICATOR DISP
40. lace LMI board e refer to E17 9 Check the voltages on the LMI main board AGND MP0 Check sensors plugs and cable replace if need be Replace LMI board e The supply voltage is falsified by one of the sensors DAV LWG e Electronic component is defective SkyAz l Equipment Solutions www skyazul com 301 371 6126 8 Service Manual IP 4XTF Ds 160 5 4 Errors 31 and up Miscellaneous mE TZE most of them caused by electronics E31 Error in the system program Error in the program run System program and data EPROM do not match Error in the internal write read memory RAM of the computer component 80C537 Error in the external write read memory 1st part RAM Error in the internal write read memory RAM Error in the data EPROM or EEPROM Error in load chart PROM Error in the data EEPROM Error in the external write read memory 2nd part SkyAz l Equipment Solutions e EPROM with System program is defective e Electronic component on the main board is defective e The system program in the LMI does not match to the programming in the data EPROM e Computer component 80C537 defective e CPU module defective Processor board defective e Write read memory CMOS RAM or processor board defective refer to E42 e Computer component 80C537 defective Processor board defective e No valid data in the data EEPROM e Memory module wrongl
41. ng diagram 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 gt from terminal block Connect new assembly to terminal block Reinstall mounting plate gear wheel and slip rings With boom fully retracted reset potentiometer by turning it slowly counter clockwise until it reaches a soft stop Refer to system wiring diagram and sensor adjustment procedure YES Measure signal from length transducer in central unit The return signal is a current output and must be measured in series Set Voltmeter to measure amps Remove Wire 2 from X1 34 in the central unit and connect one voltmeter lead to wire 2 and the other lead to X1 34 The measurement should be between 4 20ma 4ma with the boom fully retracted and the length potentiometer set fully counter clockwise to a soft stop 20ma with the length potentiometer turned completely clockwise 10 turns to the soft stop Refer to system wiring diagram and sensor adjustment procedure Faulty wiring between central unit and cable reel Check wiring YES C END SkyAzul Equipment Solutions www skyazul com 301 371 6126 Angle Reading Problem 19 10 ANGLE READING PROBLEM PROBLEM Angle displayed incorrect Crane is not in
42. nnection NO bo Refer to connection and wiring diagrams Drawings 1 YES Find out which component of the crane electric is spiking out e g dump valve Install a diode or resistor across terminals of spiking component Diode type such as 1N4003 can be used watch d and connection for diode Refer to Crane Electrical Diagrams E C END 2 SkyAzul Equipment Solutions www skyazul com 301 371 6126 Procedures 13 DRAWINGS 13 4 System Wiring Diagram 031 300 060 361 Central Unit INTERFACE Se m 2 E 5 2 x5 2 3 112 3 4 SA b d 225 e Y 5 L 2 4 SS 6 d SA 1 E 3 Ch rrek AS dds 2 eo lt p Be 4 Be aa add gt Guren Pe ES 4 e 031 300 060 361 CENTRAL UNIT 044 314 LL WIRES NO JUTER SHIELD CONNECTED TO RELIEF INSERT 05 0011 2 gt 01105 S N RELIEF ITION NUMBER REFERENCE POSITION N CENTRAL UNIT 3 gt CABLE LENGTH CABLE MLIES ARE e MEASURED FRON RELIEF TC RAIN RELIEF 4 gt IN
43. ounting weld tabs or can be bolted in place Refer to 13 4 Central Unit Main Board Termination and Breakdown Parts List for CU dimensions and 13 3 System Wiring Diagram 17 3 Software The existing software for the DS50C must be sent to Hirschmann Electronics The data on the EPROM s will be reconfigured for the DS160 Use the EPROM module supplied with the DS160 17 4 Pressure Transducer Replacement Use the 031 300 050 689 hydraulic adapter 9 16 18 UNF 2B M16 X 1 56 18 UNF 2B to replace the existing passive pressure transducers with the new 4 20mA pressure transducer Refer to 13 8 Pressure Transducer DAVS300 3401 SkyAz l Equipment Solutions www skyazul com 301 371 6126 48 Service Manual ESAT Ds 160 17 5 DS160 COMPONENT INSTALLATION PROCEDURE 1 Retract the boom fully Refer to the manufacturer s operator s manual and familiarize yourself with its operation and the LMI bypass Lower the boom to gain access to the DS 50 system Switch crane power off Remove the cable reel cover face by loosening all 10 screws The screws should remain secured in the lid 4 Remove all connections located at X 1 X 2 X 7 and X 8 Remove the two screws that secure the EPROM module and remove it 2 screws that secure the EPROM module The EPROM is a sensitive device and can be damaged if not handled properly To prevent damage discharge any static electricity in your body before handling the EPROM s This can be accomplished
44. p 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 Refer to Cable Reel LWG308 0001 Adjustment Procedure SkyAzul Equipment Solutions www skyazul com 301 371 6126 A0 Service Manual ESAT Ds 160 15 TROUBLESHOOTING MOISTURE The PAT DS 160 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 15 1 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
45. re that clutch is not slipping on potentiometer axle Refer to system wiring diagram and sensor adjustment procedure Replace the gear wheel clean potentiometer axle Reset MD length potentiometer Refer to system wiring diagram and sensor adjustment procedure Check power supply to length transducer on main board terminal X1 31 UB and X1 39 GND Refer to system wiring diagram Main board defective Replace main board NO Refer to system wiring diagram and main borad replacement procedure YES C NEXT PAGE SkyAzul Equipment Solutions www skyazul com 301 371 6126 18 Service Manual ESAT Ds 160 PREVIOUS PAGE Y Measure supply to length transducer in cable reel between terminal 1 4 UB and 3 ground Refer to system wiring diagram Faulty wiring between central unit and length transducer Check wiring Y Measure signal from length transducer in cable reel The return signal is a current output and must be measured in series Set Voltmeter to measure amps Remove Wire 2 from X1 2 in the cable ree and connect one voltmeter lead to wire 2 and the other lead to X1 2 The measurement should be between 4 20ma 4ma with the boom fully retracted and the length potentiometer set fully counter clockwise to a soft stop 20ma with the length potentiometer turned completely clockwise 10 turns to the soft stop Refer to system wiri
46. start 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 Verify correct operation of the velocity fuse Error in Telecode e The selected telecode is not e Select an available available telecode e Error in the radius e determination The computed radius is too small negative deflection UB supply voltage to the console is interrupted Interruption or accidental ground in the line between console electronics and central unit Transmitter receiver module is defective Check the programming in the data EPROM Check UB voltage at terminal X1 of the console electronics Check the connection console electronics central unit In case of an accidental ground the transmitter module of the console electronics might be damaged Exchange console electronics or LMI main board resp Error in the data transmission from the central unit to the console No data trans mission form the console to the central unit Error in the data transmission from console to central unit SkyAzul Equipment Solutions Loose connection in the line between console electronics and central unit Transmitter receiver module is defective refer to E92 www skyazul com Check the connection between console electronics and central unit Exchange console electronics or LMI main board resp refer to E92 301 371 61
47. the crane out of the condition If Error Code is displayed goto Section 5 Start Use the console by pass buttons or the central unit key switch to override the overload When by passing the system the following instructions must be obeyed e 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 e Never use the by pass function to either overload or operate the crane in a non permissible range Corrected NO 7 The LMI by pass warning light and or anti two block YES PB warning light is lit on the console LED s H1 H2 and H3 are lit on the main terminal board Fault in crane electric hydraulic system or electronic board Relay defective on the main board Replace main board Refer to main board replacement procedure SkyAzul Equipment Solutions LA Check lever lockout The fault is located in LMI cables system in crane wiring fuses or console service manual Read error code displayed on console and go to error code section www skyazul com 301 371 6126 12 Service Manual ESAT Ds 160 7 NO DISPLAY PROBLEM Blank console display with no warning light shown All crane moments have been stopped C START v Check fuses in central unit
48. type of crane capacity chart being tested 1 Most crane manufacturer calibrate the cranes with the jib removed it is recommended that this is done to carry out the following test How ever on some cranes this might not be the case if in doubt contact the manufacturer 2 For calibration verification a test load is to be employed for each of the following configuration NOTE For safety reasons first measure the allowable radius for the load being used have a spotter to ensure the system stops the functions at or before this point 3 Maximum Boom Length and Middle Radius select a load that will lock out the functions about the middle of the load chart in the long boom length step 4 The following test should be recorded signed and dated A copy of this test sheet should be available at all times 5 Test load to be applied by suspending known weights accurate to 1 Weights of all additional equipment such as blocks slings sensors etc are included in the test load The total load is to be known to an accuracy of 1 With extended boom and the load suspended move the load smoothly from the short radius to overload lock out measure and record radius calculate cut off see section 6 Ensure the appropriate functions are disabled 6 Computations For each radius measured in the above tests refer to the applicable load rating chart and determine the rated load At radii intermediate to those on the load chart rated loa
49. uestion slewing zone The selected operating mode is Check programming of the not available in the data data EPROM EPROM or blocked The boom is in a non permitted Slew the crane into a slewing permitted area E05 Forbidden e Boom has been extended too e Retract or extend boom to length range of far or not enough e g the boom the correct length the main boom length has been moved out of the permitted range for load charts e The length sensor adjustment e Retract the boom Check was modified e g cable slid off the pretension on the the length sensor reel cable Open the length sensor and carefully turn the length pot counterclockwise to the detent with a screwdriver e Clutch between length sensor e Completely replace the pot and drive is defective clutch with the drive wheel and adjust length sensor pot e Failure of the 5V supply for the Check 5 V voltage If analog part of the LMI analog there is no voltage or board break down at a charge of 50 ohm approximately exchange LMI board e Length potentiometer defective e Replace length potentiometer SkyAzul Equipment Solutions www skyazul com 301 371 6126 Error Codes 5 5 2 Lockout Function Errors 07 and 08 These errors are caused by defects around the function lockouts Faulty acknowledgment of the e Overload relay or e Replace main board overload relay on the connection main board are board defective The relay should be energized e LMI board defe
50. ugh 4 at the beginning of this section complete the following procedure The zero setting consists of defining zero point offset The zero point offset is added to the transducer measurement to calculate the real physical pressure or force To define the zero point offset the pressure transducer or force sensor must be in equilibrium no load condition Therefore the boom must be lowered all the way down no rest pressure and the hydraulic hoses disconnected from the pressure transducers CAUTION Ensure there is no pressure in the hydraulic line when disconnecting the hoses from pressure transducers BOOM DOWN COMPLETELY AND DISCONNECT HYDR OK EXIT Press the OK button to zero the selected piston or rod side pressure transducer The rod and piston side pressure transducers are zeroed individually therefore you must complete this procedure for both piston and rod side pressure transducers Press EXIT to leave calibration or select the CALIBRATE SENSORS to calibrate another sensor SkyAzul Equipment Solutions www skyazul com 301 371 6126 36 Service Manual ESAT Ds 160 14 3 2 Length Sensor Calibration Procedure After selecting LEN in steps 1 through 4 at the beginning of this section complete the following procedure 1 Fully retract the main boom and adjust length pot in cable reel define in the Cable Reel LWG308 0001 Adjustment Procedure in this manual Displayed length indication FULLY RETRACT MAINBOOM amp
51. ulty C START i Check to see whether or not crane is in two block condition Correct NO y Lower hook down into safe position YES Check the operation of the A2B switch at the boom tip Turn power off or disconnect wires 5 and 6 from connection board X1 9 and X1 10 in central unit Measure the A2B signal between black core and red shield wire with an ohmmeter at the A2B switch Refer to system wiring diagrams This checks the function of the Anti Two Block switch Switch closed 4 7kOhms weight installed Switch open gt 1 Megaohm weight removed Refer to system wiring diagram Replace the A2B switch Refer to system wiring diagrams Yes v C Next Page SkyAzul Equipment Solutions www skyazul com 301 371 6126 Anti Two Block Problem PREVIOUS PAGE Ensure the A2B switch is closed weight or flag installed Measure the A2B signal in the cable reel between X1 Brown and X2 Red wires on the slip ring with an ohmmeter Switch closed 24700 5000hms Switch open gt 1 Megaohm Refer to system wiring diagram Fault in wiring between boom nose switch connection and cable No reel Check for damaged length cable and wiring Refer to system wiring diagram If broken length cable Refer to length cable replacement procedure Measure the A2B signal in the cable re
52. us 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 160 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 031 300 190 139 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 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
53. y bridged e Crane data EPROM defective e Memory module wrongly bridged e Load chart EPROM defective e Memory module wrongly bridged e Crane data EEPROM defective www skyazul com Emer Cause IER e The system program EPROM is defective Replace system program PROM D13 e Replace system program EPROM e Replace main board e Replace the system program EPROM D13 or the data EPROM D1 e Replace computer component 80C537 e Replace CPU module e Replace processor board with CPU module e Replace processor board with CPU module refer to E42 bere processor board main board e Load data EEPROM containing valid data e Bridge memory module acc to memory type e Replace crane data EPROM e Bridge memory module acc to memory type e Replace load chart EPROM e Bridge memory module acc to memory type e Replace crane data EEPROM 301 371 6126 Error Codes ErrorCode Errr Cause sd Elimination E57 Error in serial crane e data EEPROM Error in the serial analog data EEPROM No pressure change sensed during boom down or telescope out 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 Blocked velocity fuse No pressure change at piston transducer Write data on the serial crane data EEPROM by means of test program or on line function then re

DS-160 LMI Service Manual

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