1 - Badger Equipment Co.
Contents
1. 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 Ceres No crane electric or if supply is too low Yes Y Measure voltage on the connection board between X1 30 12 24V and X1 33 ground This is an output voltage to the console Refer to system wiring diagram Replace connection board and reset pressure No channel Refer to system wiring diagram and main board replacement procedure Yes v Next Page D AT REV A 10 16 01 100753_A doc 26 Service Manual PAT Ds150 PREVIOUS PAGE Measure voltage in the console between X1 1 12 24V and X1 2 ground Refer to system wiring diagram Check connections of the cable between NO p 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 PAT REV A 10 16 01 100753_A doc Troubleshooting Flow Charts 27 7 5 Anti Two Block Problem PROBLEM Function of Anti Two Block System is faulty C START p v Check to see whether or not crane is in two block condition Correct No gt Lower hook down into safe posit2. WIRE NUMBER POTENTIOMETER ALL VOLTAGES ARE MEASURED REFERENCE TO GND TERMINAL X1 23 0 TP M KR ON MAIN BOARD J TEST POINT ON MAIN BOARD nor A Gey AT REV A 10 16 01 100753 A doc 22 7 TROUBLESHOOTING FLOW CHARTS 7 1 General Flowchart Service Manual PAT Ds150 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 flow chart below which will guide you to one of the detailed flow charts shown in this section AT REV A 10 16 01 C START Y What s Wrong t Lever Lockout Activated p Broken Length Cable gt No display Anti Two Block Problem gt Length Reading Problem gt Load Reading Problem r Bad Data Transfer Between Console amp Central Unit Interference Problem s Angle Problem m Go to Flow Chart 2 Go to Flow Chart 3 Go to Flow Chart 4 Go to Flow Chart 5 Go to Flow Chart 6 Go to Flow Chart 7 Go to Flow Chart 8 Go to Flow Chart 9 Go to Flow Chart 10 100753 A doc Troubleshooting Flow Charts 23 7 2 Lever Lockout
3. 5 0V ae CODE OOV MIN ERROR CODE ff PRES m N N p gt 19 A D CONVERTER cy MP 12 P2 JTEST POIN P2 ZERO POINT ADJUSTMENT MP12 VOLTAC S ARI REFERE TERMINAL X1 14 ON MAIN BOARD 14 0 0V GND gt MAX 50V MAX MEASURED WITH OR MP 100753_A doc Theory 6 5 Main Boom Angle Measuring Channel Q 9 8 FIXED RESISTOR OF THE ANGLE OTENTIOMETER BOOM ANC PAR 21 OV OV MIN 4 ANGLE SENSOR M d 4 9 ejn CABLE REEL TERMINA EE X X FIXED A CENTRAL UNIT TERMINAL BOARD RES JR PART OF THE ANGLE f 9E NIIMBER POTENTIOMETER Al V f RE NUMBER REFERENCE TO GND 1 E ON MAIN FEST POINT ON MAIN BOARD FE 14 J UV X1 6 6 Second Angle Measuring Channel A ae 0 V 4 50V MAX E 25 NGLE MIN SIGNAL NGLE Pd s FIXED ae EU RESISTOR PART OF THE ANGLE OTENTIOMETER fh aL MINIMUM SIGNAL 1 875V 9 ANGLE SENSOR d waman CONVERTER MAXIMUM SIGN 3 125V FN LATEST POINT MP15 P5 ZERO POINT ADJ F500MV ANGLE MIN SIGNAL X1 FIXED 2 50 45 ANGLE E TERMINA ORAR oan RESISTOR 4 50V 0 ANGLE MAX SIGNAL PART OF THE ANGI
4. 15 4 SCREW 12mm x 30MM HEX HEAD 16 1 BRACKET MTG CABLE REEL ARM TWO SLOTS 17 1 COVER CABLE REEL KT200 18 10 CABLE REEL ACCY SCREW CABLE REEL COVER 19 10 WASHER LOCK 6mm 20 1 STRAIN RELIEF PG 13 5 8 12mm RED WHITE 21 1 STRAIN RELIEF PG7 BLACK PAT REV A 10 16 01 100753 A doc Drawings 4 6 Central Unit Board Layout And Measuring Points MP4 A MEMORY EXT O x4 an MP5 ma B 5V REF B mpe PS MP7 ma USP 5V USP 5V 000000000000C OJ SYSTEM PX QG ZI 0000000000004 S MP3 MP2 P 4 9v 9V a X N UN 00000000000000 1 DATA q did o O oooooooooooooo 7 8 d MP10 GND 4 MP8 9V HES wa 5 K10 MP15 9 b RELAY LOAD 5 w es P2 P3 gt lo 9 K9 Em WG2 DAV2 LGI A2B h rh I D MP13 z eb I A O o O LG1 e ib MP1 NE GND 43 42 41 40 39 38 57 36 35 34 35 32 31 50 25 24 25 22 2120 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 X1 Measuring Points MP1 MP2 MPs MP4 MP5 MP6 MP7 MP8 AGND 9V 9V 5V TTL 5V REF 5V UPS sensors supply 5V UPS sensors supply 9V HES MP10 AGND MP11 DAV1 piston pressure signal MP12 DAV2 rod pressure signal MP13 LW1 length signal MP14 WG1 angle signal 1 MP15 WG2 angle signal 2 LED s LOA
5. 2 3 el 5 7 2 gt IS pm 1 5 all oue 10A el S M x a e D T x 1 pi 5 4 m 2 3 4 ves o B 1 5 1 BCD CONSOLI D S A B C dg P 5 dda 7 l l 1 l l l 1 2 4 51 6 7 1 je de Pas e e e e kd e e e e kd l I 2 4 5 7 8 9 AAA AAA vi 3 4 5 B m 10 1 9 l 2 3 4 5 6 7 B 910 AN AS ANS ANN l l FFT b TAPE AND STOW ALL WIRES NOT CONNECTED t 1 1 T Iel 3 4 6 7 I oT s Tol i s P eas ar La I a OUTER SHIELD CONNECTED TO STRAIN RELIEF INSERT l3 Z er 2 m o 10 PIN RECEPTACLE Ail INNER SHIELD INSULATED AND CONNECTED SHOWN o 2 55 INNER SHIELD CUT AND INSULATED E E lt 4 DIODE ASSY IS PREWIRED INSTALL al 9 T NEN FIA PREWIRED AND POTTED 7 no qe SHIELD gt lt T VVV N ejo 67 e ram NPUT RING 2 2 gt 2 o 9 5 2 a gt 3 3 gt 3 3 5 z a4 4 4 5 5 5 6 6 6 CORE lerpass PLUG x 208 060 013 LENGTH CABLE BIL 5 S 8 AT REV A 10 16 01 100753 A doc Drawings Spare Parts List 4 2 Central Unit 100753 A doc AT REV A 10 16 01 8 Service Manual PAT Ds150 CENTRAL UNIT DS150 0002 STANDARD PARTS LIST NO PART NO QTY DESCRIPTION BOARD MAIN DS150 CU 12V 1 02 1 CENTRAL UNIT ACCY SCREW SET DS150 03 1 CENTR
6. 5V Mp7 o oO VDC Mp 10 Ground Length and Main J ib Angle Fully Retracted eae VDC X1 10 DC MP13 Fully Extended Ft S S VDC X1 10 _ _ DC MP13 5 Volt Reference Voltage 0 VDC X1 11 5 Boom Angle MP10 Ground for Meter Minimum Angle SA VDC X1 9 VDC Mp14 Maximum Angle ee ee ae VDCOXI 9 VDC Q Mp14 5 Volt Reference Voltage VDC Q X1 11 6 Pressure Transducers MP10 Ground for Meter Piston Zero Point VDC Q X1 21 VDC Mp11 Rod Zero Point VDC X1 16 VDC Q Mp12 AT REV A 10 16 01 100753 A 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 SIA Length E12 22 1 Pressure Piston side 19 2 ee E 5 E13 23 Pressure Rod side 14 15 E15 25 Angle Main boom 11 Angle Jb Signal Voltage Terminal Board Amplified Signal Terminal X1 on main board use MP10 GND Error i i and MP supply Code Channel l i voltage 0 5 4 5V E11 21 E12 22 ds MP11 E13 23 m MP12 E15 25 Angle Main boom 8 9 L 1 875 3 125 MP14 E16 26 Angle Jib 8 24 1 875 3 125 MP15 AT REV A 10 16 01 100753 A doc
7. terminal X1 8 ground and X1 11 5V Refer to system wiring diagram Replace connection board and reset pressure No channel Refer to system wiring diagram and main board replacement procedure Yes Y V NEXT PAGE PAT REV A 10 16 01 100753 A doc Troubleshooting Flow Charts 31 Continued from previous page PREVIOUS PAGE Measure supply to length transducer in cable reel at terminal between Pin 1 ground and Pin 3 5v Refer to 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 at terminal between pin 2 signal and pin 1 ground Retract boom 0 Potentiometer turn 0 5v 10 Potentiometer turn 4 5v Replace length potentiometer assembly Remove slipring body from shaft and remove gear wheel from potentiometer axle Unscrew mounting plate and Cores 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 X1 10 signal 0 5 and 4 5v Refer to system
8. Activated PROBLEM The lever lockout system of the crane is activated Crane movements hoist up telescope out and boom down are stopped Crane is not in overload or two block condition i Set the override key switch in central unit into upper position to override LMI Refer to Operator s Handbook for LMI override instructions Fixed YES Does console indicate Anti Two block warning l T v 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 Check lever lockout Go to Flow Chart 4 Go to Flow Chart 5 Read etrot code displayed system in crane AT REV A 10 16 01 on console and go to Section 6 100753 A doc Service Manual PAT Dsi5o 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 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 4 Remove cable reel from
9. Replace computer component 80C537 Replace CPU module Replace processor board with CPU module Replace processor board with CPU module e Replace processor board e Replace processor board e Replace computer component 80C537 e Replace CPU module e Replace processor board with CPU module e Load crane data EEPROM containing valid data e Bridge memory module acc to memory type e Replace crane data EPROM 100753 A doc Error Codes 45 Error Code Error Case Elimination 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 24 V supply of the console Check 24 V at terminal X1 of t
10. adjustments procedure END J AT REV A 10 16 01 100753 A doc 40 8 ERROR CODE TABLE Fallen below radius range or angle range exceeded Radius range exceeded or fallen below angle range Operating mode not acknowledged or non permitted slewing zone Prohibited length range Service Manual PAT Ds150 Luff down the boom to a radius or angle specified in the load chart Fallen below the minimum radius or gone past the maximum angle specified in the respective load chart due to luffing up the boom too far 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 e Luff up the boom to a radius or angle specified in the load chart Non permitted The slewing zone with load je Slew to permitted area slewing zone no is not permitted load area e Anon existing operating mode has been selected e Setthe correct operating mode for the operating state in question e The boom is in a non permitted slewing zone e Boom has been extended e 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 e Length sensor adjustment has changed e g the cable slid off the length sensor reel e Slew the boom to a permitted area Extend retract boom to the correct
11. 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 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 D YES 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 C NEXT PAGE AT REV A 10 16 01 100753 A doc 34 Service Manual PAT Ds150 C Pervious Page Check power supplv and measure between test point MP10 ground to Correct No MP7 5 0v and between test point MP10 ground to MP6 5 0v Refer to main board layout lt Yes Correct Check power supply and measure between test point MP10 ground to MP2 9 0v and between test point MP10 ground to MP3 9 0v Refer to 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 powe
12. 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 AT REV A 10 16 01 100753 A doc Error Codes 41 Radius range exceeded or fallen below angle range with luffing jib operation E07 Faulty acknow ledgment of the overload relay on the main board The relay should be energized the 2nd contact how ever is indicated to be off or the 2nd contact is indicated to be on while the relay should be de energized No acknow ledge ment from the anti tw o block relay AT REV A 10 16 01 e Clutch between length sensor pot and drive is defective Failure of 5V supply of analog part of analog board Cable betw een central unit and length sensor is defective or disconnected Defective length potentiometer M aximum radius as specified in the load chart exceeded or fallen below minimum angle due to luffing down the luffing jib too far Overload relay or main board are defective Processor board defective e Refer to E07 e Replace the complete clutch including drive w heel and adjust length sensor pot as described above Check 5 V supply Exchange main board in case of voltage failure or breakdown when loaded with 50 ohms approx Check cable and plugs replace if need be Replace length potentiometer Luff the jib to a radius o
13. mounting brackets Remove damaged length cable which is mounted to the slip rings in the cable reel from slip ring connection 6 On the backside of the cable reel open the strain relief attached to the axle in the center of the drum Pull existing length cable out of the cable reel 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 clockw ise until it stops Recheck length and angle display PAT REV A 10 16 01 100753_A doc Troubleshooting Flow Charts 25 7 4 No Display PROBLEM Blank console display with no warning light shown All crane moments have been stopped Start b Check fuses on CPU box Correct No Replace fuses Yes
14. of the load being lifted and all additional equipment such as blocks slings sensors etc Also referred to as working load Indicator 100 to 110 CRANE CONFIGURATION The physical arrangement of the crane which is prepared for a particular operation in conformance with the manufacturer s operating instructions and load rating chart TWO BLOCKING Contact of the lower load block or hook with the upper load block boom point or boom point machinery ANALOG Electrical signals that vary in proportion to the quantities they represent Boom length angle and pressure transducer DIGITAL Electrical signals of an on and off state two different voltage levels to represent some quantity of operation A2B area definition switch AT REV A 10 16 01 100753 A doc 4 DRAWINGS 4 1 CENTRAL UN 024 350 061 005 SYSTEM Electrical Diagram Service Manual PAT Ds150 E E r Ad l z z 8 6 a E 0 o z o gt gt 6 IUBE 9 o gg o SRS 98 T 68 5 8 5 lt g 3 a Oo ez Vl 2 lt i e 2 20 21 23 24 25 47 8 9 lioli 55 L AA x 4 2 4
15. wiring diagram Correct No Faulty wiring between central unit and length transducer Check wiring Yes Y C NEXT PAGE p AT REV A 10 16 01 100753_A doc 32 Service Manual PAT Ds150 Continued from previous page C PREVIOUS PAGE pe l Measure length signal of amplified output on connection board between test point MP10 and test point MP13 5V NOTE Negative signal at terminal X1 11 will be converted into positive signal at MP13 i e input at terminal X1 11 0 5V and gnd Refer to system wiring diagram Replace connection board and reset pressure channel Correct No Refer to system wiring diagram and main board replacement Procedure Yes C END PAT REV A 10 16 01 100753 A doc Troubleshooting Flow Charts 33 7 7 Load Reading Problem PROBLEM Load reading incorrect C START I Check selected operating mode code on operating mode switch Select operating mode switch to correct position see operating mode in load chart KU Yes v Check boom length reading on display Reset length potentiometer With fully retracted boom turn potentiometer axle counter clockwise until it stops see Section 3 and 6 Refer to length amp angle adjustments procedure lt o o Z o Y Measure radius and
16. 1 12v Refer to system wiring diagram Faulty wiring in cable from central unit to console Correct No gt Replace cable 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 Refer to system wiring diagram and transducer replacement procedure Correct No Y Yes END AT REV A 10 16 01 100753_A doc 38 Service Manual PAT Ds150 7 9 Interference Problem PROBLEM Interference from crane C START electric Error Code E93 E94 intermittent Frozen console displays Refer to Section 8 Bad Data Transfer Between Console amp Central Unit Correct No Replace or repair part which is defective Yes 4 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 Y Ensure that cable shields are connected correctly Refer to connection and wiring diagrams Refer to system wiring diagram Make correct shield connection NO Refer to system wir
17. 33 7 8 BAD DATA TRANSFER BETWEEN CONSOLE CENTRAL UNIT 0ecceeeceeeceeeceeeceeeceeeeeeeeeeeeeees 36 7 9 INTERFERENGE PROBLEM u a i A eiae n eiiis 38 710 ANGLE PROBLEM t E ce Te v ad OE on ERE CER LEE OU Pe OE A 39 8 ERROR CODE TABIE ranura meram nk MA MM 40 ADDENDUM A BASIC ADJUSTMENT AND VOLTAGE CHECKS 46 ADDENDUM B REFERENCE TABLES FOR MEASURING SUPPLY AND SIGNAL VOLTAGES FOR SENSOR CHANNELS m US 47 AT REV A 10 16 01 100753 A 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 cylinder The pressure transducer is connected to the central unit with a four conductor double shielded cable The power supply voltage is 5V The output signal is 0 00V under 0 pressure 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
18. AL UNIT ACCY GROUNDING KIT FOR COVER 04 1 CENTRAL UNIT ACCY WALL MOUNT SET DS150 350 05 1 HOUSING CENTRAL UNIT DS150 06 1 KEYSWITCH CENTRAL UNIT NEW STATIONARY 07 1 KEY ASSY ONE OLD STYLE KEY ONE NEW STYLE KEY 08 2 STRAIN RELIEF ASSY PG 11 GRN W NUT WASHER 09 2 FUSE HOLDER CENTRAL UNIT MAIN BOARD 10 1 FUSE 2 AMP 1 4 x 1 1 4 250V FAST ACTING 11 1 FUSE 10 AMP 1 4 x 1 1 4 250V FAST ACTING 12 1 RELAY SHUT OFF 12 V BOSCH 13 1 CENTRAL UNIT ACCY GASKET FOR C U COVER 14 1 STRAIN RELIEF PG 13 5 12 15mm GRY WHT INSERT 15 1 STRAIN RELIEF ASSY PG 13 5 RED W NUT WASHER 16 4 STRAIN RELIEF ACCY PG11 HOLE PLUG 17 4 NUT PG11 18 1 STRAIN RELIEF ACCY PG13 5 HOLE PLUG 19 1 NUT PG13 5 20 1 STRAIN RELIEF ACCY PG16 HOLE PLUG 21 1 NUT PG16 22 1 CENTRAL UNIT ACCY BASEPLATE DS150 23 1 CHEMICAL MOISTURE PACK 24 1 COVER CENTRAL UNIT DS150 PAT REV A 10 16 01 100753 A doc Drawings 9 4 3 Console Spare Parts List OVERALL D CLOSED 15 1 8 x 5 1 2 X 6 MENSIONS COVER 14 X 1 1 4 X 5 1 4 To change DS150 0006 12V to D8150 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 AT REV A 10 16 01 100753 A doc 10 Service Manual PAT Ds150 NO PART NO QTY DESCRIPTION CONSOLE BOARD W ROTARY SWITCH DS150 I 02 1 LCD DISPLAY D
19. America Inc makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and or its fitness for a particular purpose PAT America Inc will not be liable for errors contained in this manual or for incidental or consequential damages in connection with the furnishing performance or use of this manual This document contains proprietary information which is protected by copyright and all rights are reserved No part of this document may be photocopied reproduced or translated to another language without the prior written consent of PAT America Inc PAT America Inc reserves proprietary rights to all drawings photos and the data contained therein The drawings photos and data are confidential and cannot be used or reproduced without the written consent of PAT America Inc The drawings and or photos are subject to technical modification without prior notice All information in this document is subject to change without notice MANUAL REVISIONS REV DATE NAME DESCRIPTION A 10 16 01 CSH ECN 01 283 2001 PAT America Chambersburg PA 17201 USA AT REV A 10 16 01 100753_A doc Service Manual PAT Ds150 TABLE OF CONTENTS 1 MECHANICAL DESCRIPTION OF THE SYSTEM COMPONENTS 1 2 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UNIT 2 2 1 BASIC SY
20. D Overload relay ON energized normal conditions OFF de energized A2B A2B relay ON energized normal conditions OFF de energized AT REV A 10 16 01 100753_A doc Service Manual PPAR Ds150 5 PROCEDURE 5 1 EPROM replacement in Central Unit Follow this procedure when changing EPROM s in the DS150 central units 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 follow ed 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 3 Installing the new EPROM e Ensure the notch is in the correct direction The direction of the EPROM is determined by the notch on the end of the EPROM e The DATA and TLK EPROM s fill the bottom of the socket as shown by the arrows e Place EPROM in the correct EPROM socket as shown 4 Inspect gasket and install cover using the follow ing procedures to prevent any moisture from entering the central unit Reference material 031 300 340 002 Central Unit Cover Installation and Tightening Procedure Rev A 031 300 340 003 Central Unit Gasket Recommendations Rev 5 2 Piston amp Rod Pressure Channel Zero Point Adjustment Use the central unit main board layou
21. EORY sec eee ce eure hi we u ee atte eh vid idm cepi tdv nrc 19 6 1 ANTI TWO BLOCK SHUTOFF CIRCUIT ccecceecceeeceeeceeeceeeceeecueecaeeceeeceeecaeecaeeeaeesaeeseesneeeaeeens 19 6 2 LENGTH MEASURING CHANNEL 02cceeeceeeceeeceeeceeeceeeceeceeeceeceeeceeeceeseeeceeeseeeseeeceeeneeeneeeneeenes 19 6 3 PISTON SIDE PRESSURE MEASURING CHANNEL 20 6 4 ROD SIDE PRESSURE MEASURING CHANNEL KEE EEA ren ren reet rre rer rre retenus 20 6 5 MAIN BOOM ANGLE MEASURING CHANNEL KEE ren retener rennen 21 6 6 SECOND ANGLE MEASURING 21 7 TROUBLESHOOTING FLOW CHARTS U 22 TA GGENERAL FLOWCHART oe28 eA eee ee A ee Ba 22 7 2 LEVER EOGKOUT AAGTIVATED et eee dede eed dude aaa ha 23 732 BROKEN EENGTH CABLE 5 Euler unie ERN 24 LSAS INOIDISBUAY EET EP 25 17 5 UANTUDTWOBEOCKPROBEEM azu tbe Ru E ERO OI ER qa E ER ERR Alea eun 27 7 6 LENGTH READING PROBLEVM ttnt rert rne rree rre rre PAEPAE EEE trier rre rre riens 30 Tt LOAD READING PROBEEM ys i tec ec eec sets uqa a hatu e ca ua bb oh oec
22. HT BULB 28V 10 1 SWITCH ACCY LENS CAP RED A2B 11 1 SWITCH ACCY LENS CAP YELLOW PREWARNING 12 1 SWITCH ACCY LENS CAP RED STOP BUZZER OFF 13 1 SWITCH ACCY LENS CAP ORANGE LOAD 14 1 SWITCH ACCY LENS CAP ORANGE INFO 15 1 SWITCH ACCY LENS CAP ORANGE ANGLE 16 1 SWITCH ACCY LENS CAP GREEN ENTER 17 1 KEYSWITCH W KEYS CONSOLE DS150 18 1 KEY CONSOLE KEYSWITCH 19 1 SWITCH ACCY KNOB WITH SCALE DISK 1 63 20 1 SWITCH ACCY KNOB WITH SCALE DISK 1 16 21 1 ALARM BUZZER DS150 amp DS350C CONSOLE 22 1 FACEPLATE DS150 CONSOLE LARGE DISPLAY STD 23 1 GASKET HOUSING 24 1 SCREW 3mm x 10mm PANHEAD PHILLIPS FACEPLATE PAT REV A 10 16 01 100753 A doc 13 Drawings Spare Parts List 4 5 Cable Reel 18 19 100753 A doc AT REV A 10 16 01 14 Service Manual PAT Ds150 NO PART QTY DESCRIPTION 01 1 SENSOR LENGTH TRANS LGE 100 KT200 LWG208 02 1 SENSOR ACCY GEAR WHEEL KT200 CABLE REEL 03 1 SENSOR ACCY GEAR WHEEL T 50 CENTER SHAFT 04 1 SENSOR ANGLE WG103 05 2 SCREW 6M X 12 SOCKET CAP 06 3 WASHER FLAT 6MM 07 1 SCREW 6M x 100M SOCKET CAP 08 1 WASHER LOCK 6MM 09 1 SLIPRING 2 CONDUCTOR 10 1 CONNECTION STRIP 11 1 CABLE REEL KT200 HOUSING BKT CABLE DRUM NYLON CABLE COVER 12 1 CABLE REEL ACCY CABLE DRUM KT 200 LWG208 13 139 CABLE LENGTH SENSOR 1 CORE W SHEILD per ft 14 1 BRACKET MTG CABLE REEL ARM ONE SLOT
23. Pm Mali Manitowoc Boom Trucks C PAT LMI MANUAL DS150 Troubleshooting Handbook For Truck Mounted Cranes Manitowoc Boom Trucks Inc 3000 S Austin Ave Georgetown TX 78627 1609 Sales 512 942 3000 Sales Fax 512 863 3776 Service 512 942 3000 Service Fax 512 942 3094 Web Site www manitowocbt com 7600004 003A A Qanitowoc Company FORWARD The purpose of this manual is to provide the customer with the operating procedures essential for the promotion of safe and proper machine operation for its intended purpose It is impor tant to over stress proper usage All information in this manual should be READ and UNDER STOOD before any attempt is made to operate the machine SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICA TION AND OPERATION CONFORMANCE WITH GOOD SAFETY PRACTICE IN THIS AREA IS THE RESPONSIBILITY OF THE USER AND HIS OPERATING PERSONNEL ALL PROCEDURES HEREIN ARE BASED ON THE USE OF THE MACHINE UNDER PROPER OPERATING CONDITIONS WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN ALTERATION AND OR MODIFICATION OF THE MACHINE IS STRICTLY FOR BIDDEN WITHOUT WRITTEN APPROVAL FROM MANITOWOC BOOM TRUCKS INC REMEMBER EQUIPMENT IS ONLY AS SAFE AS THOSE WHO OPERATE IT A Qantowoc Companv PAT America Inc www patamerica co PAT PAT LOAD MOMENT INDICATOR DS150 SERVICE MANUAL P N 031 300 100 753 REV A 10 16 2001 Service Manual PAT Ds150 NOTICE PAT
24. S150 03 1 CONSOLE HOUSING W LID 04 1 STRAIN RELIEF LONG RED 05 2 LUMINOUS HOUSING 06 5 LUMINOUS PUSH BUTTON HOUSING 07 7 LIGHTBULB 12V 07 7 LANP SPARE LIGHT BULB 28V 08 1 CAP A2B RED 09 1 CAP PREWARNING YELLOW 10 1 CAP STOP ALARM OFF RED 11 1 CAP LOAD ORANGE 12 1 CAP INFO ORANGE 13 1 CAP ANGLE ORANGE 14 1 CAP ENTER GREEN 15 1 KEY SWITCH 16 1 CONSOLE OVERRIDE KEY DS150 350 17 1 ALARM BUZZER 18 1 FRONT PANEL 19 850mm GASKET FOR FRONT PANEL 20 1 CONSOLE LID DS150 0006 21 1 GASKET FOR LID 22 3 LATCH ASSEMBLY 23 2 KNOB FOR ROTARY SWITCH 23 1 LABYRINTH MOISTURE ELEMENT PAT REV A 10 16 01 100753_A doc Drawings 11 4 4 Console Spare Parts List Sl ER sw LUZ 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 AT REV A 10 16 01 100753_A doc 12 Service Manual PAT Ds150 NO PART NO QTY DESCRIPTION BOARD MAIN DS150 CONSOLE 12V FOR 4x20mm DISPLAY 1 02 1 INDICATOR DISPLAY LCD DS150 CONSOLE 03 1 HOUSING DS150 CONSOLE COMPLETE 04 1 BRACKET CONSOLE DS150 COMPLETE 05 2 KNOB MOUNTING KNOB 06 1 STRAIN RELIEF ASSY PG 13 5 RED WHITE W NUT WASHER 07 2 LAMP ACCY PILOT BASIC HOUSING 08 5 SWITCH PUSHBUTTON w o LENS amp BULB 09 7 LAMP SPARE LIGHT BULB 12V 09 7 LAMP SPARE LIG
25. STEM COMPONENT 3 2 2 BASIC ADJUSTMENT OF THE COMPONENTS ene trier rre rrr 4 8 DEFINITIQNS ERR 5 L MEE Lr eT 6 4 1 SYSTEM ELECTRICAL DIA amp GRAM uu 1 u u u nnn ANA ree ree ree rte rte reir tre tree tret 6 4 2 CENTRAL UNIT 024 150 060 002 SPARE PARTS LIST nanna nanna nn nn nn nnnnnni 7 4 3 CONSOLE 050 150 060 006 SPARE PARTS LIST nn rna meme rr mentes tene rrr en 9 44 CONSOLE 050 150 060 008 SPARE PARTS LIST nn n nn nn nn nn mnn 11 4 5 CABLE REEL 068 208 060 013 LWG208 SPARE PARTS LIST 13 4 6 CENTRAL UNIT BOARD LAYOUT AND MEASURING POINTS 024 150 300 001 15 PROCEDURE i tu aka 16 5 1 EPROM REPLACEMENT IN CENTRAL UNIT mem rennen treten rer rrr rens 16 5 2 PISTON ROD PRESSURE CHANNEL ZERO POINT ADJUSTMENT a 16 5 3 LENGTH ANGLE ADJUSTMENTS ene MAKE ANA rer reet ree ree ree ree rette tret rer renun 17 5 4 MAIN BOARD REPLACEMENT u 2 a EMAN a ANA IEEE S au rre GG LOS 18 6 TH
26. SUPPLY 12V CA Cn ERMINAL BOARD REFER TO CRANE MANUFACTURER S AL DOCUMENTATION FOR LOCKOUT SIGNAL ELECTRIC CONNECTION Of WIRE NUMBER J AN D 1 S i A 4 E 11 f ve z RA V 900 TIT WORKING RANGE d MAX ERROR 2 z CODE J UV EJT 10 TO A D NN CONVERTER U O Lk V SIGNAL 6 SENS oh A dus x 8 ENGTH NTER 10 KO ERMINAL 30ARD ERMINAI J TEST POINT BOARD ON MAIN AT REV A 10 16 01 CA P3 ZERO AD A JJUSTMENT POINT 100753 A doc 20 6 3 Piston Side Pressure Measuring Channel CENTRAL UN WIRE NUMBER TEST POINT ON MAIN PRESSURE TRANS PISTON SIE TERMINAI OARD DUAR U BOARD JUCER EA 4 50 a 5 0V Service Manual PAT Ds150 WORKING RANGE OUTPUT ZERO PRES AS MAX PR A 5 MV D is 28 E b EZ s A MP1 B P1 FROM OF LIFT CYLINDER 6 4 Rod Side Pressure Measuring Channel X1 CENTRAL UN NUMBER TEST POINT ON MAIN PRESSURE TRANSDUCER ROD SIDE ERMINAL P1 ZERO POINT ADJUSTMEN BOARD PAT REV A 10 16 01 5 SOY 2 O CND 2 J NU x1 ki ON 1314 5 0V
27. configurations and a switch for the Reeving of the hook block It also has a warning light for anti two block conditions and an override switch for overload or anti two block condition Duty Selection Switches Digital Inputs The system has to be programmed for the lifting area configuration The crane is going to be worked in e g main boom on outriggers over front or rear or over the side for 360 degrees For obtaining this information from the crane micro switches are installed in the electrical swivel that tells the system the exact location of the boom Micro switches are also located on the counterweight which tells the system if the counterweight is installed or not where applicable AT REV A 10 16 01 100753_A doc 2 Service Manual IPA W 5 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 actual information of the crane This is computed against the reference data and the crane status is continuously monitored Description of the Housing The central unit 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 o
28. d replacement procedure Y Reconnect Wire 6 to X1 34 and Wire 5 to X1 35 Refer to system wiring diagram Co AT REV A 10 16 01 100753 A doc 30 Service Manual F 4QTW DS150 7 6 Length Reading Problem PROBLEM Length reading incorrect Crane is not in out of load chart condition C START p Y Check mechanical adjustment of length potentiometer in cable reel When main boom is fully retracted adjust length potentiometer counter clockwise until it stops Refer to 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 Check out clutch in big gear wheel of length transducer Extend and retract boom to ensure that clutch is not sipping on potentiometer axle Replace the gear wheel clean potentiometer No axle Reset length potentiometer Refer to length angle adjustments procedure Yes Y Check power supply to length transducer on connection board
29. eplace LMI main board or processor board Fallen below lower limit value in measuring channel angle 2 Fallen below lower limit value in the measuring channel pressure rod side OPAT REV A 10 16 01 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 A doc Error Codes 43 Enor and or e The supply voltage is e Check the voltages on the supply voltage falsified by one of the LMI main board Check defective sensors DAV LWG sensors plugs and cable replace if need be e Electronic component is Replace LMI main board defective Analog and or e The analog voltage is Check the voltages on the supply voltage falsified by one of the LMI main board Check defective sensors sensors plugs and cable replace if need be e Electronic componentis je Replace LMI main board defective Upper limit value in e Refer to E11 Refer to E11 measuring channel main boom length has been exceeded Upper limit value in e Refer to E12 Refer to E12 measuring channel pressure piston side has been exceeded Upper limit value in e Refer to E12 Refer to E12 measuring channel pressure rod side has been exceeded Upper limit value in e Refer t
30. he 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 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 AT REV A 10 16 01 100753 A doc 48 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 X1 4 GND VDC 2 Main Board Power Supply Reference Voltages 50 MV 9V Mp2 VDC Mp 10 Ground Piston amp Rod Pressure 9V M B VDC Mp 10 Ground Piston amp Rod Pressure 5SV Mp4 OO VDC Mp 10 Ground TTL on Board 5V Mp VDC Mp 10 Ground Reference on Board 5V Mp6 VDC Mp 10 Ground Internal on Board
31. ing diagram Yes Y Find out which component of the crane electric is spiking out e g dump valve outrigger relay Install a diode or resistor across terminals of spiking component Diode type such as 1N4001 can be used however ensure the correct plus and minus connections for diode q END PAT REV A 10 16 01 100753 A doc Troubleshooting Flow Charts 39 7 10 Angle Problem PROBLEM Displayed Angle Incorrect Actual measured angle is different from displayed angle C START p 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 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 voltage Refer to Section 7 4 No Display this manual Yes Check the voltage at angle sensor between connector pins A AGND and C 45V Refer to system wiring diagram Cable defective replace cable or cable assembly No a a 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 03 2 5V 45 1 875V 90 Refer to angle sensor theory Replace Angle Sensor Refer to length angle
32. ion 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 Y Replace Anti Two Block switch Yes vY C Next Page AT REV A 10 16 01 100753 A doc 28 Service Manual PAT Ds150 PREVIOUS 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 4500Ohms Switch open gt 1 Megaohm Reconnected slip ring wires Refer to system wiring diagram Fault in wiring between boom nose box and cable reel Check for damaged length cable and wiring Refer to system wiring diagram If broken length cable Refer to length cable replacement l No gt i Measure the A2B signal in the cable reel between terminal 7 and 8 with an ohmmeter Switch closed 24700 4500Ohms Swi
33. n 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 EPROMs 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 lockout 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 sig
34. nal 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 AT REV A 10 16 01 100753 A doc Mechanical Description Of The System 3 2 1 Basic System Component Layout F ANTI TWO BLOCK SWITCH SA2B WEIGHT 7 CABLE REEL W LENGTH AND ANGLE SENSORS CENTRAL UNIT _ CONSOLE s PRESSURE TRANSDUCERS AT REV A 10 16 01 100753_A 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 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
35. o E15 Refer to E15 measuring channel main boom angle has been exceeded Upper limit value in e Refer to E16 Refer to E16 measuring channel angle 2 has been exceeded Reference and or e Refer to E19 e Refer to E19 supply voltage defective E31 Error in the e The system program e Replace system program E37 PROM is defective PROM PROM No 0 System program e The system program in e Replace the system program and data EPROM the LMI does not match to PROM or the data EPROM do not match the programming in the PROM No 1 data EPROM AT REV A 10 16 01 100753 A doc 44 ErrorCode Error Cause Error in the internal write read memory RAM of the component 80C537 Redundancy error in the A D conversion Error in the A D converter uPD Cyclic RAM test error in the internal write read memory RAM of the Error in the crane data EPROM or EEPROM OPAT REV A 10 16 01 Service Manual PAT Ds150 e Computer component 80C537 defective e CPU module defective e Processor board defective CMOS RAM or processor board defective e The A D converter on the processing board and the redundant A D converter in the CPU 80C537 provide different results e No acknowledgment of the A D converter uPD 7004 e Computer component 80C537 defective e CPU module defective defective e No valid data in the crane data EEPROM e Memory module wrongly bridged e Crane data EPROM defective e
36. r angle specified in the load chart Replace main board Replace processor board e Refer to E07 100753 A doc 42 Service Manual PAT Ds150 ErrorCode Error Cause Elimination 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 e Cable between central unit and length sensor is defective or disconnected Water inside the plug of the length angle sensor Length potentiometer is defective Electronic component in the measuring channel is defective Cable between the central unit and pressure transducers defective or water inside the plugs Pressure transducer is defective Electronic component in the measuring channel is defective Refer to E12 Cable between central unit and the length angle sensor defective or loose Water inside the plug of the length angle sensor Angle potentiometer defective Electronic component in the measuring channel defective 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 R
37. r supply at transducer plugs Measure between B ground and A 5V Measure between B ground and C 5V No Faulty wiring Check wiring of pressure transducer cable Yes lt NEXT PAGE D PAT REV A 10 16 01 100753_A doc Troubleshooting Flow Charts 35 PREVIOUS PAGE Y Check transducer signals in central unit Connect pressure transducers to cable Disconnect wire No 4 of transducer cable from X1 21 signal piston side Measure transducer signals 0 1V between Pin 19 ground and wire No 4 of piston cable Disconnect wire No 4 of transducer cable from terminal block X1 Pin 16 single rod side Measure transducer signals 0 1V between Pin 19 ground and wire No 4 of rod cable Refer to system wiring diagram Correct Check wiring in pressure transducer cable Continuity Good No Correct Yes Transducer defective replace transducer and reset pressure channel Yes Y Connect wire No 4 from transducer cables back to terminal X1 16 rod side and terminal X1 21 piston side Without pressure in pipes or hydraulic pipes disconnected from transducer check O point adjustment on connection board Measure between test point MP10 ground and test point MP11 Signal should be 0 50V piston side Measure between test point MP10 ground and test point MP12 Signal should be 0 50V rod side Refer
38. t 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 Adjust P1 to obtain a reading of 0 500 volts 500mv on meter Disconnect hydraulic hose from the rod side pressure transducer Connect a digital voltmeter to main board A BLACK lead to MP10 B RED 4 lead to MP12 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 WwW AT REV A 10 16 01 100753 A doc 5 3 Length amp Angle Adjustments L ji JE N 17 WC103 e 6 PARALLEL WITH BOOM FULLY RETRA A SOFT S AT REV A 10 16 01 ADJUST LENGTH POTENTIOMETER TURN THE CENTER SCREW COUNTER CLOCKWISE TO ji ADJUST TOP OF ANGLE TIT ADJUSTMENT QPREWQ SCREWS SENSOR WITH BOOM CTED TOP 100753 A doc 18 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 uni
39. t lid NOTE Take care not to damage the boards with the screw driver 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 central 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 PAT REV A 10 16 01 100753 A doc Theory 6 THEORY 6 1 Anti Two Block amp Shutoff Circuit BIX 19 ie 4 7K 0h RESISTOR T gt 48 86 K lum Via 85 vT LMI OVERLOAD JR FROM CRANE p 1L
40. tch open gt 1 Megaohm Reconnected slip ring wires Refer to system wiring diagram Replace slip ring No Refer to cable reel parts list t 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 ib C NEXT PAGE p PAT REV A 10 16 01 100753_A doc Troubleshooting Flow Charts 29 PREVIOUS PAGE 2 l Connect wire 5 back to the terminal X1 35 on the connection board Refer to svstem 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 0Ohms Anti Two Block switch open gt 1 Megaohm Refer to system wiring diagram Faulty wiring between cable reel and central unit NO gt Check cable YES Y Disconnect X1 34 and X1 35 Check main board function by installing a temporary resistor 4700 Ohms between X1 34 and X1 35 in central unit With resistor connected alarm should be inactive Refer to system wiring diagram Replace main board and reset pressure channel NO A Refer to main boar
41. the length cable on the drum which is a two conductor cable screen and live It is connected to the anti two block switch at the boom head and to a slip ring body in the reel The angle transducer is fitted into a small box filled with oil A pendulum drives the axle of the angle potentiometer The power supply voltage for both is 5 00V The output signal for the length transducer is 0 500V up to 4 500V The output signal for the angle transducer is 1 875V up to 3 125V Anti Two Block Switch The anti two block switch monitors the load block and its relationship with the head of the boom In working condition the switch is closed When the hook block strikes the weight the circuit opens disengaging a relay output to the lockout solenoid valves where applicable To check the cable for damage short circuit to ground there is a 4 7k resistor between ground and the contact of the switch The weight at the anti two block switch keeps the switch closed until the hook block strikes it Console The console displays the geometrical information such as length and angle of main boom working radius and head height of 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
42. the main board Adjust P1 and P2 on the main board to 500mV at test points MP11 and MP12 Connect hydraulic hoses back to the pressure transducers See Procedure 2 Duty Selection Switches Digital Inputs Check the duty selection switches for correct operation Check the voltage on digital input connections Check the function of the hoist limit switch anti two block Check function of lever lockout Measure and record the power supply voltages See Addendum A PAT REV A 10 16 01 100753 A 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 03 93 RADIUS OF LOAD The horizontal distance from a vertical projection of the crane s axis of rotation to the supporting surface before loading to the center of the vertical hoist 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
43. to system wiring diagram Measure voltage between test point MP10 ground and test point MP11 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 No mo AT REV A 10 16 01 100753 A doc 36 Service 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 sme 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 X 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 NEXT PAGE p PAT REV A 10 16 01 100753_A doc Troubleshooting Flow Charts 37 Continued from previous page PREVIOUS PAGE 3 Check power supply to console between console terminal 2 ground and terminal
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