HIRSCHMANN TROUBLESHOOTING MANUAL LOAD MOMENT
Contents
1. Flowcharts 19 C PREVIOUS PAGE Connect wire 5 back to the terminal X1 31 on the connection board Refer to Drawing 3 in Section 4 Turn system power off Check Anti Two Block signal in central unit with ohmmeter measure between X1 31 and X1 32 Anti Two Block switch closed 4700 Ohms x50 0Ohms Anti Two Block switch open gt 1 Megaohm Refer to Drawing 3 in Section 4 Faulty wiring between boom base box and central unit NO Check connections and cable if necessary YES Disconnect X1 31 and X1 32 Check board function by installing a temporary resistor 4700 Ohms between X1 31 and X1 32 in central unit With resistor connected alarm should be inactive Refer to Drawing 3 in Section 4 Defect on main board Replace main board NO Refer to Drawing 4 in Section 4 and Replacement Procedure 3 in Section 5 v Reconnect Wire 5 to X1 31 and Wire 6 to X1 32 Refer to Drawing 3 in Section 4 gt Rev 05 01 01 SB 190113_A 20 Service Manual PAT DS 350 GM 3 7 LENGTH READING PROBLEM PROBLEM Length displayed incorrect Crane is not in out of load chart condition CL START 2 Check mechanical adjustment of length potentiometer in cable reel With boom fully retracted reset potentiometer by turning it slowly2. 39 48 DRAWING 9 CENTRAL UNIT ANALOG INPUT 40 5 PROCEDURES ess LI 41 5 1 PROCEDURE 1 STRAIN RELIEF INSTALLATION eee 41 5 2 PROCEDURE 2 EPROM LOCATION AND 42 5 3 PROCEDURE MAIN BOARD 43 54 PROCEDURE 4 PRESSURE TRANSDUCER ZERO ADJUSTMENT 44 5 4 1 USING GRAPHIC CONSOLE FOR ZERO SETTING OF PRESSURE TRANSDUCER amp FORGE INPUTS sr He ea 44 55 PROCEDURE 5 LENGTH AND ANGLE SENSOR ADJUSTMENT 45 6 THEORY u nie EIE MI I 46 6 1 THEORY 1 OPERATION OF BOOM LENGTH 46 Measuring Surfen RR 46 o E 46 6 2 THEORY 2 OPERATION OF PISTON SIDE LOAD SENSOR 47 63 THEORY OPERATION ROD SIDE LOAD 48 6 4 THEORY 4 OPERATION OF ANGLE 49 Rev A 05 01 01 SB 190113 A General Information 1 1 GENERAL INFORMATION This troubleshooting manual is designed to assist a service or maintenance person in identifying system problem areas or malfunctions A digital voltmeter with the capability to also measure current will be required Regular m
3. Rev 05 01 01 SB 190113_A Flowcharts 21 PREVIOUS PAGE Y Measure supply to length transducer in cable reel between terminal 1 ground and 3 12 24v Refer to Drawing 3 in Section 4 NO 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 Drawings 3 amp 6 in Section 4 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 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 Drawing 6 in Section 4 and adjustment Procedure 5 in Section 5 YES Measure si
4. Bern 250 ohms ERROR UE CODE 1 HH gt L NES 250 ohms AmA 1 1V papas WORKING x RANGE 20mA 5 5V i M x s EEA Um TE _ __ _ za NA 7 Rr Rev A 05 01 01 SB 190113 A MANUAL REVISIONS DATE NAME DESCRIPTION 05 01 01 Update format in manual Rev A 05 01 01 SB 190113_A
5. Reset length potentiometer With fully retracted boom turn potentiometer axle counter clockwise until it stops Refer to Section 3 7 YES v Measure radius and check with the displayed radius Check if mechanical adjustment of angle transducer is correct Angle transducer NO e box should be in line with boom and adjusted to actual boom angle Refer to Section 3 8 YES Check power supply to pressure transducers piston side Check each transducer by unpluging the transducer cable from transducer Measure voltage at the cable connection between A 12 24v and C ground at each connector Refer to Drawing 1 in Section 4 Check power supply in the central unit between X1 20 12 24v and X1 22 ground for piston side and X1 23 12 24v and X1 25 ground for rod side Refer to Drawing 1 and 4 in Section 4 YES p Fault in pressure transducer cable Refer to Drawing 1 in Section 4 v C NEXT PAGE NO Main board defective Replace main board Refer to Drawing 4 in Section 4 and Replacement Procedure 3 in Section 5 Correct NO gt YES Rev A 05 01 01 SB 190113_A 26 Service Manual DS 350 GM 3 10 BAD DATA TRANSFER BETWEEN CONSOLE amp CENTRAL UNIT OR INTERFERENCE PROBLEM C PREVIOUS PAGE y be measured in series Set Voltmeter to
6. 5V MP2 7V 4 N 24V MP6 MP7 MPO GND 1 BOARD PART NUMBER 050 150 30 0051 Rev A 05 01 01 SB J5 J2 J4 J3 lt gt J1 39 X5 HN O IS 00 H 190113_A 40 Service Manual PAT DS 350 GM 4 8 DRAWING 9 CENTRAL UNIT ANALOG INPUT MODULE BOARD P N 024 352 300 020 X1 1 7 ADC INPUT 0 5V 4 5V Note If channel adjustments are made through the software and graphic console DO NOT adjust offset with P1 P7 1 8 TEMP 0 5V 10mV C 1 9 VREFA 5 000V reference X1 10 AGND reference GND X1 11 VREF 5 0V power ADC X1 12 15 CH01 04 DIN1 4 10 X1 16 UBS 10 X1 17 CH06 HESIN A2B 4 X1 18 CHO7 9 4 X1 19 VREFA 2 2 500V X1 20 UKLEMM app VREFA limits ADC input to 5 0V 1 8 5V MP1 7 Input channels 1 7 0 5V AmA 2 5V 20mA MP14 13V REFO2 MP16 HESIN input voltage MP17 app 5 4V clamp for inputs The analog input module converts the sensor signals on channels 1 7 to signals that will be process at the CPU and software The incoming signal measured at the measuring points MP will be 0 5V 4mA 2 5V 20mA The analog input module then converts the channel signals to 0 5V 4 5V which can be measured on X1 1 through X1 7 The signal voltage can be measured at either point using ground and the signal input Rev A 05 01 01 SB 190113 A Theory 41 5 PROCEDURES 5 1
7. 6 THEORY 6 1 THEORY 1 OPERATION OF BOOM LENGTH SENSOR OPERATING WINDOW The system sensors provide a 4 to 20mA output however due to ERROR a fixed resistor circuit in the central unit the input signal can be CODE E11 measured using ammeter current or voltmeter voltage The 4mA 1 1V input signal operating window is 4 to 20mA measured in series at the analog input terminal OR 1 1 to 5 5V measured in parallel between the analog input and ground GND terminals At 4mA the voltage is 1 1V and at 20mA the voltage is 5 5V When AREE 20 5 5 troubleshooting this system a current or voltage needs to be CODE 21 measured to determine the status or condition of the sensor Measuring current The ammeter Adis used to measure current at the length input signal Remove the wire from X1 27 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 is used to voltage between pins X1 27 length signal and X1 28 gnd on the main board 024 352 300 001 9333103287 The resistors are there to show that at 4mA the voltage is 1 1V because current multiplied with resistance equals voltage therefore 4mA x 275 ohms total resistance 1 1V lame eeu mer sehn ri Rev A 05 01 01 SB 190113 A Theory 47 6 2 THEORY 2 OPERATION OF PISTON SIDE LOAD SENSOR Measuring current The a
8. a Check cable b Check angle sensor and reset adjustment Check signal on main board and analog input module a Check cable and connectors b Check sensor of channel 7 and reset adjustment Check signal on main board and analog input module Outrigger overloaded Front outrigger overloaded Check outrigger sensor Error in the reference voltage Below limiting value for slewing angle 1 E1A Below limiting value for slewing angle 2 Upper limiting value for the measuring channel length exceeded Rev A 05 01 01 SB Electronic component on the main board defective a Cable from central unit to the slewing angle sensor defective or loose b Slewing angle potentiometer defective c Electronic component in the measuring channel defective on main board a Cable from central unit to the length angle sensor defective or loose b Length potentiometer defective c Electronic component in the measuring channel defective on main board Replace main board Refer to Drawing 4 and Procedure 3 a Check cable b Check and reset slewing angle potentiometer Check signal on main board and analog input module Refer to Section 3 7 a Check cable and connector b Check and reset length sensor Potentiometer Refer to Procedure 5 Check signal on main board and analog input module 190113 A Flowcharts ACTION ERRO ERROR CAUSE R CODE E22 Upper limiting va
9. b Sensor of channel 7 defective Electronic component in the measuring channel 7 defective a The total of the supply and the reference voltages on MP10 is more than 3 3V b A D converter defective a Cable from central unit to the slewing angle sensor defective or loose b Slewing angle potentiometer defective c Electronic component in the measuring channel defective on main board a EPROM with system program defective b Electronic component on the main board defective a EPROM with system program defective b Electronic component on the main board defective The system program in the LMI does not correspond to the programming in the data EPROM The system program in the LMI does not correspond to the programming in the data EPROM Defective electronic component a Check cable and connectors b Check sensor of channel 7 and reset adjustment Check signal on main board and analog input module a Check supply voltages b Replace main board or analog input module Refer to Drawing 4 and Procedure 3 Steps 1 2 4 11 12 a Check cable b Check and reset slewing angle potentiometer c Check signal on main board and analog input module a Replace system program EPROM b Check signal on main board and analog input module a Replace system program EPROM b Check signal on main board and analog input module Replace system program EPROM or Data EPROM Ref
10. Drawings 4 4 1 2 2 2I ____ _ _ gt _ _____ ___ z 8 ra 5 u EF n Z MJIS 5 x u ee EQ 2 r 1 M315 Q CR 25 no A z i KO O lt amp jo ert E SS GO Lm m FQ godi X Tas i I c4 iy anti em _ 1 5 EUM dE d lt ss go 1 mm lt 4 EO NOlSId S N a 3 en j o besessen 2 E 4 Z 5 u TA NO TA NO S INT 5 95 m Jos 5 qN9 s r r lt lt amp N aNd lt an e gt an x 190113 A Rev A 05 01 01 SB 30 Service Manual PAT DS 350 GM 4 2 DRAWING 2 ELECTRICAL WIRING FOR CENTRAL UNIT TO CONSOLE CENTRAL UNIT DS350GM MAIN BOARD PAT 024 352 300 001 a DVA CH iin Seite See reference notes on Drawing 1 Rev A 05 01 01 SB 190113_A Drawings 31 43 DRAWING 3 ELECTRICAL WIRING
11. www hirschmann com HIRSCHMANN PAT LOAD MOMENT INDICATOR DS 350GM TROUBLESHOOTING MANUAL P N 031 300 190 113 REV A 05 01 2001 Service Manual PAT DS 350 GM NOTICE The information in this document is subject to change without notice Hirschmann makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose Hirschmann shall not be liable for errors contained in this manual or for incidental or consequential damages in connection with the furnishing performance or use of this manual This document contains proprietary information which is protected by copyright All rights are reserved No part of this document may be photocopied reproduced or translated into another language without the prior written consent of Hirschmann Hirschmann reserves proprietary rights to all drawings and to the data shown thereon The drawings and data are confidential and are not to be used or reproduced without prior written consent of Hirschmann The drawings are subject to technical modification without prior notice 1999 PAT GmbH D 76275 Ettlingen Germany 2006 Hirschmann Chambersburg PA 17201 USA Rev 05 01 01 SB 190113 A Service Manual PAT DS 350 GM TABLE OF CONTENTS 1 GENERAL INFORMATION ce 1 2 2 97 EFEOW
12. counter clockwise until it reaches a soft stop Refer to Drawing 6 in Section 4 and Adjustment Procedure 5 in Section 5 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 NOB 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 Drawing 3 amp 6 in Section 4 and Adjustment Procedure 5 in Section 5 YES Check out clutch in big gear wheel of length transducer Extend and retract boom to ensure that clutch is not slipping on potentiometer axle Refer to Drawing 6 in Section 4 and Adjustment Procedure 5 in Section 5 Replace the gear wheel clean potentiometer axle Reset N length potentiometer Refer to Drawing 6 in Section 4 and Adjustment Procedure 5 in Section 5 Check power supply to length transducer on main board terminal X1 28 ground and X1 26 12 24v Refer to Drawing 3 in Section 4 Main board defective Replace main board NO gt Refer to Drawing 4 in Section 4 and Replacement Procedure 3 in Section 5 YES v NEXT PAGE 1
13. 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 tip junction box 13 Connect the length cable into the boom tip junction box Refer to Drawing 3 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 Procedure 5 in Section 5 5 Rev A 05 01 01 SB 190113 A Flowcharts 15 3 5 NO DISPLAY PROBLEM Blank console display with no warning light shown All crane moments have been stopped C START p Check fuses in central unit NO gt Replace fuses YES Y Measure voltage on the main board terminal strip between X1 1 12 24V and X1 2 ground This is an input voltage from the crane Refer to Drawing 1 in Section 4 Check crane power supply for faulty NO crane electric YES Y Measure voltage on the main board between X1 3 12 24V and X1 4 ground This is an output voltage to the console Refer to Drawing 1 in Section 4 Replace the main board in central unit NO Refer to Drawing 4 in Section 4 and Replacement Procedure 3 in Section 5 YES v C NEXT PAGE p Rev A 05 01
14. to Section 3 7 a Check cable and connector b Check and reset length sensor Potentiometer Refer to Procedure 5 Check signal on main board and analog input module Refer to Section 3 9 a Check cable and connector b Check pressure transducer and reset pressure channel Check signal on main board and analog input module Refer to Section 3 9 a Check cable and connector b Check pressure transducer and reset pressure channel Check signal on main board and analog input module a Check cable and connectors as well and replace if necessary b Check force transducer Check signal on main board and analog input module Refer to Section 3 8 a Check cable b Check angle sensor and reset adjustment Refer to Procedure 5 Check signal on main board and analog input module 190113 A Fallen below lower limit value for the measuring channel 7 a Cable from central unit to angle sensor defective or disconnected or water inside the plug b Angle sensor defective c Electronic component in the measuring channel defective a Cable leading from the central unit to the sensor of channel 7 defective loose or water in the connectors b Sensor of channel 7 defective c Electronic component in the measuring channel 7 defective Service Manual PAT DS 350 ERRO ERROR CAUSE ACTION R CODE Fallen below lower limit value for measuring channel Luffing Jib Angle
15. 0 313 062 002 1 FUSE 10amp 250V FAST ACTING 11 000 313 064 00 1 1 FUSE 4amp 250V FAST ACTING 12 000 214 340 013 1 HOLE PLUG PG13 5 13 021 441 131 013 2 STRAIN RELIEF PG13 5 RED WHT 14 021 441 161 213 1 STRAIN RELIEF PG13 5 W GREY WHT 15 021 441 090 709 3 STRAIN RELIEF PG9 W BLACK WHITE 16 024 000 100 260 5 FERRITE FILTER PG13 5 17 024 000 100 261 1 FERRITE FILTER PG16 18 024 350 100 661 1 KEYSWITCH 19 031 300 101 131 1 SPARE KEY 20 024 000 100 095 2 MEMBRANE ELEMENT BREATHER Rev A 05 01 01 SB 190113 A DRAWING 5B CONSOLE DS350 1318 PARTS LIST 11 Rev A 05 01 01 SB 190113 A Drawings 35 DRAWING 5B CONSOLE DS350 1318 PARTS LIST continued GRAPHIC CONSOLE HORIZONTAL PARTS LIST PART NO PAT 050 350 061 318 NO PART NO QTY DESCRIPTION 01 031 300 110 049 1 CONSOLE ACCY FRONT FACE amp DIS 02 050 150 300 052 1 BOARD PUSHBUTTON SET KEYBRDS 03 003 051 905 235 1 SWITCH KEY 04 050 350 1 10 139 1 KEY SPARE 05 002 053 703 101 6 SCREWS FRONT PANEL MOUNTING 06 050 150 300 050 1 BOARD 07 050 150 300 051 1 TERMINAL BOARD 08 050 000 050 625 1 SEALING FRONT PANEL 09 050 000 100 180 1 HOUSING 10 050 350 1 10 263 1 MOUNTING KIT FOR HOUSING 11 021 448 161 213 1 STRAIN RELIEF PG13 5 GREY WHT 12 031 300 100 173 1 GASKET 13 031 300 100 392 1 CANNON CONN 7 SOCKET RECPT 14 031 300 100 024 1 DUST CAP 15 000 208 010 210 1 TOOTHWASHER M12 16 000 214 210 013 1 LOCKNUT PG13 5 17 050 3
16. 01 SB 190113_A 16 Service Manual DS 350 GM 4 PREVIOUS PAGE p Measure voltage in the console between X1 1 12 24V and X1 2 ground Refer to Drawing 2 amp 8 in Section 4 Check connections of the cable between console and central unit Replace cable if necessary Refer to Drawing 2 in Section 4 YES Console Display is defective Replace the console Refer to Drawing 3 in Section 4 YES C END p Rev A 05 01 01 SB 190113 A Flowcharts 17 3 6 ANTI TWO BLOCK PROBLEM PROBLEM Function of Anti Two Block System is faulty C START Check to see whether or not crane is two block condition Correct NO gt Lower hook down into safe position YES Y Check Bypass plug installed Refer to Drawing 3 in Section 4 Plug appropriate bypass plug into socket of No junction box YES Y Turn power off or disconnect wire from connection board X1 31 in central unit Remove the bypass plug and measure the resistance at the boom nose box between terminals 1 and 6 with a ohmmeter This checks the function of the Anti Two Block switch Switch closed OOhms weight installed Switch open gt 1 Megaohm weight removed Pug the bypass plug into the boom nose box Refer to Drawing 3 in Section 4 Check wire connect
17. 50 300 076 1 BOARD TERMINAL INTERFACE FOR LIGHTBAR Rev A 05 01 01 SB 190113 A 45 DRAWING 6 CABLE REEL PARTS LIST 9 XC gt E Rev 05 01 01 SB 190113 A Drawings 37 DRAWING 6 CABLE REEL PARTS LIST continued CABLE REEL ASSEMBLY PARTS LIST PART NO PAT 068 308 060 001 11 NO PART NO QTY DESCRIPTION 01 068 000 300 060 1 BOARD TERMINAL W EMC FILTERS 02 064 103 060 007 1 ANGLE SENSOR WG103 0007 03 068 000 300 018 1 LENGTH POTENTIOMETER UNIT 04 002 050 206 012 2 SCREW M6 X 12 HEX SOCKET CAP 05 000 207 010 064 2 WASHER M6 FLAT 06 068 000 100 152 1 HOUSING KT200 07 000 214 340 013 1 PG13 5 HOLE PLUG 08 000 673 020 002 139 CABLE LENGTH SINGLE CORE 09 002 148 131 013 1 STRAIN RELIEF PG13 5 RED WHT 10 031 300 100 206 1 CHEMICAL CORROSION INHIBITOR 1 068 000 100 064 SLIP RING ASSEMBLY 2 POLE Rev A 05 01 01 SB 190113 A Service Manual PAT 05 350 4 6 DRAWING 7 CENTRAL UNIT MAIN BOARD LAYOUT 24 MP26 MP4 MP9 MP8 W pri v gt THU DIS 1 MP25 Rev A 05 01 01 SB BOARD P N 024 352 300 001 1 KGND MP4 5 MP8 9 MP9 6 MP24 BATT MP25 UBS console sensors 015 MP26 GND MP29 5V hand terminal LED S H08 LOAD H09 A2B H10 MAIN IN OUT 11 POWER H12 TxD 190113_A Drawings 4 7 DRAWING 8 CONSOLE CONNECTION BOARD MP5
18. BLEM Angle displayed incorrect Crane is not in out of load chart condition START Check the cable reel for damages or movement of mounting bracket Refer to Drawing 6 in Section 4 and Adjustment Procedure 5 in Section 5 Repair or replace cable reel if damaged or NO adjustments can not be made YES Place the boom at 0 Measure the angle sensor supply voltage in the central unit between terminals X1 26 12 24v and X1 28 ground Refer to Drawing 3 in Section 4 Main board defective Replace main board NO Refer to Drawing 4 in Section 4 and Replacement Procedure 3 in Section 5 Open cable reel cover Measure angle sensor supply voltage in the cable reel between terminals X1 1 12 24v and X1 3 ground Refer to Drawing 3 in Section 4 Faulty wiring between central unit and cable reel NO Check wiring Refer to Drawing 3 in Section 4 Yes v C NEXT PAGE p Rev A 05 01 01 SB 190113_A 24 Service Manual DS 350 GM 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 th
19. EHARTS wrens pec cas vee bcs Sa su 3 ESEE ES 3 3 2 ERROR CODE DISPLAY DEDE NNI M Nek 4 33 LEVER LOCKOUT ACTIVATED A sn an dn tetto etes 13 34 BROKEN LENGTH CABLE 2 nali nt 14 3 5 NO DISPEAY 22222222 EEE 15 36 ANEI TWVO BLOCK PROBLEM 17 37 JEENISTEHASEADING PROBEENIT 2 222222 eee eee 20 3 8 ANGLE READING PROBLEM 2 2 2 2 onde snes ernennen 23 39 LOAD READING PROBLEM Z Ares es o ice eee PE CE ere oe ence tO cen es 25 3 10 BAD DATA TRANSFER BETWEEN CONSOLE amp CENTRAL UNIT OR INTERFERENCE PROBEEM iex eene en nete etike 26 4 DRAWING S 555 555205555065555955655959556559555965 95 lt 569555 59 555955095965 5695965 905 95 255 5959599969595 29 4 1 DRAWING 1 ELECTRICAL WIRING FOR CENTRAL UNIT TO PRESSURE TRANSDUCBERS AND CRANE iioi a oerte onde eerdere 29 4 2 DRAWING 2 ELECTRICAL WIRING FOR CENTRAL UNIT TO CONSOLE 30 4 3 DRAWING 3 ELECTRICAL WIRING FOR CENTRAL UNIT TO CABLE REEL ANTETWO BEOCK 2 3 22 31 44 DRAWING 4 CENTRAL UNIT PARTS LIST 32 4 5 DRAWING 6 CABLE REEL PARTS LIST 36 4 6 DRAWING 7 CENTRAL UNIT MAIN BOARD 38 4 7 DRAWING 8 CONSOLE CONNECTION
20. FOR CENTRAL UNIT TO CABLE REEL ANTI TWO BLOCK CENTRAL UNIT DS350GM a Mc c Re I AN N N STNEGA Meroe zi IL El Pareo gr ehe eed aspa ee s Leine 1 1 1 i i i i i i i i i i i i i i i gt e A x i 2 e i ee gt i i i zu i i i i i i i i i i i i i i i i i i i i i i i Dese A L i i i i i i i i i i i i i i i i i i i i i i i i i i i i i sasa E sas MAIN BOARD 024 352 300 001 Rev A 05 01 01 SB 190113 A 4 4 DRAWING 4 CENTRAL UNIT PARTS LIST 4 8 13 e ss Rev 05 01 01 SB 190113_A Drawings 33 DRAWING 4 CENTRAL UNIT PARTS LIST continued PART NO A PAT 024 350 063 001 PART NO B PAT 024 350 063 002 NO PART NO QTY DESCRIPTION 01 024 350 050 292 1 HOUSING W COVER CENTRAL UNIT 02 024 350 110 067 1 GASKET 03 024 352 300 001 1 MAIN BOARD 04 024 352 300 020 1 ANALOG INPUT MODULE 05 024 351 300 007 1 CPU MODULE 06 024 351 300 01 1 1 EPROM MODULE 07A 000 304 140 112 1 RELAY 12V 07B 000 304 140 241 1 RELAY 24V 08 024 350 100 135 1 SCREW SET 09 000 314 022 006 2 FUSE HOLDER 10 00
21. PROCEDURE 1 STRAIN RELIEF INSTALLATION RATE Rev A 05 01 01 SB 190113 A 5 2 PROCEDURE 2 EPROM LOCATION AND INSTALLATION e Ensure the notch is in the correct direction e The DATA and EPROMs fill the bottom of the socket as shown the arrows e Place EPROMs the correct EPROM socket as shown Rev A 05 01 01 SB 190113_A Theory 43 5 3 PROCEDURE 3 MAIN BOARD REPLACEMENT Refer to Drawing 4 central unit parts list for board location 1 Turn system power off 2 Remove the central unit lid NOTE Take care not to damage the boards with the screwdriver when removing and inserting screws NOTE Use care when lifting the CPU module board and analog input module from the main board because these boards have pins on the bottom side which insert into the main board 3 Remove CPU module board by taking out the 4 small Philips screws holding it in place 4 Remove analog input module board by taking out the 6 small Philips screws holding it in place 5 Remove the relay from the main board item 7 on Drawing 4 in Section 4 4 6 Mark all connection wires before removing to identify location for reconnecting Disconnect all X1 terminal wires from the main board 7 Remove the 14 large Philips screws holding the main board in place 8 Take notice of the orientation of the main board in the central unit Remove main board and place in the packing material that the replacement main board came in 9 Carefu
22. aintenance and service tools will also be required NOTE Knowledge of how to use a voltmeter to measure both voltage and current is assumed REFERENCE For system operation refer to the operator s manual for the console This may differ from crane manufacturer and model Section 3 1 is a general flow chart that directs you to detailed flow charts and sections Section 3 2 provides a list of error codes error cause and possible action for the error Sections 3 3 3 11 provide detailed flow charts to define and correct the root cause Section 4 provides drawings that will be referenced for troubleshooting Section 5 provides procedures that will be referenced for troubleshooting Section 6 provides drawings for the theory of operation of all the different sensing devices used in the DS350G Modular System Use these reference drawings to better understand the operation of the system Rev A 05 01 01 SB 190113 A 2 Service Manual PAT DS 350 GM 2 WARNINGS The LMI is an operational aid that warns a crane operator of approaching overload conditions and overhoist conditions that could cause damage to equipment and personnel Therefore 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 understoo
23. back into admissible range range no load area with load Operating mode not Operating mode switch in the Set operating mode switch available console set incorrectly correctly to the code assigned to Operating mode is not the operating mode of the crane permissible with actual crane configuration E05 Length range not Boom has been extended Refer to Section 3 7 permitted too far or not far enough Retract or extend boom to Length sensor adjustment correct length given in the load changed i e length sensor chart cable slid off the cable drum E06 Fallen below angle Fallen below the minimum jib Luff in the jib to a radius or angle range with luffing jib angle specified n the specified in the load chart operation respective load chart due to luffing out the jib too far E07 No acknowledgment Overload relay is stuck Replace main board in central signal from overload defective or not being unit Refer to Drawing 4 and relay K1 selected Procedure 3 in Section 5 3 E08 No acknowledgment Anti Two Block switch relay Replace main board in central signal from Anti Two is defective or not being unit Refer to Drawing 4 Section Block switch relay selected 4 4 and Procedure 3 in Section K2 5 3 Error in length With the boom fully Refer to Section 3 7 measurement retracted the length differs by more than 2 Rev A 05 01 01 SB 190113 A Flowcharts ACTION ERRO ERROR CAUSE R CODE E11 Fallen below limit fo
24. d and observed Prior to operating the crane the operator must carefully and thoroughly read and understand the information in the crane s operating manuals to ensure that the operator knows the operation and limitations of indicator and crane PAT Load Moment Indicator LMI DS 350 Modular The PAT Load Moment Indicator LMI DS 350 Modular has been designed to provide the crane operator with the essential information required to operate the machine within the designed parameters Using different sensing devices the DS 350 Modular LMI monitors various crane functions and provides the operator with a continuous display of the crane s capacity The display continually changes as the crane moves through the motions needed to make a lift If non permitted conditions are approached the DS 350 LMI will warn the operator by sounding an audible alarm and lighting a warning light In addition the LMI system has the capability to provide a signal to the solenoids and thereby locking out those functions that may aggravate the crane s condition Rev A 05 01 01 SB 190113 A Flowcharts 3 FLOWCHARTS 3 1 GENERAL FLOWCHART This section explains how to handle a problem that may arise with the PAT DS 350 Modular LMI The procedures are given in flowchart format for the following sections Start with the general flowchart below that will guide you to one of the detailed flowcharts shown in this section The drawings and procedures that are reference
25. d in these sections can be found in Sections 4 and 5 What s Wrong Error Code Displayed Go to Section 3 1 z Lever Lockout Activated gt Go to Section 3 3 Broken Length Cable Go to Section 3 4 No display Go to Section 3 5 z Anti Two Block Problem gt Go to Section 3 6 gt Length Reading Problem gt Go to Section 3 7 m Angle Reading Problem Go to Section 3 8 Load Reading Problem Go to Section 3 9 Bad Data Transfer Interference p Between Central Unit and Console Go to Section 3 10 Rev A 05 01 01 SB 190113 A 4 Service Manual PAT DS 350 GM 3 2 ERROR CODE DISPLAY PROBLEM Error code displayed Lever lockout activated Warning lights on _ RE z R CODE E01 Minimum radius or Fallen below the minimum Lower boom back to a radius or a maximum angle range radius or above the angle angle given in the load chart exceeded given in the load chart due to raising the boom to far Maximum radius or The maximum radius or Raise boom back to a radius or minimum angle range minimum angle given in the angle given in the load chart exceeded load chart was exceeded due to lowering the boom too far Prohibited slewing Slewing range prohibited Slew
26. d on console amp go to Section 3 2 Rev A 05 01 01 SB 190113_A 14 Service Manual PAT DS 350 GM 3 4 BROKEN LENGTH CABLE PROBLEM Damaged or broken length cable Replace length cable using the following procedure Refer to Section 4 for the following drawings Drawing 3 Electrical Wiring Central Unit to Cable Reel Drawing 6 Cable Reel Parts List 1 Cutold cable at cable drum 2 Disconnect damaged length cable from junction box at the boom nose Refer to Drawing 3 3 Open cable reel cover and disconnect wiring from terminal block Pull 7 conductor cable out of strain relief Note Mark wires to make re connection simpler 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 Refer to Drawing 3 6 Onthe back side of the cable reel open the strain relief attached to the axle in the center of the drum Pull existing length cable out of the cable reel 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 Refer to Drawing 3 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
27. e boom at 0 or with the boom a 90 Refer to Drawing 3 amp 6 in Section 4 Replace angle sensor Correct NO Refer to Drawing 6 in Section 4 and Adjustment Procedure 5 in Section 5 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 4 in the central unit 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 at 90 Refer to Drawing 3 amp 6 in Section 4 Faulty wiring between central unit and cable reel Correct NO Check wiring Refer to Drawing 3 in Section 4 YES Measure angle signal analog input module between test point MPO AGND and X1 4 ang sig The measurement should be between 0 5 4 5v 0 5v 500mv with the boom at 0 or 4 5v with the boom at 90 Refer to Drawing 9 in Section 4 Analog Input board defective Replace analog input board Refer to Drawing 4 in Section 4 and Replacement Procedure 3 steps 4 11 amp 12 in Section 5 END p Rev A 05 01 01 SB 190113 A Correct NO Flowcharts 25 3 9 LOAD READING PROBLEM PROBLEM Load reading incorrect C START v Check boom length reading on display
28. er to Procedure 2 Replace system program EPROM or TLK EPROM Refer to Procedure 2 Replace main board or analog input module Refer to Drawing 4 and Procedure 3 Steps 1 2 4 11 and 12 190113_A Flowcharts R CODE E42 Error in the external Internal defect in digital part Exchange write read memory write read memory of CPU CMOS RAM Replace CPU RAM Part 1 module Refer to Drawing 4 and Procedure 3 Steps 1 3 13 14 E43 Error in the external Internal defect in digital part Exchange write read memory write read memory of CPU CMOS RAM Replace CPU RAM Part 2 module Refer to Drawing 4 and Procedure 3 Steps 1 3 13 14 E45 Redundancy error in Defective electronic Replace analog input module A D conversion component Refer to Drawing 4 and Procedure 3 Steps 1 2 4 11 12 E46 Error in A D Defective electronic Replace analog input module conversion component Refer to Drawing 4 and Procedure 3 Steps 1 2 4 11 12 E47 Malfunction in the Internal defect in digital part Replace CPU module Refer to monitored write read of CPU Drawing 4 and Procedure 3 memory Steps 1 3 13 14 Cyclic RAM test Error Internal defect in digital part Replace CPU module Refer to in the internal of CPU Drawing 4 and Procedure 3 write read memory Steps 1 3 13 14 Error in data EPROM EPROM Module not bridged Replace Data EPROM Make correctly sure BR3 on the main board is Data EPROM on the main installed Refer to Proced
29. gnal 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 27 in the central unit and connect one voltmeter lead to wire 2 and the other lead to X1 27 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 Drawing 3 amp 6 in Section 4 Faulty wiring between central unit and cable reel Check wiring YES v C NEXT PAGE Rev A 05 01 01 SB 190113 A 22 Service Manual DS 350 GM PREVIOUS PAGE Measure length signal of amplified output on analog input module between test point MPO and X1 3 The measurement should be between 0 5 4 5v 0 5v 500mv with the boom fully retracted and the length potentiometer set fully counter clockwise to a soft stop OR 4 5v with the length potentiometer turned completely clockwise 10 turns to the soft stop Refer to Drawing 9 in Section 4 Analog Input board defective Replace analog input board Refer to Drawing 4 in Section 4 and Replacement Procedure 3 steps 4 11 amp 12 in Section 4 Correct NO YES 4 END gt Rev A 05 01 01 SB 190113 A Flowcharts 23 3 8 ANGLE READING PROBLEM PRO
30. in the measuring channel defective Refer to Section 3 9 a Check cable and connector b Check pressure transducer and reset pressure channel c Check signal on main board and analog input module Refer to Section 3 9 a Check cable and connector b Check pressure transducer and reset pressure channel c Check signal on main board and analog input module a Check cable and connectors as well and replace if necessary b Check force transducer c Check signal on main board and analog input module Refer to Section 3 8 a Check cable b Check angle sensor and reset adjustment Refer to Procedure 5 c Check signal on main board and analog input module a Check cable b Check angle sensor and reset adjustment c Check signal on main board and analog input module 190113 A Service Manual PAT DS 350 ACTION ERRO ERROR CAUSE R CODE Upper limit value for the measuring channel 7 exceeded Reference voltage defective Above limiting value for slewing angle 1 Above limiting value for slewing angle 2 29 2A 2B 31 Error in the system program 37 38 39 41 Error in the program run System program and Data EPROM do not match E E E E E E E System program and TLK EPROM do not match Error in the external RAM Rev A 05 01 01 SB a Cable leading from the central unit to the sensor of channel 7 defective loose or water in the connectors
31. ions in boom nose Correct No gt box Replace Anti Two Block switch Refer to Drawing 3 in Section 4 Yes v C Next Page 3 Rev A 05 01 01 SB 190113 A 18 Service Manual DS 350 GM PREVIOUS PAGE Ensure the byass plug is plugged into the boom nose box 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 Reconnected slip ring wires Refer to Drawing 2 amp 6 Section 4 Fault in wiring between boom nose box and cable reel Check for damaged length cable and wiring Refer to Drawing 3 Section 4 If broken length cable Refer to Section 3 4 Measure the 2 signal in the cable reel between terminal 7 and 8 with ohmmeter Switch closed 4700 5000hms Switch open gt 1 Megaohm Reconnected slip ring wires Refer to Drawing 3 Section 4 Replace slip ring Refer to Drawing 3 amp 6 in Section 4 Y Measure the A2B signal in the boom base box between terminals 5 and 6 with an ohmmeter Switch closed 24700 5000hms Switch open gt 1 Megaohm Reconnected slip ring wires Refer to Drawing 3 Section 4 Fault in 7 conductor cable between cable reel and boom base box Check connections and replace No P cable if necessary Refer to Drawing 3 in Section 4 C NEXT PAGE p Rev A 05 01 01 SB 190113 A
32. lly insert the new main board in place Refer to Drawing 4 in Section 4 4 for location 10 Insert the 14 Philips mounting screws be sure to attach the ground wire to the KGND screw in the lower left corner Refer to Drawing 4 11 Insert analog input module board by lining up the pins into the sockets X16 and X17 and the 6 screw holes 12 Insert the 6 small Philips screws and washers 13 Insert CPU module board by lining up the pins into the sockets X11 and X12 and the 4 screw holes 14 Insert the 4 small Philips screws and washers 15 Insert the relay on to the main board item 7 on Drawing 4 16 Connect the X1 terminal wires to the main board Refer to Drawings 1 2 and 3 17 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 Rev A 05 01 01 SB 190113 A 44 Service Manual PAT DS 350 GM 5 4 PROCEDURE 4 PRESSURE TRANSDUCER ZERO ADJUSTMENT 5 4 1 USING GRAPHIC CONSOLE FOR ZERO SETTING OF PRESSURE TRANSDUCER amp FORCE INPUTS 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 re
33. lue for the measuring channel pressure piston side exceeded Upper limit value for the measuring channel pressure transducer rod side exceeded Upper limit value for the measuring channel force exceeded E E E Upper limit value for the measuring channel angle main boom exceeded E Upper limit value for the measuring channel Luffing Jib Angle exceeded Rev A 05 01 01 SB 23 24 25 26 a Cable from central unit to the pressure transducer defective loose or water in the plug b Pressure transducer on piston side defective c Electronic component in the measuring channel defective on main board a Cable lead in from the central unit to press trans defective not connected or water in the connectors b Pressure transducer on rod side defective Electronic component in the measuring channel defective a Cable leading from the central unit to the force transducer defective not connected or water in the connectors b Force transducer defective Electric component in the measuring channel defective a Cable leading from the central unit to the length angle sensor defective loose or water in the connectors b Angle sensor defective Electronic component in the measuring channel defective a Cable leading from the central unit to the jib angle sensor defective loose or water in the connectors b Jib angle sensor defective c Electronic component
34. measure amps pressure in the hydraulic lines O psi and the other lead to X1 24 The measurement should be between 4 20ma 4ma when there is no pressure in the hydraulic lines O psi Refer to Drawing 1 in Section 4 Measure signal from pressure transducers in central unit The return signal is a current output and must Piston Side remove Wire 2 from X1 21 in the central unit and connect one ammeter lead to wire 2 and the other lead to X1 21 The measurement should be between 4 20ma 4ma when there is no Rod Side remove Wire 2 from X1 24 in the central unit and connect one voltmeter lead to wire 2 Check continuity of wire 2 and pin B in pressure transducer cable by first 8 Correct NIE between A 12 24v and B ground for each connector Re connect the wiring a shown on Drawing 1 in Section 4 Refer to Drawing 1 in Section 4 unplugging the transducer cable from transducer and second moving wire 2 to the ground terminal X1 22 or X1 25 Measure voltage at the cable connection v No Fault in cable v Adjust zero point on pressure transducers Adjustment Procedure 4 in Section 5 i If transducer s are not adjustable Replace pressure transducer s and adjust zero point Refer to Procedure 4 in Section 5 YES Y Measure pressure transducer signals on the analog input module between test points Piston Side MPO ground and X1 1 Rod Side MPO g
35. mmeter A is used to measure current at the piston side input signal Remove the wire from X1 21 terminal in the central unit and measure the current with the ammeter in series The measurement should be between 4 20mA M 5 CENTRAL UNIT Measuring voltage chin Au The voltmeter V is used to measure voltage between pins oho 250 ohms 1 21 piston side signal and X1 22 gnd on the main board L 024 352 300 001 The resistors are there to show thatat4mA the voltage is 1 1 because current multiplied with resistance D equals voltage therefore 4mA x 275 ohms total resistance s 1 1V 90 8 OPERATING WINDOW ERROR BH CODE E PU AmA 1 1V E BIS EI WORKING 20mA 5 5V ERROR 7 CODE Le _ z poe q A B A B C AN ZN ZN 1 xcu FO o N PRESS TRANS PISTON j Rev A 05 01 01 SB 190113 A 48 Service Manual PAT DS 350 GM 6 3 THEORY 3 OPERATION OF ROD SIDE LOAD SENSOR Measuring current The ammeter A is used to measure current at the rod side input signal Remove the wire from X1 24 terminal in the central unit and meas
36. o Section 3 10 Rev A 05 01 01 SB a 24V supply of console interrupted b Interruption or accidental ground in the line from console electronics to central unit c Transmitter receiver module defective a Temporary interruption of the data line from console electronics to central unit b Transmitter receiver module defective a Temporary interruption of the data line from console electronics to central unit b Transmitter receiver module defective a Interruption or accidental ground in the line from console electronics to central unit b Transmitter receiver module defective c Data EPROM defective d CPU defective e Electromagnetic interference when switching contractors or valves 11 ACTION a Check 24V at terminal X1 of console electronics b Check the connection between console electronics and central unit C If accidental ground occurs the transmitter module in the console electronics can be damaged Replace the console electronics or main board respectively a Check the connection between console electronics and central unit Refer to Section 3 10 a Check the connection between console electronics and central unit b Replace console electronics or main board respectively Refer to Section 3 10 a Check the connection between console electronics and central unit If you find an accidental ground the transmitter module in the console elect
37. r the measuring channel length Fallen below lower limit value for the measuring channel pressure transducer piston side E E Fallen below lower limit value for the measuring channel pressure transducer rod side E Fallen below lower limit value for the measuring channel force E Fallen below lower limit value for the measuring channel angle main boom Rev A 05 01 01 SB 12 13 14 15 a Cable between length sensor and central unit defective not connected or water in the connectors b Length sensor Potentiometer defective c Electronic board in the measuring channel defective a Cable leading from the central unit to the pressure transducer defective loose or water in the connector b Pressure transducer on piston side defective c Electronic component in the measuring channel defective a Cable leading from the central unit to the pressure transducer defective loose or water in the connector b Pressure transducer on rod side defective c Electronic component in the measuring channel defective a Cable leading from the central unit to the pressure transducer defective loose or water in the connector b Force transducer defective c Electronic component in the measuring channel defective a Cable from central unit to the length angle sensor defective or loose b Angle sensor defective c Electronic component in the measuring channel defective Refer
38. ronics can be damaged Replace the console electronics b Replace console electronics or main board respectively c Check data EPROM d Replace CPU module Refer to Drawing 4 and Procedure 3 Steps 1 3 13 14 e Eliminate interference source by inverse diodes or varistors 190113 A 12 Service Manual DS 350 GM ERRO ERROR CAUSE ACTION R CODE Error in the crane data a Data EPROM defective a Replace data EPROM EPROM b Position of jumper for the b Check the jumper position selection of the type of EPROM is wrong Replace CPU module Refer c Electronics component to Drawing 4 and Procedure 3 on the main board defective Steps 1 3 13 14 E96 Error in the internal CPU or main board of the Replace CPU module Refer to RAM of the CPU of the console defective Drawing 4 and Procedure 3 console Steps 1 3 13 14 E97 Error in the external a External RAM of the a Replace console main board RAM of the CPU of the console defective console b Electronic component on b Replace console main board the main board defective Refer to Drawing 5 E98 Wrong jumper position a The jumper position BR a Check the jumper position in the console 9 BR 10 in the console does not correspond to the actual type of central unit b Electronic component on b Replace console main board the main board defective Refer to Drawing 5 EAB Short circuit in the A2B Short circuit in the A2B switch Refer
39. round and X1 2 The measurements should be between 0 5 4 5v 0 5v 500mv at Opsi to 4 5v at 4410psi Refer to Drawing 4 amp 9 in Section 4 Analog Input board defective Replace analog input board Refer to Drawing 4 in Section 12 and Replacement Procedure 3 steps 4 11 amp 12 in Section 5 NO YES V END P Rev A 05 01 01 SB 190113 A Flowcharts 27 PROBLEM Error Code E93 E94 No data transfer to and from console interference from crane electric or console display frozen START C 2 2 Check H12 TxD LED on the main board ON OFF Refer to Drawing 7 in Section 4 v Make sure that the eprom s are correct and plugged into the Eprom Module on the main board Refer to Procedure 2 in Section 5 Correct NO gt Place EPROM in correct socket Refer to Procedure 2 in Section 5 YES OFF Measure process voltage on the Main Board in the central unit between MP42 5v and MPO ground Refer to Drawing 4 amp 7 in Section 4 O Make sure external and internal power supply is correct Refer to Section 3 5 No Display 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 5 and console X1 3 central unit main board X1 6 and console X1 4 Refer to Drawing 2 in Sec
40. st 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 5 4 1 ACTIVATING THE ZERO SETTING FUNCTION To activate the zero setting Function press the INFO key on the console to activate the INFO Function Now press the CTRL key At this point a five digit Authorization Number must be entered Only authorized personnel may adjust the zero point settings Example 64356 5 4 1 8 ZERO SETTING THE TRANSDUCER INPUTS Now having successfully entered a valid password the piston side zero point setting function is activated The display shows which transducer piston side rod side or force is being zeroed and a horizontal dial marks the present pressure or force difference in By pressing the key the input pressure or force is adjusted upwards and by pressing the minus key the input value is adjusted downwards When the plus and minus keys are pressed simultaneously the zero setting occurs automatically Manual adjustments may be preformed using or The return key toggles between the piston side the rod side and the force zero setting When the operator is finished pressing the EXC or INFO key returns the console display to normal Rev A 05 01 01 SB 190113 A Theory 45 5 5 PROCEDURE 5 LENGTH AND ANGLE SENSOR ADJUSTMENT Rev A 05 01 01 SB 190113 A
41. tion 4 Check connections and replace cable from central unit to NO console if necessary Refer to Drawing 2 in Section 4 and Procedure 1 in Section 5 NEXT PAGE Rev A 05 01 01 SB 190113 A 28 Service Manual PAT DS 350 GM PREVIOUS PAGE j Check if additional ground link between main board MP1 and central unit box mounting bracket is in place Refer to Drawing 7 in Section 4 Install ground line single cable minimum of AWG14 2 0mm NO between terminal 1 and central unit box mounting bracket Refer to Drawing 7 in Section 4 YES Ensure that cable shields are connected correctly Refer to connection and wiring diagrams Drawings 1 2 3 in Section 4 and Procedure 1 in Section 5 Make correct shield connection NO Refer to connection and wiring diagrams Drawings 1 2 3 in Section 4 and Procedure 1 in Section 5 YES Find out which component of the crane electric is spiking out e g dump valve outrigger relay Install a diode or resistor across terminals of spiking component Diode type such as 1N4001 can be used watch and connection for diode Refer to Crane Electrical Diagrams Rev A 05 01 01 SB 190113 A 29 DRAWING 1 ELECTRICAL WIRING FOR CENTRAL UNIT TO PRESSURE DRAWINGS TRANSDUCERS AND CRANE MAIN BOARD PAT 024 352 300 001 CENTRAL UNIT DS350GM
42. to Section 3 6 switch circuit Short circuit in the cable to Replace A2B switch the A2B switch Replace cable to the A2B switch Electronic component on the analog input module Check analog input module defective Replace if necessary Refer to Drawing 4 and Procedure 3 Steps 1 2 4 11 12 Note If an error message is displayed which is not contained in above list please contact the PAT service department Rev A 05 01 01 SB 190113 A Flowcharts 13 3 3 LEVER LOCKOUT 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 CT Use the key switch and the LMI by pass button the console to override the LMI Refer to the Operator s Handbook for LMI override instructions pages12 and 13 Corrected YES Does console indicate Anti Two block warning NO YES If console display If the display Load Moment Fault in crane electric blank The fault is Fault in Anti Two Limit Light is lit The fault is or hydraulic system located in power supply Block system located in LMI cables wiring wiring or fuses fuses or console Check lever lockout system in crane service manual Go to Section 3 5 Go to Section 3 6 Read error code displaye
43. ure 2 board defective Error in load chart EPROM Module not bridged Replace EPROM Module and EPROM correctly reset pressure channels Refer to Data EPROM on the main Drawing 4 and Procedure 4 board defective Memory module wrongly Bridge memory module acc To bridged memory type Replace crane data EEPROM Crane data EEPROM Replace EPROM Module and defective reset pressure channels Refer to Drawing 4 and Procedure 4 Error in crane data EEPROM Rev A 05 01 01 SB 190113 A 10 Service Manual PAT DS 350 Central unit unable to correspond with digital output module a Anti Two block relay is stuck or defective E70 Error in digital output module E71 Incorrect acknowledgment of the 1 Relay on the main board b Anti Two Block relay is not being selected due to a break on the main board CODE E57 Error in serial crane data Serial crane data EEPROM Write data on the serial crane data EEPROM does not contain valid data EEPROM by means of test program or on line function then restart the LMI Replace EPROM Module and Memory module defective reset pressure channels Refer to Drawing 4 and Procedure 4 E58 Error in the serial analog No valid data in the serial Write data on the serial analog data EEPROM analog data EEPROM data EEPROM by means of the test program then restart the LMI Replace LMI main board LMI main board defective E69 Error in the load chart Memor
44. ure the current with the ammeter in series The measurement should be between 4 20mA Measuring voltage The voltmeter is used to measure voltage between pins 1 24 side signal and 1 25 on the main board 024 352 300 001 The resistors are there to show that at 4mA the voltage is 1 1V because current multiplied with resistance equals voltage therefore 4mA x 275 ohms total resistance 1 1V __ _ a CENTRAL UNIT 05550 MODULAR SATIN VAJIN 250 ohms Z 150 250 ohms V ohms VW x x i NORKING z m Z a 165 M X1 23 24 25 V pss 1 1 5 5 12 3 _ CV o x 1 2 3 A B PRESS TRANS ROD Rev A 05 01 01 SB 190113 A Theory 49 6 4 THEORY 4 OPERATION OF ANGLE SENSOR Measuring current The ammeter A is used to measure current at the angle input signal Remove the wire from X1 29 terminal in the central unit and measure the current with the ammeter in series The measurement should be between 4 20mA Measuring voltage The voltmeter is V used to measure voltage between pins X1 29 angle signal and X1 28 gnd on the main board 024 352 300 001 The resistors are there to show that at 4mA the voltage is 1 1V because current multiplied with resistance eguals voltage therefore 4mA x 275 ohms total resistance lt 1 1V OPERATING WINDOW
45. y module wrongly Bridge memory module acc to EPROM bridged memory type The number of the Load chart EPROM defective Replace load chart EPROM selected EPROM base and the programmed value are not identical a Check supply voltage b Replace digital output module Replace main board Refer to Drawing 4 and Procedure 3 E72 Analogous to E71 for Analogous to E71 for the Analogous to E71 for the relays E77 the relays 2 7 relays 2 7 2 7 Wrong rigging condition The selected rigging condition is not contained in the data EPROM Error in the radius The computed radius is too determination small negative deflection Change of the The operating mode switch operating code during in the console was used lifting a load during lifting a load Rev A 05 01 01 SB Select another rigging condition Check the programming in the data EPROM Check the programming in the data EPROM Lower the load and set the operating mode switch correctly to the code assigned to the actual operating mode of the crane 190113 A Flowcharts ERROR ERROR CAUSE CODE E 91 No data transmission from console to central unit Refer to Section 9 E Error in the data transmission from console to central unit Refer to also Section 3 10 E 92 93 Error in the data transmission from central unit to console Refer to also Section 3 10 94 E No data transmission for central unit to console Refer to als
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