PAT DS150 Service Manual
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PAT DS150 Service Manual

Load moment indicator
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PAT America, Inc.
www.patamerica.co
LOAD MOMENT INDICATOR
DS150
SERVICE MANUAL
P/N 031-300-100-753 REV B 03/08/02

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Summary of Contents for PAT DS150

  • Page 1 PAT America, Inc. www.patamerica.co LOAD MOMENT INDICATOR DS150 SERVICE MANUAL P/N 031-300-100-753 REV B 03/08/02...
  • Page 4 DS150 NOTICE PAT 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.
  • Page 5 Service Manual DS150...

  • Page 6: Table Of Contents

    Service Manual DS150 TABLE OF CONTENTS MECHANICAL DESCRIPTION OF THE SYSTEM COMPONENTS ..........1 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UNIT ......2 ASIC YSTEM OMPONENT AYOUT ......................ASIC DJUSTMENT OMPONENTS ....................DEFINITIONS ..........................5 DRAWINGS ........................... 6 SYSTEM E LECTRICAL IAGRAM........................
  • Page 7 Service Manual DS150...

  • Page 8: Mechanical Description Of The System Components

    Mechanical Description Of The System 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.

  • Page 9: Mechanical And Electrical Description Of The Central Unit

    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.

  • Page 10: Basic System Component Layout

    Mechanical Description Of The System Basic System Component Layout...

  • Page 11: Basic Adjustment Of The Components

    Mechanical Description Of The System 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.

  • Page 12: Definitions

    Definitions 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.

  • Page 13: Drawings

    Drawings 4 DRAWINGS SYSTEM Electrical Diagram...

  • Page 14: Central Unit 024-150-060-002 Spare Parts List

    Drawings Central Unit 024-150-060-002 Spare Parts List...
  • Page 15 Drawings PART NO. 024-150-060-002 CENTRAL UNIT, DS150/0002 STANDARD PARTS LIST PART NO. DESCRIPTION 024-150-300-001 BOARD, MAIN, DS150, CU, 12V 024-350-100-135 CENTRAL UNIT ACCY, SCREW SET, DS150 024-000-100-041 CENTRAL UNIT ACCY, GROUNDING KIT FOR COVER 024-350-100-139 CENTRAL UNIT ACCY, WALL MOUNT SET, DS150/350...

  • Page 16: Console 050-150-060-006 Spare Parts List

    Drawings Console 050-150-060-008 Spare Parts List To change DS150/0006 (12V) to DS150/0036 (24V) a jumer wire must be soldered on main board, J3 added, and the ligth bulbs changed. When ordering spare part please specify 12 or 24 volt machine.
  • Page 17 Drawings Console 050-150-060-008 Spare Parts List PART NO. DESCRIPTION 050-150-300-003 CONSOLE BOARD W/ROTARY SWITCH - DS150 050-350-110-292 LCD DISPLAY DS150 050-000-100-060 CONSOLE HOUSING W/LID 050-350-110-116 STRAIN RELIEF/LONG RED 000-305-045-141 LUMINOUS HOUSING 003-051-405-423 LUMINOUS PUSH BUTTON HOUSING 000-311-023-114 LIGHT BULB 12V...

  • Page 18: Console 050-150-060-008 Spare Parts List

    Drawings Console 050-150-060-008 Spare Parts List To change DS150/0008 (12V) to DS150/0012 (24V) a jumer wire must be soldered on main board, J3 added, and the ligth bulbs changed. When ordering spare part please specify 12 or 24 volt machine.
  • Page 19 Drawings Console 050-150-060-008 Spare Parts List NO. PART NO. DESCRIPTION 050-150-300-003 BOARD, MAIN, DS150 CONSOLE 12V FOR 4x20mm DISPLAY 050-350-110-292 INDICATOR, DISPLAY, LCD, DS150 CONSOLE 050-000-100-048 HOUSING, DS150 CONSOLE, COMPLETE 050-150-110-001 BRACKET, CONSOLE, DS150 COMPLETE 050-350-110-183 KNOB, MOUNTING KNOB 050-350-110-116 STRAIN RELIEF ASSY, PG 13.5 RED/WHITE W/NUT+WASHER...

  • Page 20: Cable Reel 068-208-060-013 Lwg208 Spare Parts List

    Drawings Cable Reel 068-208-060-013 LWG208 Spare Parts List...
  • Page 21 Drawings Cable Reel 068-208-060-013 LWG208 Spare Parts List NO. PART NO. QTY DESCRIPTION 006-710-006-002 SENSOR, LENGTH TRANS. LGE 100 (KT200/LWG208) 068-000-110-038 SENSOR ACCY, GEAR WHEEL, KT200 CABLE REEL 067-000-050-065 SENSOR ACCY, GEAR WHEEL, T=50 CENTER SHAFT 064-103-060-002 SENSOR, ANGLE WG103 002-050-206-012 SCREW, 6M X 12 SOCKET CAP 000-207-010-064...

  • Page 22: Central Unit Board Layout And Measuring Points 024-150-300-001

    Drawings Central Unit Board Layout And Measuring Points 024-150-300-001 Measuring Points MP1: AGND MP2: +9V MP3: -9V MP4: 5V TTL MP5: 5V REF MP6: +5V/+UPS sensors supply MP7: -5V/-UPS sensors supply MP8: +9V HES MP10: AGND MP11: DAV1 piston pressure signal MP12: DAV2 rod pressure signal MP13: LW1 length signal MP14: WG1 angle signal #1...

  • Page 23: Procedure

    Central Unit Board Layout And Measuring Points 024-150-300-001 5 PROCEDURE 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.

  • Page 24: Length & Angle Adjustments

    Procedures Length & Angle Adjustments...

  • Page 25: Main Board Replacement

    Theory Main Board Replacement Refer to Drawing 1, central unit parts list for board location. 1. Turn system power off. 2. Remove the central unit lid. NOTE: Take care not to damage the boards with the screwdriver, when removing and inserting screws.

  • Page 26: Theory

    Theory 6 THEORY Anti-Two Block & Shutoff Circuit Length Measuring Channel...

  • Page 27: Piston Side Pressure Measuring Channel

    Theory Piston Side Pressure Measuring Channel Rod Side Pressure Measuring Channel...

  • Page 28: Main Boom Angle Measuring Channel

    Theory Main Boom Angle Measuring Channel Second Angle Measuring Channel...

  • Page 29: Troubleshooting Flow Charts

    7 TROUBLESHOOTING FLOW CHARTS General Flowchart This section explains how to handle a problem that may arise with the PAT Load Moment Indicator System-PAT DS150. The procedures are easy to follow and are given in flowcharts on the following pages. Start with the general flowchart below, which will guide you to one of the detailed flowcharts shown in this section.

  • Page 30: Lever Lockout Activated

    Troubleshooting Flow Charts 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. Start Set the override key switch in central unit into upper position to override Fixed Does console indicate Anti-Two-block warning? If console display is...

  • Page 31: Broken Length Cable

    Troubleshooting Flow Charts 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.

  • Page 32: N O Display

    Troubleshooting Flow Charts No Display PROBLEM: Blank console display with no warning light shown. All crane moments have been stopped. Start Check fuses on CPU box. Replace fuses. Correct? Measure crane voltage on connection board between X1-2 (+12V) and X1-4 (ground). Refer to system wiring diagram.
  • Page 33 Troubleshooting Flow Charts 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 Correct? console and central unit. Replace cable if necessary. Refer to system wiring diagram. Display is defective.

  • Page 34: Anti Two Block Problem

    Troubleshooting Flow Charts Anti Two Block Problem PROBLEM: Function of Anti-Two-Block System is faulty. START Check to see whether or not crane is in two-block condition. Correct? Lower hook down into safe position Check if jumper/dummy plug in receptacle at boom nose is plugged in. Refer to system wiring diagram.
  • Page 35 Troubleshooting Flow Charts PREVIOUS PAGE Measure the A2B signal in the cable reel between X1:Brown and X2:Red wires on the slip ring with an ohmmeter. Switch closed =4700 ±500Ohms Switch open => 1 Megaohm Reconnected slip ring wires. Refer to system wiring diagram. Fault in wiring between boom nose box and cable reel.
  • Page 36 Troubleshooting Flow Charts PREVIOUS PAGE Connect wire #5 back to the terminal X1:35 on the connection board. Refer to system wiring diagram. 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 =>...

  • Page 37: Length Reading Problem

    Troubleshooting Flow Charts Length Reading Problem PROBLEM: Length reading incorrect. Crane is not in “out of load chart” condition. START 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.
  • Page 38 Troubleshooting Flow Charts PREVIOUS PAGE Continued from 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 Correct? length transducer. Check wiring. Measure signal from length transducer in cable reel between pin 2(signal) and pin 1(ground).
  • Page 39 Troubleshooting Flow Charts Continued from previous page. PREVIOUS PAGE 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.

  • Page 40: Load Reading Problem

    Troubleshooting Flow Charts Load Reading Problem PROBLEM: Load reading incorrect. START Check selected operating mode (code on operating mode switch). Select operating mode switch to correct position Correct? (see operating mode in load chart). Check boom length reading on display. Reset length potentiometer.
  • Page 41 Troubleshooting Flow Charts Pervious Page Correct? MP7(+5.0v) and between test point MP10 (ground) to MP6(-5.0v) Refer to main board layout. Correct? MP2(+9.0v) and between test point MP10 (ground) to MP3(-9.0v) Refer to main board layout. Correct? Power supply on connection board faulty. Replace connection board and reset pressure channel.
  • Page 42 Troubleshooting Flow Charts PREVIOUS PAGE 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).

  • Page 43: Bad Data Transfer Between Console & Central Unit

    Troubleshooting Flow Charts Bad Data Transfer Between Console & Central Unit PROBLEM: Error Code “E93/E94" No data transfer to and from console. START Make sure that the eproms are plugged into the correct socket and orientated. Refer to EPROM replacement procedure. Correct? Place EPROM in correct socket.
  • Page 44 Troubleshooting Flow Charts Continued from previous page PREVIOUS PAGE Check power supply to console between console terminal 2(ground) and terminal 1 (+12v) Refer to system wiring diagram. Faulty wiring in cable from central unit to console. Correct? Replace cable. Ensure that wires are properly connected between CU X1:31 and console terminal 4 and between CU X1:32 and console terminal 3.

  • Page 45: Interference Problem

    Troubleshooting Flow Charts Interference Problem START PROBLEM: Interference from crane electric. Error Code “E93/E94" intermittent. Frozen console displays. Refer to Section 8 - Bad Data Transfer Between Console & Central Unit. Correct? Replace or repair part which is defective. Check if additional ground link between main board terminal X1:3 and central unit box mounting bracket is in place.

  • Page 46: Angle Problem

    Troubleshooting Flow Charts Angle Problem PROBLEM: Displayed Angle Incorrect. Actual measured angle is different from displayed angle. START Use a calibrated inclinometer to measure the actual main boom angle and compare with displayed angle on console. Refer to length/angle adjustments procedure. between X1:11 (+5VDC) and X1:8 (ground).

  • Page 47: Error Code Table

    Troubleshooting Flow Charts 8 ERROR CODE TABLE Error Error Cause Elimination Code  Fallen below the minimum  Luff down the boom to a radius Fallen below radius range or angle radius or gone past the or angle specified in the load range exceeded maximum angle specified in chart....
  • Page 48 Error Codes Error Code Error Cause Elimination  Clutch between length  Replace the complete sensor pot and drive is clutch including drive defective wheel and adjust length sensor pot as described above  Failure of +5V supply of  Check +5 V supply. analog part of analog Exchange main board in case of voltage failure or...
  • Page 49 Error Codes Error Cause Elimination Error Code  Cable between central  Check cable as well as Fallen below lower limit value for unit and length sensor is plugs, replace, if need be. measuring channel defective or disconnected. "length main boom" Water inside the plug of the length/angle sensor...
  • Page 50 Error Codes Error Code Error Cause Elimination  The supply voltage is  Check the voltages on the Reference and/or supply voltage falsified by one of the LMI main board. Check defective sensors (DAV, LWG) sensors, plugs and cable, replace, if need be. ...
  • Page 51 Error Codes Error Cause Elimination Error Code  Computer component  Replace computer Error in the internal write/read memory 80C537 defective component 80C537. (RAM) of the  CPU module defective  Replace CPU module. computer component 80C537  Processor board ...
  • Page 52  Replace processor board. defective  Electro-magnetic  Eliminate the source of interferences (e.g. when interference by inverse diodes or varistors. switching contacts or valves) Note: If an error message is displayed which is not contained in above list, please contact PAT...
  • Page 53 Error Codes America, Inc. service department...

  • Page 54: Addendum A Basic Adjustment And Voltage Checks

    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 &...

  • Page 55: Addendum B Reference Tables For Measuring Supply And Signal Voltages For Sensor Channels

    Addendums 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...

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