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PAT DS 350GM Service Manual

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PAT America, Inc.
www.patamerica.com
LOAD MOMENT INDICATOR
DS 350GM
for Grove Cranes
SERVICE MANUAL
TROUBLESHOOTING MANUAL
P/N 031-300-190-041 REV J 11/07/2002

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  • Page 1 PAT America, Inc. www.patamerica.com LOAD MOMENT INDICATOR DS 350GM for Grove Cranes SERVICE MANUAL TROUBLESHOOTING MANUAL P/N 031-300-190-041 REV J 11/07/2002...
  • Page 3 NOTICE The information in this document is subject to change without notice. PAT 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.

  • Page 5: Table Of Contents

    TRANSDUCER & FORCE INPUTS ..............49 PROCEDURE 5. LENGTH AND ANGLE SENSOR ADJUSTMENT ......50 PROCEDURE 6. SLEW POT POTENTIOMETER ZERO ADJUSTMENT ....51 5.6.1 USING GRAPHIC CONSOLE FOR ZERO-SETTING OF SLEW POT POTENTIOMETER ..................51 © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 6 THEORY 2. OPERATION OF PISTON SIDE LOAD SENSOR .........53 THEORY 3. OPERATION OF ROD SIDE LOAD SENSOR........54 THEORY 4. OPERATION OF ANGLE SENSOR ............55 THEORY 5. OPERATION OF SLEW POTENTIOMETER SENSOR......56 THEORY 6. OPERATION AXLE OSCILLATION OUTPUT ........57 © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 7: General Information

    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. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 8: Warnings

    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.

  • Page 9: Flowcharts

    FLOWCHARTS 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 Sections 2 through 11. The drawings and procedures that are referenced in these sections can be found in Sections 12 and 13.

  • Page 10: Error Code Display

    Refer to Drawing 4 and Procedure 3 Block switch relay (K2). selected. in Section 5.3. Error in length With the boom fully retracted, Refer to Section 3.7. measurement the length differs by more than © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 11 Check angle sensor and reset boom””. b.)Angle sensor defective. adjustment. Refer to Procedure 5 c.)Electronic component in the c.) Check signal on main board and measuring channel defective. analog input module. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 12 Check and reset length sensor b.)Length potentiometer Potentiometer. Refer to Procedure defective. c.)Electronic component in the c.) Check signal on main board and measuring channel defective analog input module. on main board. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 13 Check signal on main board and b.) Jib angle sensor defective. analog input module. c.) Electronic component in the measuring channel defective. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 14 EPROM Error in the external Defective electronic Replace main board or analog input RAM. component. module. Refer to Drawing 4 and Procedure 3, Steps 1,2,4, 11, and © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 15 Memory module wrongly Bridge memory module acc. To EEPROM. bridged. memory type Replace crane data EEPROM Crane data EEPROM defective Replace EPROM Module and reset pressure channels. Refer to Drawing 4 and Procedure 4. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 16 Error digital inputs 9 - 16 Module for digital inputs in the Replace the module for the digital in the boom control Boom control extension inputs extension. defective Boom control extension Replace the boom control extension defective © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 17 Check the programming in the data EPROM. EPROM. Error in the radius The computed radius is too Check the programming in the data determination small (negative deflection) EPROM. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 18 CPU defective. d.) Replace CPU module. Refer to Drawing 4 and Procedure 3 Steps e.) Electromagnetic 1-3, 13,14. interference (when switching e.) Eliminate interference source by contractors or valves) inverse diodes or varistors. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 19 Check values in the data prom DGA area the engine hood, prewarning 11.5. Note: If an error message is displayed which is not contained in above list, please contact the PAT service department. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 20: Lever Lockout Activated

    . Check lever lockout Go to Section 3.5 Go to Section 3.6 Read error code displayed on system in crane console & go to Section 3.2. service manual. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 21: Broken Length Cable

    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. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 22: Display

    This is an output voltage to the console. Refer to Drawing 1 in Section 4. Replace the main board in central unit. Correct? Refer to Drawing 4 in Section 4 and Replacement Procedure 3 in Section 5. NEXT PAGE © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 23 Check connections of the cable between Correct? console and central unit. Replace cable if necessary. Refer to Drawing 2 in Section 4. Console/Display is defective. Replace the console. Refer to Drawing 3 in Section 4. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 24: Anti-Two Block Problem

    Pug the bypass plug into the boom nose box. Refer to Drawing 3 in Section 4. Check wire connections in boom nose Correct? box. Replace Anti-Two-Block switch. Refer to Drawing 3 in Section 4. Next Page © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 25 Refer to Drawing 3 Section 4. Fault in 7 conductor cable between cable reel and boom base box. Check connections and replace Correct? cable if necessary. Refer to Drawing 3 in Section 4. NEXT PAGE © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 26 Correct? Refer to Drawing 4 in Section 4 and Replacement Procedure 3 in Section 5. Reconnect Wire #5 to X1:31 and Wire #6 to X1:32 Refer to Drawing 3 in Section 4. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 27: Length Reading Problem

    X1:28 (ground) and X1:26 (+12/24v) Refer to Drawing 3 in Section 4. Main board defective. Replace main board. Correct? Refer to Drawing 4 in Section 4 and Replacement Procedure 3 in Section 5 . NEXT PAGE © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 28 20ma with the length potentiometer turned completely clockwise 10 turns to the soft stop. Refer to Drawing 3 & 6 in Section 4. Faulty wiring between central unit and cable reel. Correct? Check wiring. NEXT PAGE © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 29 Refer to Drawing 9 in Section 4. Analog Input board defective. Replace analog input board. Correct? Refer to Drawing 4 in Section 4 and Replacement Procedure 3 steps 4,11, & 12 in Section 4. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 30: Angle Reading Problem

    X1:1 (+12/24v) and X1:3 (ground). Refer to Drawing 3 in Section 4. Faulty wiring between central unit and cable reel. Correct? Check wiring Refer to Drawing 3 in Section 4. NEXT PAGE © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 31 Refer to Drawing 9 in Section 4. Analog Input board defective. Replace analog input board. Correct? Refer to Drawing 4 in Section 4 and Replacement Procedure 3 steps 4,11, & 12 in Section 5. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 32: Load Reading Problem

    Fault in pressure transducer cable. Correct? Refer to Drawing 1 in Section 4. NEXT PAGE Main board defective. Replace main board. Refer to Drawing 4 in Section 4 and Replacement Procedure 3 in Section 5. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 33 Refer to Drawing 4 & 9 in Section 4. Analog Input board defective. Replace analog input board. Correct? Refer to Drawing 4 in Section 12 and Replacement Procedure 3 steps 4,11, & 12 in Section 5. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 34: Bad Data Transfer Between Console & Central Unit Or Interference Problem

    Refer to Drawing 2 in Section 4. Check connections and replace cable from central unit to Correct? console, if necessary. Refer to Drawing 2 in Section 4 and Procedure 1 in Section 5. NEXT PAGE © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 35 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. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 36: Slewing Angle Reading Problem

    X1:1 (+12/24v) and X1:4 (ground). Refer to Drawing 3 in Section 4. Faulty wiring between central unit and slew pot. Correct? Check wiring Refer to Drawing 3 in Section 4. NEXT PAGE © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 37 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. Correct? Faulty analog input module or CPU module in central unit. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 38: Drawings

    Service Manual DS 350 GM DRAWINGS DRAWING 1. ELECTRICAL WIRING FOR CENTRAL UNIT TO PRESSURE TRANSDUCERS AND CRANE CENTRAL UNIT DS350GM MAIN BOARD: PAT 024-352-300-001 / GROVE 9-333-103287 © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 39: Drawing 2. Electrical Wiring For Central Unit To Console

    Drawings DRAWING 2. ELECTRICAL WIRING FOR CENTRAL UNIT TO CONSOLE CENTRAL UNIT DS350GM MAIN BOARD: PAT 024-352-300-001 / GROVE 9-333-103287 See reference notes on Drawing 1. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 40: Drawing 3. Electrical Wiring For Central Unit To Cable Reel/Anti-Two Block

    Service Manual DS 350 GM DRAWING 3. ELECTRICAL WIRING FOR CENTRAL UNIT TO CABLE REEL/ANTI- TWO BLOCK CENTRAL UNIT DS350GM MAIN BOARD: PAT 024-352-300-001 / GROVE 9-333-103287 © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 41: Drawing 4. Central Unit - Parts List

    Drawings DRAWING 4. CENTRAL UNIT - PARTS LIST Item 21 digital output board, refer to section 6.6 for location. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 42 Service Manual DS 350 GM DRAWING 4. CENTRAL UNIT - PARTS LIST - continued PART NO. A) PAT 024-350-063-001 / GROVE 9-333-103280 (12V) PART NO. B) PAT 024-350-063-002 / GROVE 9-333-103281 (24V) PART NO. PAT / GROVE DESCRIPTION 024-350-050-292 / 9333103549...

  • Page 43: Drawing 5A. Console Ds350/1319 - Parts List

    Drawings DRAWING 5A. CONSOLE DS350/1319 - PARTS LIST GRAPHIC CONSOLE (VERTICAL), PARTS LIST PART NO. 050-350-061-319 / 9333103278 © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 44 Service Manual DS 350 GM DRAWING 5A. CONSOLE DS350/1319 - PARTS LIST - continued GRAPHIC CONSOLE (VERTICAL), PARTS LIST PART NO. PAT 050-350-061-319 / GROVE 9-333-103278 PART NO. PAT / GROVE DESCRIPTION 031-300-110-048 / 9333103587 CONSOLE ACCY, FRONT FACE & DIS.

  • Page 45: Drawing 5B. Console Ds350/1318 - Parts List

    Drawings DRAWING 5B. CONSOLE DS350/1318 - PARTS LIST © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 46 Service Manual DS 350 GM DRAWING 5B. CONSOLE DS350/1318 - PARTS LIST - continued GRAPHIC CONSOLE (HORIZONTAL), PARTS LIST PART NO. PAT 050-350-061-318 / GROVE 9-333-103279 PART NO. PAT / GROVE DESCRIPTION 031-300-110-049 / 9333103588 CONSOLE ACCY, FRONT FACE & DIS.

  • Page 47: Drawing 6. Cable Reel - Parts List

    Drawings DRAWING 6. CABLE REEL - PARTS LIST © PAT Rev. J 11/07/02 // CH 190041_J.DOC...
  • Page 48 Service Manual DS 350 GM DRAWING 6. CABLE REEL - PARTS LIST - continued CABLE REEL ASSEMBLY, PARTS LIST PART NO. PAT 068-308-060-001 / GROVE 9333103306 PART NO. PAT / GROVE DESCRIPTION 068-000-300-060 / 9333103309 BOARD, TERMINAL W/ EMC FILTERS...

  • Page 49: Drawing 7. Central Unit Main Board Layout

    MP24 -= +BATT MP25 -= +UBS console, sensors, DI’’s MP26 -= GND MP29 -= +5V hand terminal LED’’S H08 - LOAD H09 - A2B H10 - MAIN IN/OUT H11 - POWER H12 - TxD © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 50: Drawing 8. Console Connection Board

    Service Manual DS 350 GM DRAWING 8. CONSOLE CONNECTION BOARD BOARD PART NUMBER 050 150 30 0051 / 9333103300 © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 51: Drawing 9. Central Unit Analog Input Module

    (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. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 52: Procedures

    Service Manual DS 350 GM PROCEDURES PROCEDURE 1. STRAIN RELIEF INSTALLATION © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 53: Procedure 2. Eprom Location And Installation

    Ensure the notch is in the correct direction. The DATA and TLK EPROMs fill the bottom of the socket as shown by the arrows. Place EPROMs in the correct EPROM socket as shown. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 54: Procedure 3. Main Board Replacement

    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. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 55: Procedure 4. Pressure Transducer Zero Adjustment

    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. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 56: Procedure 5. Length And Angle Sensor Adjustment

    Service Manual DS 350 GM PROCEDURE 5. LENGTH AND ANGLE SENSOR ADJUSTMENT © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 57: Procedure 6. Slew Pot Potentiometer Zero Adjustment

    By pressing the ““+”” and ““-““ keys simultaneously, the zero setting occurs automatically. Note: The indicator line will move to zero on the bar graph. When the operator is finished, pressing the EXC or INFO key returns the console display to normal. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 58: Theory

    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. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 59: Theory 2. Operation Of Piston Side Load Sensor

    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. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 60: Theory 3. Operation Of Rod Side Load Sensor

    (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. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 61: Theory 4. Operation Of Angle Sensor

    (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. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 62: Theory 5. Operation Of Slew Potentiometer Sensor

    X1:34 (slew signal 2) and X1:35 (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. © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

  • Page 63: Theory 6. Operation Axle Oscillation Output

    Measuring voltage: The voltmeter is used to measure voltage between pins X2/1:1 (digital output 1) and X2/1:3 (gnd) on digital output module (024-352-300-041 / 9333103291). Digital Output Connector Module To solenoid Fuse © PAT Rev. J 11/07/02 // CH 190041_J.DOC...

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