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Troubleshooting Flow Charts

32

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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.

Correct?

No

Replace connection board and reset pressure channel.

Refer to system wiring diagram and main board

replacement Procedure.

Yes

END

Continued from previous page.

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Summary of Contents for DS 150

Page 1: ...www patamerica co PAT America Inc LOAD MOMENT INDICATOR DS150 SERVICE MANUAL P N 031 300 100 753 REV B 03 08 02...

Page 2: ......

Page 3: ......

Page 4: ...e 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 anot...

Page 5: ...Service Manual DS150...

Page 6: ...6 PISTON ROD PRESSURE CHANNEL ZERO POINT ADJUSTMENT 16 LENGTH ANGLE ADJUSTMENTS 17 MAIN BOARD REPLACEMENT 18 6 THEORY 19 ANTI TWO BLOCK SHUTOFF CIRCUIT 19 LENGTH MEASURING CHANNEL 19 PISTON SIDE PRESS...

Page 7: ...Service Manual DS150...

Page 8: ...th 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...

Page 9: ...e 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 sen...

Page 10: ...Mechanical Description Of The System 3 Basic System Component Layout...

Page 11: ...ees 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 transduc...

Page 12: ...cular 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 weigh...

Page 13: ...Drawings 6 4 DRAWINGS SYSTEM Electrical Diagram...

Page 14: ...Drawings 7 Central Unit 024 150 060 002 Spare Parts List...

Page 15: ...HOLDER CENTRAL UNIT MAIN BOARD 10 000 313 062 001 1 FUSE 2 AMP 1 4 x 1 1 4 250V FAST ACTING 11 000 313 062 002 1 FUSE 10 AMP 1 4 x 1 1 4 250V FAST ACTING 12 000 304 140 122 1 RELAY SHUT OFF 12 V BOSCH...

Page 16: ...e 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 1...

Page 17: ...1 CAP A2B RED 09 050 350 110 278 1 CAP PREWARNING YELLOW 10 050 350 110 279 1 CAP STOP ALARM OFF RED 11 050 350 110 280 1 CAP LOAD ORANGE 12 050 350 110 281 1 CAP INFO ORANGE 13 050 350 110 282 1 CAP...

Page 18: ...le 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...

Page 19: ...10 050 350 110 074 1 SWITCH ACCY LENS CAP RED A2B 11 050 350 110 073 1 SWITCH ACCY LENS CAP YELLOW PREWARNING 12 050 350 110 075 1 SWITCH ACCY LENS CAP RED STOP BUZZER OFF 13 050 350 110 076 1 SWITCH...

Page 20: ...Drawings 13 4 5 Cable Reel 068 208 060 013 LWG208 Spare Parts List...

Page 21: ...8 000 100 064 1 SLIPRING 2 CONDUCTOR 10 068 000 110 029 1 CONNECTION STRIP 11 068 000 100 152 1 CABLE REEL KT200 HOUSING BKT CABLE DRUM NYLON CABLE COVER 12 068 000 110 011 1 CABLE REEL ACCY CABLE DRU...

Page 22: ...P6 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 MP15 WG2 angle sig...

Page 23: ...s Place EPROM in the correct EPROM socket as shown 4 Inspectgasketand installcover using the following procedures to prevent anymoisture from entering the central unit Reference material 031 300 340 0...

Page 24: ...Procedures 17 Length Angle Adjustments...

Page 25: ...in board in place 7 Notetheorientationofthemainboardinthecentral unit Removemainboardandplaceitin the same packing material that the replacement in which the main board came 8 Carefully insert the new...

Page 26: ...Theory 19 6 THEORY Anti Two Block Shutoff Circuit Length Measuring Channel...

Page 27: ...Theory 20 Piston Side Pressure Measuring Channel Rod Side Pressure Measuring Channel...

Page 28: ...Theory 21 Main Boom Angle Measuring Channel Second Angle Measuring Channel...

Page 29: ...Between Console Central Unit Go to Flow Chart 8 Interference Problem Go to Flow Chart 9 Angle Problem Go to Flow Chart 10 7 TROUBLESHOOTING FLOW CHARTS General Flowchart This section explains how to h...

Page 30: ...t into upper position to override Fixed YES NO Does console indicate Anti Two block warning NO Yes Fault in crane electric or hydraulic system If console display is blank fault is located in power sup...

Page 31: ...ng 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 Reconne...

Page 32: ...tage is measured below 10V system will switch off Correct Check crane power supply for faulty No crane electric or if supply is too low Yes Measure voltage on the connection board between X1 30 12 24V...

Page 33: ...in the console between X1 1 12 24V and X1 2 ground Refer to system wiring diagram Correct NO Check connections of the cable between console and central unit Replace cable if necessary Refer to system...

Page 34: ...is plugged in Refer to system wiring diagram Correct No Yes Turn power off or disconnect wire from connection board X1 35 in central unit Remove ohmmeter between wires 2 and 3 of switches or between...

Page 35: ...cable Refer to length cable replacement Measure the A2B signal in the cable reel between terminal 7 and 8 with an ohmmeter Switch closed 4700 500Ohms Switch open 1 Megaohm Reconnected slip ring wires...

Page 36: ...h open 1 Megaohm Refer to system wiring diagram Correct NO Faulty wiring between cable reel and central unit Check cable YES Disconnect X1 34 and X1 35 Check main board function by installing a tempor...

Page 37: ...es 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...

Page 38: ...e the voltage of an extended boom will be between 0 500 to 4 500 volts Correct No Replace length potentiometer assembly Remove slip ring body from shaft and remove gear wheel from potentiometer axle U...

Page 39: ...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 Correct No Replace connectio...

Page 40: ...displayed radius Correct No 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 a...

Page 41: ...to MP3 9 0v Refer to main board layout Yes Correct Power supply on connection board faulty Replace connection board and reset pressure channel Refer to system wiring diagram and main board replacement...

Page 42: ...sducer and reset pressure channel Yes 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...

Page 43: ...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...

Page 44: ...ring in cable from central unit to console 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 syste...

Page 45: ...ket is in place Correct No Install ground line single cable minimum of AWG14 2 0mm between terminal X1 3 and central unit box mounting bracket Refer to system wiring diagram Yes Ensure that cable shie...

Page 46: ...efer to system wiring diagram Correct 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 5V Refe...

Page 47: ...mode has been selected The boom is in a non permitted slewing zone Boom has been extended either too far or not far enough e g if it is prohibited to go beyond a certain maximum boom length or with lo...

Page 48: ...between central unit and length sensoris defective or disconnected Defective length potentiometer Maximum radius as specified in the load chart exceeded or fallen below minimum angle due to luffing d...

Page 49: ...onic 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 poten...

Page 50: ...ROM do not match Cause The supply voltage is falsified by one of the sensors DAV LWG Electronic component is defective The analog voltage is falsified by one of the sensors Electronic component is def...

Page 51: ...r processor board defective Refer to E42 The A D converter on the processing board and the redundant A D converter in the CPU 80C537 provide different results No acknowledgment of the A D converter uP...

Page 52: ...Transmitter receiver module is defective Computer module is defective Electro magnetic interferences e g when switching contacts or valves Elimination Check 24 V at terminal X1 of the console electron...

Page 53: ...Error Codes 46 America Inc service department...

Page 54: ...nd Reference on Board 5V Mp6 VDC Mp 10 Ground Internal on Board 5V Mp7 VDC Mp 10 Ground Length and Main Jib Angle 4 Boom Length MP10 Ground for Meter Fully Retracted Ft Fully Extended Ft VDC X1 10 DC...

Page 55: ...C E11 21 E12 22 E13 23 E15 25 E16 26 2 Length 8 11 5 1 Pressure Piston side 19 20 5 19 18 5 0 Pressure Rod side 14 15 5 14 13 5 3 Angle Main boom 8 11 5 4 Angle Jib 23 25 5 Signal Voltage Terminal Boa...

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