DS350GW Service - SkyAzul

SkyAzúl, Soluciones de Equipos www.skyazul.com 301-371-6126

SERVICE MANUAL

DS350G/GW

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126

NOTICESkyAzúl 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.

SkyAzúl will not be liable for errors contained in this manual or for incidental or consequential damages in connection with the furnishing, performance, or use of this manual. This document contains proprietary information, which is protected by copyright, and all rights are reserved.

No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of SkyAzúl.

SkyAzúl reserves proprietary rights to all drawings, photos and the data contained therein. The drawings, photos and data are confidential and cannot be used or reproduced without the written consent of SkyAzúl. The drawings and/or photos are subject to technical modification without prior notice.

All information in this document is subject to change without notice.

SkyAzúl, Inc. 200 W. Main Street, Suite, 2A Middletown, MD 21769 Fax 301-371-0029 [email protected]

SkyAzúl, Equipment Solutions SERVICE MANUAL DS350G/GW

www.skyazul.com (301) 371-6126 DS350GW Service

TABLE OF CONTENTS SECTION 1. MECHANICAL DESCRIPTION OF THE SYSTEM ................................... 1

1.0 MECHANICAL DESCRIPTION OF THE COMPONENTS.................................... 1 2.0 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UNIT.... 2 3.0 BASIC ADJUSTMENT OF THE HARDWARE ..................................................... 3

SECTION 2. DEFINITIONS ........................................................................................... 4 SECTION 3. DRAWINGS .............................................................................................. 5

DRAWING 1. Cable Reel 068-208-060-013 LWG208 Spare Parts List ...................... 5 DRAWING 2. Cable Reel LWG208 ............................................................................. 6 DRAWING 3. Length Sensor Assembly 006-710-006-002.......................................... 7 DRAWING 4. Angle Sensor WG103 Assembly 064-103-060-002 .............................. 8 DRAWING 5. Angle Sensor WG203 Adjustment 006-420-306-001............................ 9 DRAWING 6. Anti-Two Block Switch 031-002-060-011 ............................................ 10 DRAWING 7. Pressure Transducer 044-213-060-001 .............................................. 11 DRAWING 8. Pressure Transducer Cable Assembly................................................ 11 DRAWING 9. Jumper Cable Assembly for Extension 031-300-103-541................... 12 DRAWING 10. Eprom replacement in Central Unit ................................................... 13 DRAWING 12. Central Unit Electrical Diagram ......................................................... 15 DRAWING 13. Cable Reel Electrical Diagram .......................................................... 16 DRAWING 14. A-Frame or Swingaway Extension Electrical Diagram ...................... 17 DRAWING 15. Offset Swingaway Extension Electrical Diagram............................... 18 DRAWING 16. Tele Swingaway Extension Electrical Diagram ................................. 19 DRAWING 17. Electrical Diagram - Console to Central Unit ..................................... 20 DRAWING 18. Electrical Diagram - Cable Reel to Central Unit ................................ 21 DRAWING 19. Electrical Diagram - Pressure Transducer to Central Unit................. 23

SECTION 4. THEORY .................................................................................................. 25 THEORY 1. Anti-Two Block & Shutoff Circuit............................................................ 25 THEORY 2. Length Measuring Channel #1............................................................... 25 THEORY 3. Piston Side Pressure Measuring Channel #2 ........................................ 26 THEORY 4. Rod Side Pressure Measuring Channel #3............................................ 27 THEORY 5. Force Transducer Measuring Channel #4 ............................................. 27 THEORY 6. Main Boom Angle Measuring Channel #5 ............................................. 29 THEORY 7. Jib Angle Measuring Channel #6........................................................... 29 THEORY 8. BASIC ADJUSTMENT AND VOLTAGE CHECKS ................................ 30

5. TROUBLESHOOTING FLOW CHARTS................................................................... 32 1. GENERAL FLOWCHART...................................................................................... 32 4. NO DISPLAY ......................................................................................................... 35 5. ANTI TWO BLOCK PROBLEM ............................................................................. 37 6. LENGTH READING PROBLEM ............................................................................ 40 7. LOAD READING PROBLEM................................................................................. 43 8 BAD DATA TRANSFER BETWEEN CONSOLE & CENTRAL UNIT ..................... 46 9. INTERFERENCE PROBLEM ................................................................................ 48 10. LIGHTBAR MALFUNCTION................................................................................ 49

6. ERROR CODE DISPLAY.......................................................................................... 51 REFERENCE GUIDE.................................................................................................... 58

Mechanical Description

1

SECTION 1. MECHANICAL DESCRIPTION OF THE SYSTEM

1.0 MECHANICAL DESCRIPTION OF THE COMPONENTS

1.1 Pressure Transducer: The pressure transducer transforms hydraulic pressure into an electric analogue voltage signal. Two pressure transducers are connected, one to the rod side and one to the piston side of the lift cylinder. The pressure transducer is connected to the central unit with a four conductor, double - shielded cable.

The power supply voltage is ± 5V. The output signal is 0.00V under 0 pressure to -1.00V at max. pressure (4410psi)

1.2 The Length-Angle Transducer: The length-angle sensor (LWG) is a combination of two transducers in one box, fitted at the base section of the boom. It measures the length and the angle of the boom.

A reeling drum drives a potentiometer, which is the length transducer. Part of the length transducer circuit is the length cable on the drum, which is a two-conductor cable (screen and live). It is connected to the anti-two-block switch at the boom head and to a slip ring body in the LWG. The angle transducer is fitted in a small box filled with oil. A pendulum drives the axle of the angle potentiometer.

The power supply voltage for both is -5.00V The output signal for the length transducer is: -0.500V up to -4.500V The output signal for the angle transducer is: -1.875V up to -3.125V

1.3 Anti-Two-Block Switch: The anti-two-block switch monitors the load block and it’s relationship with the head of the boom. In working condition the switch is closed. When the hook block strikes the weight the circuit opens, disengaging a relay output to the lock out solenoid valves, where applicable. To check the cable for damage, (short circuit to ground) there is a 4.7k resistor between ground and the contact of the switch, to give a signal back to the central unit. The weight at the anti-two-block switch keeps the switch closed until the hook block strikes it.

1.4 Console: The console displays all geometrical information such as length and angle of main boom, working radius and head height of the boom. It also displays the actual load and the maximum load permitted by load chart. Furthermore, it has an alarm horn, a warning light for overload, and a pre-warning light. The analog instrument shows a percentage of the total permissible moment. The console has a switch for the operating modes (duty-selection switch for crane configurations) and a switch for the reeving of the hook block. It also has a warning light for anti-two-block conditions and an override switch for overload or anti-block condition. The console also has a toggle switch that engages digital inputs to identify various hoist options.


SERVICE MANUAL DS350G/GW


2

1.5 Duty Selection Switches (Digital Inputs): The system has to be programmed for the

lifting area configuration. The crane is going to be worked in e.g. main boom on outriggers over front, or rear, or over the side for 360 degrees. For this information from the crane, we use micro switches that are installed in the electrical swivel and tells the system the location of the boom. We also use micro switches on the counterweight that informs the system if the counterweight is installed or not where applicable.

2.0 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UNIT

All the data of the crane are stored inside the central unit in E-Proms. The central unit gets all actual information of the crane. This is computed against the reference data and the crane status continually monitored. 2.1 Description of the Housing: The central unit DS350 has a rugged, waterproof sheet

steel housing. It is mounted on the left side of the turntable weldment or on the counterweight. The cables are led into the central unit via strain reliefs and connected with fast-ons. On the housing is mounted an override connected with fast-ons. On the housing is mounted an override switch to override the LMI function. The system is protected by a 2 AMP fuse which is mounted on the lower right side. The output signal is protected by a 10 AMP fuse, which is mounted on the lower mid.

2.2 Description of the Boards: Inside the central unit there is one board. The main

board and the terminal board are two separate boards connected by a pair of ribbon cables. Power and are also connected from the terminal board to the main board. The wires from the various components are connected with fast-ons to the terminal board. The main board is the heart of the system. It contains the main computer and the necessary electronics to receive, evaluate, process and direct the continuous data. There are overload and anti-two-block relays mounted on this board that control the lever lockout(s),. A power supply prepares all the necessary voltages for the transducers and the electronics on the main board. An analogue input part, which receives and prepares all the signals from the transducers for further processing. An analogue/digital converter converts all the processed analogue signals into digital ones. A digital circuit contains the main computer and the ancillary electronics.

2.3 Incoming Signals: The signals from the transducers are connected to the terminal

board. The signals of the angle-length transducer are connected to terminal #9 (angle) and terminal #10 (length). The signal on terminal #9 (angle) is between -1.875V (90�) and -3.125V (0�). The signal on terminal #10 (length) is between -0.500V retracted M/B and -4.500V. The signals from the pressure transducers are connected to terminal #16 (rod side) and terminal #21 (piston side). The signals on terminals #16 and #21 are between 0.00V @ 0PSI and -1.00V @ max PSI.

Mechanical Description


3

The signal from the force transducer is connected to the terminals #28 and #29. The signal between #29 (negative output) and #28 (positive output) is between 0.00V @ 0 force and +2.500V @ max force. The inputs for the duty selection switches are the terminals #38, 40, 42 for positive signals, or #37, 39, 41 for negative signals. The input for the anti-two-block switch is terminal #35.

2.4 Outgoing Signal: The outgoing signal of the terminal board is the signal for lever

lockout of terminal #48. In normal working conditions there are 12 volts at this terminal. If there is an overload or anti-two-block condition, the signal becomes 0 volts. Furthermore, all supply voltages for the transducers are going out via the terminal board.

3.0 BASIC ADJUSTMENT OF THE HARDWARE

3.1 Length: Ensure that the length cable tension is correct with fully retracted boom by

turning the cable reel 5 to 8 turns counterclockwise. Then remove cover form LWG and adjust counterclockwise the potentiometer to end stop.

3.2 Angle: Set the boom between 0 and 5 degrees and set the inclinometer to the boom

angle. Adjust the angle sensor to the same angle as the boom. Check the angle at 20 degrees, 45 degrees, 70 degrees. Angle display should be less than ± .5 degrees of the value of the inclinometer.

3.3 Pressure Channel: Rest the boom and disconnect hydraulic hoses from the pressure

transducers. Measure and record the zero-points of both pressure transducers on the terminal board X1-16 (rod) X1-21 (piston). Adjust P4 and P5 on the main board to 500mV at test points MP4 and MP5. Connect hydraulic hoses back to the pressure transducers. Bleed the air.

3.4 Duty Selection Switches Digital Inputs): Check the duty selection switches for

correct operation. Check the voltage on digital input terminals. 3.5 Check the function of the hoist limit switch (anti-two-block) 3.6 Check function of lever lockout. 3.7 Measure and record the power supply voltages.



4

SECTION 2. DEFINITIONS

1. BOOM LENGTH The straight line thru 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%)

2. BOOM ANGLE The angle between the longitudinal centerline of the boom base section

and the horizontal plane. (Indicator 65° to 90° boom angle + 0°/2°; less than 65° boom angle + 0°/-3°)

3. RADIUS OF LOAD The horizontal distance from a vertical projection of the crane’s center

of rotation, to the center of the vertical hoist line or tackle with rated load applied. (Indicator 100% to 110%)

4. RATED LOAD The load value shown on the applicable load rating chart of the crane for

the particular crane configuration, boom length, boom angle, or functions or these variables. For radii outside those shown on the load rating chart, the rated load is to be considered as zero.

5. ACTUAL LOAD The weight of the load being lifted and all additional equipment such as

blocks, slings, sensors, etc. Also referred to as working load. (Indicator 100% to 110%) 6. CRANE CONFIGURATION The physical arrangement of the crane as prepared for a

particular operation in conformance with the manufacturer’s operating instructions and load rating chart.

7. TWO-BLOCKING Contact of the lower load block or hook with the upper load block, boom

point, or boom point machinery. 8. ANALOG Electrical signals that vary in proportion to the quantities they represent. (Boom

length, angle, and pressure transducer) 9. DIGITAL Electrical signals of an on and off state (two different voltage levels) to represent

some quantity of operation. (A2B, area definition switch)

Drawings


5

SECTION 3. DRAWINGS

DRAWING 1. Cable Reel 068-208-060-013 LWG208 Spare Parts List



6

NO. PART NO. QTY DESCRIPTION

01 006-710-006-002 1 SENSOR, LENGTH TRANS. LGE 100 (KT200/LWG208) 02 068-000-110-038 1 SENSOR ACCY, GEAR WHEEL, KT200 CABLE REEL 03 067-000-050-065 1 SENSOR ACCY, GEAR WHEEL, T=50 CENTER SHAFT 04 064-103-060-002 1 SENSOR, ANGLE WG103 05 002-050-206-012 2 SCREW, 6M X 12 SOCKET CAP 06 000-207-010-064 3 WASHER, FLAT 6MM 07 002-050-206-100 1 SCREW, 6M x 100M SOCKET CAP 08 000-208-040-083 1 WASHER, LOCK 6MM 09 068-000-100-064 1 SLIPRING, 2 CONDUCTOR 10 068-000-110-029 1 TERMINAL STRIP 11 068-000-110-010 1 SPRING PACK, W/ HOUSING KT200/LWG208/LWG221 12 068-000-110-011 1 CABLE REEL ACCY, CABLE DRUM,KT 200/ LWG208 13 000-673-020-002 139' CABLE, LENGTH SENSOR, 1 CORE W/SHEILD (per ft) 14 006-800-005-058 1 BRACKET, MTG. CABLE REEL ARM, ONE SLOT 15 000-205-031-230 4 SCREW, 12mm x 30MM HEX HEAD 16 006-800-005-057 1 BRACKET, MTG. CABLE REEL ARM, TWO SLOTS 17 005-682-000-001 1 COVER, CABLE REEL, KT200 18 068-000-110-031 10 CABLE REEL ACCY, SCREW CABLE REEL COVER 19 021-441-131-013 1 STRAIN RELIEF, PG 13.5, 8-12mm RED+WHITE

DRAWING 2. Cable Reel LWG208

Drawings


7

DRAWING 3. Length Sensor Assembly 006-710-006-002



8

DRAWING 4. Angle Sensor WG103 Assembly 064-103-060-002

Drawings


9

DRAWING 5. Angle Sensor WG203 Adjustment 006-420-306-001

The angle φ shown in drawing below, needs to be within +0, -0.4 of the actual angle of the boom. Check boom angle at base/heel Section only. After adjustment, compare the actual boom angle with the displayed angle at about 0°, 30° and 60°. To comply with the SAE J375 standards the displayed angle must be +0.0° to -2.0° of the actual angle.

WG 203

φ φ



10

DRAWING 6. Anti-Two Block Switch 031-002-060-011

Drawings


11

DRAWING 7. Pressure Transducer 044-213-060-001

DRAWING 8. Pressure Transducer Cable Assembly

(Part Number is depends cable length)



12

DRAWING 9. Jumper Cable Assembly for Extension 031-300-103-541

Drawings


13

DRAWING 10. EPROM replacement in Central Unit

1. Remove cover, from central unit. CAUTION: Before handling the EPROM, discharge any static electricity from your body by touching a grounded point. The EPROM could be damaged by static electricity. 2. Remove the old DATA EPROM, from the main board. Be careful to pull the EPROM out,

without bending the legs. Refer to drawing above.

NOTE: The notch on the EPROM and in the socket determines the correct orientation of the EPROM. Refer to the drawing below for correct EPROM locations. 3. Carefully align the

new EPROM legs with the socket and push the EPROM into place. Be careful not to bend any of the legs.

4. Install the cover and tighten screws, making sure the rubber gasket, is positioned correctly, to prevent any moisture, from entering the central unit.



14

DRAWING 11. Main Board - Piston & Rod Pressure Channel Zero Point Adjustment

1. LOWER BOOM ALL THE WAY DOWN (NO REST PRESSURE) THEN DISCONNECT

HYDRAULIC HOSE FROM THE PISTON SIDE PRESSURE TRANSDUCER. 2. CONNECT A DIGITAL VOLTMETER TO MAIN P.C. BOARD

A) BLACK (-) LEAD TO MP15 B) RED (+) LEAD TO MP4

3. ADJUST P4 TO OBTAIN A READING OF 0.500 VOLTS (500MV) ON METER. 4. DISCONNECT HYDRAULIC HOSE FROM THE ROD SIDE PRESSURE TRANSDUCER. 5. CONNECT A DIGITAL VOLTMETER TO MAIN P.C. BOARD

A) BLACK (-) LEAD TO MP15 B) RED (+) LEAD TO MP5

6. ADJUST P5 TO OBTAIN A READING OF 0.500 VOLTS (500MV) ON METER. 7. RECONNECT HYDRAULIC HOSES TO PRESSURE TRANSDUCERS, THEN BLEED

THE AIR FROM HYDRAULIC LINES.

Drawings


15

DRAWING 12. Central Unit Electrical Diagram

Refer to Drawings 17 to 21 for individual component wiring.



16

DRAWING 13. Cable Reel Electrical Diagram

Drawings


17

DRAWING 14. A-Frame or Swingaway Extension Electrical Diagram



18

DRAWING 15. Offset Swingaway Extension Electrical Diagram

Drawings


19

DRAWING 16. Tele Swingaway Extension Electrical Diagram



20

DRAWING 17. Electrical Diagram - Console to Central Unit

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Drawings


21

DRAWING 18. Electrical Diagram - Console to Central Unit

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RA

NG

E =

-4.5

VS

EE

NO

TE

@ C

AB

LE

RE

EL

PR

ES

SU

RE

SIG

NA

L R

AN

GE

0.5

00

V T

O 4

.5V

ZE

RO

PR

ES

SU

RE

AD

JU

ST

ME

NT

F

OR

PIS

TO

N M

P 4

- R

OD

MP

5S

ET

TO

0.5

V W

ITH

NO

PR

ES

SU

RE

ON

TR

AN

SD

UC

ER

.A

DJ

US

T P

4 F

OR

0.5

00V

AT

MP

4A

DJ

US

T P

5 F

OR

0.5

00V

AT

MP

5U

SE

MP

15 F

OR

GN

D.

RE

FE

R T

O M

AIN

BO

OM

AN

GL

EC

HA

NN

EL

FO

RS

IGN

AL

RA

NG

ES

.

FO

RC

E T

RA

NS

DU

CE

R A

MP

LIF

IER

OU

TP

UT

SIG

NA

L R

AN

GE

0.5

00V

TO

4.5

V @

MP

3

DIF

FE

RIN

TIA

L IN

PU

T S

IGN

AL

R

AN

GE

0.0

V T

O 2

.5V

@ 2

8 &

29

ZE

RO

PO

INT

(N

O F

OR

CE

) S

HO

UL

DB

E B

EL

OW

25

MV

DIG

ITA

L IN

PU

TS *

US

AG

E D

EP

EN

DS

ON

CR

AN

E M

OD

EL

RE

FE

R T

O P

AT

WIR

ING

DIA

GR

AM

F

OR

CO

NN

EC

TIO

N P

AR

TIC

UL

AR

MO

DE

LD

E1

- T

ER

M.

38

(+

) &

37 (

-)D

E2

- T

ER

M.

40

(+

) &

39 (

-)D

E3

- T

ER

M.

42

(+

) &

41 (

-)

*

CE

NT

RA

L U

NIT

DS

35

0G

W

AN

GL

E S

IGN

AL

0 D

EG

= -

3.1

25

V4

5 D

EG

= -

2.5

0V

90 D

EG

= -

1.8

75V

W1

CE

NT

RA

LG

ND

12

11 12

13 14

LM

I B

YP

AS

S

KE

Y S

WIT

CH

14326 5 7(

(

10 A

F2

2 A

F1

2 13

GN

D =

IN

NE

R S

HIE

LD

CO

NN

EC

TIO

N

UB

= C

RA

NE

SU

PP

LY

PO

SIT

IVE

VO

LTA

GE

0

(UB

) =

CR

AN

E G

ND

RX

D =

RE

CE

IVE

DA

TA

TX

D =

TR

AN

SM

ITT

DA

TA

12345678

(+12

V)

(GN

D)

1234567

CA

B

1 3 4 2

B C

A2B

LM

I

DA

TA

FR

OM

C.U

.

DA

TA

TO

C.U

.

CO

NS

OLE

B

Y-P

AS

S

KE

Y

"G

W"

CO

NS

OL

E

DS

350

GW

CO

NSO

LE T

O C

.P.U

.C

ON

NE

CTI

ON

S=

WIR

ES

AR

EG

RO

UP

ED

TO

GE

TH

ER

49

48

47

46

45

44

43

42

41

40

39

38

37

36

35

34

33

32

31

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10 9 8 7 6 5 4 3 2 1



22

DRAWING 19. Electrical Diagram - Cable Reel to Central Unit

PR

ES

S. T

RA

NS

.S

IGN

AL

RA

NG

E0 B

AR

= 0

.0V

300 B

AR

= -1.0

V

1

3 2 1+1

2 VO

LTS

GN

DD

C P

OW

ER

LEV

ER

LO

CK

OU

TS

OLE

NO

ID V

ALV

E O

R V

ALV

ES

X1

X2 X3

123

SIG-5

VG

ND

+5

V

-5V

SIG

-SIG

4 3 2 1

40 26

X5

X2

X3

3 20 (U

B)

/GN

D1

+12

V1

2

BR

.14

X9

X8

10

X1

X7

X4

MEMORY EXTENSION

2X S

ER

IAL

INTE

RFA

CE

X6

MEASURE PINS

A100MAIN BOARD24 350 30 0001

X1

K2

K3

K1

0 (

UB

)

UB

UB

DE

3

DE

2

DE

1

}DIG

ITA

LIN

PU

TS

0 (

UB

)S

IG

0-S

IGA

2B

CO

MP

AR

AT

OR

0 (

UB

)

RX

DT

XD

UB

-SIG

+S

IG

-9V

+9

V

-5V

GN

D

-5V

+5

VG

ND

SIG

SIG G

ND

X4

4

0 (

UB

)

+U

B

26 W4

40 W5


24 350 30 0073

A2

B ST

OP

FO

RC

EM

P 3

AN

GL

EJIB

MP

9

PR

ES

SU

RE

PIS

TO

NS

IDE

MP

4

PR

ES

SU

RE

RO

DS

IDE

MP

5

LE

NG

TH

BO

OM

MP

6

AN

GL

EM

AIN

BO

OM

MP

8A

NG

LE

SIG

NA

L0 D

EG

= +

4.5

V45 D

EG

= +

2.5

V90 D

EG

= +

0.5

00V

LE

NG

TH

SIG

NA

LM

IN =

+0.5

00V

MA

X =

+4.5

V(1

0)

TU

RN

/ P

OT

= M

AX

)

BO

OM

LE

NG

TH

SIG

NA

LR

ET

RA

CT

ED

= -

0.5

00V

MA

X R

AN

GE

= -

4.5

VS

EE

NO

TE

@ C

AB

LE

RE

EL

PR

ES

SU

RE

SIG

NA

L R

AN

GE

0.5

00V

TO

4.5

VZ

ER

O P

RE

SS

UR

E A

DJU

STM

EN

T

FO

R P

IST

ON

MP

4 -

RO

D M

P 5

SE

T T

O 0

.5V

WIT

H N

O P

RE

SS

UR

EO

N T

RA

NS

DU

CE

R.

AD

JU

ST P

4 F

OR

0.5

00V

AT M

P 4

AD

JU

ST P

5 F

OR

0.5

00V

AT M

P 5

US

E M

P 1

5 F

OR

GN

D.

RE

FE

R T

O M

AIN

BO

OM

AN

GL

EC

HA

NN

EL

FO

RS

IGN

AL

RA

NG

ES

.

FO

RC

E T

RA

NS

DU

CE

R A

MP

LIF

IER

OU

TP

UT

SIG

NA

L R

AN

GE

0.5

00V

TO

4.5

V @

MP

3

DIF

FE

RIN

TIA

L IN

PU

T S

IGN

AL

R

AN

GE

0.0

V T

O 2

.5V

@ 2

8 &

29

ZE

RO

PO

INT (

NO

FO

RC

E)

SH

OU

LD

BE

BE

LO

W 2

5 M

V

DIG

ITA

L IN

PU

TS *

US

AG

E D

EP

EN

DS

ON

CR

AN

E M

OD

EL

RE

FE

R T

O P

AT

WIR

ING

DIA

GR

AM

F

OR

CO

NN

EC

TIO

N P

AR

TIC

UL

AR

MO

DE

LD

E1

- T

ER

M.

38

(+

) &

37

(-)

DE

2 -

TE

RM

. 40

(+

) &

39

(-)

DE

3 -

TE

RM

. 42

(+

) &

41

(-)

*

CE

NT

RA

L U

NIT

DS

350

GW

AN

GL

E S

IGN

AL

0 D

EG

= -3.1

25V

45 D

EG

= -

2.5

0V

90 D

EG

= -

1.8

75V

W1

CE

NT

RA

LG

ND

12

11 12

13 14

LM

I B

YP

AS

S

KE

Y S

WIT

CH

10 A

F2

2 A

F1

2 13

GN

D =

IN

NE

R S

HIE

LD

CO

NN

EC

TIO

N

UB

= C

RA

NE

SU

PP

LY

PO

SIT

IVE

VO

LT

AG

E0

(U

B)

= C

RA

NE

GN

DR

XD

= R

EC

EIV

E D

AT

AT

XD

= T

RA

NS

MIT

T D

AT

A

DS

350

G/G

WB

OO

M L

ENG

TH &

BO

OM

AN

GLE

TO

C.P

.U.

CO

NN

ECT

ION

S

4 123C

H.#

1 =

BO

OM

LE

NG

TH

. C

H.#

5=

BO

OM

AN

GL

E.

10

9 10

10

10

10

10

10

10

10 8 7 6 5 4 3 2 19

PIN

1 &

5 =

GN

DP

IN 3

& 6

= -

5V

PIN

2 =

LE

NG

TH

SIG

NA

LP

IN 4

= A

NG

LE

SIG

NA

L6 5 4 3 2 1

17

18

WG LG1 2 3 4 5 6

4.7K

1

23

2

3

5 6

BO

OM

CO

NN

EC

TIO

N

SE

E W

IRIN

G D

IAG

RA

M F

OR

TH

E S

PE

CIF

IC M

OD

EL

MA

CH

INE

CA

BL

E R

EE

L

SH

IELD

RE

SIS

TOR

SH

IELD

BO

OM

NO

SE

CO

NN

EC

TOR

JUM

PER

PLU

G A2B

SW

ITC

HA

SS'Y

WE

IGH

TA

SS'Y

R.F

.F

ILT

ER

S

= W

IRE

S A

RE

G

RO

UP

ED

TO

GE

TH

ER

49

48

47

46

45

44

43

42

41

40

39

38

37

36

35

34

33

32

31

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10 9 8 7 6 5 4 3 2 1

Drawings


23

DRAWING 20. Electrical Diagram - Pressure Transducer to Central Unit

PR

ES

S. T

RA

NS

.S

IGN

AL

RA

NG

E0 B

AR

= 0

.0V

300 B

AR

= -1

.0V

PR

ES

SU

RE

TR

AN

SD

UC

ER

PIS

TO

N S

IDE

4

1234

ABCD

DAVS

CH

. # 3

123

3 2 1+1

2 V

OLT

S

GN

DD

C P

OW

ER

LEV

ER

LO

CK

OU

TS

OLE

NO

ID V

ALV

E O

R V

ALVE

S

X1

X2 X3

123

SIG-5

VG

ND

+5

V

-5V

SIG

-SIG

4 3 2 1

40 26

X5

X2

X3

3 20 (U

B) /G

ND

1+12

V1

2

BR

.14

X9

X8

10

X1

X7

X4

MEMORY EXTENSION

2X S

ER

IAL

INTE

RFA

CE

X6

MEASURE PINS

A100MAIN BOARD24 350 30 0001

X1

K2

K3

K1

0 (

UB

)

UB

UB

DE

3

DE

2

DE

1

}DIG

ITA

LIN

PU

TS

0 (

UB

)S

IG

0-S

IGA

2B

CO

MP

AR

AT

OR

0 (

UB

)

RX

DT

XD

UB

-SIG

+S

IG

-9V

+9

V

-5V

GN

D

-5V

+5

VG

ND

SIG

SIG G

ND

X4

4

0 (

UB

)

+U

B

26 W4

40 W5


24 350 30 0073

A2

B ST

OP

FO

RC

EM

P 3

AN

GL

EJIB

MP

9

PR

ES

SU

RE

PIS

TO

NS

IDE

MP

4

PR

ES

SU

RE

RO

DS

IDE

MP

5

LE

NG

TH

BO

OM

MP

6

AN

GL

EM

AIN

BO

OM

MP

8A

NG

LE

SIG

NA

L0 D

EG

= +

4.5

V45 D

EG

= +

2.5

V90 D

EG

= +

0.5

00V

LE

NG

TH

SIG

NA

LM

IN =

+0

.500V

MA

X =

+4

.5V

(10)

TU

RN

/ P

OT

= M

AX

)

BO

OM

LE

NG

TH

SIG

NA

LR

ET

RA

CT

ED

= -

0.5

00V

MA

X R

AN

GE

= -

4.5

VS

EE

NO

TE

@ C

AB

LE

RE

EL

PR

ES

SU

RE

SIG

NA

L R

AN

GE

0.5

00V

TO

4.5

VZ

ER

O P

RE

SS

UR

E A

DJ

US

TM

EN

T

FO

R P

IST

ON

MP

4 -

RO

D M

P 5

SE

T T

O 0

.5V

WIT

H N

O P

RE

SS

UR

EO

N T

RA

NS

DU

CE

R.

AD

JU

ST P

4 F

OR

0.5

00V

AT M

P 4

AD

JU

ST P

5 F

OR

0.5

00V

AT M

P 5

US

E M

P 1

5 F

OR

GN

D.

RE

FE

R T

O M

AIN

BO

OM

AN

GL

EC

HA

NN

EL

FO

RS

IGN

AL

RA

NG

ES

.

FO

RC

E T

RA

NS

DU

CE

R A

MP

LIF

IER

OU

TP

UT

SIG

NA

L R

AN

GE

0.5

00V

TO

4.5

V @

MP

3

DIF

FE

RIN

TIA

L IN

PU

T S

IGN

AL

RA

NG

E 0

.0V

TO

2.5

V @

28 &

29

ZE

RO

PO

INT

(N

O F

OR

CE

) S

HO

UL

DB

E B

ELO

W 2

5 M

V

DIG

ITA

L IN

PU

TS *

US

AG

E D

EP

EN

DS

ON

CR

AN

E M

OD

EL

RE

FE

R T

O P

AT

WIR

ING

DIA

GR

AM

F

OR

CO

NN

EC

TIO

N P

AR

TIC

UL

AR

MO

DE

LD

E1

- T

ER

M.

38

(+

) &

37

(-)

DE

2 -

TE

RM

. 4

0 (

+)

& 3

9 (

-)D

E3

- T

ER

M.

42

(+

) &

41

(-)

*

CE

NT

RA

L U

NIT

DS

35

0G

W

AN

GL

E S

IGN

AL

0 D

EG

= -3.1

25V

45 D

EG

= -

2.5

0V

90 D

EG

= -

1.8

75

V

W1

CE

NT

RA

LG

ND

12

11 12

13 14

LM

I B

YP

AS

S

KE

Y S

WIT

CH

14 3 2

10 A

F2

2 A

F1

2 13

GN

D

=

IN

NE

R S

HIE

LD

CO

NN

EC

TIO

N

UB

= C

RA

NE

SU

PP

LY

PO

SIT

IVE

VO

LT

AG

E0

(U

B)

= C

RA

NE

GN

DR

XD

= R

EC

EIV

E D

AT

AT

XD

= T

RA

NS

MIT

T D

AT

A

DS

350

G/G

WPI

STO

N &

RO

DTR

AN

SDU

CER

TO

C.P

.U.

CO

NN

EC

TIO

NS

1234

ABCD

DAVS

CH

. # 2

PR

ES

SU

RE

TR

AN

SD

UC

ER

RO

D S

IDE

= W

IRE

S A

RE

GR

OU

PE

D T

OG

ETH

ER

49

48

47

46

45

44

43

42

41

40

39

38

37

36

35

34

33

32

31

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10 9 8 7 6 5 4 3 2 1



24

DRAWING 21. Electrical Diagram - Jib Angle and Force Transducer to Central Unit

PR

ES

S. T

RA

NS

.S

IGN

AL

RA

NG

E0 B

AR

= 0

.0V

300 B

AR

= -

1.0

V

123C

H.

# 6

13

ABC D

WG 203

3 2 1+1

2 VO

LTS

GN

DD

C P

OW

ER

LEV

ER

LO

CK

OU

TS

OLE

NO

ID V

ALV

E O

R V

ALVE

S

X1

X2 X3

123

SIG-5

VG

ND

+5

V

-5V

SIG

-SIG

4 3 2 1

40 26

X5

X2

X3

3 20 (U

B) /G

ND

1+12

V1

2

BR

.14

X9

X8

10

X1

X7

X4

MEMORY EXTENSION

2X S

ER

IAL

INTE

RFA

CE

X6

MEASURE PINS

A100MAIN BOARD24 350 30 0001

X1

K2

K3

K1

0 (

UB

)

UB

UB

DE

3

DE

2

DE

1

}DIG

ITA

LIN

PU

TS

0 (

UB

)S

IG0

-SIG

A2

BC

OM

PA

RA

TO

R0

(U

B)

RX

DT

XD

UB

-SIG

+S

IG

-9V

+9

V-5

V

GN

D

-5V

+5

VG

ND

SIG

SIG G

ND

X4

4

0 (

UB

)

+U

B

26 W4

40 W5


24 350 30 0073

A2

B ST

OP

FO

RC

EM

P 3

AN

GL

EJIB

MP

9

PR

ES

SU

RE

PIS

TO

NS

IDE

MP

4

PR

ES

SU

RE

RO

DS

IDE

MP

5

LE

NG

TH

BO

OM

MP

6

AN

GL

EM

AIN

BO

OM

MP

8A

NG

LE

SIG

NA

L0 D

EG

= +

4.5

V45 D

EG

= +

2.5

V90 D

EG

= +

0.5

00V

LE

NG

TH

SIG

NA

LM

IN =

+0

.50

0V

MA

X =

+4

.5V

(10)

TU

RN

/ P

OT

= M

AX

)

BO

OM

LE

NG

TH

SIG

NA

LR

ET

RA

CT

ED

= -0

.50

0V

MA

X R

AN

GE

= -

4.5

VS

EE

NO

TE

@ C

AB

LE

RE

EL

PR

ES

SU

RE

SIG

NA

L R

AN

GE

0.5

00V

TO

4.5

VZ

ER

O P

RE

SS

UR

E A

DJU

ST

ME

NT

F

OR

PIS

TO

N M

P 4

- R

OD

MP

5S

ET

TO

0.5

V W

ITH

NO

PR

ES

SU

RE

ON

TR

AN

SD

UC

ER

.A

DJU

ST P

4 F

OR

0.5

00V

AT

MP

4A

DJU

ST P

5 F

OR

0.5

00V

AT

MP

5U

SE

MP

15

FO

R G

ND

.

RE

FE

R T

O M

AIN

BO

OM

AN

GL

EC

HA

NN

EL

FO

RS

IGN

AL

RA

NG

ES

.

FO

RC

E T

RA

NS

DU

CE

R A

MP

LIF

IER

OU

TP

UT

SIG

NA

L R

AN

GE

0.5

00V

TO

4.5

V @

MP

3

DIF

FE

RIN

TIA

L I

NP

UT

SIG

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Theory


25

SECTION 4. THEORY

THEORY 1. Anti-Two Block & Shutoff Circuit

THEORY 2. Length Measuring Channel #1



26

THEORY 3. Piston Side Pressure Measuring Channel #2

Piston Pressure Channel Zero Point Adjustment

1. Lower boom all the way down (no rest pressure) then disconnect hydraulic hose from the piston side pressure transducer.

2. Connect a digital voltmeter to main p.c. board, black (-) lead to MP15, red (+) lead to MP4 3. Adjust P4 to obtain a reading of 0.500 volts (500mv) on meter. Rod Pressure Channel Zero Point

Adjustment 4. Disconnect hydraulic hose from the rod side pressure transducer. 5. Connect a digital voltmeter to main p.c. board, black (-) lead to MP15, red (+) lead to MP5 6. Adjust P5 to obtain a reading of 0.500 volts (500mv) on meter. 7. Reconnect hydraulic hoses to pressure transducers, then bleed the air from hydraulic lines.

Theory


27

THEORY 4. Rod Side Pressure Measuring Channel #3

THEORY 5. Force Transducer Measuring Channel #4



28

Theory


29

THEORY 6. Main Boom Angle Measuring Channel #5

THEORY 7. Jib Angle Measuring Channel #6



30

THEORY 8. BASIC ADJUSTMENT AND VOLTAGE CHECKS

Theory


31

MODEL: S/N: PAT DS350G PART #024-350-300-081 and 024-350-300-068

1. Crane Supply Voltage @ X1-1 (+) & X1-4 (GND) = VDC

2. Supply Voltage to Main Board @ X1-1 (=) & X1-3 (GND) = VDC

3. Main Board Power Supply (Reference Voltages +/ -50 MV):

+ 9V @ Mp 14 = _______________ VDC Mp 15 Ground - Force Transducer - 9V @ Mp 16 = _______________ VDC Mp 15 Ground - Force Transducer + 5V @ Mp 17 = _______________ VDC Mp 15 Ground - Internal to Board - 5V @ Mp 19 = _______________ VDC Mp 15 Ground - Internal to Board + 5V @ Mp 1 = _______________ VDC Mp 15 Ground - Internal to Board - 5V @ Mp 2 = _______________ VDC Mp 15 Ground - Jib-Angle, Length/Angle, Rod,

Piston Supply + 5V @ Mp 18 = _______________ VDC Mp 15 Ground - Piston & Rod Supply + 5V @ Mp 12 = _______________ VDC Mp 13 Ground - Internal to Board +12V @ Mp21 = _______________ VDC Mp 15 Ground - Internal to Board + 6 V @ Mp 20= _______________ VDC Mp 15 Ground - Internal to Board

4. Boom Length: (Mp 15 Ground for Meter)

Fully Retracted _________ Ft. __________VDC @ X1-10 __________DC @ Mp 6 Fully Extended _________ Ft. __________VDC @ X1-10 __________DC @ Mp 6 -5 Volt Reference Voltage ____________VDC @ X1-11

5. Boom Angle: (MP 15 Ground for Meter)

Minimum Angle ________ ° ____________VDC @ X1-9 ___________VDC @ Mp8

Maximum Angle________ ° ____________VDC @ X1-9 ___________VDC @ Mp8 -5 Volt Reference Voltage ___________VDC @ X1-11

6. Pressure Transducers: (Mp 15 Ground for Meter)

Piston Zero Point ______ VDC @ X1-21 _________VDC @ Mp 4 Rod Zero Point ________ VDC @ X1-16 _________VDC @ Mp 5 +5 Volt Reference Voltage __________ VDC @ X1-13 & 18 -5 Volt Reference Voltage __________ VDC @ X1-15 & 20

SERVICE MANUAL DS350G/G


32

5. TROUBLESHOOTING FLOW CHARTS

1. GENERAL FLOWCHART This section explains how to handle a problem that may arise with the PAT Load Moment Indicator System-PAT DS350G. 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 more detailed flowcharts shown in this section.

What’s Wrong?

START

Lever Lockout Activated Go to Section 2

Length Cable Problem

No display

No Function Anti-Two Block

Wrong Length Displayed

Wrong Load Displayed

Error Code Displayed

Console DS350 is notFunctioning.

Go to Section 3

Go to Section 4

Go to Section 5

Go to Section 6

Go to Section 7

Go to Section 8, 9, 10

Go to Section 13

Light Bar Malfunction Go to Section 12

Troubleshooting


33

2. LEVER LOCKOUT ACIVATED

Does console indicate Anti-Two-block warning?

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.

Fixed

Fault in Anti-TwoBlock system.

Fault in crane electricor hydraulic system.

Check lever lockoutsystem in crane.

If console display isblank fault is located inpower supply, wiring or

fuses .

If Load Moment Limit Light(10) displays fault is locatedin LMI, cables, wiring, fuses,

or console.

Read error code displayedon console (1) and go to

Section 10.

Go to Section 4 Go to Section 5

Start

Set the override key switch in central unit into upper position to override LMI.Refer to Operator’s Handbook for LMI override instructions.

YES

NO

YesNO



34

3. BROKEN LENGTH CABLE

PROBLEM: Damaged or broken length cable.

Replace length cable using the following procedure: 1 Cut old cable at cable drum 2 Disconnect damaged length cable from junction box at the boom nose. 3 Open cable reel cover and disconnect wiring from connection block. Pull 7 conductor cable out of

strain relief. 4 Remove cable reel from mounting brackets. 5 Remove damaged length cable, which is mounted to the slip rings in the cable reel, from slipring

connection. Refer to Drawing 1 in Section 11 - Drawings 6 On the 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 strain relief to ensure sealing. 8 Reconnect the length cable to the slipring. Refer to Drawing 1 in Section 11 - Drawings. 9 Remount cable reel to the boom. 10 Turn reeling drum clockwise to spool the new cable neatly onto the drum. 11 Set preload on cable reel by turning the drum counter-clockwise 5 to 8 turns. 12 Wrap the new length cable around the boom tip anchor pin (4 or 5 wraps) and secure with tie

wraps. Leave enough length cable to connect into the boom tip junction box. 13 Connect the length cable into the boom tip junction box. Refer to Drawing 1 in Section 11 -

Drawings. 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 Drawing 6 in Section 11 - Drawings.

Troubleshooting


35

4. NO DISPLAY

PROBLEM: Blank console display with no warning light shown. All crane moments havebeen stopped.

Measure crane voltage on connection board between X1-2 (+UB) and X1-4 (ground).Refer to Drawing 3, Terminal Board, Section 11 - Drawings.

NOTE: If crane voltage is measured below 10V system will switch off.

Check fuses on CPU box.

Replace fuses.

Correct?

Correct?

Start

No

Check crane power supply for faulty craneelectric or if supply is too low.No

Measure voltage at console terminal block between Pin 1 = +12Vand Pin 2 = crane ground.

Fault in wiring between terminal block X1 andconsole board. Check wiring.

Replace console board.

Correct?

End

Yes

No

Yes

Yes



36

4. NO DISPLAY -continued

Short circuit in external wiring. Check externalwiring of system for defects.

Continued from previous page

PREVIOUS PAGE

Correct?

Disconnect ribbon cables from X2 and X3 of mainboard. Measure voltage out of power supply between:

MP15 = ground (analog) and MP1 = +5VMP15 = ground (analog) and MP2 = -5VMP13 = ground (digital) and MP12 = +5V

MP 15 = ground (analog) and MP 18 = +5VMP15 = ground (analog) and MP19 = -5V

MP are test points on main board.Refer to Drawing 4, “Main Board”, Section 11-Drawings.

Measure voltage at console terminal block between Pin 1 = +12Vand Pin 2 = crane ground.

Refer to Drawing 5, Console Board, Section 11 - D ratings.

Fault in wiring between terminal block X1 andconsole board. Check wiring.

Refer to Drawing 5, Console Board, Section11 - Drawings.

Replace console board.

Correct?

End

Yes

No

Yes

No

Troubleshooting


37

5. ANTI TWO BLOCK PROBLEM

Check if jumper/dummy plug in receptacle at boom nose is plugged in.Refer to Drawing 2, Anti-Two Block Junction, Section 11 - Drawings.

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

Plug appropriate plug into socket of junction box.

Remove jumper-dummy plug and check function of Anti-Two Block switches withohmmeter between wires 1 and 2 of switches.

Safe condition = 0 OhmBlock-to-block > 1 Megohm

Replace Anti-Two-Block switch.

Next Page

Correct?

Correct? No

Yes

Yes

No

No

Yes



38

5. ANTI TWO BLOCK PROBLEM - continued

Fault in wiring between junction box and cable reel. Check fordamaged length cable and wiring.

Refer to Section 3 - Length Cable Problem.

Continued from previous page.

PREVIOUS PAGE

Disconnect wire from terminal block X1- 35 in Central unit.At boom nose junction box measure between terminals 1 and 13 with ohmmeter.

Check switch condition and campair.Switch closed =0 ohm

Switch open > 1 MegohmRefer to Drawing 3, Terminal Board, Section 11 - Drawings.Reconnect wire from terminal block X1- 35 in Central unit.

Correct? Fault in wiring between switch and junction box. Check wiring.

Next measure the A2B signal in the cable reel. Connect jumper cable/dummy plug. Disconnect theBlack(#1) and the Brown(#11) wires from the slipring in the cable reel. Measure the the resistance

between the two wires with an ohmmeter. Switch closed =4700 ±500Ohms

Switch open > 1 Megohm Reconnected slipring wires.

Refer to Drawing 1, Slip Ring Unit, Section 11 - Drawings.

Correct?

End

No

Yes

No

Yes

Troubleshooting


39

5. ANTI TWO BLOCK PROBLEM - continued

Defect on main board. Replace main board andreset pressure channel. Refer to Section 7.


PREVIOUS PAGE

Check Anti-Two-Block signal in central unit. With ohmmeter measure between wiredisconnected from terminal block X1, Pin 35 and Pin 34.Anti-Two-Block switch closed = 4700 Ohms ±50 Ohms

Anti-Two-Block switch open > 1 Megohm.Refer to Drawing 3, Terminal Board, Section 11 - Drawings.

Correct? Faulty wiring between cable reel and central unit.Check cable.

Check main board function by installing a temporary resistor, 4700 Ohms at terminal betweenX1-35 and X1-34 in central unit. With resistor connected alarm should be inactive.

Correct?

End

No

Yes

No

Yes



40

6. LENGTH READING PROBLEM

Check out clutch in big gear wheel of length transducer. Extend and retract boom toensure that clutch is not slipping on potentiometer axle.

Refer to Drawing 6, Length/Angle Transducer, Section 11 - Drawings.

Replace length potentiometer assembly. Remove slip ring body from shaft andremove gear wheel from potentiometer axle. Unscrew mounting plate and remove

potentiometer assembly from mounting plate. Remove assembly wires formterminal block. Connect new assembly to terminal block. Reinstall mounting plate,gear wheel and slip rings. With boom fully retracted, reset potentiometer by turning

counter-clockwise until it stops.Refer to Drawing 6, Length/Angle Transducer, Section 11 - Drawings.

Check mechanical adjustment of length potentiometer in cable reel. When main boom is fully retracted, adjustlength potentiometer counter-clockwise until it stops.


START

PROBLEM: Length reading incorrect. Crane is not in “out of load chart” condition.

Replace the gear wheel, clean potentiometeraxle. Reset length potentiometer.

Refer to Drawing 6, Length/Angle Transducer, Section 11.

Check power supply to length transducer on connection board, terminal X1, Pin 8 (ground) and Pin 11 (-5V)

Refer to Drawing 3, Terminal Board, Section 11 - Drawings.

Main board defective. Replace main board andreset pressure channel. Refer to Section 7.

NEXT PAGE

Correct?

Correct?

Correct?

No

No

Yes

No

Yes

Yes

Troubleshooting


41

6. LENGTH READING PROBLEM - continued

Measure signal from length transducer in cable reel at terminalbetween pin 2(signal) and pin 1(ground). Retract boom - 0Potentiometer turn = -0.5v 10 Potentiometer turn = -4.5v

Replace length potentiometer assembly. Remove slipring body from shaft andremove gear wheel from potentiometer axle. Unscrew mounting plate and remove

potentiometer assembly from mounting plate. Remove assembly wires formterminal block. Connect new assembly to terminal block. Reinstall mounting plate,gear wheel and slip rings. With boom fully retracted, reset potentiometer by turning

counter-clockwise until it stops.

Measure signal from length transducer in central unit connection board between X1-8 (ground) and X1-10(signal: -0.5 and -4.5v) Refer to Drawing 3, Terminal Board, Section 11 - Drawings.

Measure supply to length transducer in cable reel at terminal between Pin 1(ground) and Pin 3 (-5v)


Continued from previous page. PREVIOUS PAGE

Faulty wiring between central unit and lengthtransducer. Check wiring.Correct?

NEXT PAGE

Correct? No

Yes

No

Yes

Faulty wiring between central unit andlength transducer. Check wiring.Correct? No

Yes



42

6. LENGTH READING PROBLEM - continued

Measure length signal of amplified output on main board between test point MP15 andtest point MP6.

NOTE: Negative signal at terminal X1 Pin 15 will be converted into positive signal at MP6(i.e.: input at terminal X1 Pin 15 = -0.5V; output test between MP15 and MP6 = +0.5v).

Refer to Drawing 4, Main Board, Section 11 - Drawings.

Main board defective. Replace Main board. Resetpressure channel. Refer to Section 7.Correct?


PREVIOUS PAGE

END

No

Yes

Troubleshooting


43

7. LOAD READING PROBLEM

Measure radius and check with the displayed radius.

Check boom length reading on display.

Check selected operating mode (code on operating mode switch).

PROBLEM: Load reading incorrect. START

Select operating mode switch to correct position(see operating mode in load chart).

Reset length potentiometer. With fully retracted boom, turn potentiometeraxle counter-clockwise until it stops (see Section 3 and 6).


Check if mechanical adjustment of angle transducer is correct. Angle transducerbox should be in line with boom and adjusted to actual boom angle.


Check power supply to pressure transducer (rodside). Unplug transducer cable fromtransducer. Measure connection board between X1-14 to X1-13 (-5.0v) and X1-14 to

X1-15 (+5.0) for rod sideRefer to Drawing 3, Terminal Board, Section 11 - Drawings.

NEXT PAGE

Correct?

Correct?

Correct?

No

Yes

No

Yes

Correct? No

YES

Yes

Check power supply and measure between test point Mp 15 (ground) toMP18(+5.0v) and between test point Mp 15 (ground) to MP2(-5.0v) If incorrect,power supply on main board defective, replace main board and reset pressure

channels.Refer to Drawing 4, Main Board, Section 11 - Drawings.

No



44

7. LOAD READING PROBLEM - continued

Check power supply at transducer plugs.Measure between B (ground) and A = +5V.Measure between B (ground) and C = -5V.

Check power supply to pressure transducer (piston side). Unplug transducer cable from transducer.Measure connection board between X1-19 to X1-20 (-5.0v) and X1-19 to X1-18 (+5.0)

Refer to Drawing 3, Terminal Board, Section 11 - Drawings.

Pervious Page

Check power supply and measure between test point Mp 15 (ground) toMP18(+5.0v) and between test point Mp 15 (ground) to MP2(-5.0v) If incorrect,power supply on main board defective, replace main board and reset pressure

channels.Refer to Drawing 4, Main Board, Section 11 - Drawings.

Faulty wiring. Check wiring of pressure transducer cable.

NEXT PAGE

Correct? No

Correct? No

Yes

Yes

Yes

Correct?

Check transducer signals in central unit. Disconnect wire No. 4 of transducer cable fromterminal block X1, Pin 21 (signal piston side). Disconnect wire No 4 of transducer cable fromterminal block X1, Pin 16 (single rod side). Measure transducer signals (0. . .-V) between Pin

19 (ground) and wire No. 4 (piston and rod side transducer cable).Refer to Drawing 3, Terminal Board, Section 11 - Drawings.

Faulty wiring. Check wiring (pressure transducer cable).Transducer defective-replace transducer and reset pressure

channel.No

Troubleshooting


45

7. LOAD READING PROBLEM - continued

PREVIOUS PAGE

Check hydraulic input vs transducer outputs

Check hydraulic system.Correct? No

END

Yes

Reconnect wire No. 4 from transducer cables back to terminal X1, Pin 16 (rod side) and terminal X1,Pin 21 (piston side). Without pressure in pipes, check 0-point adjustment on main board by

disconnecting hydraulic pipes from transducer. Measure between test point MP15 (ground) and testpoint MP4. Signal should be 0.50V (piston side). Measure between test point MP15 (ground) and test

point MP5. Signal should be 0.50V (rod side).Refer to Drawing 4, “Main Board”, in Section 11 - Drawings.

Measure voltage between test point MP15 (ground) and test point MP4and reset with P4 to 0.50V (piston side). Measure voltage between testpoint MP15 (ground) and test point MP5 and reset with P5 to 0.50V (rod

side). If not adjustable, replace transducer.Refer to Drawing 4, “Main Board”, in Section 11 - Drawings.

Correct? No

Yes



46

8 BAD DATA TRANSFER BETWEEN CONSOLE & CENTRAL UNIT

PROBLEM: Error Code “E93/E94" No data transfer to and from console.

Make sure that Data EPROM is plugged into main board socket D5 and System EPROM isplugged into main board socket D4. Check that EPROM's are inserted with notch on EPROM to

matching notch on socket.Refer to Drawing 4, Main Board, Section 11- Drawings.

Place EPROM in correct socket.Correct?

START

No

Yes

Ensure that wires are properly connected between CU X1-31 and console pin 4 andbetween CU X1-32 and console pin 3.

Refer to Drawing 3, Terminal Board, Section 11 - Drawings.Refer to Drawing 5, Console Board, Section 11 - Drawings.

Check power supply to console between console terminal 2(ground) and terminal 1 (+12v)Refer to Drawing 5, Console Board, Section 11 - Drawings.

Faulty wiring in cable from central unit to console.Replace cable.

Defective electrical components on main board. Replacemain board and reset pressure channel. See Appendix A.

OrDefect in connection board. Replace connection board.

END

Correct?

Correct? No

Yes

No

Yes

Troubleshooting


47

8 BAD DATA TRANSFER BETWEEN CONSOLE & CU - continued

Ensure that wires are properly connected between CU X1-31 and console pin 4 andbetween CU X1-32 and console pin 3.

Refer to Drawing 3, Terminal Board, Section 11 - Drawings.Refer to Drawing 5, Console Board, Section 11 - Drawings.

Continued from previous page

Check power supply to console between console terminal 2(ground) and terminal 1 (+12v)Refer to Drawing 5, Console Board, Section 11 - Drawings.

Faulty wiring in cable from central unit to console.Replace cable.

Defective electrical components on main board. Replacemain board and reset pressure channel. See Appendix A.

OrDefect in connection board. Replace connection board.

END

Correct?

Correct?

PREVIOUS PAGE

No

Yes

No

Yes



48

9. INTERFERENCE PROBLEM

PROBLEM: Interference from craneelectric. Error Code “E93/E94"

intermittent. Frozen console displays.

Find out which component of the crane electric is spiking out (e.g. dump valve, outrigger relay). Installa diode or resistor across terminals of spiking component. Diode type such as 1N4001 can be used

(watch + and - connection for diode).

END

Make correct shield connection.Refer to connection and wiring diagrams, Drawings 9A, B, C

Section 11 - Drawings.

Ensure that cable shields are connected correctly. Refer to connection andwiring diagrams, Drawings 9A, B, C Section 11 - Drawings.

Install ground line - single cable minimum of AWG14 (2.0mm ) betweenterminal X9/1 and central unit box mounting bracket.

Refer to Drawing 4, “Main Board”, in Section 11 - Drawings.

Check if additional ground link between mainboard terminal X9 and central unit box mounting bracket is in place.

Refer to Drawing 4, “Main Board”, in Section 11 -Drawings.

Replace or repair part which is defective.

Check system out; refer to Section 8 - Bad DataTransfer Between Console & Central Unit.

START

Correct?

Correct?

No

Yes

No

Yes

NoCorrect?

Yes

Troubleshooting


49

10. LIGHTBAR MALFUNCTION

PROBLEM Lightbar is Malfunctioning START

Either LMI is not operational (not switched on) or defectivecomponent on console board. Check if LMI is powered andoperational. If not corrected replace console terminal board.

Remove console face from the enclosure carefully and connect the voltmeter with the (+)positive probe to terminal X 8/1 and with (-) negative problem to terminal X 8/2. The indicated

voltage shall equal the crane voltage (e.g. 12V or 24 V).

CONSOLE Check crane electric fuse andwiring from crane electric supply. Refer toCrane Manufacturer’s Service Document.

Connect a voltmeter with (+) probe to console terminal X 7/1 andwith (-) probe to X7/2. The indicated voltage shall equal crane

voltage (e.g. 12 V or 24V).

Switch power off. Disconnect lightbar connector and measurecrane voltage between connector terminal A and B.

Wiring Defective or wiring is incorrect between terminal strip X7and lightbar connector. Check wiring or rewire connections.

Inspect and clean connector contacts.

Wiring Defective or wiring is incorrect betweenterminal strip X7 and lightbar connector. Check wiringor rewire connections. Inspect and clean connector

contacts.

Correct?

Continued on nextpage

Correct?

Correct? NO

YES

No

YES

No

Yes



50

10. LIGHTBAR MALFUNCTION - continued

Measure voltage on console terminal X 7/3 and X 7/4. Voltage will increase with increasingload moment and decrease with decreasing load moment.

NOTE: voltage varies in relation to beam position; therefore, a voltage value cannot be given.Ensure crane power is switched on.

Previous Page

Defect in lightbar electronic. Contact factory service department for repair.

Defective electronic components on console terminalboard. Replace console terminal board.

Measure voltage on lightbar connector betweenC and D. Voltage should vary in relation to load

moment as described previously.

Defect in wiring or incorrect wiring betweenconsole terminal X7 and lightbar connector.

Correct wiring.Correct?

Correct? No

YES

No

YES

Error Code


51

6. ERROR CODE DISPLAY PROBLEM: Error code displayed. Lever lockout activated. Warning lights on. ERROR CODE

ERROR CAUSE ACTION

E01 Minimum radius or maximum angle range exceeded

Fallen below the minimum radius or above the angle given in the load chart due to raising the boom to far.

Lower boom back to a radius or angle given in the load chart.

E02 Maximum radius or minimum angle range exceeded

The maximum radius or minimum angle given in the load chart was exceeded due to lowering the boom too far.

Raise boom back to a radius or angle given in the load chart.

E03 Prohibited slewing range (no load area)

Slewing range prohibited with load.

Slew back into admissible range.

E04 Operating mode not available

Operating mode switch in the console set incorrectly. Operating mode is not permissible with actual crane configuration.

Set operating mode switch correctly to the code assigned to the operating mode of the crane.

E05 Length range not permitted

Boom has been extended too far or not far enough. Length sensor adjustment changed; i.e. length sensor cable slid off the cable drum.

Retract or extend boom to correct length given in the load chart.

E06 Fallen below angle range with luffing jib operation.

Fallen below the minimum jib angle specified n the respective load chart due to luffing out the jib too far.

Luff in the jib to a radius or angle specified in the load chart.

E07 No acknowledgment signal from overload relay (K1).

Overload relay is stuck, defective or not being selected.

Replace relay.

E08 No acknowledgment signal from Anti-Two-Block switch relay (K2).

Anti-Two-Block switch relay is defective or not being selected.

Replace relay.

E11 Fallen below limit for the measuring channel “length”.

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.)Check cable and connector as well and replace, if necessary. Section 6. b.)Replace and reset length sensor Potentiometer. See Section 6. c.)Replace main board and reset pressure channels.



52

ERROR CODE

ERROR CAUSE ACTION

E12 Fallen below lower limit value for the measuring channel “pressure transducer piston side”.

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.)Check cable and connector as well and replace, if necessary. b.)Replace pressure transducer and reset pressure channel.. c.)Replace main board and reset pressure channels.

E13 Fallen below lower limit value for the measuring channel “pressure transducer rod side”.

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.)Check cable and connectors as well and replace, if necessary. b.)Replace pressure transducer and reset pressure channel. c.)Replace main board and reset pressure channels..

E14 Fallen below lower limit value for the measuring channel “force”.

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.)Check cable and connectors as well and replace, if necessary. b.)Replace force transducer. c.)Replace main board and reset pressure channels. .

E15 Fallen below lower limit value for the measuring channel “angle main boom”.

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.

a.)Check cable. Replace if necessary. See Section 6 b.)Replace angle sensor and reset adjustment. c.)Replace main board and reset pressure channels. .

E16 Fallen below lower limit value for measuring channel “Luffing Jib Angle”.

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).Check cable as well as plug, replace if need be. b.)Replace angle sensor. c.)Replace Main board and reset pressure channels.

Error Code


53

ERROR CODE

ERROR CAUSE ACTION

E17 Fallen below lower limit value for the measuring channel 7.

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.

a.)Check cable as well as connectors and replace, if necessary. b.)Replace sensor of channel 7 and reset adjustment. c.)Replace main board and reset pressure channels.

E19 Error in the reference voltage.

Electronic component on the main board defective.

Replace main board and reset pressure channels.

E20 No analog voltages a.)The crane supply voltage is too low. b.)The voltage converter is defective or short circuit in the wiring.

a.)Check crane voltage. b.)Check supply voltages.

E21 Upper limiting value for the measuring channel “length” exceeded.

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.

a.)Check cable. Replace if necessary. See Section 6. b.)Replace and reset length potentiometer. c.)Replace main board and reset pressure channels.

E22 Upper limiting value for the measuring channel “pressure piston side” exceeded.

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.)Check cable as well as plug. Replace if necessary. b.)Replace pressure transducer and reset pressure channels. c.)Replace main board and reset pressure channels.

E23 Upper limit value for the measuring channel “pressure transducer rod side” exceeded.

a.) Cable from the central unit to press trans defective, not connected or water in the connectors. b.) Pressure transducer on rod side defective. c.) Electronic component in the measuring channel defective.

a.) Check cable and connectors as well and replace, if necessary. b.) Replace pressure transducer c.) Replace main board and reset pressure channels.



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ERROR CODE

ERROR CAUSE ACTION

E24 Upper limit value for the measuring channel “force” exceeded.

a.) Cable leading from the central unit to the force transducer defective, not connected or water in the connectors. b.) Force transducer defective. c.) Electric component in the measuring channel defective.

a.) Check cable and connectors as well and replace, if necessary. b.) Replace force transducer. c.) Replace main board and reset pressure channels.

E25 Upper limit value for the measuring channel “angle main boom” exceeded.

a.) Cable leading from the central unit to the length/angle sensor defective, loose or water I the connectors. b.) Angle sensor defective c.) Electronic component in the measuring channel defective.

a.) Check cable as well as connectors and replace, if necessary. Section No. 6. b.) Replace angle sensor and reset adjustment. c.) Replace main board and reset pressure channels.

E26 Upper limit value for the measuring channel “Luffing Jib Angle” exceeded.

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 in the measuring channel defective.

a.) Check cable as well as connectors and replace, if necessary. b.) Replace jib angle sensor and reset adjustment. c.) Replace main board and reset pressure channels.

E27 Upper limit value for the measuring channel 7 exceeded.

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.

a.) Check cable as well as connectors and replace, if necessary. b.) Replace sensor of channel 7 and reset adjustment. c.) Replace main board and reset pressure channels.

E29 Reference voltage defective.

a.) The total of the supply and the reference voltages on MP10 is more than 3.3V b.) A/D converter defective.

a.) Check supply voltages. b.) Replace main board and reset pressure channels.

Error Code


55

ERROR CODE

ERROR CAUSE ACTION

E31 Error in the system program.

a.) EPROM with system program defective. b.) Electronic component on the main board defective.

a.) Replace system program EPROM b.) Replace main board and reset pressure channels.

E37 Error in the program run a.) EPROM with system program defective. b.) Electronic component on the main board defective.

a.) Replace system program EPROM. b.) Replace main board and reset pressure channels. .

E38 Wrong system program in the LMI.

The system program in the LMI does not correspond to the programming in the data EPROM

Replace system program EPROM

E 41 Error in the external RAM.

Replace main board and reset pressure channels. Section7

E 42 Error in the external write/read memory (RAM).

Internal defect in digital part of CPU.

Exchange write/read memory (CMOS-RAM). Replace main board and reset pressure channels. See Section 7.

E 45 Error in internal communications.

Defective electronic component.

Replace main board and reset pressure channels. Section 7.

E 48 Malfunction in the monitored write/read memory.

Internal defect in digital part of CPU

Replace main board and reset pressure channels.

E 51 Error in data memory. Data EPROM on the main board defective.

Replace Data EPROM. Make sure BR3 on the main board is installed.

E71 Incorrect acknowledgment of the 1. Relay on the terminal board A101.

a.) Anti Two-block relay is stuck or defective. b.) Anti Two-Block relay is not being selected due to a break on the terminal board A101, main board or ribbon cables.

a.) Replace 1. relay. b.) Check terminal board A101, main board and ribbon cables as well as replace defective part, if necessary.

E72 - E77

Analogous to E71 for the relays 2...7.

Analogous to E71 for the relays 2...7.

Analogous to E71 for the relays 2..7.



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ERROR CODE

ERROR CAUSE ACTION

E89 Change of the operating code during lifting a load.

The operating mode switch in the console was used during lifting a load.

Lower the load and set the operating mode switch correctly to the code assigned to the actual operating mode of the crane.

E 91 No data transmission from console to central unit. (See Section 8 and 9)

a.)This causes no display. b.)Interruption or accidental ground in the line from console electronics to central unit. c.)Transmitter/receiver module defective.

a.)Check the connection between console electronics and central unit. b.)If you find an accidental ground, the transmitter module in the console electronics can be damaged. You should, therefore, replace the console electronics. Replace console electronics or main board respectively.

E92 Error in the data transmission from console to central unit. (See also Section 8 and 9)

a.) Temporary interruption of the data line from console electronics to central unit. b.) Transmitter/receiver module defective.

a.) Check the connection between console electronics and central unit.

E93 Error in the data transmission from central unit to console. (See also Section 8 and 9)

a.) Temporary interruption of the data line from console electronics to central unit. b.) Transmitter/receiver module defective.

a.) Check the connection between console electronics and central unit. b.) Replace console electronics or main board respectively.

Error Code


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ERROR CODE

ERROR CAUSE ACTION

E94 No data transmission from central unit to console.

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)

a.) Check the connection between console electronics and central unit. If you find an accidental ground, the transmitter module in the console electronics can be damaged. Replace the console electronics. b.) Replace console electronics or main board respectively. c.)Check data EPROM. d.) Replace main board. e.) Eliminate interference source by inverse diodes or varistors.

E95 Error in the crane data EPROM

a.) Data EPROM defective b.) Position of jumper for the selection of the type of EPROM is wrong c.) Electronics component on the main board defective.

a.) Replace data EPROM b.) Check the jumper position c.) Replace main board and reset pressure channels.

E96 Error in the internal RAM of the CPU of the console

CPU or main board of the console defective

Replace console main board & Appendix A.

E97 Error in the external RAM of the CPU of the console

a.) External RAM of the console defective b.) Electronic component on the main board defective.

a.) Replace console main board b.) Replace console main board

E98 Wrong jumper position in the console

a.) The jumper position BR 9/BR 10 in the console does not correspond to the actual type of central unit. b.) Electronic component on the main board defective.

a.) Check the jumper position b.) Replace console main board.



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REFERENCE GUIDE 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

Error Code

Channel

Pin ‘ground’

Pin ‘supply’

Nominal Voltage (VDC)

E11/21 1 Length 8 11 -5 E12/22 2 Pressure Piston side 19 20 -5 19 18 +5 E13/23 3 Pressure Rod side 14 15 -5 14 13 +5 E14/24 4 Force 27 26 +18 E15/25 5 Angle Main boom 8 11 -5 E16/26 6 Angle Jib 23 25 -5 E17/27 7

Signal Voltage Terminal Board

Terminal X1 Amplified Signal on main board

Error Code

Channel

Pin

‘ground’

Pin

‘supply’

Voltage (VDC)

use MP15 - GND and MP supply voltage 0.5...4.5V

E11/21 1 Length 8 10 -0.5...-4.5 MP6 E12/22 2 Pressure Piston side 8 21 0...-1 MP4 E13/23 3 Pressure Rod side 8 16 0...-1 MP5 E14/24 4 Force 29 28 0...-1 MP3 E15/25 5 Angle Main boom 8 9 -1.875...-3.125 MP8 E16/26 6 Angle Jib 8 24 -1.875...-3.125 MP9 E17/27 7 8 7 -0.5...-4.5 MP7

SkyAzúl, Inc. 200 W. Main Street, Suite, 2A Middletown, MD 21769Phone 301-371-6126 Fax 301-371-0029 [email protected]

DS350GW Service - SkyAzul

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