Manitowoc Boom Trucks

PAT LMI MANUAL - DS150

•Troubleshooting Handbook
For Truck Mounted Cranes

Manitowoc Boom Trucks, Inc.

3000 S. Austin Ave
Georgetown, TX 78627-1609
Sales: (512) 942-3000
Sales Fax: (512) 863-3776
Service: (512) 942-3000
Service Fax: (512) 942-3094
Web Site: www.manitowocbt.com

7600004-003A A Company October 2001

 FORWARD
The purpose of this manual is to provide the customer with the operating procedures essential
for the promotion of safe and proper machine operation for its intended purpose. It is impor-
tant to over-stress proper usage. All information in this manual should be READ and UNDER-
STOOD before any attempt is made to operate the machine.

SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICA-

TION AND OPERATION, CONFORMANCE WITH GOOD SAFETY PRACTICE IN THIS
AREA IS THE RESPONSIBILITY OF THE USER AND HIS OPERATING PERSONNEL.

ALL PROCEDURES HEREIN ARE BASED ON THE USE OF THE MACHINE UNDER
PROPER OPERATING CONDITIONS, WITH NO DEVIATIONS FROM THE ORIGINAL
DESIGN. ALTERATION AND/OR MODIFICATION OF THE MACHINE IS STRICTLY FOR-
BIDDEN WITHOUT WRITTEN APPROVAL FROM MANITOWOC BOOM TRUCKS, INC.

REMEMBER, EQUIPMENT IS ONLY AS SAFE AS THOSE WHO OPERATE IT!

A Company
 www.patamerica.co
PAT America, Inc.

LOAD MOMENT INDICATOR

DS150

SERVICE MANUAL
P/N 031-300-100-753 REV A 10/16/2001
 Service Manual DS150

NOTICE

PAT America, Inc. makes no warranty of any kind with regard to this material, including, but not limited
to, the implied warranties of merchantability and/or its fitness for a particular purpose.

PAT America, Inc. will not be liable for errors contained in this manual or for incidental or
consequential damages in connection with the furnishing, performance, or use of this manual. 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 PAT America, Inc.

PAT America, Inc. 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 PAT America, Inc. The drawings and/or photos are subject to technical modification
without prior notice.

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

MANUAL REVISIONS

REV DATE NAME DESCRIPTION

A 10/16/01 CSH ECN 01-283

©2001 PAT America, Chambersburg, PA 17201, USA

©PAT REV. A 10/16/01 100753_A.doc

 Service Manual DS150

TABLE OF CONTENTS

1 MECHANICAL DESCRIPTION OF THE SYSTEM COMPONENTS ..............................................1

2 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UNIT .............................2

2.1 BASIC SYSTEM COMPONENT LAYOUT..........................................................................................3
2.2 BASIC ADJUSTMENT OF THE COMPONENTS ................................................................................4
3 DEFINITIONS ................................................................................................................................5

4 DRAWINGS ...................................................................................................................................6
4.1 SYSTEM ELECTRICAL DIAGRAM ................................................................................................6
4.2 CENTRAL UNIT 024-150-060-002 SPARE PARTS LIST .................................................................7
4.3 CONSOLE 050-150-060-006 SPARE PARTS LIST .........................................................................9
4.4 CONSOLE 050-150-060-008 SPARE PARTS LIST .......................................................................11
4.5 CABLE REEL 068-208-060-013 LWG208 SPARE PARTS LIST ....................................................13
4.6 CENTRAL UNIT BOARD LAYOUT AND MEASURING POINTS 024-150-300-001 ..............................15
5 PROCEDURE ..............................................................................................................................16
5.1 EPROM REPLACEMENT IN CENTRAL UNIT ................................................................................16
5.2 PISTON & ROD PRESSURE CHANNEL ZERO POINT ADJUSTMENT ................................................16
5.3 LENGTH & ANGLE ADJUSTMENTS .............................................................................................17
5.4 MAIN BOARD REPLACEMENT ....................................................................................................18
6 THEORY ......................................................................................................................................19
6.1 ANTI-TWO BLOCK & SHUTOFF CIRCUIT .....................................................................................19
6.2 LENGTH MEASURING CHANNEL ................................................................................................19
6.3 PISTON SIDE PRESSURE MEASURING CHANNEL ........................................................................20
6.4 ROD SIDE PRESSURE MEASURING CHANNEL .............................................................................20
6.5 MAIN BOOM ANGLE MEASURING CHANNEL ................................................................................21
6.6 SECOND ANGLE MEASURING CHANNEL .....................................................................................21
7 TROUBLESHOOTING FLOW CHARTS ......................................................................................22
7.1 GENERAL FLOWCHART .............................................................................................................22
7.2 LEVER LOCKOUT ACTIVATED ....................................................................................................23
7.3 BROKEN LENGTH CABLE ..........................................................................................................24
7.4 NO DISPLAY ............................................................................................................................25
7.5 ANTI TWO BLOCK PROBLEM .....................................................................................................27
7.6 LENGTH READING PROBLEM.....................................................................................................30
7.7 LOAD READING PROBLEM ........................................................................................................33
7.8 BAD DATA TRANSFER BETWEEN CONSOLE & CENTRAL UNIT .....................................................36
7.9 INTERFERENCE PROBLEM ........................................................................................................38
7.10 ANGLE PROBLEM .....................................................................................................................39
8 ERROR CODE TABLE ................................................................................................................40

ADDENDUM A BASIC ADJUSTMENT AND VOLTAGE CHECKS....................................................46

ADDENDUM B REFERENCE TABLES FOR MEASURING SUPPLY AND SIGNAL VOLTAGES FOR
SENSOR CHANNELS........................................................................................................................47

©PAT REV. A 10/16/01 100753_A.doc

 Mechanical Description Of The System 1

1 MECHANICAL DESCRIPTION OF THE SYSTEM COMPONENTS

Pressure Transducer: The pressure transducer transforms hydraulic pressure into an electric analog
voltage signal. Two pressure transducers are connected, one to the rod side and one to the piston
side of the lift cylinder. 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)

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 angle of the boom.

A reeling drum drives a potentiometer, which is the length transducer. Part of the length transducer 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 reel. The angle transducer is
fitted into 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

Anti-Two-Block Switch: The anti-two-block switch monitors the load block and its 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 lockout 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. The weight at the anti-two-block switch keeps the switch closed until the
hook block strikes it.

Console: The console displays the 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 and 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-two block condition.

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 obtaining this information from the crane, micro switches are
installed in the electrical swivel that tells the system the exact location of the boom. Micro switches
are also located on the counterweight which tells the system if the counterweight is installed or not,
where applicable.

©PAT REV. A 10/16/01 100753_A.doc

 2 Service Manual DS150

2 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UNIT

All the data of the crane is stored inside the central unit in EPROM’s. The central unit receives all
actual information of the crane. This is computed against the reference data and the crane status is
continuously monitored.

Description of the Housing: The central unit DS150 is a rugged, waterproof sheet steel housing. It is
mounted on the left side of the turn table weldment or on the counterweight. The cables are led into
the central unit via strain reliefs and connected with fast-ons. An override switch is mounted on the
housing, which overrides 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, mounted on the
lower mid.

Description of the Boards: Inside the central unit (CU) there is a main board. The main board and
CPU is the heart of the system, and it contains the processor and the system and data EPROMs. The
system EPROM holds the operating system and data EPROM hold the crane and calibration
information. The 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 sensors to the processor.
Main board components:
Power supply: Provides all the necessary voltages for the transducers and the electronics on the main
board.
Analog input part: Receives and prepares all the signals from the transducers for further processing.
Relays, an overload and anti-two-block relay: Controls the Bosch relay for lever lockout.

Incoming Signals: Signals from the transducers are connected to the main board. The signals vary
depending on the sensor:
Angle transducer signal is between -1.875V and -3.125V.
Length transducer signal is between -0.500V and -4.500V.
Pressure transducer signals are between 0.00V and -1.00V. (measured between the negative and
positive outputs)
Anti-two-block switch resistance is 4.7Kohms.
Digital inputs for the duty selection switches are on or off.

Outgoing Signal: The outgoing signal of the main board is the signal for lever lockout of connection
#48. In normal working conditions there are 12 volts at this connection. If there is an overload or anti-
two-block condition the signal becomes 0 volts. Furthermore, all voltages for the transducers are going
out through the main board.

©PAT REV. A 10/16/01 100753_A.doc

 Mechanical Description Of The System 3

2.1 Basic System Component Layout

©PAT REV. A 10/16/01 100753_A.doc

 4 Service Manual DS150

2.2 Basic Adjustment Of The Components

Length: Ensure that the length cable tension is correct with fully retracted boom and no tension on the
cable reel. Turn the cable drum 5 to 8 turns counter clockwise. Then remove cover from cable reel
and adjust the potentiometer counter clockwise to end stop. See Procedure 3.

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, 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 transducers.
Measure and record the zero-points of both pressure transducers on the main board. Adjust P1 and
P2 on the main board to 500mV at test points MP11 and MP12. Connect hydraulic hoses back to the
pressure transducers. See Procedure 2.

Duty Selection Switches Digital Inputs): Check the duty selection switches for correct operation.
Check the voltage on digital input connections.

Check the function of the hoist limit switch (anti-two-block)

Check function of lever lockout.

Measure and record the power supply voltages. See Addendum A.

©PAT REV. A 10/16/01 100753_A.doc

 Definitions 5

3 DEFINITIONS

BOOM LENGTH: The straight line through the centerline of boom pivot pin to the centerline of the
boom point load hoist sheave pin, measured along the longitudinal axis of the boom. (Indicator ± 2%)

BOOM ANGLE: The angle between the longitudinal centerline of the boom base section and the
horizontal plane. (Indicator 65° to 90° boom angle + 0°/2°; less than 65° boom angle + 0°/-3°)

RADIUS OF LOAD The horizontal distance from a vertical projection of the crane’s axis of rotation to
the supporting surface, before loading, to the center of the vertical hoist line or tackle with rated load
applied. (Indicator 100% to 110%)

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.

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%)

CRANE CONFIGURATION The physical arrangement of the crane which is prepared for a particular
operation in conformance with the manufacturer’s operating instructions and load rating chart.

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

ANALOG: Electrical signals that vary in proportion to the quantities they represent. (Boom length,
angle, and pressure transducer)

DIGITAL: Electrical signals of an on-and-off state (two different voltage levels) to represent some
quantity of operation. (A2B, area definition switch)

©PAT REV. A 10/16/01 100753_A.doc

 6 Service Manual DS150

4 DRAWINGS
4.1 SYSTEM Electrical Diagram

©PAT REV. A 10/16/01 100753_A.doc

 Drawings 7

4.2 Central Unit 024-150-060-002 Spare Parts List

©PAT REV. A 10/16/01 100753_A.doc

 8 Service Manual DS150

PART NO. 024-150-060-002 CENTRAL UNIT, DS150/0002 STANDARD PARTS LIST

NO. PART NO. QTY DESCRIPTION

01 024-150-300-001 1 BOARD, MAIN, DS150, CU, 12V
02 024-350-100-135 1 CENTRAL UNIT ACCY, SCREW SET, DS150
03 024-000-100-041 1 CENTRAL UNIT ACCY, GROUNDING KIT FOR COVER
04 024-350-100-139 1 CENTRAL UNIT ACCY, WALL MOUNT SET, DS150/350
05 024-150-100-001 1 HOUSING, CENTRAL UNIT, DS150
06 024-350-100-661 1 KEYSWITCH, CENTRAL UNIT, NEW STATIONARY
07 031-300-101-131 1 KEY ASSY, ONE OLD STYLE KEY/ONE NEW STYLE KEY
08 024-350-110-067 2 STRAIN RELIEF ASSY, PG 11, GRN W/NUT+WASHER
09 000-314-022-006 2 FUSE 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)
13 024-350-110-066 1 CENTRAL UNIT ACCY, GASKET, FOR C.U. COVER
14 021-441-161-213 1 STRAIN RELIEF, PG 13.5,12-15mm GRY/WHT INSERT
15 050-350-110-116 1 STRAIN RELIEF ASSY, PG 13.5 RED, W/NUT+WASHER
16 000-214-340-011 4 STRAIN RELIEF ACCY, PG11 HOLE PLUG
17 000-214-210-011 4 NUT, PG11
18 000-214-340-013 1 STRAIN RELIEF ACCY, PG13.5 HOLE PLUG
19 000-214-210-013 1 NUT, PG13.5
20 000-214-340-016 1 STRAIN RELIEF ACCY, PG16 HOLE PLUG
21 000-214-210-016 1 NUT, PG16
22 024-150-100-002 1 CENTRAL UNIT ACCY, BASEPLATE, DS150
23 031-300-100-078 1 CHEMICAL, MOISTURE PACK
24 024-150-110-002 1 COVER, CENTRAL UNIT, DS150

©PAT REV. A 10/16/01 100753_A.doc

 Drawings 9

4.3 Console 050-150-060-006 Spare Parts List

To change DS150/0006 (12V) to DS150/0036 (24V) a jumer wire must be soldered on main board, J3
added, and the ligth bulbs changed. When ordering spare part please specify 12 or 24 volt machine.

©PAT REV. A 10/16/01 100753_A.doc

 10 Service Manual DS150

NO. PART NO. QTY DESCRIPTION

01 050-150-300-003 1 CONSOLE BOARD W/ROTARY SWITCH - DS150
02 050-350-110-292 1 LCD DISPLAY DS150
03 050-000-100-060 1 CONSOLE HOUSING W/LID
04 050-350-110-116 1 STRAIN RELIEF/LONG RED
05 000-305-045-141 2 LUMINOUS HOUSING
06 003-051-405-423 5 LUMINOUS PUSH BUTTON HOUSING
07 000-311-023-114 7 LIGHT BULB 12V
07 000-311-023-128 7 LAMP, SPARE LIGHT BULB 28V
08 050-350-110-277 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 ANGLE (ORANGE)
14 050-350-110-283 1 CAP ENTER (GREEN)
15 003-051-903-364 1 KEY SWITCH
16 050-350-110-139 1 CONSOLE OVERRIDE KEY DS150/350
17 050-000-110-007 1 ALARM BUZZER
18 050-150-100-006 1 FRONT PANEL
19 000-209-022-095 850mm GASKET FOR FRONT PANEL
20 050-000-100-092 1 CONSOLE LID DS150/0006
21 050-150-110-005 1 GASKET FOR LID
22 050-000-110-014 3 LATCH ASSEMBLY
23 050-000-700-301 2 KNOB FOR ROTARY SWITCH
23 024-350-100-312 1 LABYRINTH MOISTURE ELEMENT

©PAT REV. A 10/16/01 100753_A.doc

 Drawings 11

4.4 Console 050-150-060-008 Spare Parts List

To change DS150/0008 (12V) to DS150/0012 (24V) a jumer wire must be soldered on main board, J3
added, and the ligth bulbs changed. When ordering spare part please specify 12 or 24 volt machine.

©PAT REV. A 10/16/01 100753_A.doc

 12 Service Manual DS150

NO. PART NO. QTY DESCRIPTION

01 050-150-300-003 1 BOARD, MAIN, DS150 CONSOLE 12V FOR 4x20mm DISPLAY
02 050-350-110-292 1 INDICATOR, DISPLAY, LCD, DS150 CONSOLE
03 050-000-100-048 1 HOUSING, DS150 CONSOLE, COMPLETE
04 050-150-110-001 1 BRACKET, CONSOLE, DS150 COMPLETE
05 050-350-110-183 2 KNOB, MOUNTING KNOB
06 050-350-110-116 1 STRAIN RELIEF ASSY, PG 13.5 RED/WHITE W/NUT+WASHER
07 000-312-043-141 2 LAMP ACCY, PILOT,BASIC HOUSING
08 003-051-403-423 5 SWITCH, PUSHBUTTON w/o LENS & BULB
09 000-311-023-114 7 LAMP, SPARE LIGHT BULB 12V
09 000-311-023-128 7 LAMP, SPARE LIGHT BULB 28V
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 ACCY, LENS CAP, ORANGE (LOAD)
14 050-350-110-077 1 SWITCH ACCY, LENS CAP, ORANGE (INFO)
15 050-350-110-078 1 SWITCH ACCY, LENS CAP, ORANGE (ANGLE)
16 050-350-110-079 1 SWITCH ACCY, LENS CAP, GREEN (ENTER)
17 003-051-903-364 1 KEYSWITCH W/KEYS, CONSOLE DS150
18 050-350-100-001 1 KEY, CONSOLE KEYSWITCH
19 050-150-110-002 1 SWITCH ACCY, KNOB WITH SCALE DISK 1-63
20 050-350-110-140 1 SWITCH ACCY, KNOB WITH SCALE DISK 1-16
21 050-350-110-049 1 ALARM, BUZZER, DS150 & DS350C CONSOLE
22 050-150-100-008 1 FACEPLATE, DS150 CONSOLE, LARGE DISPLAY (STD.)
23 050-000-050-309 1 GASKET, HOUSING
24 002-053-703-101 1 SCREW, 3mm x 10mm, PANHEAD, PHILLIPS FACEPLATE

©PAT REV. A 10/16/01 100753_A.doc

 Drawings 13

4.5 Cable Reel 068-208-060-013 LWG208 Spare Parts List

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 14 Service Manual DS150

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 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 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
19 000-208-020-006 10 WASHER, LOCK 6mm
20 021-441-131-013 1 STRAIN RELIEF, PG 13.5, 8-12mm RED+WHITE
21 000-214-030-703 1 STRAIN RELIEF, PG7 BLACK

©PAT REV. A 10/16/01 100753_A.doc

 Drawings 15

4.6 Central Unit Board Layout And Measuring Points 024-150-300-001

Measuring Points
MP1: AGND
MP2: +9V
MP3: -9V
MP4: 5V TTL
MP5: 5V REF
MP6: +5V/+UPS sensors supply
MP7: -5V/-UPS sensors supply
MP8: +9V HES
MP10: AGND
MP11: DAV1 piston pressure signal
MP12: DAV2 rod pressure signal
MP13: LW1 length signal
MP14: WG1 angle signal #1
MP15: WG2 angle signal #2
LED's
LOAD: Overload relay ON(energized/normal conditions)/OFF (de-energized)
A2B: A2B relay ON(energized/normal conditions)/OFF (de-energized)

©PAT REV. A 10/16/01 100753_A.doc

 16 Service Manual DS150

5 PROCEDURE
5.1 EPROM replacement in Central Unit
Follow this procedure when changing EPROM’s in the DS150 central units.

1. Remove cover, from central unit.

CAUTION: Before handling the EPROM, discharge any static electricity from your body by
touching a ground source. The EPROM could be damaged if this procedure is not followed.

Use the central unit main board layout and measuring point drawing to locate the system and data
EPROM’s.

2. Remove the old EPROM from the main board using an EPROM puller. Be careful not to bend the
legs of the EPROM when removing it.

3. Installing the new EPROM:

• Ensure the notch is in the correct direction. The direction of the EPROM is determined by the notch
on the end of the EPROM.
• The DATA and TLK EPROM’s fill the bottom of the socket as shown by the arrows.
• Place EPROM in the correct EPROM socket as shown.

4. Inspect gasket and install cover using the following procedures to prevent any moisture from
entering the central unit.

Reference material:
031-300-340-002 Central Unit Cover Installation and Tightening Procedure; Rev A.
031-300-340-003 Central Unit Gasket Recommendations; Rev -.

5.2 Piston & Rod Pressure Channel Zero Point Adjustment

Use the central unit main board layout and measuring point drawing to make the following
adjustments.

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 board
A) black (-) lead to mp10
B) red (+) lead to mp11
3. Adjust P1 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 board
A) BLACK (-) lead to MP10
B) RED (+) lead to MP12
6. Adjust P2 to obtain a reading of 0.500 volts (500mv) on meter.
7. Reconnect hydraulic hoses to pressure transducers, and then bleed the air from hydraulic lines.

©PAT REV. A 10/16/01 100753_A.doc

 Procedures 17

5.3 Length & Angle Adjustments

©PAT REV. A 10/16/01 100753_A.doc

 18 Service Manual DS150

5.4 Main Board Replacement

Refer to Drawing 1, central unit parts list for board location.

1. Turn system power off.
2. Remove the central unit lid.
NOTE: Take care not to damage the boards with the screwdriver, when removing and inserting
screws.
3. Remove the system and data software from the main board.
4. Remove the relay from the main board.
5. Mark all connection wires before removing, to identify location for reconnecting. Disconnect
all X1 terminal wires from the main.
6. Remove the 9 large Philips screws holding the main board in place.
7. Note the orientation of the main board in the central unit. Remove main board and place it in
the same packing material that the replacement in which the main board came.
8. Carefully insert the new main board in place.
9. Insert the 9 Philips mounting screws.
10. Insert the relay into the main board.
11. Insert the system and data software into the main board.
12. Connect the X1 terminal wires to the main board. Refer to Wiring Diagram.
13. Zero pressure transducers using the zeroing procedure in this section.
14. 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. A 10/16/01 100753_A.doc

 Theory 19

6 THEORY
6.1 Anti-Two Block & Shutoff Circuit

6.2 Length Measuring Channel

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 20 Service Manual DS150

6.3 Piston Side Pressure Measuring Channel

6.4 Rod Side Pressure Measuring Channel

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 Theory 21

6.5 Main Boom Angle Measuring Channel

6.6 Second Angle Measuring Channel

©PAT REV. A 10/16/01 100753_A.doc

 22 Service Manual DS150

7 TROUBLESHOOTING FLOW CHARTS

7.1 General Flowchart

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

What’s Wrong?

Lever Lockout Activated Go to Flow Chart 2

Broken Length Cable Go to Flow Chart 3

No display Go to Flow Chart 4

Anti-Two Block Problem Go to Flow Chart 5

Length Reading Problem Go to Flow Chart 6

Load Reading Problem Go to Flow Chart 7

Bad Data Transfer Between

Go to Flow Chart 8
Console & Central Unit

Interference Problem Go to Flow Chart 9

Angle Problem Go to Flow Chart 10

©PAT REV. A 10/16/01 100753_A.doc

 Troubleshooting Flow Charts 23

7.2 Lever Lockout Activated

PROBLEM: The lever lockout system of the crane is activated. Crane movements “hoist up”, “telescope
out”, and “boom down” are stopped. Crane is not in overload or two-block condition.

Start

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

Fixed YES

NO

Does console indicate Anti-Two-block warning?

NO Yes

If console display is If Load Moment Limit Light

Fault in crane electric blank fault is located in Fault in Anti-Two displays fault, it is located in
or hydraulic system. power supply, wiring or Block system. LMI, cables, wiring, fuses, or
fuses . console.

Check lever lockout Read error code displayed

Go to Flow Chart 4 Go to Flow Chart 5
system in crane. on console and go to
Section 6.

©PAT REV. A 10/16/01 100753_A.doc

 24 Service Manual DS150

7.3 Broken Length Cable

PROBLEM: Damaged or broken length cable.

Refer to cabel reel parts list and system wiring diagram.

Replace length cable using the following procedure:

1 Cut old cable at cable drum

2 Disconnect damaged length cable from junction box at the boom nose.
3 Open cable reel cover and disconnect wiring from connection block. 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 slip
ring connection.
6 On the backside 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 slip ring.
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.
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.

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 Troubleshooting Flow Charts 25

7.4 No Display

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

Start

Check fuses on CPU box.

Correct? No Replace fuses.

Yes

Measure crane voltage on connection board between X1-2 (+12V) and X1-4 (ground).
Refer to system wiring diagram.
NOTE: If crane voltage is measured below 10V system will switch off.

Check crane power supply for faulty

Correct? No
crane electric or if supply is too low.

Yes

Measure voltage on the connection board between X1:30 (+12/24V) and X1:33
(ground). This is an output voltage to the console.
Refer to system wiring diagram.

Replace connection board and reset pressure

Correct? No channel. Refer to system wiring diagram and
main board replacement procedure.

Yes

Next Page

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 26 Service Manual DS150

PREVIOUS PAGE

Measure voltage in the console between X1:1 (+12/24V) and X1:2 (ground).
Refer to system wiring diagram.

Check connections of the cable between

Correct? NO console and central unit. Replace cable if
necessary. Refer to system wiring diagram.

YES

Display is defective.
Refer to console parts list.

YES

END

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 Troubleshooting Flow Charts 27

7.5 Anti Two Block Problem

PROBLEM: Function of Anti-Two-Block System is faulty.

START

Check to see whether or not crane is in two-block condition.

Correct? No Lower hook down into safe position

Yes

Check if jumper/dummy plug in receptacle at boom nose is plugged in.

Refer to system wiring diagram.

Correct? No Plug appropriate plug into socket of junction box.

Yes
Turn power off or disconnect wire from connection board X1:35 in central unit. Remove
bypass plug and check function of Anti-Two Block switches with
ohmmeter between wires 2 and 3 of switches or between terminals 1 and 6 at boom nose
box. This checks the function of the Anti-Two Block switch. Install bypass plug.
Switch closed = 0 Ohm (weight installed)
Switch open => 1 Megaohm (weight removed)
Refer to system wiring diagram.

Correct? No Replace Anti-Two-Block switch.

Yes

Next Page

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 28 Service Manual DS150

PREVIOUS PAGE

Measure the A2B signal in the cable reel between X1:Brown and X2:Red
wires on the slip ring with an ohmmeter.
Switch closed =4700 ±500Ohms
Switch open => 1 Megaohm
Reconnected slip ring wires.
Refer to system wiring diagram.

Fault in wiring between boom nose box and cable reel. Check
for damaged length cable and wiring.
Correct? No
Refer to system wiring diagram.
If broken length 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.
Refer to system wiring diagram.

Replace slip ring

Correct? No
Refer to cable reel parts list.

Measure the A2B signal in the boom base 10 pin receptacle between terminal 5 and 6
with an ohmmeter.
Switch closed =4700 ±500Ohms
Switch open => 1 Megaohm
Reconnected slip ring wires.
Refer to system wiring diagram.

Fault in 7 conductor cable between cable reel and

Correct? No boom base box.
Refer to system wiring diagram.

NEXT PAGE

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 Troubleshooting Flow Charts 29

PREVIOUS PAGE

Connect wire #5 back to the terminal X1:35 on the connection board.

Refer to system wiring diagram.

Turn system power off. Check Anti-Two-Block signal in central unit with ohmmeter
measure between X1:34 and X1:35.
Anti-Two-Block switch closed = 4700 Ohms ±50 0Ohms
Anti-Two-Block switch open => 1 Megaohm.
Refer to system wiring diagram.

Faulty wiring between cable reel and central unit.

Correct? NO
Check cable.

YES

Disconnect X1:34 and X1:35. Check main board function by installing a temporary
resistor, 4700 Ohms between X1-34 and X1-35 in central unit. With resistor connected
alarm should be inactive.
Refer to system wiring diagram.

Replace main board and reset pressure channel.

Correct? NO
Refer to main board replacement procedure .

Reconnect Wire #6 to X1:34 and Wire #5 to X1:35

Refer to system wiring diagram.

End

©PAT REV. A 10/16/01 100753_A.doc

 30 Service Manual DS150

7.6 Length Reading Problem

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

START

Check mechanical adjustment of length potentiometer in cable reel. When main boom is fully retracted,
adjust length potentiometer counter-clockwise until it stops.
Refer to length/angle adjustments procedure.

Replace length potentiometer assembly. Remove slip ring body from shaft and
remove gear wheel from potentiometer axle. Unscrew mounting plate and
remove potentiometer assembly from mounting plate. Remove assembly wires
Correct? 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 stops.
Refer to Cable Reel Parts List.

Yes

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

Replace the gear wheel, clean potentiometer

Correct? No axle. Reset length potentiometer.
Refer to length/angle adjustments procedure.
Yes

Check power supply to length transducer on connection board,

terminal X1:8 (ground) and X1:11 (-5V)
Refer to system wiring diagram.

Replace connection board and reset pressure

Correct? No channel. Refer to system wiring diagram and main
board replacement procedure.

Yes

NEXT PAGE

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 Troubleshooting Flow Charts 31

Continued from previous page. PREVIOUS PAGE

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

Faulty wiring between central unit and

Correct? No
length transducer. Check wiring.

Yes

Measure signal from length transducer in cable reel at terminal

between pin 2(signal) and pin 1(ground). Retract boom - 0
Potentiometer turn = -0.5v 10 Potentiometer turn = -4.5v

Replace length potentiometer assembly. Remove slipring body from shaft and
remove gear wheel from potentiometer axle. Unscrew mounting plate and
remove potentiometer assembly from mounting plate. Remove assembly wires
Correct? 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 stops.

Yes

Measure signal from length transducer in central unit main board between X1:8 (ground) and X1:10
(signal: -0.5 and -4.5v) Refer to system wiring diagram.

Faulty wiring between central unit and length

Correct? No
transducer. Check wiring.

Yes

NEXT PAGE

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 32 Service Manual DS150

Continued from previous page.

PREVIOUS PAGE

Measure length signal of amplified output on connection board between test

point MP10 and test point MP13. (+5V)
NOTE: Negative signal at terminal X1:11 will be converted into positive signal
at MP13 (i.e.: input at terminal X1:11 = -0.5V and gnd).
Refer to system wiring diagram.

Replace connection board and reset pressure channel.

Correct? No Refer to system wiring diagram and main board
replacement Procedure.

Yes

END

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 Troubleshooting Flow Charts 33

7.7 Load Reading Problem

PROBLEM: Load reading incorrect.

START

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

Select operating mode switch to correct position

Correct? No
(see operating mode in load chart).

Yes

Check boom length reading on display.

Reset length potentiometer. With fully retracted boom, turn potentiometer

Correct? No axle counter-clockwise until it stops (see Section 3 and 6).
Refer to length & angle adjustments procedure.

Yes

Measure radius and check with the displayed radius.

Check mechanical adjustment of angle transducer is correct. Angle transducer

box should be in line with boom and adjusted to actual boom angle should
Correct? No
match displayed boom angle.
Refer to length & angle adjustments procedure.

YES

Check power supply to pressure transducer (rodside). Unplug transducer cable from transducer.
Measure connection board between X1:14 to X1:13 (-5.0v) and X1:14 to X1:15 (+5.0) for rod side

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 system wiring diagram.

NEXT PAGE

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 34 Service Manual DS150

Pervious Page

Check power supply and measure between test point MP10 (ground) to
Correct? No MP7(+5.0v) and between test point MP10 (ground) to MP6(-5.0v)
Refer to main board layout.

Yes Correct?

Check power supply and measure between test point MP10 (ground) to
MP2(+9.0v) and between test point MP10 (ground) to MP3(-9.0v)
Refer to main board layout.
Yes

Yes Correct?

Power supply on connection board faulty. Replace connection board and reset
pressure channel. Refer to system wiring diagram and main board
replacement procedure.

Check power supply at transducer plugs.

Measure between B (ground) and A = +5V.
Measure between B (ground) and C = -5V.

Correct? No Faulty wiring. Check wiring of pressure transducer cable.

Yes

NEXT PAGE

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 Troubleshooting Flow Charts 35

PREVIOUS PAGE

Check transducer signals in central unit. Connect pressure transducers to cable.

Disconnect wire No. 4 of transducer cable from X1:21 (signal piston side).
Measure transducer signals (0. . .-1V) between Pin 19 (ground) and wire No. 4 of piston cable.
Disconnect wire No 4 of transducer cable from terminal block X1: Pin 16 (single rod side).
Measure transducer signals (0. . .-1V) between Pin 19 (ground) and wire No. 4 of rod cable.
Refer to system wiring diagram.

Correct? No Check wiring in pressure transducer cable. Continuity Good?

No Correct?

Yes

Transducer defective-replace transducer 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 from transducer, check 0-point
adjustment on connection board.
Measure between test point MP10 (ground) and test point MP11. Signal should be 0.50V (piston side).
Measure between test point MP10 (ground) and test point MP12. Signal should be 0.50V (rod side).
Refer to system wiring diagram.

Measure voltage between test point MP10 (ground) and test point MP11
and reset with P1 to 0.50V (piston side).
Measure voltage between test point MP10 (ground) and test point MP12
Correct? No
and reset with P2 to 0.50V (rod side).
If not adjustable, replace transducer.
Refer to system wiring diagram and zeroing transducer procedure.

END

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 36 Service Manual DS150

7.8 Bad Data Transfer Between Console & Central Unit

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

START

Make sure that the eproms are plugged into the correct socket and orientated.
Refer to EPROM replacement procedure.

Correct? No 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 Section 4.
Refer to system wiring diagram.

Replace main board and reset pressure channel. Refer to

Correct? No system wiring diagram and transducer replacement
procedure .

Yes

NEXT PAGE

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 Troubleshooting Flow Charts 37

Continued from previous page

PREVIOUS PAGE

Check power supply to console between console terminal 2(ground) and terminal 1 (+12v)
Refer to system wiring diagram.

Faulty wiring in cable from central unit to console.

Correct? No
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 system wiring diagram.

Replace main board and reset pressure channel.

Correct? No Refer to system wiring diagram and transducer replacement
procedure.

Yes

END

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 38 Service Manual DS150

7.9 Interference Problem

PROBLEM: Interference from crane START

electric. Error Code “E93/E94"
intermittent. Frozen console displays.
Refer to Section 8 - Bad Data
Transfer Between Console & Central Unit.

Correct? No Replace or repair part which is defective.

Yes

Check if additional ground link between main

board terminal X1:3 and central unit box mounting bracket is in place.

Install ground line - single cable minimum of AWG14 (2.0mm ) between

Correct? No terminal X1:3 and central unit box mounting bracket.
Refer to system wiring diagram.

Yes

Ensure that cable shields are connected correctly. Refer to connection and
wiring diagrams, Refer to system wiring diagram.

Make correct shield connection.

Correct? No
Refer to system wiring diagram.

Yes

Find out which component of the crane electric is spiking out (e.g. dump valve, outrigger relay). Install
a diode or resistor across terminals of spiking component. Diode type such as 1N4001 can be used,
however, ensure the correct plus and minus connections for diode.

END

©PAT REV. A 10/16/01 100753_A.doc

 Troubleshooting Flow Charts 39

7.10 Angle Problem

PROBLEM: Displayed Angle Incorrect. Actual measured angle is different from displayed angle.

START

Use a calibrated inclinometer to measure the actual main boom angle

and compare with displayed angle on console.
Refer to length/angle adjustments procedure.

Check the supply voltage to angle sensor on connection board

between X1:11 (+5VDC) and X1:8 (ground).
Refer to system wiring diagram.

Check system power supply voltage.

Correct? No
Refer to Section 7.4 No Display, this manual.

Yes

Check the voltage at angle sensor between connector pins A (AGND) and C (+5V).
Refer to system wiring diagram.

Cable defective, replace cable or cable assembly.

Correct? No
Refer to system wiring diagram.

Yes

Check the voltage between X1:8 (ground) and X1:9 (signal/output voltage).
Voltage should be 3.125V (0°), 2.5V(45°), 1.875V (90°).
Refer to angle sensor theory.

Replace Angle Sensor.

Refer to length/angle adjustments procedure.

END

©PAT REV. A 10/16/01 100753_A.doc

 40 Service Manual DS150

8 ERROR CODE TABLE

Error Error Cause Elimination

Code
E01 Fallen below radius• Fallen below the minimum • Luff down the boom to a radius
range or angle radius or gone past the or angle specified in the load
range exceeded maximum angle specified in chart.
the respective load chart
due to luffing up the boom
too far
E02 Radius range • Gone past the maximum • Luff up the boom to a radius or
exceeded or fallen radius or fallen below the angle specified in the load
below angle range minimum angle specified in chart.
the respective load chart
due to luffing down the
boom too far
E03 Non-permitted • The slewing zone with load • Slew to permitted area
slewing zone (no is not permitted
load area)
E04 Operating mode • A non existing operating • Set the correct operating mode
not acknowledged mode has been selected for the operating state in
or non permitted question
slewing zone
• The boom is in a non- • Slew the boom to a permitted
permitted slewing zone area.
E05 Prohibited length • Boom has been extended • Extend/retract boom to the
range either too far or not far correct length
enough, e.g. if it is
prohibited to go beyond a
certain maximum boom
length or with load curves
for jibs where the main
boom has to be extended to
a certain length
• Length sensor adjustment • Retract boom. Check the pre-
has changed, e.g. the cable stress of the cable reel (cable
slid off the length sensor must be taut). Open the length
reel. sensor and carefully turn the
length sensor pot counter
clockwise until loosened by
using a screw driver

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 Error Codes 41

Error Code Error Cause Elimination

• Clutch between length • Replace the complete
sensor pot and drive is clutch including drive
defective wheel and adjust length
sensor pot as described
above
• Failure of +5V supply of • Check +5 V supply.
analog part of analog Exchange main board in
board case of voltage failure or
breakdown when loaded
with 50 ohms approx.
• Cable between central • Check cable and plugs,
unit and length sensor is replace, if need be.
defective or
disconnected.
• Defective length • Replace length
potentiometer potentiometer.
E06 Radius range • Maximum radius as • Luff the jib to a radius or
exceeded or fallen specified in the load angle specified in the load
below angle range chart exceeded or fallen chart.
with luffing jib below minimum angle
operation due to luffing down the
luffing jib too far
E07 Faulty • Overload relay or main • Replace main board
acknowledgment board are defective
of the overload
relay on the main • Processor board
board. defective • Replace processor board.
The relay should
be energized, the
2nd contact
however is
indicated to be
off, or the 2nd
contact is
indicated to be on
while the relay
should be de-
energized.
E08 No acknowledge- • Refer to E07 • Refer to E07
ment from the
anti-two-block
relay

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 42 Service Manual DS150

Error Code Error Cause Elimination

E11 Fallen below lower • Cable between central • Check cable as well as
limit value for unit and length sensor is plugs, replace, if need be.
measuring channel defective or disconnected.
"length main boom" Water inside the plug of
the length/angle sensor
• Length potentiometer is • Replace length
defective potentiometer
• Electronic component in • Replace LMI main board or
the measuring channel is processor board.
defective
E12 Fallen below the • Cable between the central • Check cable as well as
lower limit value in unit and pressure plugs, replace, if need be.
the measuring transducers defective or
channel "pressure water inside the plugs
piston side"

• Pressure transducer is • Replace pressure transducer

defective.
• Electronic component in • Replace LMI main board or
the measuring channel is processor board.
defective.
E13 Fallen below lower • Refer to E12 • Refer to E12
limit value in the
measuring channel
"pressure rod side"
E15 Fallen below lower • Cable between central • Check cable as well as
limit value in unit and the length/angle plugs, replace, if need be.
measuring channel sensor defective or loose.
"angle main boom" Water inside the plug of
the length/angle sensor.
• Angle potentiometer • Replace angle sensor
defective
• Electronic component in • Replace LMI main board or
the measuring channel processor board.
defective.
E16 Fallen below lower • Cable between the central • Check cable as well as
limit value in unit and the angle sensor plugs, replace, if need be.
measuring channel defective or loose. Water
"angle 2" inside the plug of the
angle sensor.
• Angle potentiometer • Replace angle sensor
defective
• Electronic component in • Replace LMI main board or
the measuring channel processor board.
defective.

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 Error Codes 43

Error Code Error Cause Elimination

E19 Reference and/or • The supply voltage is • Check the voltages on the
supply voltage falsified by one of the LMI main board. Check
defective sensors (DAV, LWG) sensors, plugs and cable,
replace, if need be.
• Electronic component is • Replace LMI main board
defective
E20 Analog and/or • The analog voltage is • Check the voltages on the
supply voltage falsified by one of the LMI main board. Check
defective sensors sensors, plugs and cable,
replace, if need be.
• Electronic component is • Replace LMI main board
defective
E21 Upper limit value in • Refer to E11 • Refer to E11
measuring channel
"main boom length"
has been
exceeded.
E22 Upper limit value in • Refer to E12 • Refer to E12
measuring channel
"pressure piston
side" has been
exceeded
E23 Upper limit value in • Refer to E12 • Refer to E12
measuring channel
"pressure rod side"
has been
exceeded.
E25 Upper limit value in • Refer to E15 • Refer to E15
measuring channel
"main boom angle"
has been
exceeded.
E26 Upper limit value in • Refer to E16 • Refer to E16
measuring channel
"angle 2" has been
exceeded.
E29 Reference and/or • Refer to E19 • Refer to E19
supply voltage
defective.
E31 Error in the system • The system program • Replace system program
E37 program PROM is defective. PROM (PROM No. 0)
E38 System program • The system program in • Replace the system program
and data EPROM the LMI does not match to PROM or the data EPROM
do not match. the programming in the (PROM No. 1)
data EPROM

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 44 Service Manual DS150

Error Code Error Cause Elimination

E41 Error in the internal • Computer component • Replace computer
write/read memory 80C537 defective component 80C537.
(RAM) of the
computer • CPU module defective • Replace CPU module.
component 80C537
• Processor board • Replace processor board
defective. with CPU module.
E42 Error in the external • Write/read memory • Replace processor board
write/read memory, (CMOS RAM) or with CPU module.
1st part (RAM) processor board
defective.
E43 Error in the external • Refer to E42 • Refer to E42
write/read memory,
2nd part (RAM)
E45 Redundancy error • The A/D converter on the • Replace processor board.
in the A/D processing board and the
conversion redundant A/D converter
in the CPU 80C537
provide different results.
E46 Error in the A/D • No acknowledgment of • Replace processor board.
converter uPD the A/D converter uPD
7004 of the 7004
processor board.
E48 Cyclic RAM test: • Computer component • Replace computer
E49 error in the internal 80C537 defective component 80C537.
write/read memory
(RAM) of the • CPU module defective • Replace CPU module
computer
component 80C537 • Processor board • Replace processor board
defective. with CPU module.
E51 Error in the crane • No valid data in the crane • Load crane data EEPROM
data EPROM or data EEPROM. containing valid data.
EEPROM.
• Memory module wrongly • Bridge memory module acc.
bridged. to memory type

• Crane data EPROM • Replace crane data EPROM

defective

©PAT REV. A 10/16/01 100753_A.doc

 Error Codes 45

Error Code Error Cause Elimination

E91 No data trans- • 24 V supply of the console • Check 24 V at terminal X1 of
mission form the is interrupted the console electronics
console to the
central unit
• Interruption or accidental • Check the main console
ground in the line between electronics - central unit. In
console electronics and case of an accidental
central unit ground, the transmitter
module of the console
electronics might be
damaged. Therefore,
replaces the console
electronics.
• Transmitter/receiver • Exchange console
module is defective electronics or LMI main
board
E92 Error in the data • Loose connection in the • Check the connection
transmission from line between console between console electronics
console to central electronics and central and central unit
unit unit • Exchange console
• Transmitter/receiver electronics or LMI main
module is defective board
E93 Error in the data • Refer to E92 • Refer to E92
transmission from
the central unit to
the console
E94 No data trans- • Interruption or accidental • Check line to the console (in
mission from the ground in the line central case of accidental ground,
central unit to the unit - console replace console electronics,
console too).
• 5 V supply of the • Check connection to the
computer in the central power unit
unit is missing
• 5 V supply is too low • Exchange the LMI main
board
• Transmitter/receiver • Replace console electronics
module is defective or LMI main board
• Computer module is • Replace processor board.
defective
• Electro-magnetic • Eliminate the source of
interferences (e.g. when interference by inverse
switching contacts or diodes or varistors.
valves)

Note: If an error message is displayed which is not contained in above list, please contact PAT
America, Inc. service department.

©PAT REV. A 10/16/01 100753_A.doc

 46 Service Manual DS150

ADDENDUM A BASIC ADJUSTMENT AND VOLTAGE CHECKS

MODEL:
S/N:
PAT DS150 P/N 024-150-060-002 central unit / 024-150-300-001 main board

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

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

+ 9V @ Mp2 = ___________________ VDC Mp 10 Ground - Piston & Rod Pressure

- 9V @ Mp3 = ___________________ VDC Mp 10 Ground - Piston & Rod Pressure
5V @ Mp4 = ___________________ VDC Mp 10 Ground – TTL on Board
5V @ Mp5 = ___________________ VDC Mp 10 Ground – 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. ____________VDC @ X1:10 ____________DC @ MP13

Fully Extended ____________ Ft. ____________VDC @ X1:10 ____________DC @ MP13
-5 Volt Reference Voltage _______________ VDC @ X1:11
5. Boom Angle: (MP10 Ground for Meter)

Minimum Angle __________ ° ______________VDC @ X1:9 ______________VDC @ Mp14

Maximum Angle__________ ° ______________VDC @ X1:9 ______________VDC @ Mp14
-5 Volt Reference Voltage ______________ VDC @ X1:11
6. Pressure Transducers: (MP10 Ground for Meter)

Piston Zero Point ________ VDC @ X1:21 ___________ VDC @ Mp11

Rod Zero Point __________ VDC @ X1:16 ___________ VDC @ Mp12
+5 Volt Reference Voltage ____________ VDC @ X1:13 & 18
-5 Volt Reference Voltage ____________ VDC @ X1:15 & 20

©PAT REV. A 10/16/01 100753_A.doc

 Addendums 47

ADDENDUM B Reference Tables for measuring supply and signal voltages

for sensor channels

Use the table as a quick reference for measuring supply and signal voltages for the sensor channels
that are specific to the error code listed.

Signal Voltage
Terminal Board
Terminal X1
Nominal Voltage
Error Code Channel Pin ‘ground’ Pin ‘supply’ (VDC)
E11/21 2 Length 8 11 -5
E12/22 1 Pressure Piston side 19 20 -5
19 18 +5
E13/23 0 Pressure Rod side 14 15 -5
14 13 +5
E15/25 3 Angle Main boom 8 11 -5
E16/26 4 Angle Jib 23 25 -5

Signal Voltage
Terminal Board Amplified Signal
Terminal X1 on main board
use MP10 - GND
Error Pin Pin and MP supply
Code Channel ‘ground’ ‘supply’ Voltage (VDC) voltage 0.5...4.5V
E11/21 2 Length 8 10 -0.5...-4.5 MP13
E12/22 0 Pressure Piston side 8 21 0...-1 MP11
E13/23 1 Pressure Rod side 8 16 0...-1 MP12
E15/25 3 Angle Main boom 8 9 -1.875...-3.125 MP14
E16/26 4 Angle Jib 8 24 -1.875...-3.125 MP15

©PAT REV. A 10/16/01 100753_A.doc