EI65 Service

www.patamerica.com PAT America, Inc LENGTH-ANGLE-RADIUS-LOAD INDICATING SYSTEM EI65/0005 SERVICE MANUAL P/N 031-300-190-007, Rev.B, 03/8/02 B 03/08/02 // CLC 031-300 / 190007_b. This document contains proprietary information. is PAT makes no warranty of any kind with regard to this material. © 1999 PAT America. or translated to another language without prior consent of PAT. All rights are reserved. performance or use of this manual.DOC . but not limited to the implied warranties of merchantability and fitness for a particular purpose.EI65 SERVICE MANUAL NOTICE The information in this document subject to change without notice. No part of this document may be photocopied. PA 17201. reproduced. which is protected by copyright. Chambersburg. PAT shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing. including. USA © PAT Rev. . .. CONNECTION BOARD LAYOUT ...........................................7 DRAWING 7........................ 9 4........................EI65 SERVICE MANUAL Table of Contents 1 GENERAL INFORMATION ........................ LINERIDER SUPPLY VOLTAGES .................... 19 6..............................1 DRAWING 1...................... ANGLE SENSOR CIRCUIT .... LINERIDER CIRCUIT................5 LENGTH READING PROBLEM ..3 DRAWING 3........ 15 6..3 ANTI TWO BLOCK PROBLEM................4 4... 14 6.................................. B 03/08/02 // CLC 031-300 / 190007_b............ 18 6........................................................................... LENGTH SENSOR CIRCUIT .......... 1 2 WARNINGS ............. 6 4.......... 15 6......................................................................... 17 6...4 DRAWING 4....................8 DRAWING 8.......2 DRAWING 2...........1 GENERAL FLOW CHART ..............................................1 REFERENCE: .... CONSOLE PARTS LIST ...3 4 TROUBLESHOOTING FLOW CHARTS ............................13 6 SYSTEM DRAWINGS ................... MAIN BOARD LAYOUT ............. 16 6........ 14 6....... SYSTEM WIRING DIAGRAM (REFER TO INSTALLLATION MANUAL 031-300-190-008) ...............14 Connection Board 056-065-300-002 Designations: .2 NO DISPLAY ...... 20 © PAT Rev..........................2 3 TROUBLESHOOOTING USING THE ANALOG VALUES SCREEN .......... 8 4........................................................................ 1 SYSTEM DESCRIPTION: ............................................................5 DRAWING 5...6 LOAD READING PROBLEM ....................................... 4 4.............. 1 SYSTEM MALFUNCTION: ............................. 5 4.................4 ANGLE READING PROBLEM ............................................................................................6 DRAWING 6............................. 11 5 ERROR CODE TABLE ..DOC .............. . and describe the action. The error codes are listed in Section 4. contact your authorized dealer or service organization. tip height. When these faults occur. an error code which identifies the system malfunction will be displayed in the reeving portion of the display.0 J1 85. working radius and the total weight being lifted by the crane.DOC . the EI65 System warns the crane operator of certain approaching hazardous conditions which could occur during the operation of his crane. SYSTEM DESCRIPTION: The PAT Length-Angle-Radius-Load Indicator System EI65 has been designed to provide the crane operator with the essential information required to enable the machine to be used within its design parameters. explain each fault.0 0J 15. A digital voltmeter and regular maintenance and service tools will be required to troubleshoot the system. If the operator identifies a possible problem in the system. REFERENCE: Operator’s Manual 056-065-190-005 Calibration Manual 031-300-190-009 Installation Manual 031-300-190-008 SYSTEM MALFUNCTION: In case of a malfunction of the system. which shall be taken to correct the fault.0  J2 50. WARNING Always refer to operational instructions and load charts provided by the crane manufacturer for specific crane operation and load limits. B 03/08/02 // CLC 031-300 / 190007_b.0 E71 Faults within the electronic microprocessor shall be repaired by factory trained service personnel. perform the pre-operation inspection Section 5 in the Operator’s Manual 056-065-190-005 to define the problem. Note: Knowledge of how to use a digital voltmeter is assumed. MB 115. © PAT Rev. The EI65 System indicates the length and angle of the boom. Error Codes.GENERAL INFORMATION 1 1 GENERAL INFORMATION The purpose of this service manual is to provide additional information to assist a service or maintenance person in identifying malfunctions or system problems with the PAT System. Using the various sensors and the limits set by the operator. The table identifies various faults that can occur with the EI65. B 03/08/02 // CLC 031-300 / 190007_b. • The responsibility for the safe operation of the crane shall remain with the crane operator who shall ensure that all warnings and instructions supplied are fully understood and observed. © PAT Rev. the operator must carefully and thoroughly read and understand the information in the operator’s manual to ensure that he/she knows the operation and limitations of the indicating system and crane. • Prior to operating the crane. which could cause damage to equipment and personnel. a substitute for good operator judgment. and shall not be.2 EI65 SERVICEMANUAL 2 WARNINGS • The EI65 is an operational aid. • The device is not. which warns a crane operator of certain approaching hazardous conditions. experience and use of accepted safe crane operating procedures.DOC . 1. simultaneously press the ‘‘OK’’ and ‘‘SELECT’’ buttons.DOC . All Analog input voltages (shown in millivolts). look at the output voltage of the linerider and angle sensors and compare the reading with the following: Angle sensor 1. within 5 seconds of powering up. the screen changes to the existing operating configuration. To access the analog output screen use the following procedure.5 at 45°.OK. 3. PASSWORD’’. To start calibration. 2.Troubleshoooting Using The Analog Values Screen 3 3 TROUBLESHOOOTING USING THE ANALOG VALUES SCREEN For a sensor error or problem with a sensor. Scrole to the ANALOG VALUES screen by pressing the ‘‘UP’’ or ‘‘DOWN’’ arrows.125 at 90° Linerider under no load is 0 to 15mV not to exceed 2500 mV. 031-300 / 190007_b. At maximum load the reading should not exceed 2500 mv (+/-25mv). 8 . If these buttons are not pressed and held. or 3.875 at 0°. Use the ‘‘UP’’ and ‘‘DOWN’’ buttons to select the number and the ‘‘OK’’ button to confirm each entry. B 03/08/02 // CLC ANGLE 1 and ANGLE 2 With the boom at zero degrees this should read 3125 mv . received from the sensors will be displayed here as described below. At maximum or 90 degrees the reading should be 1875 mv (+/-25mv). The screen will display EI 65/10 software version and date. FORCE 1 and FORCE 2 With no signal or weight applied this should read 15 mv or below. 5 . Refer to Operator’s section in this manual. 2. Enter 0 . Enter the calibration password ‘‘0815’’.OK. 1 . The minimum values are show in the screen pictured. © PAT Rev.OK 4. 1950 0 15 VOLT *1000 3125 3125 LENGTH (Hydraulic Machines Only) reading should be 0 with no sensor installed. Hold these buttons (approximately 15 seconds) until the screen changes to ‘‘CALIB. pressing ‘‘OK’’ to select and show the following screen. Power up the system.OK. 1 Anti-Two Block Problem Go to Section 3. PAT Load Indicator System.5 © PAT Rev.DOC . Start with the general flowchart below that will guide you to one of the detailed flowcharts shown in this section.3 Length Reading Problem Go to Section 3.1 GENERAL FLOW CHART START What’s Wrong? No display Go to Section 3. B 03/08/02 // CLC 031-300 / 190007_b.2 Angle Reading Problem Go to Section 3. 4.4 Load Reading Problem Go to Section 3. Section 5 contains the necessary drawings needed for troubleshooting.4 EI65 SERVICEMANUAL 4 TROUBLESHOOTING FLOW CHARTS This section explains how to handle a problem that may arise with the EI65. The procedures are easy to follow and are given in flowcharts on the following pages. © PAT Rev. Yes Measure voltage on connection board between MP4 (+5. Replace console connection board. B 03/08/02 // CLC 031-300 / 190007_b. Drawings.TROUBLESHOOTING FLOW CHARTS 5 4. Section 5. Section 5.2 NO DISPLAY Start Check fuse F1 in console.DOC . Section 5. Drawings.25V) and MP1 (ground). Correct? No Replace fuse (2amp/250V) Yes Measure crane voltage on connection board between X1:1 (+UB) and X1:3 (ground). Refer to Drawing 2. Yes Measure voltage to main board between MP15 (+5. Drawings. System Diagram. Refer to Drawing 3. Correct? No Check crane power supply for faulty crane electric or if supply is too low. Refer to Drawing 1.. Main Board. Correct? No Defect on connection board. Replace console main board. Connection Board.25V) and MP1 (ground). item 1. START Check to see whether or not crane is in two-block condition. Yes Check the A2B circuit at the boom tip junction box. With the bypass plugs and switch weight in position the ohm meter reads 4.7K ohms.DOC .3 ANTI TWO BLOCK PROBLEM PROBLEM: Function of Anti-Two-Block System is faulty. 2. and 3 for switch weight positions for the main boom and extension. Correct? No Position the weight properly. With power off.6 EI65 SERVICEMANUAL 4. B 03/08/02 // CLC 031-300 / 190007_b. measure A2B signal boom tip junction box. Correct? No Lower hook down into safe position Yes Check weight position. Refer to Operator's Section of Handbook 056-065-190-005 Section 5. Pre-Operation Inspection. Correct? No Replace Anti-Two-Block switch. Yes Next Page © PAT Rev. Refer to Installation Manual for system wiring diagram. ANTI-TWO BLOCK PROBLEM 7 PREVIOUS PAGE With power off.DOC . No Yes With power on and the switch weight in position. A2B relay defective on connection board. Correct? Fault in cable assembly. Check cable assemblies and replace defective cable. B 03/08/02 // CLC 031-300 / 190007_b. Refer to Installation Manual for system wiring diagrams. measure the A2B signal in the console at the X1:9 and X1:10. Yes End © PAT Rev. Refer to Drawing 2 in Section 5. Refer to Installation Manual for system wiring diagrams. Replace Angle Sensor. Correct? No Cable Reel Sensors. 4.5V(45°). END © PAT Rev. Refer to Installation Manual for system wiring diagram.4 ANGLE READING PROBLEM PROBLEM: Displayed Angle Incorrect.125V (0°). and you will have to complete the entire calibration procedure. Refer to Installation Manual for system wiring diagrams. 4. this manual. Correct? Check system power supply voltage. Check the supply voltage to angle sensor on connection board between X1:17 (+5VDC) and X1:20 (ground). 4. Yes Complete steps 4.DOC .16 in the Calibration Manual.8 EI65 SERVICEMANUAL 4. replace cable or cable assembly. Refer to Section 3. Refer to Drawing 4.875V (90°).3. 4.8. No Yes Check the voltage at angle sensor between connector pins A (AGND) and C (+5V). 031-300-190-009. Do NOT will be lost. Section 5 Mechanical Adjustments of Cable Reel Sensors. Correct? Cable defective.8. START Use a calibrated inclinometer to measure the actual main boom angle and compare with displayed angle on console. Refer to Installation Manual for system wiring diagrams. Voltage should be 3. 1. B 03/08/02 // CLC 031-300 / 190007_b. 2. Angle Sensor Circuit in Section 5.14 through 4.2.1. No Yes Check the voltage between X1:20 (ground) and X1:18 (signal/output voltage). Refer to Installation Manual.1 and 4.2 No Display. Actual measured angle is different from displayed angle. Yes Check out clutch in big gear wheel of length transducer. Unscrew mounting Correct? assembly wires form terminal block.DOC . With boom fully retracted.LOAD READING PROBLEM 9 4. If unable to adjust. Yes NEXT PAGE © PAT Rev. No Refer to Installation Manual for system wiring diagrams and Section 5 Mechanical Adjustments of Cable Reel Sensors. Reinstall mounting plate.0V power supply to length transducer on connection board. Section 5 Mechanical Adjustments of Cable Reel Sensors. START Refer to Installation Manual. this manual. of Cable Reel Sensors. clean potentiometer axle. replace length potentiometer assembly. Refer to Installation Manual for system wiring diagram or connection board designations this manual.5 LENGTH READING PROBLEM PROBLEM: Length reading incorrect. Refer to Section 3. Yes Check 5. Remove slip ring body from shaft and remove gear wheel from potentiometer axle. Connect new assembly to terminal block. B 03/08/02 // CLC 031-300 / 190007_b. gear wheel and slip rings. Correct? No Check system power supply voltage. Correct? No Replace the gear wheel.2 No Display. Crane is not in “out of load chart” condition. Reset length potentiometer. Extend and retract boom to ensure that clutch is not sipping on potentiometer axle. Refer to Drawing 3.DOC . gear wheel and slip rings. No Yes Measure signal from length transducer in cable reel at terminal between pin 2(signal) and pin 1(ground). between Pin 1 (ground) and Pin 3 (-5v) Refer to Installation Manual for system wiring diagram Correct? Cable defective. NOTE: Negative signal at terminal X1 Pin 15 will be converted into positive signal at MP6 (i.5V. Correct? No Cable defective. Yes Measure length signal on main board between test point MP4 (signal) andMP1 (ground). Connect new assembly to terminal block. replace cable or cable assembly. Refer to Installation Manual for system wiring diagrams. Main board defective. Remove slipring body from shaft and Correct? No wires form terminal block. B 03/08/02 // CLC 031-300 / 190007_b. Replace length potentiometer assembly. Refer to Installation Manual for system wiring diagrams. replace cable or cable assembly.5 and -4.5v) Refer to Installation Manual for system wiring diagram or connection board designations this manual.: input at terminal X1 Pin 15 = -0.5v).0 Potentiometer turn = -0.5v 10 Potentiometer turn = -4. Main Board.e. Yes Measure signal from length transducer at console connection board between X1-20 (ground) and X119 (signal: -0. With boom fully retracted. END © PAT Rev. Section 5.5v Refer to Drawing 5 Length Sensor Circuit. output test between MP15 and MP6 = +0. reset potentiometer by turning counter-clockwise until it stops.10 EI65 SERVICEMANUAL PREVIOUS PAGE Measure supply to length transducer in cable reel. Reinstall mounting plate. Retract boom . Correct? No Cable defective. Next Page © PAT Rev. Complete to Section 3.2 No Display. The displayed load should be equal to or 10% greater than the actual load. B 03/08/02 // CLC 031-300 / 190007_b. No Yes Check the voltage at linerider between connector pins A (+9V) and B (-9V). Voltage = 18V Refer to Drawing 7 in Section 5 and the Installation Manual for system wiring diagram. replace cable or cable assembly. Check the Main/Aux voltages on connection board between X1:25 (+9V) and X1:8 (ground) X1:28 (-9V) and X1:8 (ground) Refer to Installation Manual for system wiring diagram or connection board designations this manual. Before changing calibration information complete the following steps. START Complete Pre-Operation Inspection in Section 5 of the Operator's Manual 056-065-190-005.6 LOAD READING PROBLEM PROBLEM: Displayed Load is out of tolerance. Correct? Check system power supply voltage.LOAD READING PROBLEM 11 4.DOC . Refer to Installation Manual for system wiring diagrams. No Complete steps 4.12 EI65 SERVICEMANUAL Previous Page Remove hoist rope so there is no load on the load cell of the linerider. Correct? No With no load on the load cell of the linerider.1. No Replace Load Cell or Linerider Assembly End © PAT Rev. 4. 4. Main X1:26 (+sig) and X1:27 (-sig) Aux X1:30 (+sig) and X1:31 (-sig) Refer to Drawing 6 Linerider Circuit in Section 5 and the Installation Manual for system wiring diagrams. Check the zero point of the linerider in the boom tip junction box or as close to the linerider as possible. Main X1:26 (+sig) and X1:27 (-sig) Aux X1:30 (+sig) and X1:31 (-sig) Voltage = 0 ±0.3.4 or all other calibration data will be lost. 031300-190-009.DOC . No Check cable continuity.025V Refer to Drawing 6 Linerider Circuit in Section 5 and the Installation Manual for system wiring diagrams.12 (Aux) through 4. Check the Main '+' and '-' signal and/or the Check the Aux '+' and '-' signal at Voltage = 0 ±0.2.11 (Main) or 4. 4. and you will have to complete the entire calibration procedure. Replace cable if necessary No Replace Load Cell or Linerider Assembly Yes Lift test load and verify linerider output voltage increases after lifting the test load. B 03/08/02 // CLC 031-300 / 190007_b.16 in the Calibration Manual. Do NOT select Default in of section 4.025V Refer to Drawing 6 Linerider Circuit in Section 5 and the Installation Manual for system wiring diagrams. Min.1 term 9&10 Cable break A2B -switch . Limit Working radius .Min.Boom .Max. Limit Boom height .Main .Boom . ADC-Measuring value KMD1 too big Turn on the system again and adjust operating data Re-calibrate the system 82 ADC-Measuring value KMD1 too low 83 ADC-Measuring value KMD2 too big 84 ADC-Measuring value KMD2 too low 91 ADC-Measuring value LG1 too big 92 ADC-Measuring value LG1 too low 93 ADC-Measuring value WG1 too big 94 ADC-Measuring value WG1 too low 95 ADC-Measuring value WG2 too big 96 ADC-Measuring value WG2 too low © PAT Rev. Limit WG .2 term 13&14 Short circuit A2B -switch .Main .SYSTEM DRAWINGS 13 5 ERROR CODE TABLE Error code 11 21 31 51 52 53 54 55 56 •61 •63 •71 •72 •73 •74 •75 •76 •77 •78 81 Reason Action Operating data in the buffered RAM Crane parameters in the serial EPROM incorrect Wrong EPROM programming or EPROM defective Short circuit min layer device term 11&12 Cable break min layer device term 11&12 Short circuit A2B -switch .DOC . Limit Boom height . Limit Working radius .1 term 9&10 Load on the main hoist hook too big Load on the auxiliary hoist hook too big Limit Length .Boom .Max.Main .Boom .2 term 13&14 Cable break A2B -switch .Min.Main .Max.Min. Limit WG .Max. Limit Length . hoist Decrease length limit Increase length limit Decrease main boom angle Increase main boom angle Decrease main boom angle Increase main boom angle Increase main boom angle Decrease main boom angle Check zero point in linerider Check zero point in linerider Check zero point in linerider Check zero point in linerider Check main length sensor circuit Check main length sensor circuit Check main angle sensor circuit Check main angle sensor circuit Check luffing angle sensor circuit Check luffing angle sensor circuit 031-300 / 190007_b. B 03/08/02 // CLC Exchange EPROM Check minimum layer device Check minimum layer device Check anti-two system Check anti-two system Check anti-two system Check anti-two system Reduce load on block block block block main hoist Reduce load on aux. 14 • EI65 SERVICEMANUAL Limit set by the operator refer to Operator’s Manual. B 03/08/02 // CLC 031-300 / 190007_b.DOC . Section 4. Activating and Setting Preset Limits © PAT Rev.3. Battery Load Limit output A2B Relay output 2 A2B Relay output 1 Peripheral ground A2B 1 input A2B Ground A2B 2 input A2B Ground 3rd Wrap Switch input 3rd Wrap Switch ground Digital input 1 Digital input 2 20 21 22 23 24 25 26 27 28 29 30 +5VDC Main Boom angle input Main Boom Length input Analog Ground +5VDC Jib Angle input Analog Ground Analog Ground +9VDC KMD1 +Signal input KMD1 -Signal input -9VDC +9VDC KMD2 +Signal input 31 32 KMD2 -Signal input -9VDC 6. SYSTEM WIRING DIAGRAM (REFER TO INSTALLLATION MANUAL 031-300-190-008) © PAT Rev. Connection Board 056-065-300-002 Designations: 1 + Battery 17 2 + Battery 18 3 . Angle Sensor Adjustment 6. Drawing List: 1. B 03/08/02 // CLC 031-300 / 190007_b.1 DRAWING 1. Use the drawings in conjunction with the flow charts to help understand the operation of the EI65 system. Main Board Layout 4. System Diagram 2. Angle Sensor Circuit 7.Battery 19 4 5 6 7 8 9 10 11 12 13 14 15 16 . The EI65 console connection board has the following terminal designations.SYSTEM DRAWINGS 15 6 SYSTEM DRAWINGS The PAT EI65 System drawings in this section are provided as reference material for the troubleshooting flow charts. Connection Board Layout 3.DOC . Anti-Two Block Circuit 5. Linerider Circuit Refer to the Operator’s Manual for basic component layout on the crane and console drawing. DOC . LENGTH CHANNEL ANGLE 2 ANGLE 1 KMD1 © PAT Rev.3 DRAWING 3. 6.25V 031-300 / 190007_b.0V +5. MAIN BOARD LAYOUT MP0 MP1 MP2 MP3 MP4 MP5 MP6 MP7 = = = = = = = = GND AGND +5.16 EI65 SERVICEMANUAL 6.6V MP3 = 5. To 4.5V max sig.0V MP15 = 5. SIGNAL. B 03/08/02 // CLC MP8 = SIGNAL. SIGNAL.2 DRAWING 2.5V MP13 = +5.6V MP4 = . CONNECTION BOARD LAYOUT MP1 = GND MP2 = 5. KMD2 MP9 = AN5 REFERENCE VOLATGE MP10 = AN6 REFERENCE VOLTAGE MP11 = AN7 REFERENCE VOLTAGE MP12 = -0.5V min sig. SIGNAL.0V SIGNAL. DOC .4 DRAWING 4.SYSTEM DRAWINGS 17 6. ANGLE SENSOR CIRCUIT © PAT Rev. B 03/08/02 // CLC 031-300 / 190007_b. B 03/08/02 // CLC 031-300 /190007_b.DOC.18 EI65 SERVICEMANUAL 6. LENGTH SENSOR CIRCUIT © PAT Rev.5 DRAWING 5.DOC . 6 DRAWING 6. B 03/08/02 // CLC 031-300 / 190007_b.SYSTEM DRAWINGS 19 6. LINERIDER CIRCUIT © PAT Rev.DOC . DOC . (A= +9v) + (B= -9v) = 18volts. B 03/08/02 // CLC 031-300 /190007_b. Using a digital voltmeter measure between pins A and B. You may need to start at the console and check the supply voltages at their proper measuring points.DOC.7 DRAWING 7. LINERIDER SUPPLY VOLTAGES The supply voltage can be checked directly at the cannon connection. © PAT Rev.20 EI65 SERVICEMANUAL 6. If this voltage is not correct refer to the system wiring diagram and verify all cable connections. EI65/0005 CONSOLE SCREW. PART NO. MOUNTING KNOB BRACKET. EI65 CONSOLE STRAIN RELIEF. EI20 BOARD.5.8 DRAWING 8. PHILLIPS BOARD. EI10. PG13. QTY DESCRIPTION 01 02 03 04 05 050-000-100-075 050-350-110-183 031-300-100-293 021-441-161-213 021-441-131-013 1 2 1 1 1 HOUSING. B 03/08/02 // CLC 031-300 / 190007_b.5. KEYBOARD.DOC . PG 13. 4 AMP FOR EI-65 CONSOLE BOARD. TERMINAL EI65. 8-12mm RED+WHITE INSERT 06 07 08 09 10 000-214-210-013 000-323-010-525 056-065-300-002 031-300-100-294 056-065-300-010 2 1 1 2 1 NUT. 3x10mm. 12V FUSE.5 ALARM. EI 65 CONSOLE GASKET 108X256mm © PAT Rev. CONSOLE PARTS LIST NO. PG13. EI65 KNOB. A2B. CONSOLE. MAIN EI65 W/RIBBON CABLE 11 12 13 14 15 050-000-100-078 056-065-100-005 002-053-703-101 056-065-300-011 050-000-050-309 1 1 6 1 1 DISPLAY FACEPLATE.SYSTEM DRAWINGS 21 6. PANHEAD. 12-15mm GRAY+WHITE INSERT STRAIN RELIEF. MTG. DOC .22 EI65 SERVICEMANUAL MANUAL REVISIONS REV A B DATE 06/27/0 0 10/09/0 1 03/08/0 2 NAME CSH DESCRIPTION EI65 SERVICE Manual created. B 03/08/02 // CLC 031-300 /190007_b. CSH UPDATED THEORY SECTION CLC CORRECTED MEASURING POINT DESCRIPTION. ECN 02-087 © PAT Rev.DOC.