PAT DS 150 User manual

User Manual IK 150 / 0031 e
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The information in this document is subject to change without notice. PAT makes no warranty of any kind
with regard to this material, including, but not limeted to, the implied warranties of merchantability and fitness
for a particular purpose. PAT shall not be liable for errors contained herein or for identical or consequential
damages in connection with the furnishing, performance, or use of this manual. This document contains
proprietary information which is protected by copyright. All rights reserved. No part of this document may be
photocopied, reproduced, or translated to another language without the prior written consent of PAT.
USER MANUAL
IK 150 / 0031
doc. no. 50 150 19 0031 e

User Manual IK 150 / 0031 e
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50 / 150 / 19_0031E.DOC / 19.03.1997 / Rev. C / rk.
TABLE OF CONTENTS
1General Information .................................................................................................. 3
2Warnings..................................................................................................................... 3
3System Description................................................................................................... 4
3.1 Operating Console ...................................................................................................... 6
4Control Identification................................................................................................ 7
5Pre- Operation Inspection and Calibration Verification................................... 12
6Service and Maintenance....................................................................................... 14
7Troubleshooting ...................................................................................................... 15
Appendix: Important Notes

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1. GENERAL INFORMATION
The PAT DS 150 Load Moment Indicator (LMI) complements the operator's know-how by
providing the information, right in the cab, needed to make the demanding lifts required of
modern cranes.
Using various sensing devices, the PAT DS 150 Load Moment Indicator monitors all crane
functions and provides the operator with a continuous reading of the crane's rated capacity.
The readings continuously change as the crane moves through the motions needed to make
the lift.
The PAT DS 150 Load Moment Indicator also provides the operator with information regard-
ing the length of the boom, angle of the boom and jib, working radius, rated load and the total
calculated weight being lifted by the crane.
If non permitted conditions are approached, the PAT DS 150 Load Moment Indicator will warn
the operator by sounding an audible alarm, lighting a warning light and locking out those func-
tions that may aggravate the crane´s condition.
2. WARNINGS
The PAT DS 150 Load Moment Indicator (LMI) is an operational aid which warns a crane op-
erator of an approaching two blocking condition as well as approaching overload conditions
which could cause damage to equipment and property, and injury to the operator or bystand-
ers. This device is not, and should not, be a substitute for good judgement, experience and
accepted safe crane operating procedures. The operator is solely responsible for the safe
operation of the crane and must observe and obey all warnings and instructions supplied by
PAT and the crane manufacturer. Prior to operating a crane equipped with a PAT operational
aid, the operator must carefully and thoroughly read and understand the information in this
manual and the crane manufacturer's manual to insure that the operator knows the operation
and limitations of the operational aid and crane. Proper functioning is dependent on proper
daily inspection and observance of the operating instructions set forth in this manual. We
draw your attention to section 5 of this handbook.
WARNING
The display (1) will only aid the operator when the LMI is properly programmed and the
proper load capacity chart and operating code are selected for the crane configuration
being utilized.
To prevent property damage or serious bodily injury or death to personnel, ensure the
LMI is properly programmed before operating the crane.

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3. SYSTEM DESCRIPTION
The PAT DS 150 load moment indicator consists of a central microprocessor unit, operator's
console and peripheral equipment to register the angles, pressures and hoist limit. The sys-
tem operates on the principle of reference/real comparison. The real values resulting from the
force or pressure measurement is compared with the reference data stored in the central
processor memory and evaluated in the microprocessor. When limits are exceeded, an
overload warning signal is generated at the operator's console. At the same time, the danger-
ous crane movements, such as hoist up, telescope out and boom down will be stopped.
The fixed data regarding the crane, such as capacity charts, boom weights, centers of gravity
and dimensions are stored in memory chips in the central processor unit. This data is the ref-
erence information used to calculate the overload conditions.
Boom length and boom angle are registerd by the length/angle sensor, mounted indide the
cable reel which is mounted on the boom. The boom length is measured by the cabel reel ca-
ble which also serves as electrical conductor for the anti-two-block switch.
The crane load is measured by pressure transducers attached to the piston and rod side of
the lift cylinders.

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SYSTEM COMPONENTS

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3.1 OPERATING CONSOLE
The console has 2 functions:
•terminal for input of instructions to the system by the crane operator
•display of important data and information

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4. CONTROL IDENTIFICATION
The following list will describe the controls and displays of the DS 150 safe load indicator. The numbers of
the illustration (on page 6) correspond to the numbers in the following list:
(1) LC DISPLAY
The LC DISPLAY will show technical information as well as operating information to the operator.
During crane operation the readout will display radius, boom length, boom angle, height of boom tip,
actual and maximum load. The load moment will also be indicated at the display in form of a bar-
graph. In case of system malfunctions the various faults will be indicated via an error code instead of
the tip height display (Described in chapter 7).
(2) BARGRAPH
This indicator displays how much of the crane rated capacity is being used. As the crane is moved
through its various motions, the bargraph will constantly change on the display.
The range is divided into 3 areas:
A green area is the normal working area, the yellow prewarning area shows the remaining portion of
the rated load capacity and the bargraph indicates the approach to the overload condition and the
red area shows that the maximum rated load capacity is exceeded.
NOTE
Operating within the red area is not permitted.

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(3) OPERATING CODE SWITCH
The operating code switch is used to set the load moment indicator (LMI) to the operating configura-
tion of the crane.
Caution
The correct setting is of utmost importance for the proper function of the system and the
crane. Therefore only operators who are thoroughly familiar with crane load capacity charts
and the use and operation of the system shall set the operating code switch. To set the op-
erating mode, the operator has to adjust the operating code switch to a code number which
is printed in the load chart in accordance with the actual crane configuration.
(4) REEVING SWITCH
The REEVING SWITCH (4) provides the load moment indicator with information regarding the num-
ber of falls (parts of line) used to reeve the hook block. The switch has 16 positions which are shown
under the window of the control knob when it is turned. The operator has to set the reeving switch to
the actual number of falls (parts of line) being used.
Caution
The correct setting is of utmost importance for the proper function of the system and the
crane.
(5) ANTI-TWO-BLOCK WARNING LIGHT
The red ANTI-TWO-BLOCK WARNING LIGHT (5) will light up when the anti-two-block limit switch
contacts open, indicating that a two-blocking condition is approaching. At the same time the audible
alarm will sound. The following crane movements will be stopped subsequently: hoist up, telescope
out, boom down.
The term "two block" is a crane term which refers to a condition when the load handling device
comes into contact with the boom head. This condition, if not prevented, may cause the wire rope to
break, allowing the load to fall. Two blocking can be caused by raising the load into the boom head
or lowering the boom without paying out hoist line.
(6) PREWARNING LIGHT

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The yellow LOAD MOMENT PREWARNING LIGHT (6) will light up when the load on the crane is
between 90 and 100 % of the crane rating, indicating that an overload condition is approaching. This
means for the operator to continue his crane operation with extreme caution.
(7) OVERLOAD LIGHT / ALARM SWITCH
This control serves a dual purpose:
•the red warning lamp lights up when the load on the crane is in excess of 100% of the crane rat-
ing, indicating that an overload condition has been reached.
•this button allows the audible alarm to be silenced for 15 seconds.
(8) TARE BUTTON
The TARE BUTTON is used to indicate the net load on the load display (ref. #1). Net load is the ac-
tual load, less lifting tackle and hook block. The tare button has to be activated before lifting.
After pushing the TARE BUTTON the display of actual load will be set to zero (taring). and the dis-
play shows max. load and net load. Net load display is blinking and set to zero. After lifting a load
the net load display shows the net load (pay load).
The net load display will change to the normal working display when the radius is changed (either by
boom angle or jib angle).
Display errors can be caused by reason of environmental factors such as wind acting upon the
crane and the load.
BOOM ANGLE LIMITS
This system is equipped with presets for boom angle range selection. There are limits for maximum
and minimum boom angle which can be set by the operator as allowed by crane geometry. After re-
start the system the limits have to be set new.
(9) SETTING OF BOOM ANGLE LIMIT: MAXIMUM
After pressing this button, the actual boom angle will be stored as maximum boom angle limit. The
LC Display shows the value "MAX xx °". To indicate that the maximum angle limit is activated, the
lamp in the button will light up. Once this angle is reached, the lamp flashes and the buzzer will
sound until the boom is moved back into a permissible angle range.
(10) SETTING OF BOOM ANGLE LIMIT: MINIMUM
After pressing this button, the actual boom angle will be stored as minimum boom angle limit. The LC
Display shows the value "MIN xx °". To indicate that the minimum angle limit is activated, the lamp in
the button will light up. Once this angle is reached, the lamp flashes and the buzzer will sound until
the boom is moved back into a permissible angle range.

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RESET ANGLE LIMITS
To reset the boom angle limits press button (9) and (10) simultaneously. The values for angle limita-
tion on the LC Display will be cleared.
(11) ENTER BUTTON "E"
This control has no function.
(12) BY-PASS KEY SWITCH
WARNING
Since this switch deactivates the cut-off function of the LMI system and the anti-two-block
system, the following instructions shall be adhered to:
•the by-pass key should be used with discretion, as unwarranted use of it to override the
control lever lockout system can result in harm to the crane and danger to property and
persons
•never use the by-pass key to either overload or operate the crane in a range not permissi-
ble
The BY-PASS KEY SWITCH (12) can deactivate the cut-off of the LMI or anti-two-block momentarily
to allow the crane operator to override the control lever lockout. It can be operated only by using the
matching key. The spring-loaded by-pass switch has 3 positions which are further described as fol-
lows:

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This position by-passes the anti-two-block control lever lockout which does not in-
fluence the LMI system. The red warning light (5) and the audible alarm (13) for
approaching two-block condition will also come on at all times. The By-Pass Key
Switch is springloaded in order to return the switch to the neutral position. To acti-
vate the switch, it therefore has to be held manually during it's operation.
This is the neutral position to which the switch returns because of it's sprin-
gloaded mechanism. In this position, the by-pass switch is without influence to the
LMI and anti-two-block control lever lockout.
In this position, the by-pass key switch deactivates the control lever lockout func-
tion of the LMI. All other display, indicating and alarm functions, as well as the
control lever lockout function of the anti-two-block system will continue to work.
The by-pass switch is springloaded in order to return the switch to the neutral po-
sition. Therefore to activate the switch, it has to be held manually during it's opera-
tion.
(13) AUDIBLE ALARM
This element is the AUDIBLE ALARM, which sounds during the following conditions:
overload situation, approaching two-block condition, boom angle preset limits are reached, in case
of a malfunction of the LMI system and in case of an recognised operating error. The alarm can be
turned off temporarily by pushing the button (7).

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5. PRE-OPERATION INSPECTION AND CALIBRATION VERIFICATION
Prior to operating the crane, the following electrical connections must be checked to ensure that the
system is properly connected for the crane configuration.
Machines with only a Main Hoist
If the crane works only with the boom and without boom extension or jib, no additional connections
are necessary. However, be sure the weight of the anti-two-block switch is properly installed on the
main hoist load line. With even parts of hoisting line, the weight shall be attached to the dead-end
line. With odd parts of hoisting line, the weight shall be attached to the line of lowest speed.
If the crane works with boom extension or jib, the connecting cable shall be installed between the
junction box on the boom extension or jib and the boom junction box. The weight attached to the
main hoist anti-two-block switch shall be removed. Then the weight shall be reattached to the boom
extension or jib anti-two-block switch.
WARNING
Failure to re-position the anti-two-block switch weight will prevent the overhoist system from func-
tioning properly. No weight shall be on the main hoist anti-two-block switch when the boom exten-
sion or jib is being used.
Machines with Main and Auxiliary Hoists
If the boom extension or jib is not in the operating position, the by-pass plug shall be installed in the
main boom junction box. The weight of the main hoist anti-two-block switch shall be installed.
If the boom extension or jib is in the operating position, the connecting cable shall be installed be-
tween the junction boxes on the boom extension or jib and the main boom. Weights shall also be
attached to the anti-two-block switches on both the main boom and boom extension or jib.
If the boom extension or jib is in the operating position and no load line is being used on main boom,
to prevent injury or damage to equipment, the weight shall be removed from main boom switch.

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After the electrical connections have been checked to insure that the system is properly connected
for the crane configuration, the following checks shall be made:
1. Check the electrical wiring connecting the various parts of the system for physical damage.
2. Check the anti-two-block switches and weights for free movement.
3. Check the spring-loaded cable reel to be sure it is free to rotate, has tension and the cable is
reeled properly.
4. Check mechanical installation and electrical connection of the force transducer(s) on jibs where
applicable.
WARNING
The following tests shall be performed with care to prevent damage to the machine or injury to per-
sonnel. Proper functioning of the system requires successful completion of these tests before oper-
ating the machine.
If the operator cannot see the load handling device approaching the boom nose, he shall have an
assistant (signal person) watch the load handling device. The operator shall be prepared to stop the
machine immediately should the LMI system not function properly as indicated by lighting the red
warning light (7), sounding the audible alarm (13) and locking the crane movements, hoist up, tele-
scope out and boom down.
Check the anti-two-block alarm light (5) and the audible alarm (13) by performing one of the following
tests:
1. By manually lifting the weight attached to the anti-two-block switches. When the weight is lifted,
the audible alarm (16) should sound, the anti-two-block alarm light (5) should light.
2. Slowly raise the main boom load handling device to create a potential two-block condition.
When the load handling device lifts the weight, the audible alarm (13) should sound, the anti-
two- block alarm light (5) should light and the motion of the load handling device should be
stopped. Lower the load handling device slightly to eliminate this condition.
3. Slowly lower the boom to create a potential two-block condition. When the load handling device
lifts the weight, the audible alarm (11) should sound, the anti-two-block alarm light (5) should
light and the boom lowering function should be stopped. Lower the load handling device slightly
to eliminate this condition.
4. Slowly extend (telesope) the boom to create a potential two-block condition. When the load
handling device lifts the weight, the audible alarm (13) should sound, the anti-two-block alarm
light (5) should light and the boom telescope out function should be stopped. Lower the load
handling device slightly to eliminate this condition.
WARNING
If the light and audible alarm do not function as described and the crane movements are not
stopped, the system is not working properly. The malfunction shall be corrected before operating the
crane.
5. If the crane is equipped with a boom extension or jib, repeat the test procedure for the boom
extension or jib anti-two-block switch.
6. Check that the display of the main boom length agrees with the actual boom length.
7. Check that the display of the main boom angle agrees with the actual boom angles.
8. Check that the display of the operating radius of the crane agrees with the actual radius.
9. Check the load display by lifting a load of known weight. The accuracy of the load indication
shall be within the tolerance of SAE J159.

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OPERATION
After being properly programmed, the LMI is operational. Therefore, the operator shall be thoroughly
familiar with all controls of the LMI and he shall properly set each switch before operating the crane.
All settings shall be checked by lifting a load of known weight and comparing the load to the infor-
mation displayed on the LMI.
Rated loads include the weight of the hook block, slings, and auxiliary load handling devices. Their
combined weights shall be subtracted from the listed load capacities as stated on the load capacity
chart to obtain the net load to be lifted.
WARNING
If any of the displays reflect a deviation between displayed and actual values an authorized PAT
service representative shall be called for repair of the system or reverification of the crane's LMI
calibration.
WARNING
Any structural modifications or changes to the crane shall require reverification of the crane's LMI
calibration.
6. SERVICE AND MAINTENANCE

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Daily maintenance of the load moment indicator consists of inspecting:
1. The electrical wiring connecting the various parts of the system. If electrical wiring is damaged,
it shall be replaced immediately.
2. If the insulation is worn on the length sensor cable or cable guides are damaged, these parts
shall be replaced.
3. Check the anti-two-block limit switches for freedom of movement.
4. The cable reel shall be under tension to operate properly.
5. Check the pressure transducers at the lift cylinder(s) and the connecting hoses for oil leakage.
6. Check mechanical installation and electrical connection of force transducer(s) on jibs where ap-
plicable.
Other than correcting the problems identified in the Malfunctions Table and replacing faulty me-
chanical parts and cables, no other repairs shall be performed by unauthorized or untrained person-
nel.

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7. TROUBLESHOOTING
GENERAL
In case of a malfunction of the system, the display (1) will indicate a code which identifies the sys-
tem malfunction.
The error codes listed in the Malfunction Table will identify various faults which can occur with the
LMI. Following the Malfunction Table are pages which explain each fault and describes the action
which should be taken to correct the fault.
Faults within the electronic microprocessor must be repaired by factory trained service personnel.
When these faults occur, the competent service organization must be contacted.
Malfunctions Table
Error Code Error
E01 Fallen below the radius or above angle range
E02 Radius range exceeded or fallen below angle range
E03 Boom position is out of the permissible working area
E04 Operating mode not existing
E05 Prohibit length range
NOTE:
If there is any Error Code displayed on the console which is not listed in the Malfunctions Table you
should call the Local Distributor.

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ERROR CODE DESCRIPTION
OPERATING ERRORS
Malfunctions in the system which are caused by range exceedings or operating errors by the crane
operator himself are indicated on the display together with an explanation. These error codes are
E01, E02, E03, E04 and E05 and they can normally be eliminated by the crane operator himself.

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ERROR CODE TABLE
Error Code Error Cause Elimination
E01 Fallen below radius
range or angle range
exceeded
•Fallen below the minimum
radius or gone past the
maximum angle specified in
the respective load chart
due to luffing up the boom
too far
•Luff down the boom to a ra-
dius or angle specified in the
load chart.
E02 Radius range ex-
ceeded or fallen be-
low angle range
•Gone past the maximum ra-
dius or fallen below the
minimum angle specified in
the respective load chart
due to luffing down the boom
too far
•Luff up the boom to a radius
or angle specified in the load
chart.
E04 Operating mode not
acknowledged •A non existing operating
mode has been selected •Set the correct operating mode for the operating state
in question
E05 Prohibited length
range •Boom has been extended
either too far or not far
enough, e.g. if it is prohib-
ited 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
•Extend/retract boom to the
correct length
•Length sensor adjustment
has changed, e.g. the cable
slid off the length sensor
reel.
•Retract boom. Check the
prestress of the cable reel
(cable must be taut). Open
the length sensor and care-
fully turn the length sensor
pot counterclockwise until
the detent by means of a
screw driver
•Clutch between length sen-
sor pot and drive is defec-
tive
•Replace the complete clutch
including drive wheel and
adjust length sensor pot as
described above
•Failure of +5V supply of
analog part of analog board •Check +5 V supply. Ex- change main board in case
of voltage failure or break-
down when loaded with 50
ohms approx.
•Cable between central unit
and length sensor is defec-
tive or disconnected.
•Check cable and plugs, re-
place, if need be.

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Error Code Error Cause Elimination
•Defective length poten-
tometer •Replace length potentiome- ter.
E06 Radius range ex-
ceeded or fallen be-
low angle range with
luffing jib operation
•Maximum radius as speci-
fied in the load chart ex-
ceeded or fallen below
minimum angle due to luffing
down the luffing jib too far
•Luff the jib to a radius or an-
gle specified in the load
chart.
E07 Faulty acknowledg-
ment of the overload
relay on the connec-
tion board.
The relay should be
energized, the 2nd
contact however is
indicated to be off, or
the 2nd contact is in-
dicated to be on
while the relay
should be de-
energized.
•Overload relay or connec-
tion board are defective
•Processor board defective
•Replace connection board
•Replace processor board.
E08 No acknowledgment
from the anti-two-
block relay
•refer to E07 •refer to E07
E10 Error in the length
measurement •With the boom retracted, the
signal "main boom length"
differs by more than 2 %
from the programmed value
for the basic length
•Check length sensor of the
main boom
•With the boom retracted, the
signal "length Tele I (+II)"
differs by more than 2 %
from the reference value 0
•Check length sensor 2.
E11 Fallen below lower
limit value for meas-
uring channel "length
main boom"
•Cable between central unit
and length sensor is defec-
tive or disconnected. Water
inside the plug of the
length/angle sensor
•Check cable as well as
plugs, replace, if need be.
•Length potentiometer is
defective •Replace length potentiome- ter
•Electronic component in the
measuring channel is defec-
tive
•Replace LMI main board or
processor board.
E12 Fallen below the
lower limit value in
the measuring chan-
nel "pressure piston
side"
•Cable between the central
unit and pressure transduc-
ers defective or water inside
the plugs
•Check cable as well as
plugs, replace, if need be.

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50 / 150 / 19_0031E.DOC / 19.03.1997 / Rev. C / rk.
Error Code Error Cause Elimination
•Pressure transducer is de-
fective. •Replace pressure trans- ducer
•Electronic component in the
measuring channel is defec-
tive.
•Replace LMI main board or
processor board.
E13 Fallen below lower
limit value in the
measuring channel
"pressure rod side"
•refer to E12 •refer to E12
E15 Fallen below lower
limit value in meas-
uring channel "angle
main boom"
•Cable between central unit
and the length/angle sensor
defective or loose. Water
inside the plug of the
length/angle sensor.
•Check cable as well as
plugs, replace, if need be.
•Angle potentiometer defec-
tive •Replace angle sensor
•Electronic component in the
measuring channel defec-
tive.
•Replace LMI main board or
processor board.
E16 Fallen below lower
limit value in meas-
uring channel "angle
2"
•Cable between the central
unit and the angle sensor
defective or loose. Water
inside the plug of the angle
sensor.
•Check cable as well as
plugs, replace, if need be.
•Angle potentiometer defec-
tive •Replace angle sensor
•Electronic component in the
measuring channel defec-
tive.
•Replace LMI main board or
processor board.
E17 Fallen below lower
limit value "length
telescope I (+II)"
•Cable between the central
unit to the length sensor
defective or loose. Water
inside the length sensor
plug.
•Check cable as well as
plugs, replace, if need be.
•Length potentiometer defec-
tive •Replace length sensor.
•Electronic component in the
measuring channel defective •Replace LMI main board or processor board.
E19 Reference and/or
supply voltage de-
fective
•The supply voltage is falsi-
fied by one of the sensors
(DAV, LWG)
•Check the voltages on the
LMI main board (AGND =
MP0). Check sensors, plugs
and cable, replace, if need
be.
•Electronic component is
defective •Replace LMI main board
•A/D converter defective. •Replace LMI main board