SkyAzúl DS350G Service manual

SIGALARM
MODEL 210
DS350G/GW
Operator's Handbook

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NOTICE
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the implied warranties of merchantability and/or its fitness for a particular purpose.
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All information in this document is subject to change without notice.
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Middletown, MD 21769
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PART 1
TABLE OF CONTENTS
1 General
Information
1
2 Warnings
2
3 System Description
3
3.1
Operating Console 5
32 System Function 6
4 System's Operation 7
4.1 Pre-Setup 7
4.2 Information Run 12
4.3 Programming Procedure 26
4.3.1 Programming of Operating Mode 26
4.32
Activating and Setting of Boom Angle Preset Limits 33
5 Pre-Operation Inspection
and Calibration Verification 38
6 Service and Maintenance 44
7 Troubleshooting
45
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DS350GW Operator's Handbook

GENERAL INFOPMATION
1
1 GENERAL INFORMATION
The PAT Load Moment lndicator1l (LMI) OS 350 GW has been designed
to provide the crane operator with the essential information required to
enable the machine to be used within its design parameters.
Using various sensing devices, the Load Moment Indicator monitors
various crane functions
and provides the operator with a continuous
reading of the crane's
capacity. The readings continuously change as
the crane moves through the motions needed
to make the lift.
The LMI provides the operator with information regarding the length and
angle of the boom, tip height, working radius, rated load and the total
calculated weight being lifted
by the crane.
If non permitted conditions are approached, the OS 350 GW Load Mo-
ment Indicator will warn the operator by sounding an audible alarm,
lighting a warning light and locking out those functions that may aggra-
vate the crane's condition
1) LOAD MOMENT: generally lhe produd of a force and Ill moment arm; apeclllcally, Iha produd
of the load
and Iha load-radius. Ueed In Ille dllarmlnallon ol lhe lifting capaclly ot a crane.
2 WARNINGS
The LMI is an operational aid which warns a crane operator of ap-
proaching overload conditions and also warns of overhoist conditions
which could cause damage to equipment
and personnel.
The device is not, and shall not, be a substitute for good operator
Judgement, experience and use
of accepted safe crane operating
procedures.
The responsibility for
the safe operation of the crane shall remain
with
the crane operator who shall ensure that all warnings and in-
structions supplied are fully understood and observed.
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DS350GW Operator's Handbook

2 Operator's Handbook PAT
OS 350 GW
Prior to operating the crane, the operator must carefully and
thoroughly read and understand the information in this manual to
ensure that he knows the operation and limitations
of the indicator
and crane.
Proper functioning is dependent upon proper daily Inspection and
observations
of the operating instructions set forth in this manual.
We draw your attention to section 5 of this handbook.
WARNING
The display (6) will only aid the operator when the LMI Is prop-
erty programmed and the proper load capacity chart and operat-
ing 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 property programmed before operat-
ing the crane.
WARNING
This system is equipped with an override key on the central mi-
croprocessor unit. This key switch bypasses control lever lock-
out function
of load moment Indicator device. The switch may
only be used
by authorized personnel during emergency situa-
tions. Failure
to follow this Instruction may result In property
damage and/or personal injury.
NORMAL OPERATION UOOVERRIDE
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DS350GW Operator's Handbook

3 3
3 SYSTEM DESCRIPTION
The PAT Load Moment Indicator DS 350 GW consists of a central micro
processor unit, operating console, length/angle sensor, pressure trans-
ducers and anti-two-block switches.
The system operates on the principle
of reference/actual comparison.
The actual value, resulting from the force
or pressure measurement is
compared with the reference data, stored in the central processor
memory and evaluated
in the micro processor. When limits are reached,
an overload warning signal is generated at the operator's console.
14.
the same time, the dangerous crane movements, such as hoist up, tele-
scope out and boom down, will be stopped.
The fixed data regarding the crane, such as
load capacity charts, boom
weights, centers
of gravity and dimensions are stored in memory chips
in the central processor unit. This data is the reference information used
to calculate the operating conditions.
Boom length and boom angle are registered by the length/angle sensor,
mounted inside the cable reel which is mounted
on the boom. The
boom length is measured by the cable reel cable which also serves as
an electrical
conductor for the anti-two-block switches.
The crane load is measured
by pressure transducers attached to the
piston and rod side of the lift cylinders.
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DS350GW Operator's Handbook

4 Operator's Handbook PAT
OS 350 GW
Fig. 1: Components of PAT LMI
System OS 350 GW
©
1 ANTI- lWO-BLOCK SWITCHES
2
PRESSURE TRANSDUCERS
3 LENGTH/ANGLE SENSOR-ANTI-
lWO-BLOCK CABLE REEL
4 OPERATING CONSOLE
5 CENTRAL MICRO PROCESSOR UNIT
NOTE:
If PAT System is to be
used
in conjunction
with a jib having an ex-
.
is1ing Grove/Krueger
Anti- Two-Block sys1em,
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DS350GW Operator's Handbook

Light bar
Insert Page
LIGHTBAR
The PAT Llghtbar is a supplementary indicator for the standard PAT
Load Moment Indicator systems. It displays the load moment in form of
a bargraph. The lightbar is located in the operator's cab In front of the
operator.
This indicator displays how much of the crane capacity Is being used.
As the crane Is moved through its various motions, the bargraph Will
constantly change.
The range of the bargraph is divided into 3 areas:
- the green area is the normal wor1<ing area,
- the yellow prewaming area shows the remaining por-
tion of the rated load capacity and the bargraph indi-
cates the approach to the overload condition,
- the red area shows that the maximum rated load
capacity Is exceeded.
Note: Operating within the red area Is notpennltted.
Brightness adjustment:
In order to adapt the PAT Llghtbar's brightness to the lighting condi-
tions of the environment a DIM-switch is installed on the right hand side
of the display. When actuating the DIM-switch the brightness increases.
After having exceeded the maximum brightness value the display turns
back to the minimum brightness value.
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DS350GW Operator's Handbook

3 OPERATING CONSOLE
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, information and instructions
Ag. 2: Operating Console
1 Dlll)t.y
2 Load Moment Indicator
3 t<.yped
4' Button °Ope!Mllig Code
5 Button "RN,<lng'
6 Button "M•n Holst'
7 Button ·~. Holst'
8 klt1·2·Block Al8rm Ugh!
9 Load Moment Pr-amlng Light
10 Loed Moment Umlt Ught
11 °"'11de K8)' Warning Ugh!
12 Button 'Horn Off'
13 Button 'Boom Data'
14' Button 'loed Indication'
15 Button "T••'
16 Button 'Boom klgle Pr-I Umlt'
17 Button 'Info'
18 Button "Enter'
19 K8)' swttch
20 By-Pus Anlt·2·81ock lockout
21 Norm• Operation
22 By·Pus LMI lockout
23 hldlble _..arm
5
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6 Operator's Handbook
PAT DS 350 GW
3.2 SYSTEM FUNCTION
The PAT Load Moment Indicator (LMI) works with a user guide system
that simplifies the operation
of the crane and the LMI system. The sys-
tem run during the start up phase is
shown in the following block dia-
Start
Sell check ol
LMI System
">-----l Error code
Information run
Programming
Procedure
Ready for
Operation
no
--- lnputby
Operator
gram.
After ignition of the engine the
system starts
with an automatic
test of all lamps, the audible
alann and the complete
LMI sys-
tem.
In case of system malfunction an
error code number will be dis-
played on the console.
After restarting the engine within 2
hours, the system will by-pass
"Pre-Setup"
and information run•.
Basic system information for
crane operator
wiU be displayed.
Experienced operators who
are
familiar with the LMI system can
by-pass the info
run
The system will display informa-
tion and directions
which the
operator will follow by using the
respective function of the key.
The system is in the program-
ming procedure.
The operator
has to set the
LMI to the configu-
ration of
the crane.
The system is ready for operation
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4.1 Pre-Setup
7
4 SYSTEM'S OPERATION
During the startup phase the crane operator will receive information
about the function and meaning of the various elements of the console.
This process will also remind the crane operator to follow the respective
operating instructions.
During the pre-setup phase the crane operator will receive general infor-
mation about his responsibility by operating the crane.
If the operator is experienced and totally familiar with the function and
operation of the system he can go directly to the programming proce-
dure
at the end of this PRE-SETUP phase.
When the crane engine Is restarted after less than approximately
two hours, the Pre-Setup and lnfonnation Run will be skipped.
4.1 Pre-Setup
The PRE-SETUP is a simple step by step procedure. The information
will be displayed until a button is pressed to call for the next info step.
The PRE-SETUP is followed by the Info f\m or by the programming
phase.
In the following the system start will be explained step by step.
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DS350GW Operator's Handbook

8 Operator's Handbook PAT DS 350 GW
MESSAGE 1
Mer the ignition of the crane has been
ON KEVPAD #3 activated and the system has passed
PUSH "1" ""OR ENGLISH
r through the system test without errors,
the console will displaythis phrase alter-
nating
in English, Spanish, French, Ger-
man
or other languages with the corresponding number.
With the button
•1•, "2", "3" or •4• on the keypad (# 3) the crane operator
can select the English, Spanish, French
or German language. The lan-
guage does not have any influence on the function
of the system.
MESSAGE 2
DISPLAV IS NOU IN
ENGLISH
Instruction: Push Button •1 •, "2~
"3" or •4• of Kewad depending on
the desired language
,;[IJ
The display will now show the
selected language.
Mer completion of programming pro-
cedure, the language can be changed
TO CONFIRM *PUSH "E" anytime by pressing the INFO button
(17) and selecting the desired language
at Message # 1 and confirming at Message #
2. Mer 15 seconds
without pressing any button, the readout will display operating informa-
tion and instructions
in the desired language.
Button
"E" has to be pressed to accept this language.
Instruction: Push Button "E"
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DS350GW Operator's Handbook

4.1 Pre-Setup
MESSAGE 3
FIND OPERATOR
MANUALS
READ AND UNDERSTAND
* PUSH "INFO"
9
Prior to operating, the crane operator
shall carefully and thoroughly read
and understand the crane load capac-
ity charts and the information con-
tained in the manuals for the crane
and the LMI, to ensure that the opera-
tor knows the operation and limita-
tions of the crane and the LMI.
Instruction: Push Button "INFO"
8
MESSAGE 4
THE Ll'II SYSTEM IS AN
OPERATIONAL AID
WHICH CAN FAIL
* PUSH "INFO"
The load moment indicator (LMI) is a
system which supports an operator in
his action to operate the crane.
But the system cannot be 100°/o fall-safe and not all causes for
danger can be recognized at the same time.
Instruction: Push Button "INFO"
8
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DS350GW Operator's Handbook

10
MESSAGE 5
CONSULT AND OPERATE
ACCORDING TO IN CAB
LOAD CAPACITY CHARTS
* PUSH "INFO"
Operator's Handbook PAT OS 350 GW
For the loading capacity of the crane
only
the load capacity charts are rele-
vant. The operator shall also observe
the operating instructions in the load
capacity charts.
The load values In the load capacity chart shall under no circum-
stances be exceeded.
It Is essential to select the correct operating
code number which Is also printed in the load capacity chart.
Instruction: Push Button •tNFO•
8
MESSAGE 6
YOU ARE ALWAYS
RESPONSIBLE FOR
YOUR LIFT OPERATIONS
* PUSH "INF"O"
The opsrator Is entirelyresponsible
for safe crane operation.
He has to make sure that the crane is
in good condition and that he works
on firm and level supporting surface.
The operator shall fully acquaint him-
self with the most recent government
regulations and industry standards rel-
evant to safe craning operations.
Instruction: Push Button •tNFO•
8
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DS350GW Operator's Handbook

4.1 Pre-Setup
MESSAGE 7
If IN DOUBT CONSULT
THE OPERATOR MANUALS
BEFORE OPERATING THE
CRANE "'PUSH "INFO"
11
If there is anything unclear or if there
are doubts about operating the crane
or LMI, the operator shall consult the
operator manuals before operating the
crane.
Instruction: Push Button •INFO•
8
MESSAGE 8
FOR FULL INFO RUN
... PUSH NI NFO"
TO SKIP CONSOLE DE-
SCRIPTION "' PUSH "E"
Only if you are totally familiar with the
LMI system functions may you go
.directly to the programming . proce-
dure
by pressing the button "E".
Instruction:
Push Button "INFO" for Info run
Push Button "E" to skip over Info
run
8
G)
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DS350GW Operator's Handbook

12 Operator's Handbook
PAT OS 350 GW
4.2 Information Run
The Information Run is a simple step by step procedure. The informa-
tion will
be displayed until a button is pressed to call for the next info
step. The Information Run is followed by the programming phase.
MESSAGE 1
YOU UILL NOW GET A
DESCRIPTION OF THE
CONSOLE
* PUSH "INFO"
MESSAGE 2
DESCRIPTION IS MADE
ACCORDING TO 11 TO
123 ON CONSOLE
* PUSH " INFO"
A description of all elements of the
front plate
such as display, controls,
switches
and buttons is given.
Instruction: Push Button "INFO" (rt,FO'l)
The description of the info run follows
the reference numbers. The numbers
are printed on the front plate of the
console next to the various operation
and information elements, such as dis-
play, lights, switches, buttons.
Instruction: Push Button "INFO" (f iM'O'~)
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4.2 Information Run
MESSAGE 3
REF #1: DISPLAY FOR
INFO/LOAD/BOOM/ERROR
CODE DATA
* PUSH "INFO"
MAX. LOAD 4,800lbs
ACT. LOAD 3,400lbs
RADIUS 115.3ft
12 FALLS IOP.MOD0001
Display will be in units correspond-
ing
to load capacity charts
MESSAGE 4
REF #2: DISPLAY OF
LOAD MOMENT
* PUSH "INFO"
©
l~I
13
The DISPLAY (1) will show technical
information as well as operating infor-
mation and instructions for the opera-
tor.
During crane operation the readout
will display max. load, actual load,
radius, number
of falls (parts of line)
and the operating code. Radius is
used if the used load capacity chart is
radius related. In case of an angle re-
lated load capacity chart
Oib), boom
angle is displayed instead
of radius.
Instruction: Push Button ,NFO" (f WO'])
The load moment will be displayed in
the INDICATOR (2). This meter dis-
plays how much
of the crane's rated
capacity is being used.
ks the crane is
moved through its various motions,
the percent
of load moment will con-
stantly change on the display.
The meter is divided into 3 areas:
- a green area is the
normal working area
- a yellow prewarning area shows the remaining portion
of the
rated load capacitiy and the meter needle indicates the
approach to the overload condition
- a red area shows that the maximum rated load capacity is
exceeded.
Operating within the red area Is not pennitted.
Instruction: Push Button "INFO' 8
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14
MESSAGE 5
REF 13: KEVPAD TO
ENTER CODE NO. AC-
CORDING TO FUNCTION
BUTTON"' PUSH "INFO"
MESSAGE 6
REF #4: OPERATING
CODE BUTTON REFER
TO LOAD CAPACITV
CHART • PUSH "INFO"
Operator's Handbook PAT DS 350 GW
The KEYPAD (3) buttons 1 to O are
used to select the languages, the
operating mode and the number of
falls (parts of line)
or other functions.
Instruction: Push Button "INFO" (rtl'O'J)
The OPERATING CODE BUTION (4)
is used to activate the programming
procedure.
Refer to programming proce-
dure in chapter
4.3. 1 [fvii~
Instruction: Push Button "INFO"
WARNING
The col1'8Ct setting is of utmost importance for the proper func-
tion 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.
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DS350GW Operator's Handbook