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ANGLE-LENGTH-RADIUS-LOAD
INDICATOR SYSTEM
EI65
TROUBLESHOOTING
HANDBOOK
Link-Belt
Construction Equipment
LATTICE BOOM CRANES
031-300-190-035 REVISION A 01/25/99
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EI65 TROUBLESHOOTING HANDBOOK
NOTICE
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 limited
to the implied warranties of merchantability
and fitness for a particular purpose.
PAT shall not be liable for errors contained herein
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. All rights are
reserved. No part of this document may be
photocopied, reproduced, or translated to
another language without prior consent of PAT.
031-300-190-035 REVISION A 01/25/99
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EI65 TROUBLESHOOTING HANDBOOK
Table of Contents
1. General Information............................................................................... 1
2. Warnings ............................................................................................... 2
3. System Flow Charts............................................................................... 3
3.1. No Display ...................................................................................... 4
3.2. Anti-Two Block Problem ................................................................. 5
3.3. Angle Reading Problem.................................................................. 7
3.4. Load Reading Problem................................................................... 8
4. Error Codes ......................................................................................... 10
5. Drawings.............................................................................................. 11
5.1. System Diagram ........................................................................... 12
5.2. Connection Board Layout............................................................. 13
5.3. Main Board Layout ....................................................................... 13
5.4. Anti-Two Block Circuit................................................................... 14
5.5. Angle Sensor Adjustment ............................................................. 15
5.6. Angle Sensor Supply Voltage....................................................... 15
5.7. Angle Sensor Circuit..................................................................... 16
5.8. Linerider Circuit ............................................................................ 17
5.9. Linerider Supply Voltage .............................................................. 18
031-300-190-035 REVISION A 01/25/99
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EI65 TROUBLESHOOTING HANDBOOK
1. GENERAL INFORMATION
The purpose of this troubleshooting handbook is to provide additional information to assist
a service or maintenance person in identifying malfunctions or system problems with the
PAT System. A digital voltmeter and regular maintenance and service tools will be
required to troubleshoot the system. Note: Knowledge of how to use a digital voltmeter is
assumed.
REFERENCE:
Operator’s and Calibration Handbook PAT 031-300-190-015
SYSTEM MALFUNCTION:
MB 115.0 J1 85.0
J2 50.0 0J 15.0 E71
Section 4, Error Codes. The table identify various faults that can occur with the EI65,
explain each fault, and describe the action which shall be taken to correct the fault.
Faults within the electronic microprocessor shall be repaired by factory trained service
personnel. When these faults occur, contact your authorized dealer or service
organization.
SYSTEM PROBLEMS:
If the operator identifies a possible problem in the system, perform the pre-operation
inspection in the Operator’s Handbook 031-300-190-015 to define the problem. Use the
following drawings to identify the problem.
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. The EI65 System indicates the length and angle of the
boom, tip height, working radius and the total weight being lifted by the crane. Using the
various sensors and the limits set by the operator, the EI65 System warns the crane
operator of certain approaching hazardous conditions which could occur during the
operation of his crane.
In case of a malfunction of the system, an error code which
identifies the system malfunction will be displayed in the
reeving portion of the display. The error codes are listed in
1
Always refer to operational instructions and load charts provided by the crane
manufacturer for specific crane operation and load limits.
031-300-190-035 REVISION A 01/25/99
WARNING
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EI65 TROUBLESHOOTING HANDBOOK
2. WARNINGS
• The EI65 is an operational aid which warns a crane operator of certain approaching
hazardous conditions which could cause damage to equipment and personnel.
• The device is not, and shall not be, a substitute for good operator judgment,
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 instructions supplied are fully
understood and observed.
• Prior to operating the crane, the operator must carefully and thoroughly read and
understand the information in the operator’s handbook to ensure that he/she knows the
operation and limitations of the indicating system and crane.
2
031-300-190-035 REVISION A 01/25/99
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EI65 TROUBLESHOOTING HANDBOOK
3. TROUBLESHOOTING FLOW CHARTS
This section explains how to handle a problem that may arise with the EI65, PAT Load
Indicator System. 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. Section 5 contains the necessary drawings
needed for troubleshooting.
START
What’s Wrong?
3
No display
Anti-Two Block Problem
Angle Reading Problem
Load Reading Problem
Go to Section 3.1
Go to Section 3.2
Go to Section 3.3
Go to Section 3.4
031-300-190-035 REVISION A 01/25/99
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EI65 TROUBLESHOOTING HANDBOOK
3.1 NO DISPLAY
PROBLEM: Blank console display with no warning light shown.
Refer to Drawing 2, Connection Board, Section 5. Drawings.
4
Start
Check fuse F1 in console.
Correct?
Yes
Measure crane voltage on connection board between X1:1 (+UB) and X1:3 (ground).
Refer to Drawing 1, System Diagram, Section 5. Drawings.
Correct?
Measure voltage on connection board between MP4 (+5.25V) and MP1 (ground).
Refer to Drawing 2, Connection Board, Section 5. Drawings.
Correct?
No
Yes
No
No
Check crane power supply for faulty
crane electric or if supply is too low.
Defect on connection board. Replace
Replace fuse (2amp/250V)
console connection board.
Measure voltage to main board between MP15 (+5.25V) and MP1 (ground).
Refer to Drawing 3, Main Board, Section 5. Drawings..
031-300-190-035 REVISION A 01/25/99
Yes
Replace console main board.
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EI65 TROUBLESHOOTING HANDBOOK
3.2 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.
5
Correct? Lower hook down into safe position
Check weight position. Refer to Operator's Section of Handbook 031-300-190-015
Section 5. Pre-Operation Inspection, item 1, 2, and 3 for
switch weight positions for the main boom and extension.
Correct?
Check the A2B circuit at the boom tip junction box.
With power off, measure A2B signal in the j-box between terminals 5 & 6.
With the bypass plugs and switch weight in position the ohm meter reads 4.7K ohms.
Refer to Drawing 4, Anti-Two Block Circuit, Section 5. Drawings.
Yes
No
Yes
No
Position the weight properly.
Correct? No
Yes
Next Page
031-300-190-035 REVISION A 01/25/99
Replace Anti-Two-Block switch.
Refer to Drawing 1 & 4 in Section 5. Drawings.
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EI65 TROUBLESHOOTING HANDBOOK
3.2 ANTI TWO BLOCK PROBLEM - continued
Continued from previous page.
PREVIOUS PAGE
With power off, measure the A2B signal in the console at the X1:9 and X1:10.
With the switch weight in position the ohm meter reads 4.7K ohms.
Refer to Drawing 4, Anti-Two Block Circuit, Section 5. Drawings.
6
Correct?
Fault in cable assembly. Check cable assemblies
No
Refer to Drawing 1, System Diagram, Section 5. Drawings.
Yes
With power on and the switch weight in position,
If the Anti-Two Block condition exists replace connection board.
A2B relay defective on connection board.
Refer to Drawing 1 & 2, Section 5. Drawings..
and replace defective cable.
Yes
End
031-300-190-035 REVISION A 01/25/99
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EI65 TROUBLESHOOTING HANDBOOK
3.3 ANGLE READING 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 Drawing 5. Angle Sensor Adjustment in Section 5. Drawings.
Check the supply voltage to angle sensor on connection board
between X1:17 (+5VDC) and X1:20 (ground).
Refer to Drawing 1, System Diagram in Section 5.
7
Correct?
Check the voltage at angle sensor between connector pins A (AGND) and C (+5V).
Correct?
Check the voltage between X1:20 (ground) and X1:18 (signal/output voltage).
No
Yes
Refer to Drawing 1 & 6 in Section 5.
No
Yes
Voltage should be 3.125V (0°), 2.5V(45°), 1.875V (90°).
Refer to Drawing 6, Angle Sensor Circuit in Section 5.
NoCorrect?
Cable assembly defective, replace cable assembly.
Refer to Drawing 1, System Diagram in Section 5.
Refer to Section 14. Angle Sensor Setup/Adjustment Procedures.
Check system power supply voltage.
Complete to Section 3.1 No Display.
Replace Angle Sensor.
Yes
031-300-190-035 REVISION A 01/25/99
Complete steps 4.1 through 4.6 and 4.12 through 4.24 in the Calibration
Section of Operator's and Calibration Handbook 031-300-190-015.
END
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EI65 TROUBLESHOOTING HANDBOOK
3.4 LOAD READING PROBLEM
PROBLEM: Displayed Load is out of tolerance. The displayed load
should be equal to or 10% greater than the actual load.
START
Complete Pre-Operation Inspection in Section 5 of the Calibration Section
of the Operator's and Calibration Handbook 031-300-190-015.
Before changing calibration information complete the following steps.
8
Correct?
Correct?
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 Drawing 1, System Diagram in Section 5.
No
Yes
Check the voltage at linerider between connector pins A (+9V) and B (-9V).
Refer to Drawing 1 & 9 in Section 5.
No
Cable assembly defective, replace cable assembly.
Refer to Drawing 1, System Diagram in Section 5.
Check system power supply voltage.
Complete to Section 3.1 No Display.
Voltage = 18V
Next Page
031-300-190-035 REVISION A 01/25/99
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EI65 TROUBLESHOOTING HANDBOOK
3.4 LOAD READING PROBLEM - continued
Remove hoist rope so there is no load on the load cell of the linerider.
Check the zero point of the Linerider on connection board between
Main X1:26 (+sig) and X1:27 (-sig)
Aux X1:30 (+sig) and X1:31 (-sig)
Voltage = 0 ±0.025V
Refer to Drawing 1,7 Linerider Circuit in Section 5.
With no load on the load cell of the linerider.
Check the zero point of the linerider in the boom tip junction box.
Correct? No
Main j-box terminal 2 (+sig) and 1 (-sig)
Aux j-box terminal 7 (+sig) and 8 (-sig)
Refer to Drawing 1, 7 Linerider Circuit in Section 5.
9
Previous Page
Voltage = 0 ±0.025V
No
Check cable continuity; Replace cable if necessary
No
Replace Load Cell or Linerider Assembly
Yes
Lift test load and verify linerider output voltage.
Complete steps 3.4 Setting the Linerider output voltage in the Calibration Section of
the Operator's and Calibration Handbook 031-300-190-015.
No
Check Calibration by completing steps 4.1 through 4.3, 4.9(Main), 4.10(Aux), and
4.12 through 4.24 in the Calibration Section of the
Operator's and Calibration Handbook 031-300-190-015.
No
031-300-190-035 REVISION A 01/25/99
Replace Load Cell or Linerider Assembly
No
End
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EI65 TROUBLESHOOTING HANDBOOK
10
4. ERROR CODE TABLE
Error code Reason Action
11 Operating data in the buffered RAM Turn on the system again and
adjust operating data
21 Crane parameters in the serial EPROM
incorrect
31 Wrong EPROM programming or EPROM
defective
51 Short circuit min layer device term 11&12 Check minimum layer device
52 Cable break min layer device term 11&12 Check minimum layer device
53 Short circuit A2B -switch - 2 term 13&14 Check anti-two block system
54 Cable break A2B -switch - 2 term 13&14 Check anti-two block system
55 Short circuit A2B -switch - 1 term 9&10 Check anti-two block system
56 Cable break A2B -switch - 1 term 9&10 Check anti-two block system
•61
•63
•71
•72
•73
•74
•75
•76
•77
•78
Load on the main hoist hook too big Reduce load on main hoist
Load on the auxiliary hoist hook too big Reduce load on aux. hoist
Limit Length - Main - Boom - Max. Decrease length limit
Limit Length - Main - Boom - Min. Increase length limit
Limit WG - Main - Boom - Max. Decrease main boom angle
Limit WG - Main - Boom - Min. Increase main boom angle
Limit Boom height - Max. Decrease main boom angle
Limit Boom height - Min. Increase main boom angle
Limit Working radius - Max. Increase main boom angle
Limit Working radius - Min. Decrease main boom angle
81 ADC-Measuring value KMD1 too big Check zero point in linerider
82 ADC-Measuring value KMD1 too low Check zero point in linerider
83 ADC-Measuring value KMD2 too big Check zero point in linerider
84 ADC-Measuring value KMD2 too low Check zero point in linerider
93 ADC-Measuring value WG1 too big Check main angle sensor circuit
94 ADC-Measuring value WG1 too low Check main angle sensor circuit
95 ADC-Measuring value WG2 too big Check luffing angle sensor
96 ADC-Measuring value WG2 too low Check luffing angle sensor
• Limit set by the operator refer to Operator’s Handbook, Section 4.3. Activating and
Setting Preset Limits
Re-calibrate the system
Exchange EPROM
circuit
circuit
031-300-190-035 REVISION A 01/25/99
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EI65 TROUBLESHOOTING HANDBOOK
5. SYSTEM DRAWINGS
The PAT EI65 System drawings in this section are provided as reference material for the
troubleshooting flow charts. Use the drawings in conjunction with the flow charts to help
understand the operation of the EI65 system.
Drawing List:
1. System Diagram
2. Connection Board Layout
3. Main Board Layout
4. Anti-Two Block Circuit
5. Angle Sensor Adjustment
6. Angle Sensor Circuit
7. Linerider Circuit
Refer to the Operator’s Handbook for basic component layout on the crane and console
drawing. The EI65 console connection board has the following terminal designations.
Connection Board 056-065-300-002 Designations:
1 + Battery
2 + Battery
3 - Battery
4 - Battery
5 Load Limit output
6 A2B Relay output 2
7 A2B Relay output 1
8 Peripheral ground
9 A2B 1 input
10 A2B Ground
11 A2B 2 input
12 A2B Ground
13 3rd Wrap Switch input
14 3rd Wrap Switch ground
15 Digital input 1
16 Digital input 2
17 +5VDC
18 Main Boom angle input
19 Main Boom Length input
20 Analog Ground
21 +5VDC
22 Jib Angle input
23 Analog Ground
24 Analog Ground
25 +9VDC
26 KMD1 +Signal input
27 KMD1 -Signal input
28 -9VDC
29 +9VDC
30 KMD2 +Signal input
31 KMD2 -Signal input
32 -9VDC
11
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031-300-190-035 REVISION A 01/25/99
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EI65 TROUBLESHOOTING HANDBOOK
5. DRAWING 2. CONNECTION BOARD LAYOUT
5. DRAWING 3. MAIN BOARD LAYOUT
MP1 = GND
MP2 = 5.6V
MP3 = 5.6V
MP4 = 5.25V
13
MP0 = GND
MP1 = AGND
MP2 = +5.0V
MP3 = +5.0V
MP4 = SIGNAL NOT USED
MP5 = SIGNAL, ANGLE 2
MP6 = SIGNAL, ANGLE 1
MP7 = SIGNAL, KMD1
031-300-190-035 REVISION A 01/25/99
MP8 = SIGNAL, KMD2
MP9 = AN5 REFERENCE VOLATGE
MP10 = AN6 REFERENCE VOLTAGE
MP11 = AN7 REFERENCE VOLTAGE
MP12 = -0.5V
MP13 = +5.0V
MP15 = 5.25V
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EI65 TROUBLESHOOTING HANDBOOK
5. DRAWING 4. ANTI-TWO BLOCK CIRCUIT
14
The anti-two block circuit can connect three A2B switches in series. The signal is divided
by a 4.7KΩ resistor; therefore, a resistance can be measured 4.7KΩ between:
• console terminal X1:9 and 10
• junction box terminal 5 and 6
• the three receptacle connection 1(A) and 2(B) in the junction box.
031-300-190-035 REVISION A 01/25/99
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EI65 TROUBLESHOOTING HANDBOOK
φ φ
5. DRAWING 5, ANGLE SENSOR ADJUSTMENT
WG 203
15
The angle φ shown above needs to be within +0, -0.4 of the actual angle of the boom.
Check boom angle at base/heel section only. After adjustment, compare the actual boom
angle with the displayed angle at about 0°, 30° and 60°. To comply with the SAE J375
standards the displayed angle must be +0.0° to -2.0° of the actual angle.
5. DRAWING 6, ANGLE SENSOR SUPPLY VOLTAGE
The supply voltage can be checked directly at the cannon connection. Using a digital volt
meter measure between pins A and C, (A=GND, C= +5V). If this voltage is not correct
refer to the system wiring diagram and verify all cable connections. You may need to start
at the main board and check the supply voltages at their proper measuring points.
031-300-190-035 REVISION A 01/25/99
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EI65 TROUBLESHOOTING HANDBOOK
5. DRAWING 7, ANGLE SENSOR CIRCUIT
16
031-300-190-035 REVISION A 01/25/99
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EI65 TROUBLESHOOTING HANDBOOK
5. DRAWING 8, LINERIDER CIRCUIT
17
031-300-190-035 REVISION A 01/25/99
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EI65 TROUBLESHOOTING HANDBOOK
18
5. DRAWING 9, LINERIDER SUPPLY VOLTAGES
The supply voltage can be checked directly at the cannon connection. Using a digital volt
meter measure between pins A and B, (A= +9v) + (B= -9v) = 18volts. If this voltage is not
correct refer to the system wiring diagram and verify all cable connections. You may need
to start at the console and check the supply voltages at their proper measuring points.
031-300-190-035 REVISION A 01/25/99
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EI65 TROUBLESHOOTING HANDBOOK
HANDBOOK REVISIONS
REV DATE NAME DESCRIPTION
- 10/19/98 CSH EI65 Troubleshooting handbook created.
A 01/25/98 CSH Pg 13 - Add both sides of main board and measuring point
Pg 15 - Chg. drawing 6 +5 volts
19
031-300-190-035 REVISION A 01/25/99
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