[KATO SERVICE MANUAL MS-10E “Compuload” With Voice Alarm KATO WORKS CO.,LTD.PREFACEe:s1-c00000¢) This is the maintenance manual for the new digital-type “Automatic Crane Stopper” (ACS) automatic overload-prevention equipment installed in KATO cranes. Unlike past analog ACS systems, the microprocessor-equipped digital type ACS has a self-diagnosis function to facilitate maintenance, as well as the automatic overload-prevention function. The maintenance data which could be found only in the analog ACS service manual are conveniently accessible through the new self-diagnosis function. In addition to which the condi of the automatic overoad-prevention system itself is automatically monitored, therefore increasing reliability. However, crane control governed by such advanced electronic technology cannot be expected to perform to its full capacity without the careful follow up of a service technician. KATO is confident that you will be able to provide prompt, effective service using this manual.CONTENTS [820469] PREFACE (8151-0000008) SYMBOLS AND TERMS 1. CONFIGURATION AND FUNCTIONS@151-0100002) 1—1 System Configuration (s1s1-o10100e) 1-2 Hardware Block Diagram (s1st-o10200e) 1~3 Software Operation Flowchart s151-010300€), 1 ~4 Display (9151-o104008) 1~5 Main Body (exploded view)¢s181-0105008, 1-6 L@ Sensor (exploded view) s151-010600E) 1-7 Pressure Sensor(s151-010700) « 1~—8 Slewing Angle Sensor (exploded view)($151-010800g) 2. CHECKS AND ADJUSTMENTS@151-020000€) 2-1 Input/Output for Each Component s1s1-020100€) (1) Main body adjustment volume layout diagram (2) Main body connector location / pin number layout diagram (3) Sensor connector pin diagram (4) L@ sensor adjustment volume layout diagram: (5) Crane ACS-related circuit diagram-~ 2-2 Troubleshooting (s151-020200)- (1) Error codes (2) Display: (3) Troubleshooting 2~3 Adjustments (s1s1-0203008)-- (1) About this section - (2) Power source adjustment (3) Boom angle adjustment (4) Boom length adjustment « (5) Pressure sensor adjustment (6) Slewing angle adjustment 3. REPLACEMENTS (8151-03000) SYMBOLS AND TERMS L 6 PB PL a op Wr Wr R H Le Software Hardware cPu ROM RAM 10 A/D LED LeD STOP I STOP I JS Boom length Boom angle Derrick cylinder head pressure Derrick cylinder rod pressure Slewing angle Operation condition Limit/reference load (total) Actual load (total) Work radius Max. lift Boom length + Boom angle The set of programs recorded onto ROM that control what happens in what order, to the computer and therefore the equipment. Tangible electronic circuitry and elements, such as CPU, ROM. Central Processing Unit. Computer system element which reads and executes programs. Read Only Memory. Computer system memory element which allows retrieval of information. Contains program information. Random Access Memory. Computer system memory element which allows both retrieval and storage of information. Input/Output. An element or circuit for input or output. Analog/Digital. Element which converts analog signals (e.g. sensor signals) to digital signals which can be used by the CPU. Light Emitting Diode. Liquid Crystal Display. Hazard lamp. Moment increase automatic stop. Upper angle limit automatic stop. Jibset1. CONFIGURATION AND. FUNCTIONS grrciosCONFIGURATION AND FUNCTIONS 1-1 System Configuration g1s+-o101008) AV sensor Switch box L.0 detector Cord reel Overhoist detector cord oO eonerteeat Overhoist detector ‘Automatic stop equipment Slew position detector Front jack setting detector (optional)CONFIGURATION AND FUNCTIONS CONFIGURATION AND FUNCTIONS 1-2 Hardware Block Diagram (s151-010200e) 1-3 Software Operation Flowchart «: ‘The CPU follows the commands stored in ROM, performs the following operations, 0103008) and so controls the crane. Lamp i tof | (ie [orem ne ee ee. —- ae mem ! 7 i | Seni endition | lpxive Circuit} —} Display 1 i er eee Initial Settings Main Boad ee Voice Rom cre Saeeeee cee RAM/ROM Check cee ot Sythesis Unit RoM_| [RAM Operation Condition Seoie poe LE Signal Receive Check Source Cireuit onl ar I c—! Sensor Signal Connector i Connector Receive Check ra a oe L—— Braker} Crane Connector }--4 Swing Angle} @ Connector H P2 Connector |} Pi Connector Wa, R calculation cm sie | a ane WR calculation ga 1 og €4--08 | | @n.8np828 8 224 ee ! BSSaaa44a 4 1 i Be taatatis sfa | Safety Operation eHgS2999 9. 2b ay! Sg Q bie b a euaG! I RES SIEE 8 258 6554 Seance Operation | Display Choice i i Connector ‘wath tnerease Width Iperease |i 1 Detection ‘Apparatus | Detection Apparatus || I I ; Display i Slewing Angle fee pe Presgure Detection i Detection Apparat: ection ection ‘Apparatus i Apparat Apparat i Output to crane : a Slewing Angle Sensor L@ Sensor Pressure sensor ‘Voice Output -2- -3-CONFIGURATION AND FUNCTIONS CONFIGURATION AND FUNCTIONS 1-4 Display (s1s1-0104006) | 1-5 Main Body (exploded view) 6151-010500e) Drum indicator (optional) ‘ACS emergency switch (Cancellation of automatic stop function) outrigger lamp lo g & Safety indicator @ KATO BRS) Rope reeving LKATO| weg ime °F ade ad ) Actual load/ gp boom length display. v ++ Reference load display il ! Boom angle display | | Working radius i 7 || aisoiey . | F | i Front jack indicator lamp a lamps \ | 7 ‘Outrigger status | System check buttor indicator lamps A | Left side outrigger status selection switch, Display Panel Panel Board Boom operation status selection switch Rope reeving selection switch Illumination Lamp ‘S151-0105E01 ‘SWITCH BOX [MIST-O30TEOTCONFIGURATION AND FUNCTIONS 1-6 L.9 Sensor (exploded view) (s1s1-or0800€) ) L Potentiometer : \ aabg tae Quadrant Plate & ‘S157-0108E01 CONFIGURATION AND FUNCTIONS 1-7 Pressure Sensor (s151.010700E) i A ooh PT-w-12 Sist-o107EOTCONFIGURATION AND FUNCTIONS 1-8 Slewing Angle Sensor (exploded view) (s1s1-010800e) ‘Cover <-> Se ats 2. CHECKS AND et ADJUSTMENTS juss Fixed Metal Fitting Gears Connector Rotary, Brush (not shown) Rotation Crank Rotary BrushCHECKS AND ADJUSTMENTS 2-1 Input/Output for each Component (3151-02010) (1) Main body adjustment volume layout diagram Adjustment volume A ‘Adjustment volume B STOP ADJUST +24VI 1 LW A BOHW2 1 VOICE Adjustment volume A Adjustment volume B ZERO —_ « P2 Pl eb “BBO ©OQOQOO OFF adjustment volume “ADJUST switch. Monitor LED Activation Conditions when auto-stop signal not output when load display change button when overhoist cut signal output when ACS power source switch ON; breaker ON ‘when A signal for sequential control output when B signal for sequential control output oN Adjustment Volumes 1) VOICE ----volume of sound adjustment (Adjusted upon shipment; do not adjust) Qa wing angle zero adjustment 3) PL 1 pressure sensor zero adjustment 4) P2 -P2 pressure sensor zero adjustment 5) 8 oom angle zero adjustment 6) L om length zero adjustment gee ‘Srs1-o201e02CHECKS AND ADJUSTMENTS (2) Main body connector location/pin number layout diagram EF ‘2 Bie P1 Pressure Breaker Le i Ser ‘Sensor: Connector Crane Connector Slewing Angle’ 22 Pressure Sensor Connector Sensor Connector Sis1 020103 NAM! Crane Connector | brown red orange, yellow! green blue Slewing Angle Sensor 1.GND 2.boom length output signal 3.+5.12V 4.GND 5.boom angle output signal 6.+5.12V 1. +8.12V -We- ‘S157-0201E05 (Sisrozeres |Boom Angle Sensor Potentiometer Max. Boom Length Boom Length Sensor Potentiometer Potentiometer for setting weserp jnoxe] ounjoa quUNSN{pe sosUas g *] (}) SLNAWLSNrav GNV SyO3HO a 1 s I q Quadrant Plate a Angle Pointer | VR-A: boom angle span adjustment volume g VR-L: boom length span adjustment volume fre —_.—_. ray Bh 7 ; Ovetising [ee] Tim wt eno ne SS, sonar Overtoing Spear =) Sree bute ener sonar(o) ou tet oveinoiing nat Speaker sect ‘Autorate sop fomate coo tb 7 Pare 7 fa Tar angeover ‘SN ry. ‘contro! relay 1 Wo Emon ooh or ' sequent [3 |S o Sequential cont A] 12 pS No] Boomerension! 1 ‘Automatic stop. 7 T2. ST ton sch (seiaetsae0) Frnt clon [10 Lond doo hogs [ cmon [Fr] aoe : 7 a = a aa prea a oe Ea! = ACS : Winch Wich Telecine Donde (tower lowe, "ae outed Ontong tt hse Meter tumination ot oe Fuse ‘Automate stop relay (0) (automatic stop of oom dering) eoarozo ISIS 3 iE et ‘ACS power > 2] lamp awtcn Sak Powersupply [ 4 fp ————_}__ (Banery) Lo “Solenoit vanelor ‘sequential ‘ont enol vane or sop Jepowt eueso YIM SiO]JIC: SLON wesSeip yOu! poqjes — Gov uwID (<) SINAWLSNravY GNV SXOSHOCHECKS AND ADJUSTMENTS 2-2 Troubleshooting (s151-020200e) (1) Error codes When an error occurs during crane operation, the safety indicator lights, an error number is displayed, and the crane stops automatically. Barer Error Countermeasures E01 | RAM error | E02 | ROM error E03 | Stabilized power source error E04 | Analog input defect E05 | Internal operation defect C10 | Outrigger status selection SW incorrectly set to “intermediate” C11 | Outrigger status selection SW set for fullyretracted outriggers with an extended front jack (front jack indicator LED lit) E12 | ) Outrigger status selection SW E13 | \defect E14 C20 | Boom operation status selection SW set to “intermediate” E21 | Boom operation status selection ‘SW inputprogram ROM mismatch E22 | ) Boom operation status E23 | |selection SW defect £24 Change main board @ Change program ROM © Change main board SEE £03 in “Troubleshooting” © Unplug external connectors one by one to confirm @ Check main. board ® Check sensor input @ Change program ROM @® Check setting of outrigger status selection SW/indicator LEDs @ Change switchbox @® Change main board ® Confirm status selection SW setting ® Change switchbox ® Change main board ® Change switchbox J Change main board © Check setting of boom operation status selection SW//indicator LEDs @ Change switchbox @ Change main board @ Check ROM and panel @ Change switchbox @ Change main board ® Check boom operation status indicator LEDs @ Change switchbox @® Change main board 14 - CHECKS AND ADJUSTMENTS Error No. Error Countermeasures C25 £40 E41 ESO E51 E61 E62 E70 E71 E72 E80 £81 Rope reeving selection SW set to. “intermediate” Boom length signal disconnection or short Boom length signal too strong“ weak Boom angle signal disconnection or short Boom angle zero adjustment circuit defect P1 signal disconnection or short PI signal too strong /weak P2 signal excessive compared to P1 signal P2 signal disconnection or short P2 signal too strong/“weak P2 calculation impossible Slewing angle signal disconnection or short Slewing angle signal defect | @ Check rope reeving selection SW ® Change switchbox @ Change main board SEE “Troubleshooting” SEE “Troubleshooting” SEE “Troubleshooting” Change main board Change P1 pressure sensor | SEE “Troubleshooting” SEE “Troubleshooting” Change P2 pressure sensor SEE “Troubleshooting” Change main board, program ROM, or P2 pressure sensor Change rotary brush or cable SEE “Troubleshooting” -15-CHECKS AND ADJUSTMENTS (2) Display (ADJ 1 SW = OFF) Operation Condition Check Main | Rooster Jibset Rope reeving display Actual load display Retoens cas | 888 Boom angle boom angle | display Working radius (ADJ 1 SW = ON) Operation Condition Rope reeving display Actual load display Reference load display Boom angle display ‘working Working radius a NOTE: 1.79% indicates that the Display change button is ON 2. “%*" negative values also displayed (A denotes negatives) 3.When error occurs IF ADJ 1 SW=OFF, error number displayed IF ADJ 2 SW=ON, display that of normal condition 4.ADJ 2 SW takes off an order of magnitude from displayed number 16 ¢ CHECKS AND ADJUSTMENTS ‘Troubleshooting Nonsense or nothing displayed Nonsense or nothing displayed a Check monitor LED +24V Check breaker, crane connector, crane wiring, fuses i Check that LCD display, Operation condition indicator LEDs function YES All fail to display ? NO Operation condition indi LEDs ON, LCD diplays LCD displays? Monitor LED STOPI is lit when crane safe, or when system check SW pressed LED displays ? Change main board and/or program ROM. Change chassis and/or ‘main board | Check display pane! ‘connectors 1 Change main board Program ROM in backward? digits/letters unreadable Change display board 1 Change main board -1W7-CHECKS AND ADJUSTMENTS Troubleshooting Stabilized power source error Cee) System check SW = ON, ADJI SW = ON, Load selector SW = OFF ~_ 3V display within 2.95 - 3.05 range Change program ROM Unplug PI, P2, L 6, slewing angle sensor connectors Plug. sensor connectors in NO one by one to check Change main board I Change and/or check wiring of the bad sensor connectors -18- CHECKS AND ADJUSTMENTS ‘Troubleshooting Error E40 Error displayed when raising/, lowering boom ? Check 1 @ cable for short /disconnection Error for a particular boom length Check L potentiometer for short disconnection Checkd L @ cable, L potentiometer connectors for short/disconnection l Change main board Turn ADJI SW ON, get boom length display 1 Adjust boom length Error corrected? Finished Change main board and/or L@ sensor 9I Troubleshooting Error E50 Error displayed when raising/ lowering boom ? Move the L@ sensor quadrant plate NO Check L @ cable, @ potentiometer connectors for short “disconnection I Change main board nT CHECKS AND ADJUSTMENTS. Check L.@ cable for short / disconnection Check @ potentiometer for short disconnection CHECKS AND ADJUSTMENTS ‘Troubleshooting Errors B61, B62, E71 Adjust pressure sensor Error corrected ? Finished Fully retract boom, set angle at a non— negative 10° | Follow directions on display, find Pl, P2 pressures | Confirm that P1 and P2 are within the following general ranges: Pl: 30~ 80kg/cm* ? O=less than 10kg/cm* I ‘Try changing Pl for P2 Display no change? Change main board Change pressure sensors BoCHECKS AND ADJUSTMENTS | ‘Troubleshooting Errors E81 — E04, E81 CHECKS ADJUSTMENTS Troubleshooting Occurs at the same time as E04 2 Crane safe, but stops automatically System check SW = ON, ADJ_1 SW= ON, 'WSW = ON Check slewing signal values Change main board 1, 2 on the display : H Watch values 1, 2 while slewing the ‘crane ‘Actual load display Stopped because of error No. blank ? displayed NOTE: Do not turn ACS power off, because error number will become unclear. Confirm whether ACS action ‘YES is correct ‘Values. change from aboct Oto | ‘about 5? oa 1 i Change slewing angle sensor j Talus stuck at about ues or about 9? 1 | Check slewing angle sensor connector cable and Slew crane and record the Connectors value when the two values agree : OE ee Tee the Change main board values agree Change program ROM “Are the, values Check boom length, boom angle on display NO Boom length” angle correct ? — 22 - ~ 23 -CHECKS AND ADJUSTMENTS CHECKS AND ADJUSTMENTS Troubleshooting 2-3 Adjustments (s151-020300e) (2) About this section How to read the following sheets y Adjusting Method Actual load incorrect ine Checks and esis Explanation stn N° | aajustments ae System | aps 1 | dpy {Indicator Aibisint | Data We | eh 1.Confirm whether the hook or parts of line are those Sw eats | established for the boom length. 2.When the actual load is incorrect for the main boom, check whether the auxiliary hook is not attached to the rooster, and whether the jib is in its housing. 3.Confirm whether the proper hook is attached to the ' main boom, when or rooster are in place. ener) 4.Is the crane on firm, level ground? 5.Checking the acti id after setting load on ground, and slowly winching it up? (Procedure) | 1) Follow the “explanation” for each “adjustment” or “check”. | Recheck pressure, boom 2) Set switches as in “setting”, and check that the values displayed as below are | peneeeeni within the permissible range listed in “data”. | | 3) If not within the permissible range, adjust with the “adjustment volume” listed. Check reference load to see 4) If still unadjustable, follow suggestions in IF NOT. ! whether operating conditions OK } 1 { i (Sisrez0ser } — 24 - — 2 -CHECKS AND ADJUSTMENTS (2) Power source adjustment (Turn ADJ 2 SW ON when decreasing displayed data CHECKS AND ADJUSTMENTS (8) Boom angle adjustment (Turn ADJ 2 SW ON when decreasing displayed data by some order of magnitude, OFF under normal conditions.) by some order of magnitude, OFF under normal conditions.) ] “Adjusting Method T ‘Adjusting Method ; Setting Checks and Setting ana é No. one Explanation Checks Explanation cad lindicator AGiusting Adjustments eigen an eR, | indicator eiusting| Data I No.) ajustments " Sater | apy a | dlay Indicator “Yotume | Date lume g @ Switch | SW” | Gitnge | Switch button | ‘Turn ACS power source tor | m i reparation [OPE Ao Bac Next Check tat boon i aration | are ly plugged. in, + 24V a kevel, f tum’ ACS power source’ it Quadrant | align the pointer of the 1 [Oat gree [E9 sensor with the zero tu ee on the quardant plate, lock ee fuse or ACS breaker adjustment | with the lockscrew, and apply locktite. NOTE: Tum ADI2 sw ae e reduce Fix the quadrant fo eau ge] ON | ON | OFF | e auadra eae oem aa 2 |zero check [10° with a piece of OFF 2 | paper Unplug the L @ sensor connector, GF Nov) |and' slewing angle. sensor’ Fix the quadrant plate at ik rat order, and REDO Span check |80° with a piece of thick OFF 2 L paper 3 1.Check wiring, connectors OF NOT) |2.Change main board or L@ sensor Reconfirm |If adjusting as in No3, zero recofnfirm as in No.2 - 2 - -o7T-(4) Boom length adjustment (Turn ADJ 2 SW ON when decreasing displayed data CHECKS AND ADJUSTMENTS by some order of magnitude, OFF under normal conditions.) ‘Adjusting Method Checks and “Setting 1o,| one Explanation a , ment Load | tndicator Adiustin Adlusients Sra [ ay, | [ntfs oon Casck change oo button Fully extend and retract 1 | Preparation equipped. Fully retract boom, turn Polentometor | Minimum, Maximum |Eounterclockwise as far as | 2 2 [retraction | Stopper. orF | on | & |x zero] min Jadjustment | NOTE : Adjustment oe Yojte shouldbe baa’ sW"ONe | T,oosen the lock screw on Maximum, | Maximum extention ore | on | L | VR |iength adjustment *0.15m 3 Check wiring, connectors. Jar Non) |Change' main’ board and / or L0 sensor, . 1 adjusting as in No.3, | 4 |Recontirm | reconfirm No.2 Fully extend and retract leat om Sequential the ‘boom. Contirm’ boom LEDs fae “am control length ‘when. monitor LED orr | on A and eee AYights and monitor LED B light ee 5 B goes out, Sewer iS om = Check wiring, connectors. | GF NOT) | Ghange’ main’ board. — 28 - CHECKS AND ADJUSTMENTS (5) Pressure sensor adjustment (Turn ADJ 2 SW ON when decreasing displayed normal conditions.) data by some order of magnitude, OFF under ‘Adjusting Method Checks and Setting ees Explanation justing P) isinens| spe | omy 1 | a, | inter |B] Gack | “Sw | change witch change @,) |P, ZERO |O~1 ka/ent Fully retract and lower ZERO check |boom, stop engine, reduce ON ON ON |R (@,) P, ZERO }O~1 derrick cylinder pressure fisted ke/cnt 1 ket/ent Check wiring, connectors. dF NOT) Change pressure sensor, main board. — 29 -CHECKS AND ADJUSTMENTS (6) Slewing angle adjustment (Turn ADJ 2 SW ON when decreasing displayed data by some order of magnitude, OFF under normal conditions.) Adjusting Method No. | ‘Explanation Saar ae oe heck | SW | change L button Slewing Set boom exactly front. a ON ON OFF WwW | @ ZERO 1. After slewing about 180° , remove rotary GF NOT) | brush, turn rotation crank 180° and refit rotary brush. . Slew crane slowly and Stewing check that slewing angle jangle changes continuously, and | 2 theo" thot the Gieslny vents 1goe | ON | ON | OFF | W check | when boom is. exactly behind ~ 30- 3. REPLACEMENTS osicseREPLACEMENTS Points to note when changing ROM (1) BE PARTICULARLY CAREFUL OF STATIC ELECTRICITY. If the glass window on the ROM is touched with a charged body, or rubbed with plastic or dry fabric, static will accumulate on the window causing erratic operation. (2) Use the designated tools for fitting and removing ROM. Use of other tools may damage the pins. (8) Take care to mount the ROM in the proper direction, as it may be damaged if mounted backward, and electricity is applied. (4) Be sure the anti—UV label on the glass window is affixed properly. Affixed at the factory, these labels shade the ROM from UV light, and if not properly affixed, the UV that leaks through will cause erratic operation. (6) When changing program ROM, confirm with the following : a) Check that ADJ 1/ADJ 2 SW are OFF. b) Turn display selector SW ON. c) Turn system check SW ON. After setting as in a, b and c, the actual load display indicates the crane code, the reference load display the model code, the boom angle display the ACS model number, and the working radius display the software code, all as follows : w 772 Crane code (w) 10 Model code ACS model (9) ied “10"indicates MS-10, and “S"indicates E. ® o1 Software code Confirm the crane code and model code when changing ROM. ROM seal : 105001 | ACS type software code si > Indicates inserting locatin. See diagram below -~31-REPLACEMENTS Main board SI: Program ROM V = Voice ROM (Gisresc0eoT] KATO WORKS CO.LTD. HEAD OFFICE: 9-97, Higashi-ohi 1-chome, Shinagawa-ku, (EXPORT DEPT.) Tokyo, 140 ‘Telephone: Tokyo 14 Telex Number: 222-451 rO J) 920305TI 5.1992-100(T) = 32-