A2B EI10 EI20 Service Manual English

SIGALARM
MODEL 210
ANTI TWO-BLOCK
EI10
EI20
Troubleshooting Manual
NOTICE
SkyAzúl makes no warranty of any kind with regard to this material, including, but not limited to,
the implied warranties of merchantability and/or its fitness for a particular purpose.
SkyAzúl will not be liable for errors contained in this manual 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, and all rights are reserved.
No part of this document may be photocopied, reproduced, or translated to another language

without the prior written consent of SkyAzúl.
SkyAzúl reserves proprietary rights to all drawings, photos and the data contained therein. The
drawings, photos and data are confidential and cannot be used or reproduced without the
written consent of Hirschmann. The drawings and/or photos are subject to technical
modification without prior notice.
All information in this document is subject to change without notice.
MANUAL REVISIONS
REV DATE NAME DESCRIPTION

- 05/17/11 SC A2B/EI10/EI20 Troubleshooting Manual (SkyAzúl) Rev -
SkyAzúl, Inc.
16 Walnut Street
Middletown, MD 21769
Fax 301-371-0029
info@skyazul.com
SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126


Troubleshooting Manual A2B
1 General Flowchart - A2B 1.1
This section explains how to handle a problem that may arise with the PAT Anti-Two-Block. 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 more detailed flowcharts shown in
Sections 2 through 4.
START
Whafs Wrong?
Lever Lockout No Function Length Cable

Activated Anti-Two-Block Problem
Go 10 Seclion 2 Go 10 Section 3 Go 10 Section 4

2 LEVER LOCKOUT ACTIVATED - A2B 2.1
PROBLEM
Control levers locked out.
( START
NO
NO
Is the crane in an anti-two-block condition? Is the anti-two-block warning light on?
.-- f--
YES
Lower the hookblock and/or headache ball to

YES
correct two-block condition. If two (2) hoists are t--
in use, both hooks must be lowered.
Unplug the 6-pin jumper plug (dummy plug) or

boom extension cable if in use, from the boom
nose receptacle. Next, connect a temporary
jumper wire between pin number6 and ground at
the boom nose receptacle. Refer to Drawing No.
2 "Anti-Two-Block Junction" in Appendix.
( NEXT PAGE ( Continue

on Page 2.5

PREVIOUS PAGE
NO Remove cover of cable reel. Move the temporary

Does the anti-twa-block warning light switch off? jumper wire from boom nose receptacle and
connect between slip ring terminals #17 and #18.
-
Refer to Drawing No. 1 "Slip Ring Unit" in
YES Appendix.
Move the temporary jumper wire from pin #6 to

pin #1 at the boom nose receptacle. Leave the
other end on ground. The boom nose anti-two-
block switch must be pulled down by its weight.
NO Main boom nose anti-twa-block switch or wiring

Does the anti-twa-block warning light remain is defective or incorrectly connected in switch or
off? boom nose receptacle.
YES
Operating on Main Boom - Problem in jumper

plug. Check wiring in jumper plug and boom
nose receptacle.
Operating on Jib - Defect in wiring or switches of
attachment (jib, boom nose, etc.). Check wiring
of switches.
NEXT PAGE

~REVIOUS PAGE
NO Move the temporary jumper wire from slip ring

Does the anti-two-block warning light switch off? terminals to cable reel terminal strip. Connect
between #9 and #10. Refer to Drawing NO.3
"Cable Reel Terminal" in Appendix.
YES
Boom length cable on cable reel is defective or

incorrectly connected in boom nose receptacle.
Refer to Section 4 and consult "Parts and In-
stallation Manual".
NO
Does the anti-two-block warning light switch off?
YES
Problem in swivel of cable reel. Faulty or corroded

contacts. Clean slip rings and contacts. Refer to
Drawing No.1 "Slip Ring Unit" in Appendix.
Move the temporary jumper wire from #9 and #10

to terminals #7 and #8. Refer to Drawing No.3
NEXT PAGE

PREVIOUS PAGE
Remove front panel on Anti-Two-Block console

NO in cab. Move temporary jumper wire to console
Does theanti-two-block warning light switch off?
and connect between terminal #3 and #4. Refer
to Drawing NO.4 "Anti-Two-Block Wiring
Diagram in Appendix.
YES
Faulty terminal strip between #7 and #9 or#8 and

#10 - check continuity on terminal strip. Replace
terminal strip. Refer to Drawing No.3 "Cable
Reel Terminal" in Appendix.

NO
I Relay in console defective.
I
YES
Faulty wiring between cable reel and console.

Check wiring. Referto Drawing No.4 "Anti-Two-
Block Wiring Diagram" in Appendix.

Continued
C from Page 2.1
Check the fuse in the face of the Anti-Two-Block

console. Refer to Drawing No.5 "Anti-Two- YES Replace 10amp. fuse and examine wiring to lever
Block Console" in Appendix. Is fuse defective? lockout solenoids.
NO
YES Relay in Anti-Two-Block console defective. Re-

Is lever lockout system functioning when key- place relay.
switch is in bypass position?
NO
No power to Anti-Two-Block console or lever

lockout system of crane is not functioning.
1. Check power supply of crane to Anti-Two-
Block console at terminal #1 = +UB and at
terminal #2 = ground.
2. Check wire connections to solenoid and
hydraulic or air system for the lever lockout.
UB = Crane Voltage (e.g. 24V112V).
END

3 NO FUNCTION ANTI-TWO-BLOCK - A2B 3.1
PROBLEM
Anti-Twa-Block System does not operate when crane is in
two-block condition.
START
Does the anti-twa-block warning light switch on YES Anti-twa-block warning light does light but con-
when crane is two-blocked? trol lever lockout system is not functioning.
1. Bypass key is turned to bypass position.

Unplug the 6-pin jumper plug (dummy plug) or 2. Bypass keyswitch may be faulty.
boom extension cable, if in use, from boom nose
3. Lever lockout solenoid valve may be faulty or
receptacle. Refer to Drawing No.2 "Anti-Two-
connected to incorrect power supply.
Block Junction" in Appendix.
Refer to Drawing No.5 "Anti-Twa-Block Con-
sole" in Appendix.
NO Remove cover on cable reel. Disconnect length

Does the anti-two-blook warning light switch on? cable core wire from slip ring terminal #17.
YES
Remove dummy plug or unplug extension jumper

from boom nose receptacle.
1. Connect an ohmmeter between Pin #1 and #6
at boom nose receptacle.
2. Check continuity of the boom nose anti-two-
block switch by operating switch by hand. Switch
should be closed when pulled down, open when
released.
Anti-two block switch is faulty or incorrectly

NO wired. Wiring may be faulty to boom nose
Does switch operate correctly? receptacle. Refer to Drawing No.4 "Anti-Twc-
Block Wiring Diagram" in Appendix and consuit
I "Parts and Installation" manual.
1YES
nose receptacle.
of switches.
SkyAzúl, Equipment Solutions www.skyazul.com ( NEXT PAGE
301-371-6126
3 NO FUNCTION ANTI-TWO-BLOCK - A2B 3.2
PREVIOUS PAGE
NO ~
Does the anti-two-block warning light switch on? Disconnect the #7 wire from cable reel terminal
strip.
1YES
Faulty length cable on reel or Incorrect con-
nections at boom nose receptacle.
NO Remove front panel on Anti-Twa-Block console.

I
DoestheantHwo-block warning lightswitch on? Disconnect wire #7 from console terminal #4.
YES
Short circuit in internal wiring of cable reei or

defective cable between cable reel and console.
Refer to Drawing No.4 "Anti-Two Block Wiring
Diagram" in Appendix.
NO Anti-two-block warning lamp may be burned

DoestheantHwo-block warning lightswitch on? out Turn buzzer switch on. If buzzer sounds,
check lamp. If buzzer does not sound, check
relay. Refer to Drawing NO.5 "Anti-Two-Block
Console" in Appendix.
YES
Faulty wiring between console and cable reel.

Check for short circuit and damaged cable
between wire '7 and crane ground. Refer to
Drawing No.4 "Anti-Twa-Block Wiring Diagram"
in Appendix.

4 BROKEN LENGTH CABLE - A2B 4.1
PROBLEM
Damaged or broken length cable.
STEP ACTION
1 Cut old cable at cable drum.
2 Open cable reel cover and disconnect wiring from terminal block. Pull 7-conductor cable out
of strain relief.
3 Remove cable reel from mounting brackets.
4 Remove damaged length cable, which is mounted to the slip rings in the cable reel, from Terminal 17
and 18.
Refer to Drawing No. 1 in Appendix.
5 Turn the cable reel and open the strain relief attached to the axle in the center of the drum. Pull existing
length cable out of the cable reel.
6 Disconnect damaged length cable from Anti-Two-Block switch receptacle at the boom nose.
7 Pull new length cable through the hole, pipe and strain relief and push it through the axle of the reeling
drum. Tighten strain relief to ensure sealing.
8 Dismantle length cable near slip ring and reconnect shield to terminal No. 18 and center to No. H.
9 Remount cable reel to the boom. Turn reeling drum clockwise to get rest of new cable onto the drum.
10 Set preload on cable reel by turning the drum counter-clockwise 5 to 8 turns.
11 Reconnect new cable to Terminal No.1 (center) and ground terminal (shield) of receptacle at the
boom nose. Refer to Drawing No.2 in Appendix and consult "Parts and Installation" manual.

APPENDIX
Drawing 4 - ANTI-TWO-BLOCK WIRING DIAGRAM
TO CONSOlE
r"-l
6 PIN ~ePTACtE
r---- {'~f.l! :----------------------------------

'~'
lj , ... '
3' \
~ ,"'"
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10 PIN
PLUG
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5:;1 :\~'
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JUMPER I
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ANTI-
1.
L _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ -'
TWO-BLOCK
SWITCH CABLE REEL
NOTES' ELECTRICAL DIAGRAM ~ BOOM

[!:> OUTER SHIELD GROUNDeD AT STRAIN
RELIEF CONNECTOR
[[> INNER SHIELD INSULATED AND CONNECTEO
AS SHOWN
tr:> INNER SHIELD CUT OFF AND TAPED
G:> OUTER SHIELD INSULATED AND CONNECTED
AS SHOWN
I~--------~-~------ --- ---1

I i,
109871$543
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NOTES
II> ~~Z,~~ ~~~~~C;~~UNOEO AT STRAIN
[1:> INSULA TED WIRE SOLDERED TO INNER 10 PIN;

PLUG,
SH!ELD AND CONNECTED AS SHOWN
[!:> INNER SHf€lD CUT OFF AND TAPED

B:> oureR SHIELD CUT OFF AND TAPED
TO CABLE REEL
ELECTRICAL DIAGRAM ~ LOWER
NOTE: This diagram may differ from the actual wiring of the system supplied, Consult the Parts & Installation Manual for your
particular crane model
SkyAzúl, for a detailed
Equipment wiring diagram. www.skyazul.com
Solutions 301-371-6126
APPENDIX
Drawing 5 - ANTI-TWO-BLOCK CONSOLE
ALARM HORN
BY-PASS

APPENDIX
Drawing 6 - EI10 CONSOLE
PAT EI 10 ALARM
1 I ,- I-'
I
1--2
I
3
-, ='. LI
J
---
1 1

APPENDIX
Drawing 7 - ANTI-TWO-BLOCK CABLE REEL
SLIP RING BOOY
MOUNTING
TERMINAL BLOCK PLATE

Troubleshooting Manual EI10
1 General Flowchart - EI10 1.1
This section explains how to handle a problem that may arise with the PAT EI-1 O. 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 more detailed flowcharts shown in Sections 2
through 6.
START
I What's Wrong?

No Display
Activated Anti-Two-Block Problem
Go to Section 2 Go to Section 3 Go to Section 4

I I Go to Section 5
I
Wrong Angle
Displayed
Go to Section 6

3 NO FUNCTION ANTI-TWO-BLOCK - EI10 3.1
PROBLEM
Anti-Twa-Block System does not operate when crane is in
( START
Does the anti-twa-block warning light switch on

when crane is two-blocked?
I YES Anti-twa-block warning light does light but Con-
trol lever lockout system is not functioning.
NO
I
boom extension cable, if in use, from boom nose
1. Bypass key is turned to bypass position.
2. Bypass keyswitch may be faulty. II
receptacle. Refer to Drawing No.2 "Anti-Two- I
!
I Refer to Drawing NO.6 "Ella Console" in I
I
Appendix. I
I
I ,
NO Remove cover on cable reel. Disconnect length I
Does the anti-twa-block warning light switch on? i -I cable core wire from slip ring terminal #17. I
I
I I
1

I
I
1. Connect an ohmmeter between Pin #1 and #6 I
2. Check continuity of the boom nose anti-two I
I I
I

should be closed when pulled down, opens when
released. I I
Does switch operate correctly? receptacle. Refer to Drawing No. 10"El10Wiring
Diagram" in Appendix and consult "Parts and
II I nstallation" manual.
y ES

nose receptacle.
of switches. NEXT PAGE
2 LEVER LOCKOUT ACTIVATED - EI10 2.1
PROBLEM
START
NO
NO
Is the crane in an anti-twa-block condition? Is the anti-two-block warning light on?
.-- t--
YES
Lower the hookblock and/or headache ball to

t-- YES
correct two-block condition. If two (2) hoists are
in use. both hooks must be lowered.

jumper wire between pin number 6 and ground at
2 "Anti-Two-Slock Junction" in Appendix.
Continue
C NEXT PAGE
on Page 2.5

c;.REVIOUS PAGE

Does the anti-twa-block warning light switch off? jumper wire from boom nose receptacle and
connect between slip ring terminals#17 and#1S.
Refer to Drawing No. 1 "Slip Ring Unit" in
YES Appendix.

pin # 1 at the boom nose receptacle. Leave the
other end on ground. The boom nose anti-two-
block switch must be pulled down by its weight.
NO Main boom nose anti-twa-block switch or wiring

Does the anti-two-block warning light remain is defective or incorrectly connected in switch or
off? boom nose receptacle.
YES

nose receptacle.
of switches.
NEXT PAGE

PREVIOUS PAGE

Does the anti-two-block warning lightswitch off? terminals to cable reel terminal strip. Connect
between #9 and #10. Refer to Drawing NO.3
YES

incorrectly connected in boom nose receptacle.
stallation Manual".
NO
YES
I
contacts. Clean slip rings and contacts. Refer to

to terminals #7 and #8. Refer to Drawing NO.3
NEXT PAGE

~REVIOUS PAGE
Remove front panel on Ell0 console in cab.
Move temporary jumper wire to console and
NO connect between terminal #9 and #2. Refer to
Does the anti-two-block warning light switch off? Drawing No. 10 "Ell0 Wiring Diagram" in
Appendix.
YES
Faulty terminal strip between #7 and #9 or #8 and

terminal strip. Refer to Drawing NO.3 "Cable
NO
Does the anti-two-block warning lightswitch off? Electronic component defective on internal board.
YES

Check wiring. Refer to Drawing No. 10 "Ell0
Wiring Diagram" in Appendix.

( Continued
from Page 2.1
Check the fuse in the attached override box of

the Ell0 console. Is fuse burned out? YES Replace 10 amp. fuse and examine wiring to lever
lockout solenoids.
NO
YES Internal defect in electronics.

Is lever lockout system functioning when key-
i
NO
No power to Anti-Two-Slock console or lever

I
1. Check power supply of crane to the Ell0
console at t",rminal #1 = +US and at terminal #2 =
ground.
Us = Crane Voltage (e.g. 24V/12V).
END

PREVIOUS PAGE
NO I
Does the anti-twa-block warning light switch on? Disconnect the #7 wire from cable reel terminal
strip.
YES
Faulty length cable on reel or incorrect con-

NO Remove front panel on El10console. Disconnect

Does the anti-twa-block warning light switch on? wire #7 from console terminal #9.
YES
Short circuit in Internal wiring of cable reel or

Refer to Drawing No. 10 "Ell0 Wiring Diagram"
in Appendix.
I
I
NO Anti-twa-block warning lamp may be burned
Does the anti-twa-block warning light switch on? out. Turn buzzer switch on. If buzzer sounds.
II
l
relay. Refer to Drawing NO.6 "E11O Console" in
YES Appendix. I
I
between wire *7 and crane ground. Refer to
Drawing No. 10 "Ell0 Wiring Diagram" in
Appendix.

4 BROKEN LENGTH CABLE - EI10 4.1
PROBLEM
STEP ACTION
of strain relief.
and 18.
5 Turn the cable reel and open the strain relief attached to the axle in the center of the drum. Pull existing
8 Dismantle length cable near slip ring and reconnect shield to terminal No. 18 and center to No. 17.
boom nose. Refer to Drawing No.2 in Appendix and consult "Parts and Installation" manual.

5 NO DISPLAY - EI10 5.1
PROBLEM
No display.
START
Check for voltage across Terminal 1 (= + UB) and NO

Faulty power supply. Check crane electric.
2 (gnd) in console. Refer to Drawing No. 10"E110
I YES
Check board fuse to see if it is blown. Refer to YES I Replace fuse.

Drawing No. 12 "E110 Console Terminals" in
Appendix.
I
I NO
Failure of electronic component. Change LCD

card (AID converter) andlor replace main board.

6 WRONG ANGLE DISPLAY - EI10 6.1
PROBLEM
Incorrect angle display.
START
Open cable reel and check voltage across

terminal#5 (+5V) and#6 (gnd) on terminal strip. YES
Voltage should be 5V. Refer to Drawing NO.3
"Cable Reef Terminal" in Appendix.
I
C NEXT PAGE )
NO
Check voltage on socket 5 (+5V) and 6 (gnd) in YES Fault is located in cable from 10-pin receptacle to
10-pin receptacle located at base boom section.
cable reel.
Voltage should be 5V.
I
Check voltage on pins 5 and 6 in 10-pin plug
located at base boom section. Voltage should be
YES Fault is located in connection of 10-pin plug and
receptacle.
5V.
NO
Check voltage across terminal 10 (+5V) and 12

YES Fault is located in cable from console to 10-pin
(gnd) in console. Voltage should be 5V. Refer to
connector.
Drawing No.3 "Cable Reel Terminal" in Appendix.
Defective electronic component. Replace main

board and reset system referring to Operator's
Handbook.

PREVIOUS PAGE
Check voltages at cable reel between terminal#4

(signal) and #6 (gnd). Voltage should be stable NO
and in the range of 1.8V to 3.1V (0" = 1.80V; 90" = Change angle transducer.
3.l0V; 45° = 2.45V). Refer to Drawing No. 3
Open 10-pin receptacle located at boom base NO Fault is located in cable from 10-pin receptacle to
section and check voltage between Pin 4 and Pin cable reel.
6. Voltage should be same as above.
YES
Open plug and check between Pin 4 (signal) and NO

Pin 6 (gnd) for same voltage as above with plug
reconnected.
·1
Faulty 10-pin connector.
I
YES
Open console and check for same voltage be- NO Defective cable from console to 1O-pin connector.
tween terminal#ll (signal) and#12 (gnd). Refer • Check wiring. Refer to Drawing No. 10 "Ell0
to Drawing No. 12 "Ell0 Console Terminals" in Wiring Diagram" in Appendix.
Appendix.

Handbook.

APPENDIX
PAT EI 10 ALARM
1 I ,- I-'
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1--2
I
3
-, ='. LI
J
---
1 1

APPENDIX
Drawing 8 - EI10 CABLE REEL
ANGLE TRANSDUCER
~ SLIP RING BODY
i ~
TERMINAL BLOCK

NOTE: This diagram may differ from the actual wiring of the system supplied. Consult the Parts & Instaliation Manual for your c
particular crane model for a detailed wiring diagram.
J.-
SkyAzúl, Equipment Solutions
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• JUMPER IF A28 !S NOT CONNECTED

APPENDIX
Drawing 12 - EI10 CONSOLE TERMINALS
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1 General Flowchart - EI20 1.1
This section explains how to handle a problem that may arise with the PAT EI-20. 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 more detailed flowcharts shown in Sections 2
through 7.
START
I What's Wrong? I

No Display
Activated Anti-Two-Slock Problem
I Go to Section 2
I Go to Section 3 Go to Section 4 Go to Section 5
I
Wrong Angle Wrong Length

Displayed Displayed
Go to Section 6 Go to Section 7 I

PROBLEM
NOTE: The ON-OFF switch on the console

must be turned to either the left or the right
on position or control levers will be locked
out.
( START
NO NO
Is the crane in an anti-two-block condition? Is the anti-two-block warning light on?
r- f--
YES
Lower the hook block and/or headache ball to

I-- YES
correct two-block condition. If two (2) hoists are
in use, both hooks must be lowered.

jumper wire between pin number6and ground at
2 "Anti-Two-Block Junction" in Appendix.
Continue
NEXT PAGE
on Page 2.5

~REVIOUS PAGE

Does the anti-two-block warning light switch off? terminals to cable reel terminal strip, Connect
between #9 and #10. Refer to Drawing No, 3
YES

incorrectly connected in boom nose receptacle,
stallation Manual".
NO
Does the anti-two-block warning lightswitch off?
YES

contacts, Clean slip rings and contacts. Refer to

to terminals #7 and #8, Refer to Drawing No, 3
"Cable Reel Terminal" in Appendix,
( NEXT PAGE

2 LEVER LOCKOUT ACTIVATED - EI20 22
~REVIOUS PAGE

Does the anti-two-block warning light switch off? jumper wire from boom nose receptacle and
connect between slip ring terminals#17 and #18,
Refer to Drawing No, 1 "Slip Ring Unit" in
YES Appendix,

pin # 1 at the boom nose receptacle, Leave the
other end on ground, The boom nose anti-two-
block switch must be pulled down by its weight
NO Main boom nose anti-two-block switch or wiring

Does the anti-two-block warning light remain is defective or incorrectly connected in switch or
off? boom nose receptacle,
YES

plug, Check wiring in jumper plug and boom
nose receptacle,
attachment (jib, boom nose, etc,), Check wiring
of switches,
NEXT PAGE

~REVIOUS PAGE
Remove front panel on EI20 console in cab.
Move temporary jumper wire to console and
connect between terminal #16 and #2. Refer to
NO Drawing No. 11 "E120 Wiring Diagram" in
Does the anti-twa-block warning light switch off?
Appendix.
YES
Faulty terminal strip between #7 and #9 or #8 and

terminal strip. Refer to Drawing NO.3 "Cable
Does the anti-twa-block warning light switch off? NO

Electronic component defective on internal board.
YES

Check wiring. Refer to Drawing No. 11 "E120

Continued
from Page 2.1
Check the fuse in the attached override box of

the EI20 console. Is fuse burned out? YES Replace 10amp. fuse and examine wiring to lever
lockout solenoids.
NO
YES
Is lever lockout system functioning when key- Internal defect in electronics.
NO
No power to Anti-Two-Block console or lever

1. Check power supply of crane to the EI20
console at terminal #1 = +UB and atterminal #2 =
ground.
UB = Crane Voltage (e.g. 24V/12V).
END

PROBLEM
Anti-Two-Block System does not operate when crane is in
START
Does the anti-two-block warning light switch on YES Anti-two-block warning light does light but con-
when crane is two-blocked? trol lever lockout system is not functioning.
i NO ~
I 1. Bypass key is turned to bypass position.
Unplug the 6-pin jumper plug (dummy plug) or 2. Bypass keyswitch may be faulty.
boom extension cable. if in use, from boom nose
receptacle. Refer to Drawing No.2 "Anti-Two-
Refer to Drawing No. 14 "E120 Console" in
Appendix.
I
Remove cover on cable reel. Disconnect length

Does the anti-two-block warn ing light switch on? cable core wire from slip ring terminal #17.

1. Connect an ohmmeter between Pin #1 and #6
2. Check continuity of the boom nose anti-two
should be closed when pulled down. opens when
released.

! Does switch operate correctly? ,
receptacle. Refer to Drawing No. 11 "E120 Wiring
I I Diagram" in Appendix and consult "Parts and
1IYES Installation" manual.

nose receptacle.
Operating onJib - Defect in wiring or switches of
attachment (jib. boom nose. etc.). Check wiring
of switches. NEXT PAGE

~REVIOUS PAGE
NO
Disconnect the #7 wire from cable reel terminal
Does the anti-twa-block warning light switch on?
strip.
j YES
Faulty length cable on reel or incorrect con-

NO Remove front panel on Anti-Twa-Block console.

Does the anti-twa-block warning lightswitch on? Disconnect wire #7 from console terminal #16.
!YES
Short circuit in internal wiring of cable reel or

Refer to Drawing No. 11 "E120 Wiring Diagram"
in Appendix.
I
I NO Anti-twa-block warning lamp may be burned

Does the anti-twa-block warning light switch on? out. Turn buzzer switch on. If buzzer sounds.
i relay. Reter to Drawing No. 14 "E120 Console" in
I YES Appendix.
I
between wire *7 and crane ground. Refer to
Drawing No. 11 "E120 Wiring Diagram" in
Appendix.

4 BROKEN LENGTH CABLE - EI20 4.1
PROBLEM
STEP ACTION
of strain relief.
and 18.
5 Turn the cable reel and open the strain relief attached to the axle in the center ofthe drum. Pull existing
8 Dismantle length cable near slip ring and reconnect shield to terminal No. 18 and center to No. 17.
boom nose. Refer to Drawing No.2 in Appendix and consult "Parts and Installation" manua1.
12 Reset length potentiometer in length angle transducer (screw is located in center of white gear); with
boom fully retracted, turn potentiometer carefully counter-clockwise until it stops. Check function of
Anti-Two-Block switch. Recheck length and angle display.

5 NO DISPLAY - EI-20 5.1
PROBLEM
No display.
( START
Check for voltage across Terminal 1 (= + US) and NO

Faulty power supply. Check crane electric.
2 (gnd) in console. Refer to Drawing No. 11 "E120
I YES
Check board fuse to see if it is blown. Refer to YES I Replace fuse.

Drawing No. 13 "E120 Console Terminals" in I
Appendix.
I NO
Failure of electronic component. Change LCD

card (AID converter) and/or replace main board.

PROBLEM
Incorrect angle display.
( START
Open cable reel and check voltage across

terminal #5 (+4.1V) and #6 (gnd) on terminal YES
strip. Voltage should be5V. Referto Drawing No.
3 "Cable Reel Terminal" in Appendix.
( NEXT PAGE)
NO
Check voltage on socket 5 (+4.1V) and 6 (gnd) in YES Fault is located in cable from 10-pin receptacle to
10-pin receptacle located at base boom section.
Voltage should be 5V. cable reel.
Check voltage on pins 5 (+ 4.1V) and 6 (gnd) in Fault is located in connection of 10-pin plug and
YES
10-pin plug located at base boom section. Voltage receptacle.
should be 5V.
NO
Check voltage across terminal 10 (gnd) and 12 (+ Fault is located in cable from console to 10-pin
4.1V) in console. Voltage shOuld be 5V. Refer to YES
connector.
Drawing No.3 "Cable Reel Terminal" in Appendix.
NO

•
Handbook.

~REVIOUS PAGE
Check voltages at cable reel between terminal#4

(signal) and #6 (gnd). Voltage should be stable
and in the range of O.OOV to 1.0V (0' = 0.0; 90° = NO
1.0; 45' = 0.5V). Refer to Drawing No, 3 "Cable Change angle transducer.
Reel Terminal" in Appendix,
YES
Open 10-pin receptacle located at boom base NO Problem is in cable from 10-pin receptacle to
section and check voltage between Pin 4 and Pin cable reel.
6. Voltage should be same as above.
YES
Open plug and check between Pin 4 (signal) and NO

Pin 6 (gnd) for same voltage as above with plug
reconnected. I
Faulty 10-pin connector.
I
YES
NO Defective cable from console to 1O-pin connector.

Open console and check for same voltage be-
• Check wiring. Refer to Drawing No. 11 "E120
tween #11 (signal) and #10 (gnd) at terminal
strip. Refer to Drawing No. 13 "E120 Console
Terminals" in Appendix.
I YES
~
Handbook.

7 WRONG LENGTH DISPLAY - EI20 7.1
PROBLEM
Incorrect length display.
( START
Open cable reel and check potentiometer to see

if it is turning with reel and is in zero position Setto zero and readjust or replace length potentio-
when boom is fully retracted (turned fully NO
meter to rectify fault.
counterclockwise). Refer to Drawing NO.9 "Cable
Reel" in Appendix.
NO
Does length display work correctly?
YES
Check voltage across cable reel terminal #1 END

(gnd) and #3 (+5V). Voltage should measure 5V.
~I
Refer to Drawing NO.3 "Cable Reel Terminal" in
Appendix.
Continued on Page 7.3.
I
Check voltage across cable reel terminal #2
(signal) and #1 (gnd). Voltage should be in the NO Replace and reset length potentiometer. Refer to
range of O.8V to 5.0V and stable. Refer to Section 4.
Drawing NO.3 "Cable Reel Terminal" in Appendix.
YES
Check for voltage at 1O-pin receptacle. located at Faultis located in cable from 10-pin plug to cable
NO
boom base section, across terminal #2 and #1. reel.
Voltage should be same as above.
YES
( NEXT PAGE

~REVIOUS PAGE
I
Check voltage on 10-pin plug, located at boom
base section, across terminal #2 (signal) and #1
(gnd). Voltage should be O.8V and 5.0V and
stable. NO Fault is located in connection of 10-pin plug
NOTE: For this measurement the plug has to be and/or socket.
connected into the receptacle.
Check voltage terminal strip of console across#8 NO Fault is located in cable from console to 10-pin
(signal) and#7 (gnd). Voltage should be same as plug and socket.
above.
YES

board and reset system by referring to the
Operator's Handbook.

APPENDIX
Drawing 1 - SLIP RING UNIT
TERMINAL BLOCK
Drawing 2 - ANTI-TWO-BLOCK JUNCTION
~ @ ~
1 •• 4
000
2 ••5
e 0 0
3• • 6
~ ~
PINS IN JUNCTION BOX DUMMY PLUG WITH RESISTOR 4700 OHM
(View From Cable Side) BETWEEN PIN 1 AND GROUND PIN

Continued from )
Page 7.1
Check voltage across Pin 1 (gnd) and 3 (+5V) of YES

10-pin receptacle located at boom base section. Defective wiring from 10-pin plug to cable reel.
Voltage should be 5V.
I
Check voltage across Pin 1 (gnd) and 3 (+5V) of
YES Fault is located in connection of 10-pin plug and
10-pin plug located at boom base section. Voltage
socket.
should be 5V.
NO
Check voltage across terminal connection #7 YES Faulty wiring from console to 10-pin plug and
(gnd) and#9 (+5V) in console. Voltage should be socket.
5V. Refer to Drawing No. 11 "E120 Wiring
Diagram" in Appendix.
NO
t
board and reset system by referring to Operator's
Handbook.

APPENDIX
Drawing 3 • CABLE REEL TERMINAL
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

APPENDIX
Drawing 9 - EI20 CABLE REEL
ANGLE TRANSDUCER
SLIP RING BODY
GEARWHEEL
LENGTH
POTENTIOMETER
ASSEMBLY
I
TERMINAL BLOCK
i
!
i
I
i
i
! ®
,
i
i
i
I
i
LENGTH POTENTIOMETER RESET

NOTE: This diagram may differ from the actual wiring of the system supplied. Consult the Parts & Installation Manual for your c
particular crane model for a detailed wiring diagram.
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t----------~2;:;;NG1~A~G-;:E-;N-;;!ZA';:--O; - --- - - -- --j

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EI20
*1 Signa! O.8V to 5.0V
~l Signal 0"'::: O.OV
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90° 1.0V
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APPENDIX
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BATTERY
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APPENDIX
PAT EI20 ALARM
[ lIS.DJ 0
TEST
0
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0 0


SkyAzúl, Inc.
16 Walnut Street
Middletown, MD 21769
Phone 301-371-6126
Fax 301-371-0029
www.skyazul.com info@skyazul.com

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REV DATE NAME DESCRIPTION

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126

1 General Flowchart - A2B 1.1

Lever Lockout No Function Length Cable

Go 10 Seclion 2 Go 10 Section 3 Go 10 Section 4

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126

2 LEVER LOCKOUT ACTIVATED - A2B 2.1

Lower the hookblock and/or headache ball to

Unplug the 6-pin jumper plug (dummy plug) or

( NEXT PAGE ( Continue

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126

2 LEVER LOCKOUT ACTIVATED - A2B 2.2

NO Remove cover of cable reel. Move the temporary

Move the temporary jumper wire from pin #6 to

NO Main boom nose anti-twa-block switch or wiring

Operating on Main Boom - Problem in jumper

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126

2 LEVER LOCKOUT ACTIVATED - A2B 2.3

NO Move the temporary jumper wire from slip ring

Boom length cable on cable reel is defective or

Problem in swivel of cable reel. Faulty or corroded

Move the temporary jumper wire from #9 and #10

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126

2 LEVER LOCKOUT ACTIVATED - A2B 2.4

Remove front panel on Anti-Two-Block console

Faulty terminal strip between #7 and #9 or#8 and

Does the anti-two-block warning light switch off?

Faulty wiring between cable reel and console.

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126

2 LEVER LOCKOUT ACTIVATED - A2B 2.5

Check the fuse in the face of the Anti-Two-Block

YES Relay in Anti-Two-Block console defective. Re-

No power to Anti-Two-Block console or lever

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126

3 NO FUNCTION ANTI-TWO-BLOCK - A2B 3.1

1. Bypass key is turned to bypass position.

NO Remove cover on cable reel. Disconnect length

Remove dummy plug or unplug extension jumper

Anti-two block switch is faulty or incorrectly

3 NO FUNCTION ANTI-TWO-BLOCK - A2B 3.2

NO Remove front panel on Anti-Twa-Block console.

Short circuit in internal wiring of cable reei or

NO Anti-two-block warning lamp may be burned

Faulty wiring between console and cable reel.

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126

4 BROKEN LENGTH CABLE - A2B 4.1

1 Cut old cable at cable drum.

3 Remove cable reel from mounting brackets.

10 Set preload on cable reel by turning the drum counter-clockwise 5 to 8 turns.

SkyAzúl, Equipment Solutions www.skyazul.com 301-371-6126

Drawing 4 - ANTI-TWO-BLOCK WIRING DIAGRAM

r---- {'~f.l! :----------------------------------

NOTES' ELECTRICAL DIAGRAM ~ BOOM

I~--------~-~------ --- ---1

II> ~~Z,~~ ~~~~~C;~~UNOEO AT STRAIN

[1:> INSULA TED WIRE SOLDERED TO INNER 10 PIN;

[!:> INNER SHf€lD CUT OFF AND TAPED

ELECTRICAL DIAGRAM ~ LOWER

Drawing 5 - ANTI-TWO-BLOCK CONSOLE

II> Z, ~~~C;UNOEO AT STRAIN