Description

PAT DS 105 1996 Troubleshooting Manual

If you are working on a PAT DS 105 system and the boom won’t extend or the cut-off is kicking in wrong, you need the factory troubleshooting path. Not a Chilton’s or some copied PDF from a forum. You need the PAT DS 105 1996 Troubleshooting Manual. I have seen too many guys start swapping sensors because they guessed. That burns billable hours and sometimes burns the wiring harness. This manual walks you through the exact test sequence – no fluff, no shortcuts. 23 pages, one revision, dated 09/20/96.

Tele-out and Lifting-down Functions: A Common Lockout

Section 2 of the manual covers exactly what to check when the tele-out and lifting-down functions are disabled. That is a frequent complaint on job sites – the operator hits the lever and nothing happens. First thing the manual tells you: check the operating displays on page 3. Then go to the troubleshooting flowchart. Do not start pulling relays until you verify the sensor signals. The voltage specs for those signals are in Appendix D. I have fixed three of these simply by finding a pinched wire at the boom pivot. Without the manual, you would be chasing ghosts.

How Does the Manual Guide You Through a System Error?

Section 3 is titled System Error. It gives you the procedure for when the control unit locks everything out. You start with the system test on page 7. If that does not function, you move to Section 4. The manual does not assume you know the error codes – it makes you check the display first. Only then do you reference the Error Code List on page 14. That list covers every code the DS 105 can throw. I keep a printed copy in my toolbox. When you get code 12, you do not guess – you go to the wiring diagram in Appendix A and check for an open ground. That is how a pro works.

Check the Boom Length Sensor Before You Swap Parts

Section 6 covers when boom length is displayed incorrectly. This is where most guys screw up. They order a new length sensor right away. The manual tells you to first inspect the length cable for damage (Section 5). Then measure the sensor voltage at the mainboard test points (Appendix E). The tolerances are right there in Appendix D: voltages for sensor signals. If the voltage is within range, the problem is in the Data Display Terminal connections (Appendix B). Do not replace parts you have not tested. That is the difference between a good day and a three-day headache.

Error Code List: What the 23 Pages Cover

The manual packs a lot into its 23 pages. You get Section 9 – the full Error Code List with cause and recommended action. That alone saves you from having to call PAT tech support. Also included: system wiring diagram (Appendix A), Data Display Terminal connections (Appendix B), length sensor drawing (Appendix C), voltages for sensor signals (Appendix D), and mainboard test points with component orientation (Appendix E). Everything is OEM, from PAT themselves. If you are working on a crane with a DS 105 LMI, you need this. A generic guide will not tell you which pin on the 25-pin connector carries the boom angle signal. This manual does.

Source Authenticity: PAT Factory vs Aftermarket Copies

I have seen reprints of this manual that are so blurry you cannot read the voltage numbers. That is dangerous. A wrong voltage reading sends you down the wrong diagnostic path and can cost you a boom truck. This product is a direct scan of the original PAT DS 105 Troubleshooting Manual, Revision 1, part number 031-300-190-006. The notice page states it contains proprietary information and is protected by copyright. That means it came from PAT, not a third-party. If you want the same document I use in my shop, get the factory version. For related crane manuals, also check PAT DS 105 1996 User Manual – Factory Operator’s Handbook for daily operation, or the PAT DS350 1999 Troubleshooting Manual | Grove TM9100 Boom Control if you have a different system. For the CM20 LMI, the PAT DS350 Troubleshooting Manual – OEM Factory Specs for CM20 LMI is the right match.

Now, if you are troubleshooting a crane’s load moment indicator, you are not dealing with a Manual Transmission – this is electronic system diagnostics. Same goes for basic mechanical knowledge: reading a wiring diagram is different from understanding a Manual Transmission, but both require precise documentation. This manual gives you that precision.

Does this manual include wiring diagrams?

Yes, the full system wiring diagram is in Appendix A.

What should I do if the boom angle is displayed incorrectly?

Go to Section 7 (page 11) in the manual. First, verify the boom angle sensor voltage at the mainboard test points against the values in Appendix D. If the voltage is correct but the display is wrong, the issue is likely in the Data Display Terminal or its cabling – check Appendix B for pin assignments. Do not replace the sensor until you confirm it is out of spec. Also inspect the sensor mounting for physical damage. I have seen cases where a loose bolt changed the angle reading by three degrees, causing the cut-off to happen too early or late. The manual walks you through that sequence step by step.

Bottom line: If you touch a PAT DS 105 system, get the factory document. Do not rely on hearsay or generic cross-reference charts. Access the Factory Manual from AutoRepairManuals and keep it on your bench. It is 23 pages of real troubleshooting, not a sales brochure.