Description

PAT DS 160 2003 Technical Manual

If you are calibrating a PAT DS 160 load moment indicator and you don’t have the factory manual, you are guessing. I’ve seen techs skip the EPROM installation step and end up with a system that reads out by 10%. That’s not a field adjustment – that’s a liability. This 26-page PAT DS 160 2003 Technical Manual is the OEM calibration document from PAT America, dated 05/16/2003. It is the only document you should trust for sensor setup, boom calibration, and the S4 Dataman interface. Everything else is aftermarket noise.

EPROM Installation and Hand Terminal Connection

Section 3 covers EPROM installation and hand terminal connection. The manual walks you through the exact jumper settings and terminal pinouts. Page 2 shows the warning that you must disconnect power before opening the control box – blow that one off and you are buying a new board. The hand terminal connection procedure uses a specific cable part number, which is listed. No generic “connect the red wire to 12V” nonsense here.

Calibration of Sensors: Pressure, Length, Angle

Section 5 breaks down each sensor calibration individually. The pressure transducer calibration procedure on page 9 requires a known load and a digital multimeter. The manual gives the exact millivolt output range you should see at zero and full scale. If your meter reads outside that window, the transducer is bad – don’t waste time tweaking the calibration pot. Length sensor calibration uses correction points (section 9.1) that map the cable extension to actual boom length. Angle sensor calibration requires a digital inclinometer; the manual tells you the mounting orientation tolerance.

Main Boom and Jib Calibration Step-by-Step

Boom calibration (section 6) is where most techs screw up. The manual lists the sequence of boom elevations and extensions you must record. Do them out of order and the system will interpolate wrong. Jib calibration is a separate procedure on page 14 because the geometry changes the load radius. If you work on a crane with a jib, you need that section. The manual even includes an extension calibration table for the DGC function “O” – addresses are in section 10.5.

What the S4 Dataman Section Tells You

Section 8 covers the S4 Dataman interface – the handheld unit used to enter configuration data. The manual explains how to access the calibration menu, read current values, and store new ones. It also gives the shortcut keys to access calibration data without wading through submenus. This is the part of the manual that saves you time if you already know the system but need the specific addresses.

Audience: Who Needs This Manual on the Workbench?

Crane operators, mobile equipment technicians, and shop owners who maintain PAT DS 160 systems. If you are a DIY guy working on a boom truck in your home garage, this manual keeps you from calling a dealer. The calibration procedures require a laptop with the PAT software and a serial cable – nothing exotic. But without the factory sequence, you’ll waste hours. The manual is also for safety inspectors who need to verify that the previous tech didn’t skip steps.

3 Systems That Depend on Accurate Calibration

1. Load moment indicator – incorrect calibration can cause an overload that bends the boom.
2. Anti-two block system – angle sensor calibration directly affects this safety circuit.
3. Length display – if the length step calibration is off, the radius calculation is off.

Each of these systems is covered in the manual. The PAT America DS 350, 1334 2002 Operators Manual – Factory Specs”>PAT America DS 350, 1334 2002 Operators Manual covers similar systems for larger cranes, but the DS 160 has its own unique EPROM configuration. Related manuals include PAT America DS 350, 1334 2001 Operators Manual – OEM Specs”>the 2001 version and the PAT America EI65 2002 Operators Manual – Factory Load Indicator Specs”>EI65 load indicator manual. For those coming from the automotive side, setting torque on a manual transmission pressure plate uses the same discipline as calibrating a pressure transducer – get it right the first time. That’s why I recommend reading the Manual Transmission”>Manual Transmission rebuild guide for similar precision, and if you are new to heavy equipment, start with a Manual Transmission”>Manual Transmission overview to understand the importance of exact specs.

Source Validity: OEM vs Aftermarket Documentation

This manual is a direct PDF of the PAT America calibration manual, part number 031-300-190-168 Rev – 05/16/2003. It is not a reprint or a third-party summarization. Aftermarket documents often omit the EPROM installation step or simplify the correction points. I have seen a generic manual that told the tech to “calibrate the boom by moving it through its full range” – that will set incorrect internal references. The OEM manual gives you the exact addresses for Accu-Cal and the DGC function “O” – that is the only way to get reliable data.

Frequently Asked Questions

Does the manual cover the S4 Dataman hardware?

Yes, section 8 is dedicated to the S4 Dataman. It shows how to navigate menus and store calibration data.

Can I calibrate the DS 160 without a hand terminal?

No. The hand terminal is required for EPROM installation and sensor setup. The manual specifies the connection procedure.

What if I lose the calibration data after replacing the battery?

The manual lists the addresses to re-enter the data manually. Page 19–20 cover the DGC function “O” for main boom and extensions. You must have the original calibration records or redo the entire calibration from scratch.

Is this manual still valid for cranes built after 2003?

For DS 160 systems with the same EPROM version, yes. But always check the revision date – PAT updated the software. If your system has a later version, you need the matching manual. This one is for the 3.0 firmware.

You have 26 pages of original factory data. No guesswork, no aftermarket shortcuts. If you need to calibrate a PAT DS 160, get the manual that the factory uses. Access the Factory Manual from AutoRepairManuals today, and keep it in your shop tablet or print it for the binder. Your crane will thank you.