Hirschmann PAT DS 350GM Troubleshooting Manual
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Hirschmann PAT DS 350GM Troubleshooting Manual

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HIRSCHMANN
www.hirschmann.com
LOAD MOMENT INDICATOR
DS 350GM
TROUBLESHOOTING MANUAL
P/N 031-300-190-113 REV A –– 05/01/2001
38 Years Specializing
in Crane Electronic Repair & Parts Sales
Call Us. We are glad to help

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  • Page 1 HIRSCHMANN www.hirschmann.com LOAD MOMENT INDICATOR DS 350GM TROUBLESHOOTING MANUAL P/N 031-300-190-113 REV A –– 05/01/2001 38 Years Specializing in Crane Electronic Repair & Parts Sales Call Us. We are glad to help...
  • Page 2 38 Years Specializing in Crane Electronic Repair & Parts Sales Call Us. We are glad to help...
  • Page 3 NOTICE The information in this document is subject to change without notice. Hirschmann 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.
  • Page 4 38 Years Specializing in Crane Electronic Repair & Parts Sales Call Us. We are glad to help...

  • Page 5: Table Of Contents

    Service Manual DS 350 GM TABLE OF CONTENTS GENERAL INFORMATION ....................1 WARNINGS ........................2 FLOWCHARTS ......................... 3 GENERAL FLOWCHART ................... 3 ERROR CODE DISPLAY.................... 4 LEVER LOCKOUT ACTIVATED ................13 BROKEN LENGTH CABLE ..................14 NO DISPLAY......................15 ANTI-TWO BLOCK PROBLEM ................. 17 LENGTH READING PROBLEM ................
  • Page 6 38 Years Specializing in Crane Electronic Repair & Parts Sales Call Us. We are glad to help...

  • Page 7: General Information

    General Information GENERAL INFORMATION This troubleshooting manual is designed to assist a service or maintenance person in identifying system problem areas or malfunctions. A digital voltmeter with the capability to also measure current will be required. Regular maintenance and service tools will also be required. NOTE: Knowledge of how to use a voltmeter to measure both voltage and current is assumed.

  • Page 8: Warnings

    Service Manual DS 350 GM WARNINGS The LMI is an operational aid that warns a crane operator of approaching overload conditions and overhoist conditions that could cause damage to equipment and personnel. Therefore, the device is not, and shall not be, a substitute for good operator judgment, experience and use of accepted safe crane operating procedures.

  • Page 9: Flowcharts

    Flowcharts FLOWCHARTS GENERAL FLOWCHART This section explains how to handle a problem that may arise with the PAT DS 350 Modular LMI. The procedures are given in flowchart format for the following sections. Start with the general flowchart below that will guide you to one of the detailed flowcharts shown in this section. The drawings and procedures that are referenced in these sections can be found in Sections 4 and 5.

  • Page 10: Error Code Display

    Service Manual DS 350 GM ERROR CODE DISPLAY PROBLEM: Error code displayed. Lever lockout activated. Warning lights on. ERRO ERROR CAUSE ACTION CODE Minimum radius or Fallen below the minimum Lower boom back to a radius or maximum angle range radius or above the angle angle given in the load chart.
  • Page 11 Flowcharts ERRO ERROR CAUSE ACTION CODE Fallen below limit for a.) Cable between length Refer to Section 3.7 the measuring channel sensor and central unit a.)Check cable and connector ““length””. defective, not connected or b.) Check and reset length water in the connectors. sensor Potentiometer.
  • Page 12 Service Manual DS 350 GM ERRO ERROR CAUSE ACTION CODE Fallen below lower limit a.)Cable from central unit to a.) Check cable. value for measuring angle sensor defective or b.) Check angle sensor and reset channel ““Luffing Jib disconnected or water inside adjustment.
  • Page 13 Flowcharts ERRO ERROR CAUSE ACTION CODE Upper limiting value for a.)Cable from central unit to Refer to Section 3.9 the measuring channel the pressure transducer a.) Check cable and connector ““pressure piston side”” defective, loose or water in b.) Check pressure transducer exceeded.
  • Page 14 Service Manual DS 350 GM ERRO ERROR CAUSE ACTION CODE Upper limit value for a.) Cable leading from the a.) Check cable and connectors. the measuring channel central unit to the sensor of b.) Check sensor of channel 7 7 exceeded. channel 7 defective, loose or and reset adjustment.
  • Page 15 Flowcharts ERRO ERROR CAUSE ACTION CODE Error in the external Internal defect in digital part Exchange write/read memory write/read memory of CPU. (CMOS-RAM). Replace CPU (RAM). Part 1 module. Refer to Drawing 4 and Procedure 3, Steps 1-3, 13,14. Error in the external Internal defect in digital part Exchange write/read memory write/read memory...
  • Page 16 Service Manual DS 350 GM ERROR ERROR CAUSE ACTION CODE Error in serial crane data Serial crane data EEPROM Write data on the serial crane data EEPROM. does not contain valid data. EEPROM (by means of test program or on-line function), then restart the LMI Replace EPROM Module and Memory module defective...
  • Page 17 Flowcharts ERROR ERROR CAUSE ACTION CODE E 91 No data transmission a.)24V supply of console a.) Check 24V at terminal X1 of from console to central interrupted. console electronics. unit. (Refer to Section b.)Interruption or accidental b.) Check the connection ground in the line from between console electronics and console electronics to...
  • Page 18 Service Manual DS 350 GM ERRO ERROR CAUSE ACTION CODE Error in the crane data a.) Data EPROM defective a.) Replace data EPROM EPROM b.) Position of jumper for the b.) Check the jumper position selection of the type of EPROM is wrong c.) Replace CPU module.

  • Page 19: Lever Lockout Activated

    Flowcharts LEVER LOCKOUT ACTIVATED PROBLEM: The lever lockout system of the crane is activated. Crane movements ““hoist up””, ““telescope out””, and ““boom down”” are stopped. Crane is not in overload or two-block condition. Start Use the key switch and the LMI by-pass button on the console to override the LMI.

  • Page 20: Broken Length Cable

    Service Manual DS 350 GM BROKEN LENGTH CABLE PROBLEM: Damaged or broken length cable. Replace length cable using the following procedure: Refer to Section 4 for the following drawings: Drawing 3 - Electrical Wiring Central Unit to Cable Reel Drawing 6 - Cable Reel - Parts List Cut old cable at cable drum.

  • Page 21: No Display

    Flowcharts NO DISPLAY PROBLEM: Blank console display with no warning light shown. All crane moments have been stopped. START Check fuses in central unit. Replace fuses. Correct? Measure voltage on the main board terminal strip between X1:1 (+12/24V) and X1:2 (ground).
  • Page 22 Service Manual DS 350 GM PREVIOUS PAGE Measure voltage in the console between X1:1 (+12/24V) and X1:2 (ground). Refer to Drawing 2 & 8 in Section 4. Check connections of the cable between Correct? console and central unit. Replace cable if necessary.

  • Page 23: Anti-Two Block Problem

    Flowcharts 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. Correct? Lower hook down into safe position Check Bypass plug installed Refer to Drawing 3 in Section 4. Plug appropriate bypass plug into socket of Correct? junction box.
  • Page 24 Service Manual DS 350 GM PREVIOUS PAGE Ensure the byass plug is plugged into the boom nose box. Measure the A2B signal in the cable reel between X1:Brown and X2:Red wires on the slip ring with an ohmmeter. Switch closed =4700 ±500Ohms Switch open =>...
  • Page 25 Flowcharts PREVIOUS PAGE Connect wire #5 back to the terminal X1:31 on the connection board. Refer to Drawing 3 in Section 4. Turn system power off. Check Anti-Two-Block signal in central unit with ohmmeter measure between X1:31 and X1:32. Anti-Two-Block switch closed = 4700 Ohms ±50 0Ohms Anti-Two-Block switch open =>...

  • Page 26: Length Reading Problem

    Service Manual DS 350 GM LENGTH READING PROBLEM PROBLEM: Length displayed incorrect. Crane is not in ““out of load chart”” condition. START Check mechanical adjustment of length potentiometer in cable reel. With boom fully retracted, reset potentiometer by turning it slowly counter-clockwise until it reaches a soft stop. Refer to Drawing 6 in Section 4 and Adjustment Procedure 5 in Section 5.
  • Page 27 Flowcharts PREVIOUS PAGE Measure supply to length transducer in cable reel between terminal 1 (ground) and 3 (+12/24v) Refer to Drawing 3 in Section 4. Correct? Faulty wiring between central unit and length transducer. Check wiring Measure signal from length transducer in cable reel. The return signal is a current output and must be measured in series.
  • Page 28 Service Manual DS 350 GM PREVIOUS PAGE Measure length signal of amplified output on analog input module between test point MP0 and X1:3. The measurement should be between 0.5-4.5v. 0.5v(500mv) with the boom fully retracted and the length potentiometer set fully counter-clockwise to a soft stop OR 4.5v with the length potentiometer turned completely clockwise 10 turns to the soft stop.

  • Page 29: Angle Reading Problem

    Flowcharts ANGLE READING PROBLEM PROBLEM: Angle displayed incorrect. Crane is not in ““out of load chart”” condition. START Check the cable reel for damages or movement of mounting bracket. Refer to Drawing 6 in Section 4 and Adjustment Procedure 5 in Section 5. Repair or replace cable reel, if damaged or Correct? adjustments can not be made.
  • Page 30 Service Manual DS 350 GM PREVIOUS PAGE Measure signal from angle transducer in cable reel. The return signal is a current output and must be measured in series. Set Voltmeter to measure amps. Remove Wire #4 from X1:4 in the cable reel and connect one voltmeter lead to wire #4 and the other lead to X1:4.

  • Page 31: Load Reading Problem

    Flowcharts LOAD READING PROBLEM PROBLEM: Load reading incorrect. START Check boom length reading on display. Reset length potentiometer. With fully retracted boom, turn potentiometer axle Correct? counter-clockwise until it stops . Refer to Section 3.7. Measure radius and check with the displayed radius. Check if mechanical adjustment of angle transducer is correct.

  • Page 32: Bad Data Transfer Between Console & Central Unit Or Interference Problem

    Service Manual DS 350 GM 3.10 BAD DATA TRANSFER BETWEEN CONSOLE & CENTRAL UNIT OR INTERFERENCE PROBLEM PREVIOUS PAGE Measure signal from pressure transducers in central unit. The return signal is a current output and must be measured in series. Set Voltmeter to measure amps. Piston Side, remove Wire #2 from X1:21 in the central unit and connect one ammeter lead to wire #2 and the other lead to X1:21.
  • Page 33 Flowcharts PROBLEM: Error Code ““E93/E94" No data transfer to and from console, interference from crane electric, or console display frozen . START Check the H12 (TxD) LED on the main board ON/OFF. Refer to Drawing 7 in Section 4. Make sure that the eprom's are correct and plugged into the Eprom Module on the main board.
  • Page 34 Service Manual DS 350 GM PREVIOUS PAGE Check if additional ground link between main board MP1 and central unit box mounting bracket is in place. Refer to Drawing 7 in Section 4. Install ground line - single cable minimum of AWG14 (2.0mm) Correct? between terminal MP1 and central unit box mounting bracket.

  • Page 35: Drawings

    Drawings DRAWINGS DRAWING 1. ELECTRICAL WIRING FOR CENTRAL UNIT TO PRESSURE TRANSDUCERS AND CRANE CENTRAL UNIT DS350GM MAIN BOARD: PAT 024-352-300-001 Rev A 05/01/01 // SB 190113_A 38 Years Specializing in Crane Electronic Repair & Parts Sales Call Us. We are glad to help...

  • Page 36: Drawing 2. Electrical Wiring For Central Unit To Console

    Service Manual DS 350 GM DRAWING 2. ELECTRICAL WIRING FOR CENTRAL UNIT TO CONSOLE CENTRAL UNIT DS350GM MAIN BOARD: PAT 024-352-300-001 See reference notes on Drawing 1. Rev A 05/01/01 // SB 190113_A 38 Years Specializing in Crane Electronic Repair & Parts Sales Call Us.

  • Page 37: Drawing 3. Electrical Wiring For Central Unit To Cable Reel/Anti-Two Block

    Drawings DRAWING 3. ELECTRICAL WIRING FOR CENTRAL UNIT TO CABLE REEL/ANTI- TWO BLOCK CENTRAL UNIT DS350GM MAIN BOARD: PAT 024-352-300-001 Rev A 05/01/01 // SB 190113_A 38 Years Specializing in Crane Electronic Repair & Parts Sales Call Us. We are glad to help...

  • Page 38: Drawing 4. Central Unit - Parts List

    Service Manual DS 350 GM DRAWING 4. CENTRAL UNIT - PARTS LIST Rev A 05/01/01 // SB 190113_A 38 Years Specializing in Crane Electronic Repair & Parts Sales Call Us. We are glad to help...
  • Page 39 Drawings DRAWING 4. CENTRAL UNIT - PARTS LIST - continued PART NO. A) PAT 024-350-063-001 PART NO. B) PAT 024-350-063-002 PART NO. DESCRIPTION 024-350-050-292 HOUSING W/COVER, CENTRAL UNIT 024-350-110-067 GASKET 024-352-300-001 MAIN, BOARD 024-352-300-020 ANALOG INPUT MODULE 024-351-300-007 CPU MODULE 024-351-300-011 EPROM MODULE 000-304-140-112...
  • Page 40 Service Manual DS 350 GM DRAWING 5B. CONSOLE DS350/1318 - PARTS LIST Rev A 05/01/01 // SB 190113_A 38 Years Specializing in Crane Electronic Repair & Parts Sales Call Us. We are glad to help...
  • Page 41 Drawings DRAWING 5B. CONSOLE DS350/1318 - PARTS LIST - continued GRAPHIC CONSOLE (HORIZONTAL), PARTS LIST PART NO. PAT 050-350-061-318 PART NO. DESCRIPTION 031-300-110-049 CONSOLE ACCY, FRONT FACE & DIS. 050-150-300-052 BOARD, PUSHBUTTON SET(KEYBRDS) 003-051-905-235 SWITCH, KEY 050-350-110-139 KEY, SPARE 002-053-703-101 SCREWS, FRONT PANEL MOUNTING 050-150-300-050 BOARD...

  • Page 42: Drawing 6. Cable Reel - Parts List

    Service Manual DS 350 GM DRAWING 6. CABLE REEL - PARTS LIST Rev A 05/01/01 // SB 190113_A 38 Years Specializing in Crane Electronic Repair & Parts Sales Call Us. We are glad to help...
  • Page 43 Drawings DRAWING 6. CABLE REEL - PARTS LIST - continued CABLE REEL ASSEMBLY, PARTS LIST PART NO. PAT 068-308-060-001 PART NO DESCRIPTION 068-000-300-060 BOARD, TERMINAL W/ EMC FILTERS 064-103-060-007 ANGLE SENSOR WG103/0007 068-000-300-018 LENGTH POTENTIOMETER UNIT 002-050-206-012 SCREW M6 X 12 HEX SOCKET CAP 000-207-010-064 WASHER M6 FLAT 068-000-100-152...

  • Page 44: Drawing 7. Central Unit Main Board Layout

    Service Manual DS 350 GM DRAWING 7. CENTRAL UNIT MAIN BOARD LAYOUT BOARD P/N 024-352-300-001 MP24 = KGND = +5V = +9V = +6V MP24 -= +BATT MP25 -= +UBS console, sensors, DI’’s MP26 -= GND MP29 -= +5V hand terminal MP26 LED’’S H08 - LOAD...

  • Page 45: Drawing 8. Console Connection Board

    Drawings DRAWING 8. CONSOLE CONNECTION BOARD -24V +24V BOARD PART NUMBER 050 150 30 0051 Rev A 05/01/01 // SB 190113_A 38 Years Specializing in Crane Electronic Repair & Parts Sales Call Us. We are glad to help...

  • Page 46: Drawing 9. Central Unit Analog Input Module

    Service Manual DS 350 GM DRAWING 9. CENTRAL UNIT ANALOG INPUT MODULE BOARD P/N 024-352-300-020 X1:1-7 = ADC INPUT 0.5V...4.5V, Note: If channel adjustments are made through the software and graphic console, DO NOT adjust offset with P1-P7. X1:8 = TEMP (0.5V + 10mV/ C) X1:9 = VREFA = 5.000V reference X1:10 = AGND (reference GND)

  • Page 47: Procedures

    Theory PROCEDURES PROCEDURE 1. STRAIN RELIEF INSTALLATION Rev A 05/01/01 // SB 190113_A 38 Years Specializing in Crane Electronic Repair & Parts Sales Call Us. We are glad to help...

  • Page 48: Procedure 2. Eprom Location And Installation

    Service Manual DS 350 GM PROCEDURE 2. EPROM LOCATION AND INSTALLATION SYSTEM DATA Ensure the notch is in the correct direction. The DATA and TLK EPROMs fill the bottom of the socket as shown by the arrows. Place EPROMs in the correct EPROM socket as shown. Rev A 05/01/01 // SB 190113_A 38 Years Specializing...

  • Page 49: Procedure 3. Main Board Replacement

    Theory PROCEDURE 3. MAIN BOARD REPLACEMENT Refer to Drawing 4, central unit parts list for board location. 1. Turn system power off. 2. Remove the central unit lid. NOTE: Take care not to damage the boards with the screwdriver, when removing and inserting screws. NOTE: Use care when lifting the CPU module board and analog input module from the main board because these boards have pins on the bottom side which insert into the main board.

  • Page 50: Procedure 4. Pressure Transducer Zero Adjustment

    Service Manual DS 350 GM PROCEDURE 4. PRESSURE TRANSDUCER ZERO ADJUSTMENT 5.4.1 USING GRAPHIC CONSOLE FOR ZERO-SETTING OF PRESSURE TRANSDUCER & FORCE INPUTS The zero setting consists of defining zero-point offset. The zero point offset is added to the transducer measurement to calculate the real physical pressure or force.

  • Page 51: Procedure 5. Length And Angle Sensor Adjustment

    Theory PROCEDURE 5. LENGTH AND ANGLE SENSOR ADJUSTMENT Rev A 05/01/01 // SB 190113_A 38 Years Specializing in Crane Electronic Repair & Parts Sales Call Us. We are glad to help...

  • Page 52: Theory

    Service Manual DS 350 GM THEORY THEORY 1. OPERATION OF BOOM LENGTH SENSOR The system sensors provide a 4 to 20mA output; however, due to a fixed resistor circuit in the central unit, the input signal can be measured using ammeter (current) or voltmeter (voltage). The input signal operating window is 4 to 20mA, measured in series at the analog input terminal OR 1.1 to 5.5V, measured in parallel between the analog input and ground (GND) terminals.

  • Page 53: Theory 2. Operation Of Piston Side Load Sensor

    Theory THEORY 2. OPERATION OF PISTON SIDE LOAD SENSOR Measuring current: The ammeter is used to measure current at the piston side input signal. Remove the wire from X1:21 terminal in the central unit and measure the current with the ammeter in series. The measurement should be between 4..20mA.

  • Page 54: Theory 3. Operation Of Rod Side Load Sensor

    Service Manual DS 350 GM THEORY 3. OPERATION OF ROD SIDE LOAD SENSOR Measuring current: The ammeter is used to measure current at the rod side input signal. Remove the wire from X1:24 terminal in the central unit and measure the current with the ammeter in series. The measurement should be between 4..20mA.

  • Page 55: Theory 4. Operation Of Angle Sensor

    Theory THEORY 4. OPERATION OF ANGLE SENSOR Measuring current: The ammeter is used to measure current at the angle input signal. Remove the wire from X1:29 terminal in the central unit and measure the current with the ammeter in series. The measurement should be between 4..20mA.
  • Page 56 Service Manual DS 350 GM MANUAL REVISIONS DATE NAME DESCRIPTION 05/01/01 Update format in manual. Rev A 05/01/01 // SB 190113_A 38 Years Specializing in Crane Electronic Repair & Parts Sales Call Us. We are glad to help...

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