Hirschmann PAT DS 160 Service Manual
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Hirschmann PAT DS 160 Service Manual

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DS 160
System
DS 160 /0005
DS 160 /0006
Service Manual
Issue 6/2005 Rev. D
This Document has the part-no.
24 160 19_0106e
Contents
General Information
Warnings
System Description
General Troubleshooting
Information
Error Codes
Function Lockout
No Display
...
PRELIMINARY ISSUE

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Summary of Contents for Hirschmann PAT DS 160

  • Page 1 DS 160 System Contents General Information Warnings System Description General Troubleshooting Information DS 160 /0005 Error Codes Function Lockout No Display … DS 160 /0006 Service Manual PRELIMINARY ISSUE Issue 6/2005 Rev. D This Document has the part-no. 24 160 19_0106e...

  • Page 2: Table Of Contents

    CONTENTS GENERAL INFORMATION............2 WARNINGS ................2 SYSTEM DESCRIPTION............3 GENERAL TROUBLESHOOTING INFORMATION....4 GENERAL FLOW CHARTS .............. 5 ERROR CODES ..............6 Operating Errors E01 through E05............ 6 Lockout Function Errors 07 and 08 ........... 7 Analog Input Channel Errors............. 7 5.3.1 Troubleshooting a Sensor Problem using the Display ...... 8 5.3.2 Error Codes for the Analog Inputs.............

  • Page 3: General Information

    1. GENERAL INFORMATION The PAT Load Moment Indicator (LMI) DS 160 has been designed to provide the crane operator with the essen- tial information required to operate the machine within its design parameters. Using different sensing devices, the Load Moment Indicator monitors various crane functions and provides the operator with a continuous reading of the crane’s capacity.

  • Page 4: System Description

    5. Central Unit (in cab or outside) Fig. 1: Components of the LMI System PAT DS 160 © 2005 PAT GmbH · D-76275 Ettlingen · Hertzstr. 32 - 34 · ++49 (0) 7243 709-0 · FAX ++49 (0) 7243 709-222 · Email: pat.ettlingen@pat-group.net...

  • Page 5: General Troubleshooting Information

    4. GENERAL TROUBLESHOOTING INFORMATION This section explains how to handle a problem that may arise with the PAT DS 160 System. 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 noted detailed sections.

  • Page 6: General Flow Charts

    GENERAL FLOW CHARTS What’s Wrong? Error Code Displayed Go to Section 5 Function Lockout Go to Section 6 No display Go to Section 7 Anti-Two Block Problem Go to Section 8 Length Reading Problem Go to Section 9 Angle Reading Problem Go to Section 10 Load Reading Problem Go to Section 11...

  • Page 7: Error Codes

    5. ERROR CODES Operating Errors E01 through E05 These errors are usually caused by operating in a way that is not allowed per the load charts. Note: If an error message is displayed which is not contained in the following list, please contact the PAT service department.

  • Page 8: Lockout Function Errors 07 And 08

    Lockout Function Errors 07 and 08 These errors are caused by defects around the function lockouts. Error Code Error Cause Elimination • Overload relay or main • Replace main board Faulty acknowledgment of board are defective the overload relay on the •...

  • Page 9: Troubleshooting A Sensor Problem Using The Display

    Troubleshooting a Sensor Problem using the Display 5.3.1 For a sensor error or problem with a sensor, look at the output voltage of the pressure transducer, length, and angle sensors and compare the reading with the following: Pressure transducers (piston and rod), 500 mV @ 0 psi Length sensor, 500 mV @ retracted boom length Angle sensor, 4500 mV at 0°, 2000 mV at 45°, or 500 mV at 90°...

  • Page 10: Error Codes For The Analog Inputs

    Error Codes for the Analog Inputs 5.3.2 If it exceeds these limits, the following errors are triggered: (NOTE: the upper limit follows the lower limit error, i.e. 11 and 21, 12 and 22, 13 and 23…) Error Code Error Cause Elimination Fallen below limit for •...
  • Page 11 Error Code Error Cause Elimination • refer to E16 • refer to E16 Upper limit value in measuring channel "middle section" ex- ceeded Fallen below lower • Angle sensor defective. • Replace angle sensor. limit value for the measuring channel •...

  • Page 12: Errors 31 And Up

    Errors 31 and up Miscellaneous Errors, most of them caused by electronics. Error Code Error Cause Elimination • The system program EPROM is • Replace system program Error in the system program defective. PROM (D13) • The system program in the LMI •...
  • Page 13 Error Code Error Cause Elimination • • Error in the radius The computed radius is too small Check the programming in (negative deflection) the data EPROM. determination • 24 V supply of the console is inter- • Check 24 V at terminal X1 No data transmission rupted of the console electronics...

  • Page 14: Function Lockout

    6. FUNCTION LOCKOUT PROBLEM: The lever lockout system of the crane is activated. Crane movements “hoist up” and (optional) “boom down” are stopped. Only if the crane is not in overload or two-block condition continue with flow chart. WARNING: If overload or A2B condition exists, use extreme caution and move the crane out of the condition.

  • Page 15: No Display

    7. NO DISPLAY PROBLEM: Blank console display with no warning light shown. All crane moments have been stopped. START Check fuses in central unit. Corrected Replace fuses. Measure voltage on the main board terminal strip between X1:1 (10-30V) and X1:3 (ground).
  • Page 16 PREVIOUS PAGE Measure voltage in the console between X1:1 (+12/24V) and X1:2 (ground). Refer to system wiring diagram. Check connections of the cable between Correct? console and central unit. Replace cable if necessary. Refer to system wiring diagram. Console/Display is defective. Replace the console. Refer to system wiring diagram.

  • Page 17: Anti-Two Block Problem

    8. 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, if necessary Refer to system wiring diagram. Plug appropriate bypass plug into socket of Correct? junction box.
  • Page 18 PREVIOUS PAGE Ensure the A2B switch is closed (weight or flag installed) and, if necessary, 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 19 PREVIOUS PAGE Connect the boom base connector. Connect wire #5 back to the terminal X1:9 on the connection board. Refer to system wiring diagram. 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 20: Length Reading Problem

    9. 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 system wiring diagram and sensor adjustment procedure.
  • Page 21 PREVIOUS PAGE Measure supply to length transducer in cable reel between terminal 1 (ground) and 3 (+UB) Refer to system wiring diagram. 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 22: Angle Reading Problem

    10. 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 system wiring diagram and sensor adjustment procedure. Repair or replace cable reel, if damaged or Correct? adjustments can not be made.
  • Page 23 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 24: Load Reading Problem

    11. 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 system wiring diagram and sensor adjustment procedure. Measure radius and check with the displayed radius.
  • Page 25 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 X1:32 in the central unit and connect one ammeter lead to wire #2 and the other lead to X1:32.

  • Page 26: Data Transfer Central Unit <--> Console

    12. DATA TRANSFER CENTRAL UNIT <--> CONSOLE PROBLEM: Error Code “E93/E94" No data transfer to and from console, interference from crane electric, or console display frozen . START Check the H1 (TxD) LED on the main board ON/OFF. Refer to main board drawing. Make sure that the EPROM's are correct and plugged into the EPROM Module on the main board.
  • Page 27 PREVIOUS PAGE Check if additional ground link between main board MP1 and central unit box mounting bracket is in place. Refer to Drawing 4. Install ground line - single cable minimum of AWG14 (2.0mm) Correct? between terminal MP1 and central unit box mounting bracket. Refer to Drawing 2 and 4.

  • Page 28: Procedures

    13. PROCEDURES EPROM Location and Installation Procedure 13.1 • Ensure the notch is in the correct direction. • The DATA,TLK, and SYSTEM EPROM’s fill the bottom of the socket as shown by the arrows. • Place EPROM’s in the correct EPROM socket as shown. ©...

  • Page 29: Main Board Replacement Procedure

    Main Board Replacement Procedure 13.2 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.

  • Page 30: Calibration Of Sensors Procedure

    Calibration of Sensors Procedure 13.3 To access the calibration sensors screen use the following procedure. 1. From the operating screen, press and held both the ⇑- button and the “OK”-button for 5 sec- onds to display the maintenance screen. 2. The screen show the following selections: CALIBRATE SENSORS SENSOR OUTPUTS EXIT...

  • Page 31: Length Sensor Calibration Procedure

    Length Sensor Calibration Procedure 13.3.2 After selecting ‘LEN’ in steps 1 through 4 at the beginning of this section complete the following pro- cedure. Fully retract the main boom. Displayed length indication FULLY RETRACT MAINBOOM XX.X ft Note: the displayed length indication is noted by XX.X in following steps.

  • Page 32: Angle Sensor Calibration Procedure

    Angle Sensor Calibration Procedure 13.3.3 After completing steps 1 through 4 at the beginning of this section, boom down to a flat angle and mechanically adjust the angle sensor. The angle should be set to be +/-0.0 of the measured angle. Material –...

  • Page 33: Cable Reel Lwg308/0001 Adjustment Procedure

    Cable Reel LWG308/0001 Adjustment Procedure 13.4 © 2005 PAT GmbH · D-76275 Ettlingen · Hertzstr. 32 - 34 · ++49 (0) 7243 709-0 · FAX ++49 (0) 7243 709-222 · Email: pat.ettlingen@pat-group.net 24 160 19_0106E_Rev D.doc / 2005-06-27 / rk.

  • Page 34: Cable Reel Length Cable Replacement Procedure

    Cable Reel Length Cable Replacement Procedure 13.5 Replace length cable using the following procedure: Refer to system electrical wiring diagram and cable reel - parts list Cut old cable at cable drum. Disconnect damaged length cable from junction box at the boom nose. Open cable reel cover and disconnect wiring from terminal block.

  • Page 35: Troubleshooting Moisture

    1) Spray Cleaning The enclosures used for the PAT DS 160 system are water protected to IP 65. This means protec- tion against the environment, such as rain. However, through the use of spray cleaner at short dis- tances, it is possible to force water through the gasket or strain relieves.

  • Page 36: Condensation

    4) Defective Gasket The gasket underneath the lid seals the unit. The gasket needs to be in good condition in order to seal correctly. If the gasket is torn, brittle or severely bent, it needs to be replaced. Order a new gasket through your Link-Belt or PAT representative.
  • Page 37 Revision History Revision Date Modifications Name 2002-01-16 original issue, english (190142_-.doc) Vers. A 2002-10-09 Corrections gk/rk Vers. B 2003-02-07 Corrections Vers. C 2005-06-27 Layout correction Vers. D © 2005 PAT GmbH · D-76275 Ettlingen · Hertzstr. 32 - 34 · ++49 (0) 7243 709-0 ·...

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