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PAT DS 50 Troubleshooting Manual

Overload warning system grove - fmtv using test equipment
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Overload Warning
Overload Warning
Overload Warning
System DS 50
System DS 50
System DS 50
Grove - FMTV
Trouble Shooting Manual
Level 2
-Using Test Equipment-
1
TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96

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Summary of Contents for PAT DS 50

  • Page 1 Overload Warning Overload Warning Overload Warning System DS 50 System DS 50 System DS 50 Grove - FMTV Trouble Shooting Manual Level 2 -Using Test Equipment- TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...

  • Page 2: Table Of Contents

    PAT Overload Warning system DS 50 Level 2 -Using Test Equipment- Item Content Page Introduction to troubleshooting the PAT Overload Warning System DS 50 1.1 System Outline 1.2 Systems operation 1.3 Troubleshooting care Getting started LED 1-6 are all dim - Power supply problem LED 2 is dim - No outgoing crane power 5.0 LED 3 - Cut off not functioning correctly...
  • Page 3 NOTE THIS TROUBLESCHOOTING MANUAL “DS 50 - LEVEL 2” IS DESIGNED TO ASSIST THE SERVICE OR MAINTENANCE PERSONAL IN IDENTIFYING THE PROBLEM AREA OF A MALFUNCTIONING SYSTEM. IN ORDER TO FOLLOW THE FOLLOWING INSTRUCTIONS THE PAT TEST ADAPTER AND A DIGITAL VOLTMETER ARE REQUIRED IN ADDITION TO THE REGULAR MAINTENANCE AND SERVICE TOOLS.

  • Page 4: Pat Overload Warning System Ds 50

    Operating the crane without using the range diagram may result in property damage, injury or death. The DS 50 system contains of a Central unit. The length sensor is part of the Central unit. The load cell is supporting the hoist drum and used to measure the load on hook.
  • Page 5 1. INTRODUCTION TO TROUBLESHOOTING THE PAT OVERLOAD WARNING SYSTEM DS 50 LENGTH SENSOR - UNDER COVER- LENGTH CABLE DS 50 SYSTEM LENGTH CABLE ENTRY LENGTH CABLE MOUNT CABLE CONNECTORS BOOM MAST LOAD CELL PROXIMITY HOIST DRUM SWITCH HOOK BLOCK BOOM...

  • Page 6: Systems Operation

    1. INTRODUCTION TO TROUBLESHOOTING THE PAT OVERLOAD WARNING SYSTEM DS 50 1.2 SYSTEM OPERATION The Microprocessor Central Unit operates as the control center of the system. The length cable is connected to the boom nose. During telescoping the length cable spools off a drum which turns the length potentiometer using a gear assembly.

  • Page 7: Troubleshooting Care

    • Never let the length cable snap back to the central unit. The length sensor drum is under high tension. Warning DS 50 Overload Warning System service and repair work shall be performed by trained and authorized personal only. TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 8 1. INTRODUCTION TO TROUBLESHOOTING THE PAT OVERLOAD WARNING SYSTEM DS 50 Hookblock storage position Crane electric Crane power switch junction box Outrigger extend proximity switches- FMTV-Cargo only. Note: The drawing shows the model FMTV-W. The FMTV-C has only single line capability.

  • Page 9: Getting Started

    2. Getting started The following drawing explains the components on the PAT test adapter. This troubleschooting manual will refer to this drawing several times. Positive voltage terminal for DVM Status LEDs Input connector Plugs - connect to System - connect input...
  • Page 10 2. Getting started Locate the PAT DS 50 overload warning system. Switch the crane electrical power off. Refer to drawing 2 in section 1 to locate the crane electric interface box with electrical power switch. Unplug the three cables from the central unit. Plug those cables into the test adapter sockets.
  • Page 11 7 section 8 section 3 section 4 section 5 section 6 Length sensor signal measurements. go to As continuation of section 4 in section 9 troubleschooting manual -level 1- TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 12 Replace cable assembly and rewire to crane electric interface box. Refer to Grove documentation for installation and wiring instructions. Repeat test. -Incorrect crane voltage- Refer to vehicle documentation for further testing of the truck and crane electric's. TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 13 3. LED 1- 6 are all dim or off. -Power supply problem- 0.000 + -- LED 1 - 6 are all dim or off DRAWING 4: LED 1- 6 are all dim or off - Power supply problem - TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 14 Inspect the connector and plug for damage, moisture or wear. Clean contacts. Plug the connector into the system and tighten the connection. Repeat the test. continue on next page TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 15 The connector pins have to be crimped tight. Be careful not to splice the wires or to crimp the insulation. After rework repeat the test. TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 16 4. LED 2 is dim or off. -No outgoing crane power- 0.000 + -- LED 2 is dim or off DRAWING 5: LED 2 - No outgoing crane power TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 17 4. LED 2 is dim or off. -No outgoing crane power- Remove covers Brown Refer to the electrical connector wiring diagram and Inspect internal wiring. DRAWING 6: Internal wiring check TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 18 4. LED 2 is dim or off. -No outgoing crane power- Inspect internal wiring and rework if necessary DRAWING 7: DS 50 internal wiring diagram TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 19 Is LED 3 (overload cut off) switching according to the range diagram? No cut off problem detected. Go to section 5 and 6 Refer to other sections of in troubleschooting manual level 1-Basics-. troubleshooting manual level 1-3. TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 20 23 to locate the system fuse. Is fuse O.K. ? Switch power off. Replace system fuse. Install a 500 mA medium blow fuse European or US style. Switch power on. Repeat test. continue on next page TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 21 Make sure the switch in the test adapter is returned to the “signal on” position. Is the voltage measured between 0 and +12 mV +/-2%. continue on Defective loadcell assembly - next page replace loadcell assembly. Refer to Grove documentation for service instructions. TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 22 Refer to DWG 10 on page 25. Is sensor wiring &mounting O.K.. ? Switch power off. Rewire and rework connections. Switch power on and test again. continue on next page TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 23 Replace the length potentiometer or the length sensor assembly. Use the Troubleshooting Manual -Level 1- section 4 for instructions. Repeat test. Main board defective. Replace main board. or complete central unit and refer to Troubleshooting Manual -Level 3- for calibration instructions. TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 24 5.1 LED 3 on all time. -Cut off not functioning correctly- check connection - internal wiring- Angle sensor check connection - internal wiring- 500 mA System Fuse check connection - internal wiring- DRAWING 8: Main board connector and components TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 25 Green LED - on when toggle simulate O V signal. Red LED - on when toggle switch switch is in loadcell signal is in O - signal simulator position. position. DRAWING 9: Test adapter use for section 5.1 TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 26 5.1 LED 3 on all time. -Cut off not functioning correctly- Remove covers Length sensor wiring Refer to the electrical Mainboard wiring diagram and Inspect internal wiring. Angle sensor DRAWING 10 : Internal wiring check TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 27 5.1 LED 3 on all time. -Cut off not functioning correctly- DRAWING 11 : DS 50 internal wiring diagram TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 28 Is power supply cable and connector in good condition ? Replace cable assembly and rewire to crane electric interface box. Refer to Grove documentation for installation and wiring instructions. Repeat test. continue on next page TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 29 32to locate the system fuse. Is fuse O.K... ? Switch power off. Replace system fuse. Install a 500 mA medium blow fuse European or US style. Switch power on. Repeat test. continue on next page TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 30 Does the red LED 3 changes to on when you approach the radius for 100-110% load? Refer to Trouble Shooting Manual -level 3- and check for errorcodes and correct calibration. continue on next page TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 31 Refer to Grove Service Documentation for disassembly and assembly instruction. Main board defective. Replace main board. or complete central unit and refer to Troubleshooting Manual -Level 3- for calibration instructions. TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 32 5.2 LED 3 off all time. -Cut off not functioning correctly- 0.000 + -- LED 1 DRAWING 12: - Checking a Power supply problem - TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 33 5.2 LED 3 off all time. -Cut off not functioning correctly- check connection - internal wiring- Angle sensor check connection - internal wiring- 500 mA System Fuse check connection - internal wiring- DRAWING 13: Main board connector and components TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 34 Red LED - on when toggle switch switch is in loadcell signal testing with load. is in O - signal simulator position. position. DRAWING 14: Test adapter use for section 5.2 TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 35 5.2 LED 3 dim all time. -Cut off not functioning correctly- Remove covers Length sensor wiring Refer to the electrical Mainboard wiring diagram and Inspect internal wiring. Angle sensor DRAWING 15 : Internal wiring check TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 36 5.2 LED 3 off all time. -Cut off not functioning correctly- DRAWING 16 : DS 50 internal wiring diagram TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 37 Refer to DWG 19 on page 40 for the internal wiring. Refer to Troubleschooting Manual -Level 3- for data exchange instructions and calibration instructions. Power supply to proximity switch is correct Verify signal using section 6 in this manual. TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 38 6. LED 4 is off. -No power to proximity switch on hoist drum- 0.000 LED 1 + -- LED 4 DRAWING 16: - Checking a proximity switch power supply problem - TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 39 6. LED 4 is off. -No power to proximity switch on hoist drum- Remove covers Length sensor wiring Refer to the electrical Mainboard wiring diagram and Inspect internal wiring. Angle sensor DRAWING 17: Internal wiring check TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 40 6. LED 4 is off. -No power to proximity switch on hoist drum- DRAWING 18 : DS 50 internal wiring diagram TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 41 Manual -Level 1- for more instructions. Repeat the test after switch assembly was replaced. Defective hoist proximity switch. Replace switch assembly and readjust to gain a gap between switch and target of 1/8” (cable follower). Refer to Grove Service documentation for further instructions. TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 42 7. LED 5 is off or on all times. -Hoist proximity switch problem- 0.000 LED 1 + -- LED 5 DRAWING 19: - Checking a hoist proximity switch signal problem - TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 43 Refer to Grove Service Documentation for installation instructions. Inspect the internal wiring. Is the wiring O.K... ? Switch power off. Rewire and rework connections. Switch power on and test again. continue on next page TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 44 Crane power supply is missing. Refer to section 3 in this Troubleshooting Manual and proceed with testing. Main board defective. Replace main board. or complete central unit and refer to Troubleshooting Manual -Level 3- for calibration instructions. TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 45 8. LED 6 is off . - Loadcell power supply problem - 0.000 + -- LED 5 LED 1 DRAWING 20: - Checking a loadcell power supply problem problem - TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 46 8. LED 6 is off. - Loadcell power supply problem - Remove covers Length sensor wiring Refer to the electrical Mainboard wiring diagram and Inspect internal wiring. Angle sensor DRAWING 21: Internal wiring check TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 47 8. LED 6 is off. - Loadcell power supply problem - DRAWING 22 : DS 50 internal wiring diagram TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...

  • Page 48: Length Sensor Signal Measurement

    1. Connect the negative probe to potentiometer terminal 3. Do you measure +5 V+/-2%? Switch power off. Rewire and rework connections. Switch power on and test again. continue on next page TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 49 0V to +5V by turning the pot from fully counter - clockwise to fully clockwise? Switch power off. Rewire and rework connections. Switch power on and test again. Length sensor electrically functioning TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 50 - internal wiring- Terminal X4 Terminal X4 Terminal X3 Terminal X3 Terminal X1 Terminal X1 check connection 500 mA System Fuse - internal wiring- Terminal X2 Terminal X2 DRAWING 23: Main board connector and components TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...
  • Page 51 9. Length sensor - Signal measurement- Length sensor cable X4/1 PINK X4/2 BLUE X4/3 DRAWING 24: Length sensor wiring - connection at X4 on main board. TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96...