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Hirschmann PAT DS 85/0002 Service Manual

Load moment indicator
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HIRSCHMANN
www.patamerica.com
LOAD MOMENT INDICATOR
DS 85/0002
central unit/ console
SERVICE MANUAL
P/N 031-300-190-166 REV G 10/05/2015

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Summary of Contents for Hirschmann PAT DS 85/0002

  • Page 1 HIRSCHMANN www.patamerica.com LOAD MOMENT INDICATOR DS 85/0002 central unit/ console SERVICE MANUAL P/N 031-300-190-166 REV G 10/05/2015...
  • Page 3 DS 85 NOTICE Hirschmann makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and/or its fitness for a particular purpose. Hirschmann will not be liable for errors contained in this manual or for incidental or consequential damages in connection with the furnishing, performance, or use of this manual.

  • Page 5: Table Of Contents

    ADIO SERVICE SCREEN FOR SENSOR CALIBRATION ............42 17.1 ........42 CTIVATING THE ERVICE CREEN FOR ENSOR ALIBRATION 17.2 ..............42 ETTING RANSDUCER NPUTS 17.3 ....................43 ALIBRATE LENGTH NPUT 17.4 .....................44 ALIBRATE NGLE NPUT ERROR CODES ......................47 © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...
  • Page 6 Service Manual DS 85 TROUBLESHOOTING MOISTURE ................53 19.1 ......................53 ATER NGRESS 19.2 ......................54 ONDENSATION © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...

  • Page 7: General Information

    To prevent material damage and serious or even fatal accidents, the correct adjustment of the LMI has to be ensured before starting the crane operation. © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...

  • Page 8: System Description

    The receiver is mounted into a receiver box located near the operating station. The receiver box provides the following indications: Power, Online, Info, and Low Battery. The receiver will work 10..30VDC and fused to 1 Amp. © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...

  • Page 9: Description Of The System Components

    W BATT B ALAR POWE 2 Pressure Console RATB RECEIVER 031-300-050- MODULE Transducers 3 Length Sensor 4 Angle Sensor/CAN Bus board 5 Radio A2B POWER Receiver 6 Radio Anti Two-Block LOCKOU Switch(es) T ALARM © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...
  • Page 10 To check the cable for damage, (short circuit to ground) there is a 4.7k resistor between ground and the contact of the switch, to give a signal back to the central unit. The weight at the anti-two-block switch keeps the switch closed until the load block strikes it. © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...

  • Page 11: Frequently Asked Questions

    CAN-Bus Communication  I NEED TO IDENTIFY A SPARE PART Please go to the Spare Part Listings  I HAVE NOTICED WATER IN SOME PART OF THE SYSTEM Please go to section Troubleshooting Moisture © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...

  • Page 12: Angle Theory

    Start by opening the angle sensor box and locate the angle sensor (top) and the CAN-Bus converter board (bottom): CAN-Bus electronics in cable reel. CAN-Bus electronics in angle sensor box. © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...
  • Page 13 Unplug angle sensor and measure again. If the voltage is still off, exchange converter board. If unplugging the angle sensor made the voltage return into the acceptable range, exchange angle sensor. If the voltage is correct continue: © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...
  • Page 14 At this point, you have verified that the angle sensor is giving you the right output to match your actual angle, but the system is displaying the wrong angle. If you can rule out software and operator error, it is most likely that the converter board is defective and it needs to be exchanged. © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...

  • Page 15: Length Theory

    The converter board supplies a voltage of about 4.7V to the length potentiometer and in return monitors the output voltage of the potentiometer. The terminal used is X20. The length sensor is connected as follows: © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...
  • Page 16 Voltage GND to X20-3 Turns to X20-3 0.00 0.16 0.46 0.62 0.93 1.09 1.40 1.56 1.87 2.03 2.34 2.50 2.81 2.97 3.28 3.44 3.75 3.91 4.22 4.38 4.68 4.84 Note: Actual voltages will vary slightly. © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...

  • Page 17: Cable Reel Length Cable Replacement Procedure

     Replace 4 conductor cable and connect to terminal strip. Refer to Drawing 1 in Appendix.  Replace cover. 7. Install cable reel into mounting brackets. 8. Run cable through U-shaped guide in boom, if applicable. 9. Connect thimble to stud in boom. 10. Check length measured and displayed. © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...

  • Page 18: Cable Reel Replacement Procedure

     Replace 4 conductor cable and connect to terminal strip. Refer to Drawing 1 in Appendix.  Replace cover. 6. Install cable reel into mounting brackets. 7. Run cable through U-shaped guide in boom, if applicable. 8. Connect thimble to stud in boom. 9. Check length measured and displayed. © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...

  • Page 19: Lwg Cable Reel Length/Angle Sensor Replacement Procedure

    (4 or 5 wraps) and secure with tie wraps. Leave enough length cable to connect to boom tip junction box. 3. Check the spooling. If spooling is not layered properly, carefully pull the cable out and respool the length cable. © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...
  • Page 20 2. The angle sensor must be level. Remove cover from reel. Adjust the level of the angle sensor by loosening the socket head cap screws and aligning the top of the angle sensor until parallel with the boom. Reinstall the cover on the reel. © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...

  • Page 21: Pressure Theory

    The CAN-Bus is digital and as such will either transmit the signal correctly or not at all. If your readings are off, chances are the pressure transducer is defective. Replace. Note: After exchanging the pressure transducer block, BOTH transducer channels need to be zeroed, see procedure Zero-Setting The Transducer Inputs. © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...

  • Page 22: Load Theory

    Indicates weak batteries specific to channel 1 or 2 when Yellow LED lights. 4. ‘INFO’ (Red) Indicates a two-block condition of the main hoist. The Red LED will light when the load-handling device has lifted the A2B weight. © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...
  • Page 23 ‘sleep’ mode Batteries of the sensor on this channel are almost exhausted Replace the batteries soon! © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...
  • Page 24 This function serves to reduce the power requirement of the hoist limit switch. The function is reset automatically upon the next switching of the hoist limit switch. © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...

  • Page 25: A2B Problem - Hardwired A2B Option

    10 A2B PROBLEM – HARDWIRED A2B OPTION © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...

  • Page 26: Console Display

    Pin 1 = +Ub and Pin 3 = GND. If the LED is on and you have power on the connector, either the software is defective or the console electronics need to be replaced. Fuses (F1 and F2) © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...

  • Page 27: Anti-Two Block System Setup

    There are no numbers, ID’s, or codes to remember or write down. Programming Button 12.2 REGISTERING DEVICES © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...
  • Page 28 Service Manual DS 85 © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...
  • Page 29 © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...

  • Page 30: Deleting Devices

    Avoid damage to the gasket which could lead to moisture ingress and corrosion of batteries and terminals. Inspect the gasket surface on the transmitter for nicks or other damage that may prevent the gasket from sealing. © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...
  • Page 31 If malfunctions occur, power the device off and have it checked. If necessary, schedule repair immediately by an authorized Hirschmann service partner. Clean the surface of the equipment occasionally with a damp cloth using a mild cleaning agent. However, you...

  • Page 32: Can-Bus Communication

    E64 (cable reel missing). E63 means that the pressure transducer is available, but is reporting an internal error. E65 means that the cable reel unit is available, but is reporting an internal error. © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...
  • Page 33 If you are sure that the sensor is being supplied, you have to replace the pressure transducer.  E63 In case of an E63, the pressure transducer is reporting an internal problem. You cannot troubleshoot any further, but need to replace the pressure transducer. © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...
  • Page 34 Pressure transducers (piston and rod), 500mV @ 0 PSI; 4500mV @ maximum PSI  Length sensor, 500mV @ retracted boom length; voltage extended depends on the various boom lengths.  Angle sensor, 4500mV at 0; 2500mV at 45; or 500mV at 90 © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...
  • Page 35 In case of an E65, the CAN-Bus converter board in the angle sensor box is reporting an internal problem. In most cases, this will be an angle sensor, or length potentiometer. Go to those chapters (Angle Sensing, Length Sensing) to continue trouble shooting. © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...
  • Page 36 Cable checks good Replace Check connector at angle the cable. sensor box or cable reel. Connector checks good Replace can bus board in Replace angle sensor or cable reel. connector. © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...

  • Page 37: Troubleshooting A Sensor Problem Using The Display

    And length and angle voltages and measurements. LENGTH / ANGLE 0502mV 2025mV 30.6 f t 55.7° The values shown in the screen here are just examples of actual values. Refer to the table listed below for actual value ranges. © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...

  • Page 38: Drawings

    Service Manual DS 85 15 DRAWINGS 15.1 CONSOLE/CENTRAL UNIT TO CRANE WIRING DIAGRAM © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...

  • Page 39: Length/Angle Sensor Wiring Diagram

    15.2 LENGTH/ANGLE SENSOR WIRING DIAGRAM © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...

  • Page 40: Hardwired A2B Wiring Diagram

    Service Manual DS 85 15.3 HARDWIRED A2B WIRING DIAGRAM © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...
  • Page 41 © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...

  • Page 42: Spare Part Listings

    PART NO. 031-300-060-443 2. CAN bus from console (90° connector) to pressure transducer block PART NO. 031-300-060-453 3. CAN bus from pressure transducer to angle sensor box PART NO. 10968 *(not shown) See next page: © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...

  • Page 43: Pressure Transducer Block

    PART NO. 10968 16.2 PRESSURE TRANSDUCER BLOCK DAV314/0014 PART NO. 044-314-060-014 Piston Side Rod Side Cutting ring for pressure transducers PART NO. 000-209-140-016 Hydraulic bulkhead adapter 9/16-18 JIC 37° x 16m x 1.5 PART NO. 000-214-600-093 © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...

  • Page 44: Angle Sensor Box

    PART NO. 031-300-060-437 PART NO. DESCRIPTION 064-143-060-009 SENSOR, ANGLE WG143/9 iFLEX CAN 068-000-300-103 CAN-BUS CONVERTER BOARD 10-30V 932321100 CONNECTOR, PANEL MOUNT SOCKET 3 + PE 092-000-060-387 CONNECTOR, BRAD HARRISON 5-PIN RECPT. MALE 092-000-060-382 CABLE, 3POL JST-PLUG 15cm © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...

  • Page 45: Cable Reel Assembly

    HARDWARE, LG105 COVER SCREW SET, M4x12 209-032-010-501 GASKET, O-RING FOR LG105 COVER 031-300-060-683 HARDWARE, LG105 EXTERNAL SET 031-300-060-684 HARDWARE, LG105 INTERNAL SET 031-300-060-578 LENGTH POT ASSY, LG105/0006 067-105-110-001 GEAR WHEEL, LG105/2,WORM WHEELCOMPLETE W/FIXING MATERIAL 031-300-100-462 TERMINAL STRIP, 4 POS. © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...

  • Page 46: Cable Reel Assembly

    Service Manual DS 85 16.5 CABLE REEL ASSEMBLY LWG508 PART NO. 068-508-060-001 © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...

  • Page 47: Radio A2B

    031-300-050-536 Card board tube 031-300-050-276 A2B Mounting standoff 031-300-050-264 A2B mounting plate 031-300-210-012 Weight and chain 031-300-100-037 Chain connector, quick link 031-300-050-272 Lynch pin 031-300-050-537 Transmitter Battery Cover 031-300-050-768 Antenna w/Screws, Gasket, Battery Tubes © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...

  • Page 48: Service Screen For Sensor Calibration

    The piston-side or rod-side zero-point setting function is activated ROD PRESS ▓ ROD PRESS and pressing to calibrate as shown in the screens above MB LENGTH selected sensor. CALIB. SENSORS ? to continue, press ▓ to calibrate, press © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...

  • Page 49: Calibrate Length Input

    FULLY EXTEND MAINBOO 100 f t fully extend the main boom, to continue, press MAINBOO 100 f t acknowledge main boom fully extended, to continue, press ▓ OK EXIT Press to calibrate. © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...

  • Page 50: Calibrate Angle Input

    Move boom so the CHANGE angle is with in ±2° of the BOOM T BOOM T 40.3 DEG -0.1 DEG angle. to continue, press BOOM T 40.3 DEG Mark CHANGE and press to change angle calibration. CHANG 40.0 DEG Mark OK if no change is necessary. © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...
  • Page 51 SAVE CALIB. ? To continue, press ▓ YES Mark YES and press to change angle calibration. Mark, NO if changes are not to be saved. ▓ EXIT Mark OK and press to save changes. © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...
  • Page 52 Using a calibrated inclinometer placed flat on the main boom, verify that the indicated boom angle matches the measured boom angle within +/- 0.2 degrees. Check the sensor outputs screen for 0°, 45°, 60°, and 70° 0502mV 2025mV 30.6 f t 55.7° main boom angle millivolts 0° 45° 60° 70° © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...

  • Page 53: Error Codes

     Clutch between length  Replace the complete clutch sensor pot and drive is including drive wheel and defective adjust length sensor pot as described above © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...
  • Page 54  refer to E1A Fallen below lower limit value in measuring channel "slewing angle 2"  refer to E11  refer to E11 Upper limit value in measuring channel “main boom length” has been exceeded. © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...
  • Page 55  Upload valid system System program and load chart file the LMI and the program file or the valid do not match programming in the load load chart file chart file do not match. © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...
  • Page 56 CAN units sensor units defective or and the sensor units not connected. (wiring harness). See section CAN-Bus Communication  Short circuit in a CAN Bus  Replace Can Bus cable cable © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...
  • Page 57 /angle sensor unit  See E62  See E62 Error in the can bus data transfer of the force sensor unit  See E63  See E63 Error in the can bus force sensor unit © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...
  • Page 58 No valid A2B switch status  CAN bus delay  Replace cable to the A2B switch Note: If an error message is displayed which is not contained in above list, please contact the PAT service department. © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...
  • Page 59 If the lid is bent or damaged, it needs to be replaced. Try to determine what has caused the lid to be bent and eliminate the reason for that. Order a new lid through your PAT representative. © Hirschmann Rev. G 10/05/15 190166_G.DOCXG...
  • Page 60 2. If the effect is more severe, the only way to get rid of this effect is then to give the box the ability to breath without sacrificing its water tightness. Contact your PAT representative for breathing elements to than can be added to the box and will help to reduce the effects of humid climates. © Hirschmann Rev.G 10/05/15 190166_G.DOCXG...

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