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PAT DS 50 Troubleshooting Manual

Overload warning system
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DS50 TROUBLE SHOOTING MANUAL
LEVEL 3
Overload Warning
System DS 50
Grove
Trouble Shooting Manual
Level 3
- Calibration Adjustments
-
TSM DS 50-003/REV.C/031-300-190-003/04-20-07
1

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  • Page 1 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 Overload Warning System DS 50 Grove Trouble Shooting Manual Level 3 - Calibration Adjustments TSM DS 50-003/REV.C/031-300-190-003/04-20-07...
  • Page 2 PAT shall 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. This document contains proprietary information which is protected by copyright.

  • Page 3: Table Of Contents

    DS50 TROUBLE SHOOTING MANUAL LEVEL 3 Table of contents Item Content Page Introduction to troubleshooting the PAT Overload Warning System DS50 1.1 System outline 1.2 System operation 1.3 Troubleshooting care 2.1 The hand terminal 2.2 The hand terminal connection 3.1 The start up menu 3.2 Displaying data and messages...
  • Page 4 Therefore only trained and authorized service personnel shall proceed with the procedures and data adjustments described in this manual. Incidental errors in the calibration or software change may result in a fatal accident. Always verify software change or calibration change results. TSM DS 50-003/REV.C/031-300-190-003/04-20-07...
  • Page 5 SERVICE TOOLS AND A DIGITAL VOLTMETER ARE AVAILABLE ON SITE. THIS TROUBLE SHOOTING MANUAL DS 50 - LEVEL 3- IS THE CONTINUATION OF TROUBLE SHOOTING MANUAL DS 50 - LEVEL 1- AND -LEVEL 2- AND ASSUMES THE KNOWLEDGE OF THE CONTENT OF THE PREVIOUS LEVELS .

  • Page 6: System Outline

    The system design allows you to operate the crane in an emergency situation or system failure without the DS 50 system in operation. In this situation leave the crane electric switch in the off position and press the override button while you operate the crane manually.
  • Page 7 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 1. INTRODUCTION TO TROUBLESHOOTING THE PAT DS 50 LENGTH SENSOR - UNDER COVER- LENGTH CABLE DS 50 SYSTEM LENGTH CABLE ENTRY LENGTH CABLE MOUNT BOOM CABLE CONNECTORS MAST LOAD CELL PROXIMITY HOIST DRUM SWITCH...

  • Page 8: System Operation

    DS50 TROUBLE SHOOTING MANUAL LEVEL 3 1. INTRODUCTION TO TROUBLESHOOTING THE PAT 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 9: Troubleshooting Care

    • Keep in mind while troubleshooting high quality electronic components to use caution and necessary care while testing and measuring DS 50 components and circuits of the crane electric's. • Tools and test equipment must be in good order and shall be inspected on a regular basis.
  • Page 10 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 1. INTRODUCTION TO TROUBLESHOOTING THE PAT DS 50 Hook block storage position Crane electric junction box Crane power switch Outrigger extend proximity switches- FMTV-Cargo only. Note: The drawing shows the model FMTV-W. The FMTV-C has only single line capability.

  • Page 11: The Hand Terminal

    Part of the hand terminal is a cable. The DB9 connector at the end of the cable shall be connected to the DS 50 main board. Refer to section 2.2 and drawing 2.2.1 and 2.2.2 for hand terminal connection.
  • Page 12 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 2.1 THE HAND TERMINAL Plus / Minus Drawing 2.1.1 TSM DS 50-003/REV.C/031-300-190-003/04-20-07...

  • Page 13: The Hand Terminal Connection

    In order to connect and use the hand terminal for data read-out or data adjustment the DS 50 hardware must be prepared as follows: • Switch the truck power off. Remove both the DS 50 central unit cover and the CPU board cover carefully as described in manual level 1&2.

  • Page 14: The Start Up Menu

    Switch the truck power on. A cursor appears on the top left of the hand terminal display and the red ‘online’ LED lights up. After the DS 50 system has passed the self test routine, the display shows the start up menu. Refer to drawing 3.1.

  • Page 15: Displaying Data And Messages

    In order to identify the need for a data adjustment, internally calculated data must be compared with the actual measured data. The DS 50 is an overload shut down system and is not classified as a scale. The consideration of government specified tolerances is part of the trouble shooting process.
  • Page 16 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 3.2 DISPLAYING DATA AND MESSAGES Drawing 3.2.1 TSM DS 50-003/REV.C/031-300-190-003/04-20-07...

  • Page 17: The Test Program

    >0<. For correct adjustment of the switch refer to documentation in level 1 &2. To return to the main menu press the >ESC< key or the letter key for the program you wish to select. TSM DS 50-003/REV.C/031-300-190-003/04-20-07...
  • Page 18 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 3.3 THE TEST PROGRAM Drawing 3.3.1 Drawing 3.3.2 TSM DS 50-003/REV.C/031-300-190-003/04-20-07...

  • Page 19: The On-Line Mode

    Refer to the flowchart diagrams of this manual for detailed information how to use the two calibration functions. • Press the >K< key to return to the start up menu. Message > End online mode<. • Press either >U< or >V< key to switch between the two calibration functions. TSM DS 50-003/REV.C/031-300-190-003/04-20-07...
  • Page 20 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 3.4 THE ON-LINE MODE Drawing 3.4.1 TSM DS 50-003/REV.C/031-300-190-003/04-20-07...

  • Page 21: Adjusting Calibration Data

    Ensure that your measuring tape is in good condition. When testing the radius mount the beginning of the tape exactly on the center line of rotation. Note the display indicates the radius or boom length in resolution of 1/10 ft. - not in inches. TSM DS 50-003/REV.C/031-300-190-003/04-20-07...

  • Page 22: Identify The Problem

    Load display for the for the actual length actual length step and step too low or too high. angle too high or too low. Go to Go to Go to Go to section 6. section 7. section 8. section 9. TSM DS 50-003/REV.C/031-300-190-003/04-20-07...

  • Page 23: Adjusting Overload Cut Off Factor

    103%, 111%, 108% which does not meet the specification. Connect the hand terminal as described in section 2.2. Select the on-line mode as described in section 3.4. Press the key >U< . continue on next page TSM DS 50-003/REV.C/031-300-190-003/04-20-07...
  • Page 24 Press the key >K< to return to the start up menu. Go to section 3.2 and observe the display while you repeat the cut off test for the actual length step. Is the problem corrected now? Return to section 5 and identify the problem. The End TSM DS 50-003/REV.C/031-300-190-003/04-20-07...

  • Page 25: Adjusting Empty Hook Load Display

    Select the on-line mode as described in section 3.4. Press the key >U< . Does the display indicate >C-EMPTY= n: < ? Note: n= calibration value. Scroll through the lines by pressing the enter key >CR< until the line is displayed. continue on next page TSM DS 50-003/REV.C/031-300-190-003/04-20-07...
  • Page 26 Press the key >K< to return to the start up menu. Go to section 3.2 and observe the hook display while you repeat booming down from high to low boom angle. Is the problem corrected now? Return to section 5 and identify the problem. The End TSM DS 50-003/REV.C/031-300-190-003/04-20-07...

  • Page 27: Adjusting Radius Display Under Load

    Select the on-line mode as described in section 3.4. Press the key >U< . Does the display indicate >CF-RAD= n: < ? Note: n= calibration value. Scroll through the lines by pressing the enter key >CR< until the line is displayed. continue on next page TSM DS 50-003/REV.C/031-300-190-003/04-20-07...
  • Page 28 Press the key >K< to return to the start up menu. Go to section 3.2 and repeat testing the radius under load. Is the problem corrected now? Return to section 5 and identify the problem. The End TSM DS 50-003/REV.C/031-300-190-003/04-20-07...

  • Page 29: Adjusting Load Display

    In example >C-LOAD I= -200< -- with a calculated correction factor of -- 4% enter >C-LOAD I= -600<. Note: The correction value is limited to +/- 1000 = +/- 10%. The program extrapolates the entry and writes the calculated values into the next stored angles continue on next page TSM DS 50-003/REV.C/031-300-190-003/04-20-07...
  • Page 30 Refer to previous page reference of stored angles. Press the key >CR< to change to the new correction factor. Repeat until you have entered all previously calculated correction factors for the stored angles. The End TSM DS 50-003/REV.C/031-300-190-003/04-20-07...

  • Page 31: Transferring Eeprom Data

    DS50 TROUBLE SHOOTING MANUAL LEVEL 3 10. TRANSFERRING EEPROM DATA In the event of DS 50 main board failure it becomes necessary to install a Replacement central unit. Note: All calibration data is stored in the E-EPROM which is installed on the main board and not removable.
  • Page 32 YES, then press the ENTER key. Press the C button to return to the main menu. .0 DEG 7.89’ E15 X14 X15 X16 UP and DOWN arrows Enter key SETUP INIT EEPROM INIT EEPROM ARE U SURE? INIT EEPROM ARE U SURE? TSM DS 50-003/REV.C/031-300-190-003/04-20-07...
  • Page 33 UP or DOWN arrows until the appropriate crane type is displayed. Now press the ENTER key to return to the main menu. SETUP INIT EEPROM SETUP CRANE TYPE CRANE TYPE FMTV-C REV 3.2 0.02 .0 DEG 7.89’ E24 TSM DS 50-003/REV.C/031-300-190-003/04-20-07...
  • Page 34 CLOCKWISE only until the error E11 is displayed. Pulling the cable out slightly should display error E05 instead of E11. Reconnect the length cable to the boom nose. 0.02 .0 DEG 7.20’ E11 0.02 .0 DEG 7.25’ E05 TSM DS 50-003/REV.C/031-300-190-003/04-20-07...
  • Page 35 Press the UP key until LENGTH OFFSET is displayed, then press the ENTER key. Use the UP or DOWN arrows until the exact length is displayed. Now press the ENTER key to return to the setup menu. SETUP INIT EEPROM SETUP LENGTH OFFSET LENGTH OFFSET 7.30’ TSM DS 50-003/REV.C/031-300-190-003/04-20-07...
  • Page 36 SENS.ZERO is displayed, then press the ENTER key. Use the UP or DOWN arrows until the exact angle is displayed. Now press the ENTER key to return to the setup menu. SETUP INIT EEPROM SETUP ANGLE SENS.ZERO ANGLE SENS.ZERO 0.0 DEG TSM DS 50-003/REV.C/031-300-190-003/04-20-07...
  • Page 37 UP/DOWN arrows to select YES to save the new values to EEPROM, then press the ENTER key to return to the main menu. SETUP INIT EEPROM SETUP FORCE SENS.ZERO FORCE SENS.ZERO -0.04 TON SAVE NEW VALUES TO EEPROM: SAVE NEW VALUES TO EEPROM: TSM DS 50-003/REV.C/031-300-190-003/04-20-07...
  • Page 38 YES to save the new values to EEPROM, then press the ENTER key to return to the main menu. SETUP INIT EEPROM SETUP RADIUS ADJUSTMNT RADIUS ADJUSTMNT .04’ SAVE NEW VALUES TO EEPROM: SAVE NEW VALUES TO EEPROM: TSM DS 50-003/REV.C/031-300-190-003/04-20-07...
  • Page 39 After each value matches the desired value, press the ENTER key to save the value and advance to the next variable. CONTINUED ON NEXT PAGE SETUP INIT EEPROM SETUP EDIT VARIABLES EDIT VARIABLES VAR #: 119 EDIT VARIABLES # 70 VAL:- TSM DS 50-003/REV.C/031-300-190-003/04-20-07...
  • Page 40 UP/DOWN arrows to select YES to save the new values to EEPROM, then press the ENTER key to return to the main menu. SAVE NEW VALUES TO EEPROM: SAVE NEW VALUES TO EEPROM: TRANSFER OF CALIBRATION VALUES IS COMPLETE TSM DS 50-003/REV.C/031-300-190-003/04-20-07...

  • Page 41: Error Code Messages

    Check the +5V supply as described in +5V supply to length pot faulty. the troubleshooting manual. Identify either a main board defect or length pot assembly defect. Replace the length pot. Refer to the Length pot defective troubleshooting manual for instructions. TSM DS 50-003/REV.C/031-300-190-003/04-20-07...
  • Page 42 Replace main board or central unit and transfer calibration data. Afterwards, load test the system. Communication Angle sensor defective or Replace main board and transfer lost to angle main board defective calibration data. Afterwards, load test sensor the system. TSM DS 50-003/REV.C/031-300-190-003/04-20-07...
  • Page 43 Clearly identify a main board defect by Analog channel on main referring to the troubleshooting manual. board defective If in doubt contact Hirschmann service for support. Replace main board or central unit and transfer calibration data. Afterwards, load test the system TSM DS 50-003/REV.C/031-300-190-003/04-20-07...
  • Page 44 EEPROM not Data in the EEPROM is Initialize the EEPROM, then re-enter initialized defective or lost calibration data into it. Turn the power on and off several times. If the problem repeats itself, replace the main board. TSM DS 50-003/REV.C/031-300-190-003/04-20-07...

  • Page 45: Removing Test And Calibration Equipment

    • Check the system performance by lifting a known test load and a cut off test. • If the test fails then you should verify the correct removal of test equipment or calibration equipment or repeat trouble shooting as described in the Troubleshooting Manual level 1, 2, and 3. TSM DS 50-003/REV.C/031-300-190-003/04-20-07...

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