Overload Warning System DS 50
Contents
1. Drawing 3 3 2 TSM DS 50 003 REV B 031 300 190 003 12 02 96 21 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 3 4 THE ON LINE MODE The calibration equipment and the system must be switched into on line mode for calibration adjustments From the start up menu select the on line mode by pressing the gt lt key The hand terminal displays the message gt 5 5 READY The operating mode code and the actual length step gt 0101 LS 7 33 confirms the operation of the on line mode Refer to the example in drawing 3 4 1 A calibration adjustment is possible for a length step only A length step is the main boom length shown in each loadchart column You can exit the on line mode any time Exit the on line mode by pressing the gt SHIFT lt key and then the gt lt key The hand terminal confirms with the message gt End online mode lt Once in the start up display of the on line mode there are two calibration functions available Press the gt U lt key to change calibration data for the actual length step e Press the 2 V key to change load calibration data for the actual length step Refer to the flowchart diagrams of this manual for detailed information how to use the two calibration functions Press gt lt key to return to the start up menu Message gt End online lt Press either gt U lt or gt V lt key to switch between the two calibration functions TSM DS 50 003 REV B 0312. Identify clearly a main board defect by referring to the troubleshooting manual If in doubt contact PAT service support Replace main board or central unit and transfer E Eprom data Load test system after Check cable and connectors and replace if necessary Refer to troubleshooting manual Replace length sensor potentiometer Refer to instructions in the troubleshooting manual Identify clearly a main board defect by referring to the troubleshooting manual If in doubt contact PAT service support Replace main board or central unit and transfer E Eprom data Load test system after DS50 TROUBLE SHOOTING MANUAL LEVEL 3 11 ERROR CODE MESSAGES Load cell channel Cable leading from the If the cable or connector is voltage is lower then central unit to the load cell is damaged replace connector the minimum limit defective or moisture in the or load cell Refer to connector troubleshooting manual Load cell defective Follow the instruction in the troubleshooting manual and use the test unit to identify clearly a load cell defect If in doubt contact the PAT service support In the event of a load cell defect replace load cell referring to the troubleshooting manual and the crane service documentation Warning Support the hoist drum while replacing the load cell Identify clearly a main board defect by referring to the Analog channel on main troubleshooting manual If in board defective doubt cont
3. TAJIK za hehceo la nizrkace ba Tans AU ho hos on T c Tan bond PA ARC boas Nets socket cen he main Drawing 2 2 1 TSM DS 50 003 REV B 031 300 190 003 12 02 96 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 22 THE HAND TERMINAL CONNECTION v 999999 9 Fa opalen wih hre amini anpe D puogod Into tbc Hp andrer thes pin ace Drawing 2 2 2 TSM DS 50 003 REV B 031 300 190 003 12 02 96 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 22 THE HAND TERMINAL CONNECTION Hand Terminal Drawing 2 2 3 TSM DS 50 003 REV B 031 300 190 003 12 02 96 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 3 1 THE START UP MENU Follow the instructions described in section 2 2 to connect the on line equipment 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 selftest routine the display shows the start up menu Refer to drawing 3 1 The following letters allow the user to select the desired program Data output to PC terminal mode Not used for hand terminal operation H Data output to hand terminal Profort 803 e O Select the on line mode The on line mode must be selected to adjust calibration data T Select the test mode The test mode allows the user to initialize the EEPROM prior to a new calibration only and to test the digital inputs suc
4. 12 02 96 30 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 8 ADJUSTING RADIUS DISPLAY UNDER LOAD continuation MAU Adjust the correction factor to increase or decrease the radius Then press the gt CR lt key to enter the value Press the key gt lt to return to the start up menu Go to section 3 2 and repeat testing the radius under load Is the problem corrected now NO YES Return to section 5 and identify the problem TheEnd _ TSM DS 50 003 REV B 03 1 300 190 003 12 02 96 3 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 9 ADJUSTING LOAD DISPLAY Problem Load indication too high or too low Retract or extend the boom to the length step with the problem Actual boom length must agree with the length step LS on the hand terminal display Hoist a known test load The test load shall be or 5 75 of the rated capacity Refer to the crane load chart Hoist the load just above the ground and read the load display on the hand terminal Compare the displayed load with the actual load Calculate the difference between the actual load and the displayed load on the hand terminal Connect the hand terminal as described in section 2 2 Select the on line mode as described in section 3 4 Press the key gt V lt The terminal display indicates gt C LOAD I n lt or gt C LOAD x n lt Note n previously entered correction factor a number between 1 and 7 A load correction value can be ent
5. 300 190 003 12 02 96 22 DS50 TROUBLE SHOOTING MANUAL 3 4 THE ON LINE MODE SYSTEM READY Un 0101 L5 Press the key CY to activate Drawing 3 4 1 TSM DS 50 003 REV B 031 300 190 003 12 02 96 23 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 4 ADJUSTING CALIBRATION DATA Use the flowcharts in the continuation of this manual to locate the section appropriate for your adjusting needs Remember you must be fully familiarized with section 2 and 3 in order to proceed with section 4 Test the hardware using trouble shooting manual 2 amp 3 before you consider adjusting the calibration data Always consider that the system left the crane manufacturer fully calibrated and passed the quality tests Always consider calibration and crane specification during the adjusting procedure Ensure a safe environment Secure the crane and the surrounding area Do not overload the crane and truck during the adjusting process Always consider and refer to the crane load chart Always measure actual geometrical values Use only tested inspected and known test weights for load testing The load must be freely suspended and lifted in a vertical straight line Always initially hoist the load of the ground The use of a dead eye hook in the ground is not permitted for any adjusting methods Use a tested inclinometer level indicator with a minimum resolution of 0 25 degree to measure the boom angle Ensure that your measuring
6. calibration adjustment to PAT Equipment Corp Inc Attn Software Dept 1665 Orchard Drive Chambersburg PA 17201 U S A If no adjustment has changed the data and no EPROM is desired skip to Transmit data to the DS 50 in this section Copy data into EPROM Switch the truck power off No power to DS 50 e Disconnect the serial interface cable from the DB 9 ribbon cable connector of the DS 50 interface Plug the blank EPROM into the DATAMAN S4 EPROM socket Refer to the user manual for correct insertion e Press the green key gt BURN lt The display indicates Microchip 27C256 13 00V Burm pin 1 00000 07 00000 if not gt Enter 500000 07 00000 lt on the last line and press gt ENTER lt gt The display scrolls through the addresses while burning the EPROM Display returns with the prompt and a tone TSM DS 50 003 REV B 031 300 190 003 12 02 96 38 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 10 TRANSFERRING EEPROM DATA To read the EPROM with the calibration data back into the DATAMAN S4 follow the procedure below If the data is already in the memory of the DATAMAN S4 skip to Transmit data to the DS 50 in this section Read EPROM data into the DATAMAN S4 Switch the truck power off No power to DS 50 e Disconnect the serial interface cable from the DB 9 ribbon cable connector of the DS 50 interface e Switch the DATAMAN 54 on Plug the EPROM with the calibration data i
7. menu to verify the load adjustment Hand terminal display indicates gt C LOAD x n Enter the calculated correction factor n for the x angle Refer to previous page reference of stored angles Press the key gt CR lt to change to the new correction factor Repeat until you have entered all previously calculated correction factors for the stored angles KN Pran sd End 7 TSM DS 50 003 REV B 031 300 190 003 12 02 96 33 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 calibration data is stored in the E EPROM which is installed on the main board and not removable By removing the defective central unit the calibration data becomes removed Extract the data prior to disconnecting the defective DS 50 central unit Truck voltage is required to extract the data Additional equipment required to transfer calibration data e Eprom programmer gt DATAMAN S4 lt Drawing 10 1 1 the next page shows the DATAMAN S4 The serial interface cable which comes with the DATAMAN S4 The charging unit which comes with the DATAMAN 54 The DS 50 System Software Version gt DS 50 1 4C lt and higher Preparation e Carefully read the user manual for the DATAMAN 54 Before removing the defective DS 50 install the interface board and the ribbon cable with t
8. 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 B 031 300 190 003 12 02 96 24 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 5 IDENTIFY THE PROBLEM Connect the hand terminal and press the gt H lt key to compare the displayed values with the actual values Identify the problem Find a square matching your problem and follow the instructions Radius display under load for the actual length step too high or too low Overload cut off for the actual length step too early or too late Empty hook display for the actual length step too low or too high Go to section 7 Go to section 6 Go to section 8 TSM DS 50 003 REV B 031 300 190 003 12 02 96 25 Load display for the actual length step and angle too high or too low Go to section 9 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 6 ADJUSTING OVERLOAD CUT OFF FACTOR Problem A The overload cut off for the actual length step is always too early tested at a high mid and low boom angle B The overload cut off for the actual length step is always too late tested at a high mid and low boom angle Retract or extend the boom to the length step with the problem Pick a test load and carefully conduct a cut off test at a high boom angle mid boom an
9. the function of the digital inputs such as the hoist layer switch function Press the key gt T lt to start the test program Refer to drawing 3 3 1 and 3 3 2 The program allows to select the test routine e Press 4 to initialize the E EPROM CAUTION DO NOT INITIALIZE A CALIBRATED SYSTEM YOU WILL LOOSE ALL CALIBRATION DATA IF YOU PRESS THE Y KEY AFTER THE MESSAG OVERWRITE Y N ALWAYS CONFIRM WITH THE N KEY IF YOU ENTERED THE ROUTINE BY MISTAKE WHEN TRANSFERRING DATA TO A REPLACEMENT SYSTEM IT MAY BECOME NECESSARY TO INITIALIZE THE REPLACEMENT SYSTEM BEFORE DATA TRANSMISSION e Press 8 to test digital inputs The hand terminal display indicates the actual status of three digital inputs DI I DI2 DI 3 1 0 0 gt 1 lt means the digital input is powered and a 50x means the digital input is not powered on In the example above the DI 1 is powered by the hoist layer switch Switch off the hoist layer switch by lowering the hoist and you can see the 51x changing to gt 0 lt For correct adjustment of the switch refer to documentation in level 1 amp 2 Note No other digital input is used for the DS 50 FMTV application To return to the main menu press the gt ESC lt key or the letter key for the program you wish to select TSM DS 50 003 REV B 031 300 190 003 12 02 96 20 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 3 3 THE TEST PROGRAM Test men refer text Drawing 3 3 1 Submenu to test 4
10. 0 190 003 12 02 96 36 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 10 TRANSFERRING EEPROM DATA Receive data from BEPROM Switch the truck power off No power to DS 50 Switch DATAMAN S4 off e Connect the serial interface cable into the connector of the DATAMAN S4 Connect the DB 9 connector of the interface cable into the DB 9 ribbon cable connector of the DS 50 interface e Switch DATAMAN S4 on and switch the truck power DS 50 power on Wait for minimum of 10 seconds The display will prompt twice 5 and the cursor flashes Switch DATAMAN S4 off and immediately on again The DATAMAN S4 will now receive the data out of the EEPROM Note The DATAMAN S4 will transmit the data one more time to the DS 50 to test the received data Please be patient as the transmission can take a little while e At the completion of receiving and testing data the DATAMAN S4 responds with 2 dual tones 2 DATA received correctly 6 dual tones Error in the data transmission e The prompt and the cursor flashes to continue transferring data or to repeat the receiving function TSM DS 50 003 REV B 031 300 190 003 12 02 96 37 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 10 TRANSFERRING EEPROM DATA At this point it is possible to burn and secure the data into an EPROM 27C256 PAT tested and approved EPROMS only The EPROM can be downloaded to a PC file using the DATAMAN 4 Note Either a copy EPROM or a PC file must be forwarded immediately after
11. 275 LB The correction value is limited to 500 Then press the gt CR lt key to enter the value Press the key gt lt 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 NO YES Return to section 5 and identify the problem TheEnd _ TSM DS 50 003 REV B 03 1 300 190 003 12 02 96 29 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 8 ADJUSTING RADIUS DISPLAY UNDER LOAD Problem Radius displays incorrect with load on hook Retract or extend the boom to the length step with the problem Actual boom length must agree with the length step LS on the hand terminal display Hoist a known test load The test load shall be or gt 75 of the rated capacity for the radius you check out Refer to the crane load chart Hoist the load just above the ground and measure the radius with a tape Compare with the displayed radius Calculate the difference between the actual measured radius and the displayed radius on the hand terminal Connect the hand terminal as described in section 2 2 Select the on line mode as described in section 3 4 Press the key gt lt Does the display indicate gt CF RAD n lt Note n calibration NO Scroll through the lines by pressing the enter key gt lt until the line is displayed continue on next page 2 TSM DS 50 003 REV B 031 300 190 003
12. DS50 TROUBLE SHOOTING MANUAL LEVEL 3 Overload Warning System DS 50 Trouble Shooting Manual Level 3 Calibration Adjustments TSM DS 50 003 REV B 031 300 190 003 12 02 96 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 NOTICE The information in this document is subject to change without notice PAT 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 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 All rights are reserved No part of this document may be photocopied reproduced or translated to another language without the prior written consent of PAT TSM DS 50 003 REV B 031 300 190 003 12 02 96 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 Table of contents Item Content Page 1 Introduction to troubleshooting the PAT Overload Warning System DS50 1 1 System outline 5 1 2 System operation T 13 Troubleshooting care 8 2 1 The hand terminal 10 22 hand terminal connection 12 3 1 The start up menu 16 3 2 Displaying data and messages 17 3 3 The test program 19 3 4 Theon line mode 21 4 Adjusting calibration data 23 5 Identify the problem 24 6 Adjusting overload cut off factor 25 7 Adjusting emp
13. In this situation leave the crane electric switch in the off position and press the override button while you operate the crane manually The DS 50 Overload Warning System is not operative and can not warn the operator with the electric power switch in off position Warning Bypassing the DS 50 Overload Warning system may results in property damage injury or death The DS 50 system contains a central unit with integrated length and angle sensor The load cell is supporting the hoist drum and used to measure the load on hook TSM DS 50 003 REV B 031 300 190 003 12 02 96 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 1 INTRODUCTION TO TROUBLESHOOTING THE PAT DS 50 LENGTH SENSOR UNDER COVER LENGTH CABLH DS 50 SYSTE LENGTH CABLE ENTR CABLE CONNECTOR BOOM LENGTH CABLE MOUNT PROXIMITY HOIST DRUN DRU Ji SWITCH LOAD HOOK BLOCK BLOCK BOOM LIFT CYLINDHR Note The drawing shows the model FMTV W The FMTV C has only single line capability DRAWING 1 1 SYSTEM LOCATION FMTV WRECKER TSM DS 50 003 REV B 031 300 190 003 12 02 96 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 The length potentiometer i
14. LAR MAINTENANCE AND 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 WE SUGGEST THAT ONLY TRAINED MAINTENANCE AND SERVICE PERSONNEL PROCEED WITH THE TROUBLE SHOOTING DESCRIBED IN THIS MANUAL TSM DS 50 003 REV B 031 300 190 003 12 02 96 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 1 INTRODUCTION TO TROUBLESHOOTING THE PAT DS 50 1 1 SYSTEM OUTLINE The PAT Overload Warning System Model DS 50 is designed to disable the boom down and up hoist up and tele out crane functions when the crane attempts to lift over its limits These limits are specified in the load capacity chart provided by the crane manufacturer When the DS 50 system detects an overload condition the following crane functions are disabled immediately a telescope out b boom up and boom down c hoist up To remove the overload condition the operator must achieve a safe working condition This can be achieved by lowering the load and repositioning the crane or decreasing the radius by telescoping in Observe that the radius can not be decreased by lifting the boom The boom up function is disabled while attempting to overload the crane The system design allows you to operate the crane in an emergency situation or system failure without the DS 50 system in operation
15. act PAT service support Replace main board or central unit and transfer E Eprom data Load test system after Angle channel voltage Angle sensor or electronic Replace main board or is lower then the component defective on central unit and transfer E minimum limit main board Eprom data Load test system after TSM DS 50 003 REV B 031 300 190 003 12 02 96 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 11 ERROR CODE MESSAGES Length channel voltage Cable between length sensor Check cable and connectors is higher then the and main board defective and replace if necessary maximum limit shorted or disconnected Refer to troubleshooting manual Length sensor Replace length sensor potentiometer defective potentiometer Refer to instructions in the troubleshooting manual Analog channel on main Identify clearly a main board board defective defect by referring to the troubleshooting manual If in doubt contact PAT service support Replace main board or central unit and transfer E Eprom data Load test system after TSM DS 50 003 REV B 031 300 190 003 12 02 96 45 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 11 ERROR CODE MESSAGES Load cell channel voltage is higher then the maximum limit Angle channel voltage is higher then the maximum limit Error in the Eprom system part TSM DS 50 003 REV B 031 300 190 003 12 02 96 Cable leading from the central unit to the load cell is defective or moistur
16. and calibration Also refer to Trouble Shooting Manual 1 and 2 for basic set up of the PAT DS 50 Overload Warning System TSM DS 50 003 REV B 031 300 190 003 12 02 96 40 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 11 ERROR CODE MESSAGES Error Code Table DS50 for Cranes FMTV C FMTV W LVS System program DS50 V1 4C Parts list No 71 050 14 0005 Error Cutoff due to overload Reduce load moment Pre warning Approaching an overload Slow crane operation and be condition alert E01 No loadchart radius Boom is elevated too high Boom down the boom to a angle available with into a non rated radius or radius or angle specified in high boom angle angle range the load chart 2 No loadchart radius Boom is lowered too low into Raise the boom to a radius angle available with low non rated radius or angle or angle specified in the load boom angle range chart TSM DS 50 003 REV B 031 300 190 003 12 02 96 41 DS50 TROUBLE SHOOTING MANUAL 11 ERROR CODE MESSAGES LEVEL 3 Forbidden length range Boom has been extended too Retract or extend boom to of the main boom TSM DS 50 003 REV B 031 300 190 003 12 02 96 far or not enough The length sensor adjustment was modified e g length cable spooled off the length sensor reel and the length sensor was not adjusted after the problem was corrected Clutch between length sensor pot and drive is defective Failure of the 5V suppl
17. ata read out or data adjustment the DS 50 hardware must be prepared as follows Switch the truck power off and remove the DS 50 central unit cover carefully as described in manual level 1 amp 2 Carefully insert the interface board into the interface board socket on the main board CAUTION The hole location in the interface board must match the hole location on the main board Otherwise you may damage the interface and main board when powering the system up Do not break bend or skip any pins on the interface board while you plug the board into the socket Refer to drawing 2 2 1 for installation of the interface board The plug in jumper J2 next to the interface board socket must be closed mid amp top position of the 3 pin connector Refer to drawing 2 2 2 Note the hand terminal will not function with J2 not in the correct position Plug the small ribbon cable adapter with the 10 conductor female plug into the male interface connector on the main board next to the interface board socket Plug the female DB 9 connector of the hand terminal cable into the male DB 9 connector at the other end of the ribbon cable Refer to drawing 2 2 3 for cable connection Secure the ribbon and hand terminal cable with cable ties to avoid cable stress or pulling off connections while operating the crane TSM DS 50 003 REV B 031 300 190 003 12 02 96 13 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 22 THE HAND TERMINAL CONNECTION
18. awing 3 2 1 indicates a maximum load capacity of 5 000 Ib Actual load on hook in 16 1000 Note that the hook is not part of the load The sample drawing 3 2 1 indicates an actual load of 4 200 Ib Main boom length in ft The distance between the center of the boom pivot pin and and the center of the sheave wheel pin The sample drawing 3 2 1 indicates a main boom length of 14 2 ft Refer to table below for fully retracted and fully extended boom length indication Indicated length Crane model retracted extended FMTV Cargo 7 3 15 7 FMTV Wrecker 7 3 18 4 Main boom angle in degree in reference to the horizontal line The sample drawing 3 2 1 indicates a boom angle of 65 5 degree Radius in ft Radius is defined as the distance between center line of crane rotation and the center line of the load freely suspended The sample drawing 3 2 1 indicates a radius of 15 7 ft n the event of a malfunction an overload condition or an out of loadchart condition the radius display becomes replaced by the Error message Refer to the error code list to decode the message TSM DS 50 003 REV B 031 300 190 003 12 02 96 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 32 DISPLAYING DATA AND MESSAGES Error message Drawing 3 2 1 TSM DS 50 003 REV B 031 300 190 003 12 02 96 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 3 3 THE TEST PROGRAM The test program is designed to initialize the E EPROM prior to a new calibration and to test
19. ay while you repeat the cut off test for the actual length step Is the problem corrected now NO YES Return to section 5 and identify the problem 7 Na TSM DS 50 003 REV B 03 1 300 190 003 12 02 96 27 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 7 ADJUSTING EMPTY HOOK LOAD DISPLAY Problem Load displays hook display incorrect with no load on hook Retract or extend the boom to the length step with the problem Actual boom length must agree with the length step LS on the hand terminal display Boom down from high boom angle to low boom angle and observe the load hook display Since you boom down without load the load displayed should be around 0 LB Now position the boom at approximate 45 degree boom angle and lower the hook from the boom nose down to ground Observe the load display on the hand terminal Connect the hand terminal as described in section 2 2 Select the on line mode as described in section 3 4 Press the key gt U lt Does the display Scroll through the lines by pressing the enter key gt lt until the line is displayed continue on nextpage TSM DS 50 003 REV B 031 300 190 003 12 02 96 28 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 7 ADJUSTING EMPTY HOOK LOAD DISPLAY continuation MAU Enter your calculated correction in LB Example 500 increases the hook display by 500LB 275 decreases the hook display by
20. e in the connector Load cell defective Analog channel on main board defective Angle sensor or electronic component defective on main board The Eprom on the main board is defective 46 If the cable or connector is damaged replace connector or load cell Refer to troubleshooting manual Follow the instruction in the troubleshooting manual and use the test unit to identify clearly a load cell defect If in doubt contact the PAT service support In the event of a load cell defect replace load cell referring to the troubleshooting manual and the crane service documentation Warning Support the hoist drum while replacing the load cell Identify clearly a main board defect by referring to the troubleshooting manual If in doubt contact PAT service support Replace main board or central unit and transfer E Eprom data Load test system after Replace main board or central unit and transfer E Eprom data Load test system after Follow the instruction in the troubleshooting manual and replace the Eprom which is plugged into the Eprom socket on the main board Refer to the Eprom label to affirm the same Eprom version Function and load test the system after DS50 TROUBLE SHOOTING MANUAL LEVEL 3 11 ERROR CODE MESSAGES Error in the logic of the The Eprom on the main Follow the instruction in the software the Eprom board is defective troubleshooting manual and Error in the internal
21. er position of the rubber gasket Do not tighten one nut completely before you proceed with the next nut Distribute the force while tightening Finally tighten all nuts Be careful to not over tighten the nuts and brake off the threaded part of the studs e Mount the large cover and carefully tighten the four nuts Re connect the external cables with the Mil type plugs to the connectors Refer to the manual level 1 and level 2 for orientation of those connectors Be sure the plugs are tightened to seal against water ingress e Check the system performance by lifting a known test load and a cut off test e If the test fails then you should verify the correct removal of test equipment or calibration equipment or repeat trouble shooting as described in Troubleshooting Manual level 1 2 and 3 TSM DS 50 003 REV B 031 300 190 003 12 02 96 50
22. ered and stored for the following boom angles degree 60 50 40 30 20 10 0 These correspond on the hand terminal display to gt C LOAD 1 C LOAD 7 If the boom is positioned between two of those angles during the initial start of the gt lt function the hand terminal displays gt C LOAD I n lt Enter the calculated or estimated load correction factor in x 100 for the initial starting angle Note If the address has already a data you must either subtract or add your calculated correction factor In example gt C LOAD I 200 with a calculated correction factor of 4 enter gt 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 En next page TSM DS 50 003 REV B 031 300 190 003 12 02 96 32 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 9 ADJUSTING LOAD DISPLAY continuation _ Press the gt CR lt key to save the value Display indicates gt C LOAD I 7 lt Note z the value entered previously Press the gt CR lt key to confirm and the display indicates gt C LOAD x n lt Note x the next lower stored angle n the correction value entered previously for the x angle Do you want to enter correction factors for lower boom angles NO Press the key gt K lt to return to the start up menu Press the key gt H lt in the start up
23. gle and low boom angle Calculate the cut off percentage manually by using actual measured data for each of the test The allowable cut off percentage as per government specification is 10196 11096 You must be able to hoist up at 100 utilization but cut off at latest 110 utilization Ensure that you do not exceed those two limits by adjusting the overload cut off factor In example your cut off is at 98 97 99 increasing the cut off factor by 496 would enable a new cut off at 102 101 103 which is acceptable But if your cut off is 98 106 103 increasing by 5 would enable a new cut off at 10390 11196 10896 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 gt U lt continue na next page 4 TSM DS 50 003 REV B 031 300 190 003 12 02 96 26 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 6 ADJUSTING OVERLOAD CUT OFF FACTOR b Does the display indicate gt D RLFCT n lt Note n calibration NO Scroll through the lines by pressing the enter key gt lt until the line is displayed Enter your calculated correction factor in 96 x 100 Example 5 00 500 2 75 275 The correction factor is limited to 500 Then press the 2CR key to enter the value Press the key gt lt to return to the start up menu Go to section 3 2 and observe the displ
24. h as the function of the hoist layer switch Caution Do not initialize a calibrated system Incidently initialization of the EEPROM results in loss of calibration data and a recalibtaion becomes neccessary Refer to the appropriate section in this manual to distinguish what letter key of the start up menu to select Start up menu after system powers Drawing 3 1 1 TSM DS 50 003 REV B 031 300 190 003 12 02 96 17 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 32 DISPLAYING DATA AND MESSAGES Follow the instructions in section 2 2 and 3 1 In order to identify the needfor 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 Crane and truck manufacturing tolerances do not allow calibrating an overload shut down system with 0 tolerance To select the read out of geometrical data load data and error messages press the gt H lt key of the alphabetical key pad The following information is now displayed Refer to drawing 3 2 1 to identify the displays described in the text below Utilization of the lifting capacity in percentage Overload cut off should be active between 100 and 110 The sample drawing 3 2 1 indicates an utilization of 84 Maximum load capacity in 1b 1000 for the actual boom position The sample dr
25. he DB 9 connector at the end Refer to section 2 2 for installation instructions e Setup the DATAMAN S4 gt Press the red key gt SETUP lt Enter the following File Intel gt lt Baud 9600 gt lt Handshake None gt lt Download sound On gt lt UL 10 gt 5 lt gt Display returns with the prompt TSM DS 50 003 REV B 031 300 190 003 12 02 96 34 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 10 TRANSFERRING EEPROM DATA aa HS PAKANA Drawing 10 1 1 TSM DS 50 003 REV B 031 300 190 003 12 02 96 35 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 10 TRANSFERRING EEPROM DATA Select the PROM type Press the green key gt lt Display indicates a Prom type The cursor should flash on the first digit of the reference number gt Enter the reference number gt 0 04 lt using the keyboard and press gt lt The display indicates Microchip 27C256 13 00V Burn pin 1 100us No Overprog Alg 7E Ref 0C04 gt Press the gt ENTER lt key to confirm Display returns with the prompt e Reset the RAM memory gt Press the white gt FILL lt key Display indicates in example 00000 0FFFF FF gt Enter 00000 07FFF FF using the keyboard of the DATAMAN and confirm with the gt lt key DATAMAN S4 answers with one short tone and returns to the prompt TSM DS 50 003 REV B 031 30
26. 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 personnel only TSM DS 50 003 REV B 031 300 190 003 12 02 96 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 1 INTRODUCTION TO TROUBLESHOOTING THE PAT DS 50 Hookblock storage position Crane electric junction box Crane power switch Outrigger extend proximity switches FMTV Cargo only E DERRE 98 Note The drawing shows E the model FMTV W E The FMTV C has only single line capability DRAWING 1 2 Crane storage position Caution Crane is shown folded for transportation For lifting operations the mast has to be in full upright position and the hook lifted out of the transportation storage TSM DS 50 003 REV B 031 300 190 003 12 02 96 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 2 1 THE HAND TERMINAL The key board of the Profort 803 hand terminal is divided in three main areas Refer to drawing 2 1 1 and locate the keys which are described in the text below Numerical key pad Used to enter numerical data Alphabetical key pad Used to enter commands letters Function keys Used to correct delete or confirm an entry or display Some keys are assigned to special hand terminal functions Internal battery check key By pressing the key the red LED on the left top row lights
27. nto the DATAMAN S4 EPROM socket Refer to the user manual for correct insertion e Press the green key gt LOAD lt The display indicates LOAD 27C256 00000 07FFF 00000 if not gt Enter 500000 07 00000 lt on the last line and press gt ENTER lt Display returns with the prompt and a tone TSM DS 50 003 REV B 031 300 190 003 12 02 96 39 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 10 TRANSFERRING EEPROM DATA Transmit data to the EEPROM of the replacement unit Switch the truck power off No power to DS 50 Switch DATAMAN S4 off e Connect the serial interface cable into the connector of the DATAMAN S4 Connect the DB 9 connector of the interface cable into the DB 9 ribbon cable connector of the DS 50 interface Switch DATAMAN S4 on and switch the truck power DS 50 power on Wait for minimum of 10 seconds The display will prompt twice 5 with two tones and the cursor flashes e Press the white key gt send lt the display indicates gt SEND INTEL 00000 0FFFF in example gt enter 00000 000FF using the key board Press the gt ENTER lt key to confirm The DATAMAN S4 checks the data and responds with a single tone and the prompt At the completion of the transmission the DATAMAN S4 responds with 1 dual tones DATA transmitted correctly 5 dual tones Error in the data transmission After completion of the data transfer refer to section 2 1 and 2 2 to verify the system function
28. r DS50 TROUBLE SHOOTING MANUAL LEVEL 3 11 ERROR CODE MESSAGES Error E Eprom Error Remark E Eprom was not initialized Sometimes prior to calibration or prior to transferring data into a replacement unit Defective E Eprom when the E Eprom was loaded with calibration data previously Follow the instruction of the troubleshooting manual level 3 to initialize the system Caution The initializing procedure erases all existing calibration The system must be re calibrated or other valid data transferred Refer to troubleshooting manual level 3 If in doubt contact PAT service support Replace main board or central unit and transfer original E Eprom data A copy of the original calibrated data file must be obtained from the Crane manufacturer or PAT Service department Caution In some cases a re calibration of the system is necessary Load test system after If an error message is displayed that is not listed please immediately contact the competent PAT service department TSM DS 50 003 REV B 031 300 190 003 12 02 96 48 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 12 REMOVING TEST AND CALIBRATION EQUIPMENT Use the following procedure to remove the test equipment after you completed the adjustments or transfer of data TSM DS 50 003 REV B 031 300 190 003 12 02 96 Unhook any load and move the boom into a safe position Select a boom position that allows you to disconnect the calib
29. ration equipment safely Switch off the truck power Disconnect the interface cable from the ribbon cable connector DB9 Disconnect the interface cable from the Dataman S4 and store cable and Dataman S4 in a secured and protected location If you used the hand terminal the interface cable remains connected to the hand terminal Store cable and hand terminal in a secured and protected location Carefully disconnect the ribbon cable from the main board interface socket Refer to drawing 2 2 3 in section 2 2 Store cable in a secured and protected location Carefully unplug the interface board Use both hands to lift the board straight out of the socket The pins on the connector are extremely sensitive Try to avoid bending the pins Use anti static storage material to store the interface board Refer to drawing 2 2 1 in section 2 2 Remove jumper plug J2 if used for the hand terminal operation Store the jumper plug in a safe and secure area The jumper plug is needed for whenever you connect the hand terminal to the DS 50 Disconnect the external cables from the Mil type connectors 49 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 12 REMOVING TEST AND CALIBRATION EQUIPMENT e Mount the small cover Caution Check the O rings on the four studs for wear and tear The cover will not seal without the O ring being on the threaded part of the stud Use the washers and tighten the nuts While you tighten the cover you should check the prop
30. s a variable resistor which varies linearly with the boom length An angle sensor is built into the central unit which senses the boom angle The load cell provides the signal to calculate the load on hook The proximity switch located on the hoist drum switches to a different calibration factor during spooling off the hoist rope This will allow a steady load calculation and compensates for the difference in the lever arm All together the signals get processed in the central Microprocessor unit where actual and rated load are compared The system de energizes a relay and disables the appropriate crane functions when the actual load exceeds the rated load by more than 10 TSM DS 50 003 REV B 031 300 190 003 12 02 96 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 1 INTRODUCTION TO TROUBLESHOOTING THE PAT DS 50 1 3 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 Follow all safety instructions according to crane manufacturer s handbooks and safety instructions Obey recommended practice and safety standards applying to the job site e Secure the working area prior to testing and servicing the system Never remove the load cell without firm support holding the hoist drum Never let the
31. ty hook load display 27 8 Adjusting radius display under load 29 9 Adjusting load display 31 10 Transferring EEPROM data 33 11 Error code messages 40 12 Removing test and calibration Equipment 48 TSM DS 50 003 REV B 031 300 190 003 12 02 96 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 CAUTION The use of the equipment and the procedures in the following sections allow data change of the microprocessor system DS50 and its calibration Therefore only trained and authorized service personnel shall proceed with the procedures and data adjustments described in this manual Incidential 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 B 031 300 190 003 12 02 96 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 NOTICE THIS TROUBLE SCHOOTING MANUAL DS 50 LEVEL 3 IS DESIGNED TO ASSIST THE SERVICE OR MAINTENANCE PERSONNEL IN ADJUSTING THE EXISTING CALIBRATION DATA AND TRANSFERRING CALIBRATION DATA INTO A REPLACEME DS 50 CENTRAL UNIT THIS TROUBLE SHOOTING MANUAL DOES NOT REPLACE ANY CALIBRATION INSTRUCTION THEREFORE IT SHOULD NOT BE USED AS A CALIBRATION MANUAL IN ORDER TO PERFORM THE ADJUSTMENTS IN THIS TROUBLE SHOOTING MANUAL YOU REQUIRE A SPECIAL TOOL SET THE TOOL SET CONSISTS OF THE PROFORT 803 HAND TERMINAL THE DATAMAN S4 EPROM PROGRAMMER THE INTERFACE BOARD A SET OF CABLES AND A PRE PROGRAMMED E PROM WE ASSUME THAT REGU
32. up to indicate that the internal battery is charged If the LED does not light up the internal battery is not charged or is defective The hand terminal shall not be used until the battery is replaced Memory recall key With the green key on the top right of the key board the last entry can be reviewed but not changed Control LEDs The LEDs above the numerical key pad light up to confirm the on line status and various key function In example the green File LED lights up after the shift key was pressed The display LCD Indicates data and messages The use of the hand terminal in connection with the DS 50 System is described in the course of the following instructions Part of the hand terminal is a cable The DB 9 connector at the end of the cable shall be connected to the interface ribbon cable which is connected into the DS 50 main board Refer to section 2 2 and drawing 2 2 1 and 2 2 2 for hand terminal connection CAUTION The DB 9 connector is wired especially for the DS 50 interface Do not attempt to connect the hand terminal to any device other than the DS 50 TSM DS 50 003 REV B 031 300 190 003 12 02 96 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 2 1 THE HAND TERMINAL LCD indicalion c data and mc XC Contre I Drawing 2 1 1 TSM DS 50 003 REV B 031 300 190 003 12 02 96 DS50 TROUBLE SHOOTING MANUAL LEVEL 3 22 THE HAND TERMINAL CONNECTION In order to connect and use the hand terminal for d
33. write read memory RAM of the microprocessor Error in the external write read memory RAM Cyclic internal RAM test failed Error in the Eprom data part TSM DS 50 003 REV B 031 300 190 003 12 02 96 LMI board defective Microprocessor components defective on main board External RAM defective on main board Microprocessor components defective on main board The Eprom on the main board is defective 47 replace the Eprom which is plugged into the Eprom socket on the main board Refer to the Eprom label to affirm the same Eprom version Function and load test the system after Identify clearly a main board defect by referring to the troubleshooting manual If in doubt contact PAT service support Replace main board or central unit and transfer E Eprom data Load test system after If in doubt contact PAT service support Replace main board or central unit and transfer E Eprom data Load test system after If in doubt contact PAT service support Replace main board or central unit and transfer E Eprom data Load test system after If in doubt contact PAT service support Replace main board or central unit and transfer E Eprom data Load test system after Follow the instruction in the troubleshooting manual and replace the Eprom which is plugged into the Eprom socket on the main board Refer to the Eprom label to affirm the same Eprom version Function and load test the system afte
34. y for the length sensor Length potentiometer defective 42 the correct length Retract the boom Check the pretension of the cable reel refer to documented instruction Refer to the instruction in the manual and adjust length sensor carefully clockwise Completely replace the clutch with the drive wheel and adjust length sensor pot refer to instruction in the manual Check 5V voltage as described in the troubleshooting manual Identify clearly a main board defect by referring to the troubleshooting manual If in doubt contact PAT service support Replace main board or central unit and transfer E Eprom data Load test system after Replace length potentiometer Refer to the troubleshooting manual for instructions DS50 TROUBLE SHOOTING MANUAL LEVEL 3 11 ERROR CODE MESSAGES No acknowledgment from the overload relay in the OSS to the microprocessor input Length channel voltage is lower then the minimum limit TSM DS 50 003 REV B 031 300 190 003 12 02 96 Overload relay defective printed circuit board defective or microprocessor input defective Could also be caused by an external short circuit in the wiring Cable between length sensor and main board defective or disconnected Length sensor potentiometer defective Analog channel on main board defective 43 Use the instructions in the troubleshooting manual and the test box to identify the location of the problem
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