Hirschmann PAT DS 85/0002 User manual

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

Service Manual DS 85
© Hirschmann Rev. G 10/05/15 190166_G.DOCXG
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.
This document contains proprietary information, which is protected by copyright, and all rights
are reserved.
No part of this document may be photocopied, reproduced, or translated to another language
without the prior written consent of Hirschmann.
Hirschmann reserves proprietary rights to all drawings, photos and the data contained therein.
The drawings, photos and data are confidential and cannot be used or reproduced without the
written consent of Hirschmann. The drawings and/or photos are subject to technical
modification without prior notice.
All information in this document is subject to change without notice.
MANUAL REVISIONS
REV
DATE
NAME
DESCRIPTION
-
04/04/03
CSH
ECN 03-039
A
06/20/03
CSH
ECN 03-079
B
07/21/03
CSH
ECN 03-079
C
07/07/04
SB
ECN 04-032
D
09/20/04
SB
ECN 04-176
E
06/16/05
SB
ECN 05-109
F
12/26/08
SC
ECN 08-021
G
10/05/15
JPD
ECN 15-198
© 2008 Hirschmann, Chambersburg, PA 17201, USA

Service Manual DS 85
© Hirschmann Rev. G 10/05/15 190166_G.DOCXG
TABLE OF CONTENTS
1GENERAL INFORMATION ................................................................................................ 1
2WARNINGS........................................................................................................................ 1
3SYSTEM DESCRIPTION.................................................................................................... 2
3.1 DESCRIPTION OF THE SYSTEM COMPONENTS.................................................................. 3
4FREQUENTLY ASKED QUESTIONS:............................................................................... 5
5ANGLE THEORY ............................................................................................................... 6
6LENGTH THEORY............................................................................................................. 9
6.1 CABLE REEL LENGTH CABLE REPLACEMENT PROCEDURE.............................................11
6.2 CABLE REEL REPLACEMENT PROCEDURE .....................................................................12
6.3 CABLE REEL LENGTH SENSOR REPLACEMENT PROCEDURE ......................................12
6.4 LWG CABLE REEL LENGTH/ANGLE SENSOR REPLACEMENT PROCEDURE..................13
7PRESSURE THEORY .......................................................................................................15
8LOAD THEORY.................................................................................................................16
9A2B PROBLEM.................................................................................................................16
10 A2B PROBLEM –HARDWIRED A2B OPTION.............................................................19
11 CONSOLE DISPLAY.....................................................................................................20
12 ANTI-TWO BLOCK SYSTEM SETUP ...........................................................................21
12.1 SETUP OVERVIEW ........................................................................................................21
12.2 REGISTERING DEVICES .................................................................................................21
12.3 DELETING DEVICES ......................................................................................................24
12.4 SERVICE AND MAINTENANCE.........................................................................................24
13 CAN-BUS COMMUNICATION.......................................................................................26
14 TROUBLESHOOTING A SENSOR PROBLEM USING THE DISPLAY.........................31
15 DRAWINGS ...................................................................................................................32
15.1 CONSOLE/CENTRAL UNIT TO CRANE WIRING DIAGRAM.........................................32
15.2 LENGTH/ANGLE SENSOR WIRING DIAGRAM ....................................................................33
15.3 HARDWIRED A2B WIRING DIAGRAM...........................................................................34
16 SPARE PART LISTINGS...............................................................................................36
16.1 CONSOLE/CENTRAL UNIT .............................................................................................36
16.2 PRESSURE TRANSDUCER BLOCK ..................................................................................37
16.3 ANGLE SENSOR BOX ....................................................................................................38
16.4 CABLE REEL ASSEMBLY...............................................................................................39
16.5 CABLE REEL ASSEMBLY ...............................................................................................40
16.6 RADIO A2B..................................................................................................................41
17 SERVICE SCREEN FOR SENSOR CALIBRATION......................................................42
17.1 ACTIVATING THE SERVICE SCREEN FOR SENSOR CALIBRATION ......................................42
17.2 ZERO-SETTING THE TRANSDUCER INPUTS.....................................................................42
17.3 CALIBRATE LENGTH INPUT............................................................................................43
17.4 CALIBRATE ANGLE INPUT .............................................................................................44
18 ERROR CODES.............................................................................................................47

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19 TROUBLESHOOTING MOISTURE ...............................................................................53
19.1 WATER INGRESS ..........................................................................................................53
19.2 CONDENSATION ...........................................................................................................54

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1 GENERAL INFORMATION
This service manual is designed to assist a service or maintenance person in identifying system
problem areas or malfunctions. A digital voltmeter with the capability to measure current will be
required, along with standard maintenance and service tools. NOTE: Knowledge of how to use a
voltmeter to measure both voltage and current is assumed.
REFERENCE:
For system operation, refer to the consoles operator’s manual 031-300-190-165.
2 WARNINGS
The LMI is an operational aid that warns a crane operator of approaching overload conditions and of
over hoist conditions that could cause damage to equipment and personnel.
The device is not, and shall not, be a substitute for good operator judgment, experience and use of
accepted safe crane operating procedures.
The responsibility for the safe crane operation shall remain with the crane operator who shall ensure
that all warnings and instructions supplied are fully understood and observed.
Prior to operating the crane, the operator must carefully and thoroughly read and understand the
information in this manual to ensure that he knows the operation and limitations of indicator and
crane.
Proper functioning depends upon proper daily inspection and observance of the operating instructions
set forth in this manual. Refer to Section 6. Pre-Operation Inspection and Calibration Verification of
this handbook.
The LMI can only work correctly, if all adjustments have been properly set. For correct
adjustment, the operator has to answer thoroughly and correctly all questions asked during
the setup procedure in accordance with the real rigging state of the crane. 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.

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3 SYSTEM DESCRIPTION
The DS 85 system is a CAN bus system consisting of a central micro processor unit/operating
console, length/angle sensor, pressure transducers, and anti-two block switches.
The Load Moment Indicator system operates on the principle of reference/real comparison. The real
value, resulting from the pressure measurement is compared with the reference data, stored in the
central processor memory and evaluated in the micro processor. When limits are reached, an
overload warning signal is generated at the operator’s console. At the same time, the aggravating
crane movements, such as hoist up, telescope out and boom down, will be stopped.
The fixed data regarding the crane, such as capacity charts, boom weights, centers of gravity and
dimensions are stored in memory in the central processor unit. This data is the reference information
used to calculate the operating conditions.
The operating modes are selected by the operating mode key on the console by scrolling through the
text messages defining the boom truck configuration.
The crane load is measured by pressure transducers attached to the piston and rod side of the hoist
cylinders.
Boom length and boom angle are transmitted by length/angle CAN bus node mounted on the side of
the boom in the angle sensor box. The length sensor/cable reel is mounted inside the base which
measures the boom length.
The PAT RATB works like our normal Anti-Two-Block. It alerts to an impending two-block
condition. This alert can come in the form of an audible alarm and visual LED or with the
optional function lockout if the crane is so equipped.
The iSENS HES-W1 is a battery operated limit switch for the detection of the hoist limit
condition, e.g. on the lifting rope of a crane. The wireless module with integrated battery
compartment serves the wireless transmission of the hoist limit condition to suitable wireless
receivers. An operating period of up to 2 years is achieved by the use of power-saving
techniques when using lithium batteries.
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.

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3.1 DESCRIPTION OF THE SYSTEM COMPONENTS
Fig. 1: Components of the LMI system PAT DS 85
1 Operating
Console
2 Pressure
Transducers
3 Length
Sensor
4 Angle Sensor/CAN Bus
board
5 Radio A2B
Receiver
6 Radio Anti Two-Block
Switch(es)
6
4
POWER
LOCKOU
T
ALARM
DO3
A2B
DI4
2
5
1
2
7
1
6
POWE
R
RATB RECEIVER
MODULE
031-300-050-
308
LO
W
BATT
.
LIN
K
A2
B
ALAR
M
SLIP RING FROM UPPER
TO
LOWER WILL BE ONE OF
THESE TWO PLACES
3
1

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Central Unit/Console: Inside the console there is a CPU and connection board. The board has a
hard mounted connector for power, ground, bus controller, and slew indication. Displays all
geometrical information such as actual load, maximum load permitted by load chart, working radius,
and length, angle, and head height of main boom. It also has LED’s for operating condition “OK”,
overload, and a pre-warning. An output to an alarm horn and a warning light are also available. The
display allows for a simple configuration setup, as well as sensor calibration (zero adjustment), and
troubleshooting sensor output screen.
Pressure Sensor: The pressure sensor transforms hydraulic pressure into an electric signal. A
pressure sensor block houses two sensors, CAN bus controller, and two bus connectors. One
pressure sensor is connected to the piston side of the lift cylinder and the other to the rod side.
Length Sensor: A reeling drum drives a potentiometer that measures the length of the boom. This
sensor is connected to the CAN bus sensor board in the angle sensor box.
Angle Sensor: The angle sensor is a potentiometer driven by oil damped and weighted pendulum
that measures the angle of the boom. This sensor is connected to the CAN bus converter board in the
angle sensor box.
Anti-Two-Block Receiver: The anti-two block receiver console has several LED lights for quick
status indication including POWER, ONLINE, LOW BATTERY, and INFO. When the weight is lifted
on the A2B switch or a signal is not received from the transmitter, the receiver disengages a relay
output and drops power from the lock out solenoid valves.
Anti-Two-Block Transmitter and Switch: The anti-two block switch monitors the load block and its
relationship with the head of the boom. In working condition the switch is closed. The weight at the
anti-two block switch keeps the switch closed until the hook block strikes it. When the hook block
strikes the weight, the circuit opens and the transmitter sends a signal to the receiver. The transmitter
has an LED on the bottom for diagnostics. The LED should light momentarily when a two-block
condition occurs or when the weight is lifted. The LED will then flash rapidly during a two-block
condition and will stop flashing after the switch remains in this state for more than 15 seconds. The
LED will flash approximately every 2 seconds when the switch is transmitting. When in sleep mode,
the LED will not flash.
Hardwired Anti-Two-Block Switch: The anti-two-block switch monitors the load block and it’s
relationship with the head of the boom. In working condition the switch is closed. When the load
block strikes the weight the circuit opens, disengaging a relay output to the lock out solenoid valves,
where applicable. 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.

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4 FREQUENTLY ASKED QUESTIONS:
So, what’s wrong? Assuming you are reading these pages because of some kind of problem with the
PAT system, let us try to guide you quickly to solving the problem. In most cases, your problem will
fall under the following categories:
I HAVE AN ERROR CODE INDICATED ON THE CONSOLE
Please go to section Error Codes!
THE DISPLAYED ANGLE DOES NOT MATCH THE ACTUAL BOOM ANGLE
Start in section Angle Sensing to check the indicated angle.
THE DISPLAYED LENGTH DOES NOT MATCH THE ACTUAL BOOM LENGTH
Start in section Length Sensing to check the indicated length.
THE DISPLAYED LOAD DOES NOT MATCH THE ACTUAL LOAD
Please note that the indicated load is calculated by the system from the geometry information in the
computer, the operator’s selections, and all the sensor inputs. If the load display is off, it can therefore
be due to an error in any or several of these inputs! Refer to section Load sensing to narrow down the
source of your problem.
THE CONSOLE DISPLAY IS BLANK
If the console does not show any sign at all (no lights, no buzzer, no display), the problem is either in
the wiring between console and crane power, or the console itself. Refer to section No console
display for further troubleshooting.
I HAVE AN A2B PROBLEM
Please go to section A2B PROBLEM
I HAVE A CAN-BUS PROBLEM
Please go to section 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

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5 ANGLE THEORY
The System measures the angle of the main boom of the machine with an angle sensor. The angle
sensor is contained within the angle sensor box (Radio A2B option) or within the Cable Reel
(Hardwired A2B option) located on the left side of the main boom.
Block Diagram
The signal runs from the angle sensor to the Can-Bus converter board, both located in the angle
sensor box. From there, it travels as digital information on the CAN-Bus to the pressure sensor, which
acts as a T-connector to the main CAN-Bus running to the console/central unit.
So, what do you do when you are having a problem with your angle read-out?
Start by verifying the angle display. Refer to the section “Troubleshooting A Sensor Problem Using
The Display” to call up the sensor signal on your console display. The CAN-Bus is digital and as such
will either transmit the signal correctly or not at all. If your readings are off, you have to determine
what is causing the problem. 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.
Pressure Transducer
DS 85
Console/
CU
Angle
Sensor
CAN-Bus
Converter
Cable Reel Angle Sensor Box

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CAN-Bus electronics in angle sensor box.
CAN-Bus electronics in cable reel.
The angle sensor has a potentiometer built in that is driven by a pendulum. As the angle changes, so
will the pendulum and with it the potentiometer’s axle. The converter board supplies a constant
voltage of 5V to the angle sensor and in return monitors the voltage of the potentiometer. The
terminal used is X21. The angle sensor is connected as follows:
Terminal X21
1
+ 5V
3
Signal
5
GND
Verify that the sensor is being supplied with 5V by measuring between pin 5 (GND) and Pin 1 (+) of
terminal X21. If the voltage is outside of a range of 4.75 to 5.25V, the converter board might be
defective. 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:
LED
X21 (angle)
X20 (length)
X14 (A2B)
X1 (CAN)
X21 (angle)
X20 (length)

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The angle sensor returns a voltage between 1.875V at 90 degrees and 3.125V at 0 degrees:
Angle Sensor Signal on
Pin 3
Angle
Voltage
90
1.875
75
2.083
60
2.292
45
2.500
30
2.708
15
2.917
0
3.125
Note: Actual voltages will vary slightly.
Measure this voltage between Pin 5 (GND) and Pin 3 of Terminal X21.
If you need to determine the angle for voltages other than the above, do so by using the following
formula:
Angle (degrees) = 90 degrees –((Voltage-1.875) * 72)
If this angle matches your actual angle, but the indicated angle varies significantly (more than 0.4
degrees), the angle sensor is fine and the error is somewhere else. If this angle varies significantly
from your actual angle, the angle sensor is bad and needs to be exchanged. Otherwise, continue:
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.

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6 LENGTH THEORY
The system measures the length of the main boom of the machine with a length sensor. The length
sensor is contained within the cable reel, located in the base of the main boom.
Block Diagram
Radio A2B Option:
Hardwired A2B Option:
The signal runs from the length sensor to the CAN-Bus converter board, located in the angle sensor
box. From there, it travels as digital information on the CAN-Bus to the pressure transducer, which
acts as a T-connector to the main CAN-Bus running to the central unit.
So, what do you do when you are having a problem with your length read-out?
Start by verifying the length display. Refer to the section “Troubleshooting A Sensor Problem Using
The Display” to call up the sensor signal on your console display. The CAN-Bus is digital and as such
will either transmit the signal correctly or not at all. If your readings are off, you have to determine
what is causing the problem. Start by checking the length cable tension, the cable reel has 3-5 turns
of pre-loading on the reel.
Go back to your indication screen and compare indicated and actual length again. If the indicated
length varies significantly from your actual length (more than 0.3 feet), the length sensor might be bad
and needs to be exchanged. Note, however, that the error could be in the converter board.
The length sensor has a potentiometer built in that is driven by a gear drive from the cable drum. As
the length changes, the cable drum will turn and with it the potentiometer’s axle. 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:
Pressure Transducer
DS 85
Console/
CU
Cable Reel
Length
Sensor
CAN-Bus
Converter
Pressure Transducer
DS 85
Console/
CU
Angle Sensor Box
Length
Sensor
CAN-Bus
Converter

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Terminal X20
1
+ (~ 4.8V)
3
Signal
5
- (~ 0.2V)
Verify that the sensor is being supplied with about 4.7V by measuring between pin 5 (-) and Pin 1 (+)
of terminal X20. If the voltage is outside of a range of 4.5 to 5 V, the converter board might be
defective. Unplug length sensor and measure again. If the voltage is still off, exchange converter
board. If unplugging the length sensor made the voltage return into the acceptable range, exchange
length sensor. If the voltage is correct continue:
The length sensor returns a voltage between 0.16V at 0 turns of the length pot (= fully retracted) and
4.84V at 10 turns. How many turns you get at full extension depends on the gear ratio, the boom
length, the length cable used and the spooling pattern, so we cannot provide a standard table for it.
What we can give you for trouble-shooting, however is the following table that shows the expected
output voltage (measured between X20-5 and X20-3 Signal) for each complete turn of the length
potentiometer. Note that this does not sync to the number of turns of the cable reel, though:
Length Sensor Signal on Pin 3
Potentiometer
Turns
Voltage X20-5
to X20-3
Voltage GND to X20-3
0
0.00
0.16
1
0.46
0.62
2
0.93
1.09
3
1.40
1.56
4
1.87
2.03
5
2.34
2.50
6
2.81
2.97
7
3.28
3.44
8
3.75
3.91
9
4.22
4.38
10
4.68
4.84
Note: Actual voltages will vary slightly.

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6.1 CABLE REEL LENGTH CABLE REPLACEMENT PROCEDURE
Replace length cable using the following procedure:
Refer to system electrical wiring diagram and cable reel - parts list
1. Remove cable reel and guide from mounting brackets.
2. Remove old length cable from cable drum and machine.
3. Remove cover from cable reel.
4. Disconnect the 4 conductor cable from terminal strip
5. Remove strain relief outer nut and slide cable out of strain relief.
6. Replace length cable.
Loosen 7mm standoff nut holding pot bracket
Slide bracket and pot away from worm gear.
NOTE: The cable should roll over the 7/8 inch guide when the cable is extended.
Replace and feed the cable through the cable guides.
Install the cable thimble and clamp at the end of the cable.
Remove the slack in the cable, so the clamp is 1 to 2 inches from the roller guides.
Pretension the cable reel with 4 full turns on the drum.
Check the spooling. If spooling is not layered properly, carefully pull the cable out and respool
cable.
Zero pot by turning it counterclockwise until it stops.
Slide pot and bracket so gears mesh
Tighten 7mm nut
Pull cable and inspect gears for binding or slippage.
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.

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6.2 CABLE REEL REPLACEMENT PROCEDURE
Replace cable reel using the following procedure:
Refer to system electrical wiring diagram and cable reel - parts list
1. Remove cable reel and guide from mounting brackets.
2. Remove cover from cable reel.
3. Disconnect the 4 conductor cable from terminal strip
4. Remove strain relief outer nut and slide cable out of strain relief.
5. Install new cable reel preset from factory.
Loosen 7mm standoff nut holding pot bracket
Slide bracket and pot away from worm gear.
NOTE: The cable should roll over the 7/8 inch guide when the cable is extended.
Install the cable thimble and clamp at the end of the cable.
Pretension the cable reel with 4 full turns on the drum.
Check the spooling. If spooling is not layered properly, carefully pull the cable out and respool
cable.
Zero pot by turning it counterclockwise until it stops.
Slide pot and bracket so gears mesh
Tighten 7mm nut
Pull cable and inspect gears for binding or slippage.
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.
6.3 CABLE REEL LENGTH SENSOR REPLACEMENT PROCEDURE
Replace length sensor using the following procedure:
Refer to system electrical wiring diagram and cable reel - parts list
1. Remove cable reel and guide from mounting brackets.
2. Remove cover from cable reel.
3. Disconnect the 4 conductor cable from terminal strip
4. Remove strain relief outer nut and slide cable out of strain relief.
5. Replace potentiometer
Loosen 7mm standoff nut holding pot bracket
Slide bracket and pot away from worm gear.
NOTE: The cable should roll over the 7/8 inch guide when the cable is extended.
Replace potentiometer.
Zero pot by turning it counterclockwise until it stops.
Slide pot and bracket so gears mesh
Tighten 7mm nut
Pull cable and inspect gears for binding or slippage.
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.

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6.4 LWG CABLE REEL LENGTH/ANGLE SENSOR REPLACEMENT PROCEDURE
MOUNTING
Mount cable reel on cab side of boom to ensure
adequate visibility. Length cable should spool
from the top of the drum.
NOTE:
Boom with a flat side: Use four (4) 2-inch hook bolts.
Trapezoidal Boom with a slanted side: Use two (2) 2-inch and two (2) 4-inch hook bolts.
There are four (4) ½” holes on the mounting plate.
1. Thread a nut onto the upper threaded part of the hook bolt, then place a lock washer and washer onto
hook bolt. Slide bushing on to free end (curved part) of hook bolt.
2. Insert the hook bolt into the holes in the cable reel mounting plate. NOTE: For a trapezoidal boom, the
4” hook bolts go into the top two (2) holes of the mounting plate.
3. Thread a nut onto the threaded part of the hook bolt, then place a lock washer and washer onto bolt to
fasten it into place. Repeat for each hook bolt.
NOTE: ALL WELDS MUST BE APPROVED BY THE CRANE MANUFACTURER.
4. Hold plate and hook bolt up to boom and affix to boom, by placing the inside curve of the hook bolts
facing outward. Mount cable reel to holes. Front of cable reel should be 1/8” closer to boom than rear.
(Front = 2-7/8”; Rear = 3”)
5. Adjust nuts up and down to tighten, and to mount the cable reel.
6. Plate should be parallel with boom.
INSTALLATION
1. Set pretension of the cable reel by turning the drum counter-clockwise 5 to 8 turns.
2. Run the length cable through the cable guides and wrap the length cable around the boom tip anchor
pin (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.

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CALIBRATION
1. After installation, remove cover from cable reel. With the boom full retracted and boom stops
disengaged (if applicable), adjust the length potentiometer by turning the screw in the center of the
large nylon gear on the length sensor counter-clockwise until a soft stop occurs, and reinstall the cover
on the reel.
The length should be calibrated to be about 0.1 feet (or 0.05m) accurate for both retraced and extended
lengths.
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.