PAT DS 50 Programming manual

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

2TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96
Table of contents
Troubleshooting Manual
PAT Overload Warning system DS 50
Level 2
-Using Test Equipment-
Item Content Page
1. Introduction to troubleshooting the PAT Overload Warning System DS 50 3
1.1 System Outline 3
1.2 Systems operation 5
1.3 Troubleshooting care 6
2. Getting started 8
3. LED 1-6 are all dim - Power supply problem 11
4. LED 2 is dim - No outgoing crane power 13
5.0 LED 3 - Cut off not functioning correctly 18
5.1 LED 3 lit all times - Cut off not functioning correctly 19
5.2 LED 3 is dim all times - Cut off not functioning correctly 27
6. LED 4 is dim - No power to proximity switch on hoist drum 36
7. LED 5 is dim or lit all times -Hoist proximity switch problem- 40
8. LED 6 is dim - Loadcellpower supply problem 42
9. Length sensor signal measurement 47

3TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96
NOTE
THIS TROUBLESCHOOTING MANUAL “DS 50 - LEVEL 2” IS DESIGNED TO ASSIST
THE SERVICE OR MAINTENANCE PERSONAL IN IDENTIFYING THE PROBLEM AREA
OF A MALFUNCTIONING SYSTEM.
IN ORDER TO FOLLOW THE FOLLOWING INSTRUCTIONS THE PAT TEST
ADAPTER AND A DIGITAL VOLTMETER ARE REQUIRED IN ADDITION TO THE
REGULAR MAINTENANCE AND SERVICE TOOLS.
THIS TROUBLESHOOTING MANUAL MAY BE USED AS A CONTINUATION OF
TROUBLESCHOOTING MANUAL “DS 50 - LEVEL 1- BASICS.
THE KNOWLEDGE OF HOW TO USE A DIGITAL VOLTMETER IS ASSUMED.
WE SUGGEST THAT ONLY TRAINED MAINTENANCE AND SERVICE PERSONAL
PROCEED WITH THE TROUBLESCHOOTING DESCRIBED IN THIS MANUAL.

4TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96
1.1. SYSTEM OUTLINE
The PAT Overload Warning System Model DS 50 is designed to disable all functions
which may cause tipping or structural damage when the crane attempt 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 also 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 . In this situation leave the
crane electric switch in the off position and operate the crane manually. The
DS 50 Overload Warning System is not operative and can not warn the operator.
Warning
By switching the crane power switch off the DS 50 Overload Warning system
is by-passed. Operating the crane without using the range diagram may
result in property damage, injury or death.
The DS 50 system contains of a Central unit. The length sensor is part of the
Central unit. The load cell is supporting the hoist drum and used to measure the
load on hook.
1. INTRODUCTION TO TROUBLESHOOTING THE
PAT OVERLOAD WARNING SYSTEM DS 50

5TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96
1. INTRODUCTION TO TROUBLESHOOTING THE
PAT OVERLOAD WARNING SYSTEM DS 50
DS 50 SYSTEM
LENGTHCABLE
BOOM
LOADCELL
PROXIMITY
SWITCH
BOOM
LIFTCYLINDER
HOOKBLOCK
MAST
LENGTH CABLE MOUNT
LENGTH CABLE ENTRY
HOIST DRUM
CABLE CONNECTORS
DRAWING 1 - SYSTEM LOCATION (FMTV-WRECKER)
LENGTH SENSOR - UNDER COVER-
Note: The drawing shows
the model FMTV-W.
The FMTV-C has only single
line capability.

6TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96
1. INTRODUCTION TO TROUBLESHOOTING THE
PAT OVERLOAD WARNING SYSTEM DS 50
1.2 SYSTEM OPERATION
The Microprocessor Central Unit operates as the control center of the system.
The length cable is connected to the boom nose. During telescoping the length
cable spools off a drum which turns the length potentiometer using a gear
assembly. The length potentiometer is 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. Once the actual load exceeds the rated load the system de-energizes
a relay and disables the appropriate crane functions.

7TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96
1. INTRODUCTION TO TROUBLESHOOTING THE
PAT OVERLOAD WARNING SYSTEM DS 50
1.3. Troubleshooting Care
•Keep in mind that in 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 manufacturers
handbooks and safety instructions. Obey recommended practice and
safety standards applying to the job site.
•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 length cable snap back to the central unit. The length
sensor drum is under high tension.
Warning
DS 50 Overload Warning System service and repair work shall be performed
by trained and authorized personal only.

8TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96
Crane power switch Crane electric
junction box
Outrigger extend
proximity switches-
FMTV-Cargo only.
Caution !
Crane is shown folded for transportation.
For lifting operations the mast has to be in upright position
and the hook lifted out of the transportation storage.
Hookblockstorage position
1. INTRODUCTION TO TROUBLESHOOTING THE
PAT OVERLOAD WARNING SYSTEM DS 50
DRAWING 2 - Crane storage position
Note: The drawing shows
the model FMTV-W.
The FMTV-C has only single
line capability.

9TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96
2. Getting started
Positivevoltage
terminalforDVM
Inputconnector
- connect input
cables- negative voltage
terminalforDVM
Status LEDs
Connector cables
Plugs - connect to System
Loadcell zero point test switch
The following drawing explains the components on the PAT test adapter. This troubleschooting manual will
refer to this drawing several times.
DRAWING 3: PAT Test adapter for DS 50-001

10TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96
2. Getting started
Locate the PAT DS 50 overload warning system. Switch the crane electrical power off. Refer to drawing 2 in
section 1 to locate the crane electric interface box with electrical power switch.
Unplug the three cables from the central unit. Plug those cables into the test adapter sockets.
Plug the test adapter cables into the central unit connectors. Tighten all connections before you switch the
power on.
Switch crane power on and wait for at least 20 seconds. The system performs a selftestevery time the power
is switched on. During the selftest period you may see some LEDs blinking. The system performs a test routine
and switches relays and components. It is normal to see LEDs switching on and off.
After the selftestis completed check the LEDs and their performance.
Refer to the next page for further investigation of the condition

11TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96
2. Getting started
What is wrong ?
Find a square matching your
condition and follow
the instructions.
go to
section 3 go to section 4
LED 1- 6
are all dim or off.
Incoming
Crane Power.
LED 2 is dim
or off.
Outgoing
Crane Power.
go to
section 6
go to
section 7
LED 4 is dim or
off. No Power to
proximity switch
on hoist drum.
LED 5
No signal from
the proximity
switch on hoist.
go to
section 5
LED 3
Problem with
cut off signal.
go to
section 8
LED 6
Problem with
loadcell power.
LED dim or off.
Length sensor signal measurements.
As continuation of section 4 in
troubleschooting manual -level 1-
go to
section 9

12TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96
3. LED 1- 6 are all dim or off.
-Power supply problem-
NO
YES
NO
YES
Start
Is green
LED 1 on?
Refer to DWG 4
on page 12.
Connect a digital volt meter into the test adapter
as shown in DWG 4 page 12.
Do you measure a voltage between 18 V and 26 V ?
YES
No incoming power
problem!
Is power
supply cable and
connector in good
condition ?
Replace cable assembly and rewire to crane electric
interface box. Refer to Grove documentation for installation
and wiring instructions. Repeat test.
-Incorrect crane voltage-
Refer to vehicle documentation for further
testing of the truck and crane electric's.

13TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96
3. LED 1- 6 are all dim or off.
-Power supply problem-
LED 1 - 6 are all
dim or off
0.000
+--
DRAWING 4: LED 1- 6 are all dim or off
- Power supply problem -

14TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96
NO
YES
NO
continue on
next page
YES
Start
4. LED 2 is dim or off.
-No outgoing crane power-
Is red
LED 2 on?
Refer to DWG 5 on
page 15.
Connect a digital volt meter into the test adapter as
shown in DWG 5 on page 15
Do you measure crane voltage (18V and 26V) ?
YES
No outgoing power
problem!
Is the
power supply
cable connector plugged
in and tighten?
Inspect the connector and plug for damage, moisture
or wear. Clean contacts. Plug the connector into the
system and tighten the connection. Repeat the test.

15TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96
NO
YES
continuation
4. LED 2 is dim or off.
-No outgoing crane power-
Refer to
DWG 6 on page 16.
Remove both covers and check
internal wiring from the
connector to the board.
Is wiring O.K... ?
No outgoing voltage problem existing.
Refer to the systems internal wiring diagram on page 17 and
re-wire the connection between the power supply connector in
the coverand the brown connector on the board. The connector
pins have to be crimped tight. Be careful not to splice the wires
or to crimp the insulation. After rework repeat the test.

16TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96
LED 2 is
dim or off
0.000
+--
DRAWING 5: LED 2 - No outgoing crane power
4. LED 2 is dim or off.
-No outgoing crane power-

17TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96
DRAWING 6: Internal wiring check
4. LED 2 is dim or off.
-No outgoing crane power-
Refer to the electrical
wiring diagram and
Inspect internal wiring.
Brown
connector
Removecovers

18TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96
4. LED 2 is dim or off.
-No outgoing crane power-
DRAWING 7: DS 50 internal wiring diagram
Inspect internal wiring
and rework if necessary

19TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96
NO
YES
YES
Start
5.0 LED 3
-Cut off not functioning correctly-
Is red
LED 3 on all times?
Go to section 5.1
Is LED 3
off all time ?
Go to section 5.2
NO
YES
Is LED 3
(overload cut off)
switching according
to the range
diagram?
Go to section 5 and 6
in troubleschooting manual level 1-Basics-.
No cut off problem detected.
Refer to other sections of
troubleshooting manual level 1-3.
NO

20TSM DS 50-001/REV.2/ 031-300-190-002/ 09-23-96
NO
YES
continue on
next page
Start
Perform the
troubleschooting described
in section 3 of the troubleshooting
manual level1. Is the problem
corrected now?
Return to START of section 5.0
5.1 LED 3 on all time.
-Cut off not functioning correctly-
NO
YES
Remove
both covers and
refer to DWG 8 on page
23 to locate the system
fuse. Is fuse
O.K. ?
Switch power off.
Replace system fuse. Install a 500 mA
medium blow fuse European or US style.
Switch power on. Repeat test.