PAT DS 50 Programming manual

Overload Warning
System DS 50
Overload Warning
Overload Warning
System DS 50
System DS 50
Grove - FMTV
Trouble Shooting Manual
Level 2
-Using Test Equipment-
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TSM DS 50-001/REV. C/ 031-300-190-002/ 04-17-2007

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 4
1.1 System Outline 4
1.2 Systems operation 6
1.3 Troubleshooting care 7
2. Getting started 9
3. LED 1-6 are all dim - Power supply problem 11
4. LED 2 is dim - No outgoing crane power 14
5.0 LED 3 - Cut off not functioning correctly 19
5.1 LED 3 lit all times - Cut off not functioning correctly 20
5.2 LED 3 is dim all times - Cut off not functioning correctly 28
6. LED 4 is dim - No power to proximity switch on hoist drum 37
7. LED 5 is dim or lit all times -Hoist proximity switch problem- 41
8. LED 6 is dim - Load cell power supply problem 43
9. Length sensor signal measurement 48
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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.
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1. INTRODUCTION TO TROUBLESHOOTING THE
PAT OVERLOAD WARNING SYSTEM DS 50
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.
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1. INTRODUCTION TO TROUBLESHOOTING THE
PAT OVERLOAD WARNING SYSTEM DS 50
DS 50 SYSTEM
LENGTH CABLE
BOOM
LOAD CELL
PROXIMITY
SWITCH
BOOM
LIFT CYLINDER HOOK BLOCK
MAST
LENGTH CABLE MOUNT
LENGTH CABLE ENTRY
HOIST DRUM
CABLE CONNECTORS
LENGTH SENSOR - UNDER COVER-
Note: The drawing shows
the model FMTV-W.
The FMTV-C has only single
line capability.
DRAWING 1 - SYSTEM LOCATION (FMTV-WRECKER)
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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.
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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.
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1. INTRODUCTION TO TROUBLESHOOTING THE
PAT OVERLOAD WARNING SYSTEM DS 50
Crane power switch Crane electric
junction box
Outrigger extend
proximity switches-
FMTV-Cargo only.
Hook block storage position
DRAWING 2 - Crane storage position
Note: The drawing shows
the model FMTV-W.
The FMTV-C has only single
line capability.
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.
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2. Getting started
The following drawing explains the components on the PAT test adapter (031-300-060-014).
This troubleshooting manual will refer to this drawing several times.
Positive voltage
terminal for DVM
Input connector
- connect input cables -
negative voltage
terminal for DVM
Status LEDs
Connector cables
Plugs - connect to system
Load cell zero point test switch
DRAWING 3: PAT Test adapter (031-300-060-014)
for DS 50-001
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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 self test every time
the power is switched on. During the self test 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 self test is completed check the LEDs and their performance.
Refer to the next page for further investigation of the condition
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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
load cell power.
LED dim or off.
Length sensor signal measurements.
As continuation of section 4 in
troubleshooting manual -level 1-
go to
section 9
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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 13.
Connect a digital volt meter into the test adapter
as shown in DWG 4 page 13.
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.
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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 -
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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 16.
Connect a digital volt meter into the test adapter as
shown in DWG 5 on page 16
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.
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4. LED 2 is dim or off.
-No outgoing crane power-
NO
YES
continuation
Refer to
DWG 6 on page 17.
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 18 and
re-wire the connection between the power supply connector in
the cover and 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.
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4. LED 2 is dim or off.
-No outgoing crane power-
LED 2 is
dim or off
0.000
+--
DRAWING 5: LED 2 - No outgoing crane power
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4. LED 2 is dim or off.
-No outgoing crane power-
Refer to the electrical
wiring diagram and
Inspect internal wiring.
Brown
connector
Remove covers
DRAWING 6: Internal wiring check
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4. LED 2 is dim or off.
-No outgoing crane power-
Inspect internal wiring
and rework if necessary
DRAWING 7: DS 50 internal wiring diagram
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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 troubleshooting manual level 1-Basics-.
No cut off problem detected.
Refer to other sections of
troubleshooting manual level 1-3.
NO
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NO
YES
continue on
next page
Start
Perform the
troubleshooting 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
24 to locate the D2 LED.
Is the LED
lit ? Disconnect
the loadcell and
wait 30 seconds.
Does D2 LED
turn on?
NO
YES
Defective load cell assembly -
replace load cell assembly.
Refer to Grove documentation
for service instructions.
Disconnect
the length sensor
and wait 30 seconds.
Does D2 LED
turn on?
YES
Defective length sensor assembly -
replace length sensor assembly.
Refer to Grove documentation
for service instructions. NO Defective central unit -
replace central unit assembly.
Refer to Grove documentation
for service instructions.
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