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sistema lmi ds 350 manual
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PAT
GROVE
LEVEL II
P.A.T. - L.M.I. SYSTEM MANUAL
DS350 GRAPHIC (BOOM CONTROL SYSTEM)
DS350 GRAPHIC
DS350 GRAPHIC
MODULAR
MODULAR
iFLEX5 SYSTEM
P.A.T. - L.M.I. LEVEL IIMANUAL INDEX
Section Description
1. DS350 Graphic Console DescriptionsConnections & Wiring Diagram,
2. DS350 Graphic (BCS) Hydraulic, Electrical Theory & Component Location3. DS350 Graphic (BCS) Boom Length
Connections & Wiring Diagrams4. DS350 Graphic (BCS) Piston, Rod Connections
& Wiring Diagrams5. DS350 Graphic (BCS) Boom Angle
Connections & Wiring Diagrams6. DS350 Graphic (BCS) Anti - Two - Block
Connections & Wiring Diagrams7. DS350 Graphic (BCS) Digital Inputs8. DS350 Graphic (BCS) Central Unit P.C. Board
Layout9. DS350 Graphic (BCS) Basic Adjustments
and Checks.10. DS350 Graphic (BCS) Main Board and
Transducer Replacement Procedure11. DS350 Graphic (BCS) Troubleshooting Guide Appendix: Boom Length Troubleshooting
12. DS350 Graphic (BCS) Electrical Diagrams13. DS350 Graphic (BCS) Service Bulletins
& Miscellaneous Information
DS350 Graphic (BCS)
P.A.T. - L.M.I. LEVEL IIMANUAL INDEX
Section Description
14. DS350 Graphic Modular Console Connections, Wiring Diagram
15. DS350 Graphic Modular Central Unit P.C. BoardLayout
16. DS350 Graphic Modular Boom LengthConnections & Wiring Diagrams
17. DS350 Graphic Modular Piston, Rod Connections& Wiring Diagrams
18. DS350 Graphic Modular Boom Angle Connection& Wiring Diagrams
19. DS350 Graphic Modular Anti - Two - Block Connections & Wiring Diagrams
20. DS350 Graphic Modular Troubleshooting Guide
DS350 Graphic Modular
21. DS350 Graphic Modular (BCS) Console Connections, Wiring Diagrams22. DS350 Graphic Modular (BCS) Component Location23. DS350 Graphic Modular (BCS) Boom Length
Connections & Wiring Diagrams24. DS350 Graphic Modular (BCS) Piston, Rod
Connections & Wiring Diagrams25. DS350 Graphic Modular (BCS) Boom Angle Connections & Wiring Diagrams26. DS350 Graphic Modular (BCS) Anti - Two - Block
Connections & Wiring Diagrams27. DS350 Graphic Modular (BCS) Digital Inputs28. DS350 Graphic Modular (BCS) Central Unit P.C.
Modular Board Layout29. DS350 Graphic Modular (BCS) Troubleshooting
Guide30. DS350 Graphic Modular (BCS) Electrical Diagrams31. DS350 Graphic Modular (BCS) Service Bulletins
& Miscellaneous Information
Section Description
P.A.T. - L.M.I. LEVEL IIMANUAL INDEX
DS350 Graphic Modular (BCS)
This presentation and all information contained herein are confidential and proprietary information of Grove Worldwide and as such, no usage or reproduction of this information shall be done without the express written permission of Grove Worldwide.
The information in this manual is subject to change without notice.
3/22/04
MANUAL INDEX
DS350
P.A.T. - L.M.I. LEVEL II
Section Description
32. iFLEX5 Service Information
33. Troubleshooting a Sensor Problem Using the Display
34. Service Screen for Sensor Calibration
35. Boom Control
36. Luffing Boom Extension
37. Error Code Listing
iFLEX5 System
38. Troubleshooting Moisture
39. Software Transfer Instructions Information
P.A.T. – L.M.IMANUAL
SECTION 1
DS 350 GRAPHIC CONSOLEDESCRIPTION, CONNECTIONS
& WIRING DIAGRAM
F1 F4F3F2
!
STOP
STOP
! STOP
STOP
PAT DS 350
TARE
LIM
SEL
iCTRL
0335
?
156ft
90.0ft
100% 100% 100%
79.4o
50.8ft
73.5oo02(lbs)MAX
ACT (lbs)
34.900
PATLOAD MOMENT INDICATOR
DS 350 / 1319 GRAPHICOPERATOR’S HANDBOOK
1.1
NOTICE:
The information in this document is subject to change without notice.
This document was created for training purposes only and should not be a replacement for the original P.A.T.-L.M.I. operators handbookfor your specific system and crane.
1.2
P.A.T. LOAD MOMENT INDICATOR
1. GENERAL INFORMATION
The PAT Load Moment Indicator 1) (LMI) has been designed to provide the crane operator with the essential information required to enable the machine to be used within its design parameters.
Using various sensing devices, the Load Moment Indicator monitors various crane functions and providesthe operator with a continuous reading of the crane’s capacity. The readings continuously change as the crane moves through the motions needed to make the lift.
The LMI provides the operator with information regarding the length and angle of the boom, tip height,working radius, rated load and the total calculated weight being lifted by the crane.
If non permitted conditions are approached, the Load Moment Indicator will warn the operator by sounding an audible alarm, lighting a warning light and locking out those functions that may aggravatethe crane’s condition.
1)LOAD MOMENT: Generally the product of a force and its moment arm: specifically, the productof the load and the load radius. Used in the determination of the lifting capacity of a crane.
2. WARNINGS
The LMI is an operational aid which warns a crane operator of approaching overload conditions andalso warns of overhoist conditions which 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 operation of the crane 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 understandthe information in this manual to ensure that he knows the operation and limitations of the indicator and crane.
Proper functioning is dependent upon proper daily inspection and observations of the operating instructions set forth in this manual. We draw your attention to section 5 of this manual.
WARNINGThe display will only aid the operator when the LMI is properly programmed and the proper load capacity chart and operating code are selected for the crane configuration being utilized. To prevent property damage or serious bodily injury or death to personnel, ensure the LMI is properly programmed before operating the crane.
1.3
WARNINGThis system is equipped with an override key on the central mi-croprocessor unit. This key switch bypasses control lever lock-out function of load moment indicator device. The switch may only be used by authorized personnel during emergency situa-tions. Failure to follow this instruction may result in property damage and/or personal injury.
NORMAL OPERATION L/O OVERRIDE
3. SYSTEM DESCRIPTION
The PAT load Moment Indicator consists of a central micro processor unit, operating console, length/anglesensor, pressure transducers and anti-two-block switches.
The system operates on the principle of reference/actual comparison. The actual value, resulting from the force or pressure measurement is compared with the reference data, stored in the central processormemory and evaluated in the micro processor. When limits are reached, an overload warning signal is generated at the operators console. At the same time, the dangerous crane movements, such as hoist up,telescope out and boom down, will be stopped.
The fixed data regarding the crane, such as load capacity charts, boom weights, centers of gravity and dimensions are stored in memory chips in the central processor unit. This data is the reference information used to calculate the operating conditions.
Boom length and boom angle are registered by the length/angle sensor, mounted inside the cable reelwhich is mounted on the boom. The boom length is measured by the cable reel cable which also servesas an electrical conductor for the anti-two-block switches.
The crane load is measured by pressure transducers attached to the piston and rod side of the lift cylinders.
1.4
GRO
VE
1 ANTI-TWO-BLOCK SWITCHES
2 PRESSURE TRANSDUCERS
3 LENGTH/ANGLE SENSOR-ANTI- TWO-BLOCK CABLE REEL
4 OPERATING CONSOLE
5 CENTRAL MICRO PROCESSOR UNIT
NOTE:If PAT System is to be used in conjunction with a jib having anexisting Grove/Krueger Anti-Two-Block system, a special connectorcable is required. Consult Grove customer services for requirement.
CONSOLE
1
25
3
4
4
3
5
2
1.5
3.2 SYSTEM FUNCTION
The PAT Load Moment Indicator (LMI) works with a user guide system that simplifies the operation of the crane and the LMI system. The system run during the start up phase is shown in the following block diagram.
Start
Self check ofLMI System
Error? Error code
Within2 hours?
InteractiveINPUT
operating mode
InputsOK?
Ready forOperation
yesno
yesno
After ignition of the engine the system starts with an automatic test of all lamps, the audible alarm and thecomplete LMI system.
In case of system malfunction an error code number will be displayed on the console.
After restarting the engine within 2 hours, the system will by-pass “Pre-Setup”.
Basic system information for crane operator will be displayed.
Experienced operators who are familiar with the LMI system can by-pass the info run.
The system will display information and directions which the operator will follow by using the respective function of the key.
The system is in the programming procedure. The operatorhas to set the LMI to the configuration of the crane.
The system is ready for operation.
4 SYSTEM’S OPERATIONDuring the startup phase the crane operator will receive information about the function and meaning of the various elements ofthe console. This process will also remind the crane operator to follow the respective operating instructions.
During the pre-setup phase the crane operator will receive general information about his responsibility by operating the crane.
If the operator is experienced and totally familiar with the function and operation of the system he can go directly to the programming procedure at the end of this PRE-SETUP phase.When the crane engine is restarted after less than approximately two hours, the PRE-SETUP and Information Run will be skipped.
4.1 Pre-SetupThe PRE-SETUP is a simple step by step procedure. The information will be displayed until a button is pressed to call for the next info step. The PRE-SETUP is followed by the Info Run or by the programming phase.
yes
InteractiveINPUTreevings
no
1.6
4.1 Pre-Setup cont.
Before operating the machine you must be aware of some safety precautions, on some systems these precautions will be included in the normal Pre-Setup display screen after you have selected the language (DS350GW &DS350GWV).
FIND OPERATORMANUALSREAD AND UNDERSTAND * PUSH “ INFO”
Prior to operating, the operator shall carefully and thoroughly read and understandthe crane load capacity charts and the information contained in the manuals for the crane and the LMI, to ensure that the operator knows the operation and limitationsof the crane and the LMI.
THE LMI SYSTEM IS AN OPERATIONAL AIDWHICH CAN FAIL * PUSH “ INFO”
The load moment indicator (LMI) is a system which supports an operator in hisaction to operate the crane.But the system cannot be 100% fail-safe and not all causes for danger can be recognized at the same time.
CONSULT AND OPERATEACCORDING TO IN CABLOAD CAPACITY CHARTS * PUSH “ INFO”
For the loading capacity of the crane only the load capacity charts are relevant. Theoperator shall also observe the operating instructions in the load capacity charts.The load values in the load capacity chart shall under no circumstances be exceeded. It is essential to select the correct operating code number which is also printed in the load capacity chart.
YOU ARE ALWAYSRESPONSIBLE FORYOUR LIFT OPERATIONS * PUSH “ INFO”
The operator is entirely responsible for safe crane operation.
He has to make sure that the crane is in good condition and that he works on a firmand level supporting surface. The operator shall fully acquaint himself with the most recent government regulations and industry standards relevant to safe craning operations.
IF IN DOUBT CONSULTTHE OPERATOR MANUALSBEFORE OPERATING THECRANE * PUSH “ INFO”
If there is anything unclear or if there are doubts about operating the crane or LMI, the operator shall consult the operator manuals before operating the crane.
1.7
F1 F4F3F2
!
STOP
STOP
! STOP
STOP
PATDS 350
TARE
LIM
SEL
i
CTRL
4.2 Operating Console
The console has 3 functions:Inputs by the crane operator (operator mode, reeving)Input of geometry limit values and signalization of exceeded limit valuesDisplay of important data and information
The operator’s console is mounted in the crane’s cab in the operator’s field of vision. For a betteridentification of displays and operating elements, they are continuously back lit during operation.
4.3 Control IdentificationThis unit contains a display and different controls which are described as follows:
Legend to Fig. 2 :
1. LC Display Area2. Load Moment Limit Light3. Load Moment Prewarning Light4. Alarm Light “Anti - Two - Block”5. Override Key Warning Light6. Button “Alarm Stop”7. Button and Control Light “TARE”8. Button and Control Light “LIMITS”9. Button and Control Light “SELECT
OPERATION MODE”10. Button and Control Light “INFO”11. Button and Control Light “CONTROL”12. Audible Alarm13. By-Pass Key Switch14. Button and Control Light “By-Pass
ANTI - TWO - BLOCK”15. Button and Control Light “By-Pass
LMI SHUT-OFF FUNCTION”F1 Button “Function 1”F2 Button “Function 2”F3 Button “Function 3”F4 Button “Function 4”
12
1
2
3
4
5
6
14
15
13
10
11
7
8
9
Fig.2: Operating Console
1.8
! STOP
1.The LC display visualizes graphical symbols, text and numerical values. Depending on the selected operating mode the corresponding information is indicated on the display.
STOP2.
The red Load Moment Limit Light warns the operator that a rated load conditionhas been reached (at 100 % of the crane rating). It lights up when the load on the crane reaches the crane load capacity. The audible alarm also sounds when this condition has been reached. The following crane movements will be stopped concurrently: hoist up,telescope out, boom down. On units with luffing jib, in addition to the above lockouts, the luffing hoist down will be stopped.
3. !The yellow Load Moment Prewarning Light will light up when the load on the crane enters the defined prewarning area (between 90 and 100 % of crane rating). It indicates that an overload condition is approaching.This means for the operator to continue his crane operation with extreme caution.The definition and setting of the prewarning area is linked to the data EPROMused in the central unit.
4.
The red Anti-Two-Block Warning Light will light up when the Anti-Two-Blocklimit switch contacts open, indicating that a two-blocking condition is approaching. At the same time the audible alarm will sound.The following crane movements will be stopped concurrently: hoist up,telescope out, boom down. On units with luffing jib, in addition to the above lockouts, the luffing hoist down will be stopped.
STOP5.
6.
The red Override Key Warning Light flashes when the bypass key switchis turned and the button is pushed. This switch deactivates the cut-off function of the LMI.
WARNINGShould the red override key warning light continue to flash (with the by-passkey switch in the neutral position) , the LMI override key switch located on the central processing unit (CPU) has been positioned in the lockout override position. This key switch continually by-passes the control lever lockoutfunction of the load moment indicator device.
The Alarm Stop Button allows the audible alarm to be silenced for approximately 15 seconds by pressing this button.
7. TARE
The Tare Button is used to indicate the net load on the display. Net load is the actual load, less lifting tackle and hook block. The Tare Button has to be activated before lifting. After pushing the Tare Button before lifting, the display of actual load will beset to zero (taring). After pushing the tare button the display shows max. load,net load and radius. Net load display is blinking and set to zero. After lifting aload the net load display shows the net load (pay load).
The net load display will change to the normal working display when the boom radius is changed (either by angle or length).
1.9
The AUDIBLE ALARM sounds during the following conditions: overload condition, approaching two- block condition,preset limits reached, malfunction of the LMI, operating error.The alarm can be temporarily silenced by pushing button (6).
12. PAT
LIM
SEL
i
CTRL
8.
9.
10.
11.
This button will be used for future functions:- Slewing Angle Limitation- Tip Height Limitation- Radius Limitation
Boom AngleLimitation is used.
If, during the crane operation, you wish to change the craneconfiguration, this button can be pushed for quick setting without having to go through the whole LMI programmingprocedure again. (ie. Hoist Reeving, Hoist, Extension)
With the system being ready for operation, this function servesto display the system configuration. The display shows the crane symbol representing the adjustedconfiguration (marked in black), the extended operating codenumber and the reeving number.
This function serves for the contrast adjustment of the LC display.The last adjustment is stored and does not have to be repeated atevery system start.
13.B
A
When turned to position “B” the KEY SWITCH serves to release the function : - deactivate the cut-off function of the LMI- deactivate the cut-off function of the
anti-two-block switchIt can be operated only by using the matching key
WARNINGSince buttons (14) and (15) deactivate the cut-off function of the LMI system / the anti-two-block system, the following instructions must be obeyed.
- The by-pass function shall be used with discretion, as unwarranted useof it to override the control lever lockout system can result in harm to the crane and danger to property and persons.
- Never use the by-pass function to either overload or operate the crane in a non permissible range.
1.10
STOP
14.
This button can be operated only if key switch is turned toposition B.After pushing this button, the cut-off function of the anti-two-block switch is deactivated.The Override Key Warning Light (13) flashes to indicate that the cut-off function is deactivated.
15.
This button can be operated only if key switch is turned toposition B.After pushing this button, the cut-off function of the LMI switch is deactivated.The Override Key Warning Light (13) flashes to indicate that the cut-off function is deactivated.
1.11
5. Daily Inspection & ObservationsPrior to operating the crane, the following electrical connections must be checked to ensure that the systemis properly connected for the crane configuration.
Machines with only a Main HoistIf the crane works only with the boom and without boom extension or jib, no additional connections arenecessary. However, be sure the weight of the anti-two-block switch is properly installed on the main hoistload line. With even parts of hoisting line, the weight shall be attached to the dead-end line. With odd parts of hoist line, the weight shall be attached to the line of lowest speed.
If the crane works with boom extension or jib, the connecting cable shall be installed between the junctionbox on the boom extension or jib and the boom junction box. The weight attached to the main hoist anti-two-block switch shall be removed. In that case the anti-two-block switch has to be locked with the red Anti-Two-Block Retainer, which is fixed with a red lanyard at the anti-two-block switch (shown in Fig. 1-4). Then the weight shall be reattached to the boom extension or jib anti-two-block.
WARNING Failure to re-position the anti-two-block switch weight will prevent the overhoist system from functioning properly. No weight shall be on the main hoist anti-two-block switch when the boom extention or jib is being used.
Machines with Main and Auxiliary HoistsIf the boom extention or jib is not in the operating position, the by-pass plug shall be installed in the main boom junction box. The weight of the main hoist anti-two-block switch shall be installed.
If the boom extension or jib is in the operating position, the connecting cable shall be installed between the junction boxes on the boom extension or jib and the main boom. Weights shall also be attached to the anti-two-block switches on both the main boom and boom extension or jib.
If the boom extension or jib is in the operating position and no load line is being used on main boom, toprevent injury or damage to equipment, the weight shall be removed from main boom switch. In that case the anti-two-block switch has to be locked with the red Anti-Two-Block Retainer, which is fixedwith a red lanyard at the anti-two-block switch.
Installation of Anti-Two-Block Retainer in Locking Position
Procedure (see Fig. 1 and 2):
1. Pull the cable out of the switch and bend back parallel to the boom and hold (1).
2. Slide the retainer from left side with it’s slot over the cable between the crimped stop and the switch (2). Push firmly straight onto the cable guide of the Anti-Two-Block switch (3).
3. Straighten the cable completely into the slot and release the cable (4).
4. Turn the flag of the retainer for best visibility for the operator (5).1.12
5
3
2
1
4
Fig. 1 : Setting of Anti-Two-Block Retainer in Locking Position
Fig. 2 : Retainer in Locking Position
Removal and Storage of the Anti-Two-Block Retainer
Procedure (see Fig. 3 and 4):
1. Pull the cable out of the switch (1) and bend back parallel to the boom and hold (2).
2. Move the retainer down (3) and then left (4) to remove it from the Anti-Two-Block switch. Release the cable.
3. For storage slide the retainer from right side (5) over the Anti-Two-Block switch unti the clips (A) lock into the holes (B).
1.13
3
4
1
2
Fig. 3 : Removal of the Anti-Two- Block Retainer
B
A 5
Fig. 4 : Retainer in Storage Position
Pre-Operation Inspection and Calibration Verification
After the electrical connections have been checked to insure that the system is properly connected forthe crane configuration, the following checks shall be made:
1. Check the electrical wiring connecting the various parts of the system for physical damage.
2. Check the anti-two-block-switches and weights for free movement.
3. Check the spring-loaded cable reel to be sure it is free rotate, has tension and the cable is reeled properly.
4. Check mechanical installation and electrical connection of the force transducer(s) on jibs where applicable.
WARNINGThe following test shall be performed with care to prevent
damage to the machine or injury to personnel. Proper functioningof the system requires successful completion of these test before
operating the machine.
1.14
If the operator cannot see the load handling device approaching the boom nose, he shall have an assistant(signal person) watch the load handling device. The operator shall be prepared to stop the machine immediately should the LMI system not function properly as indicated by lighting the red warning light,sounding the alarm and locking the crane movements, hoist up, telescope out and boom down.
Check the anti-two-block alarm light and the audible alarm by performing one of the following test:
1. By manually lifting the weight attached to the anti-two-block switches. When the weight is lifted, the audible alarm should sound, the anti-two-block alarm light should light.
2. Slowly raise the main boom load handling device to create a potential two -block condition. When the load handling device lifts the weight, the audible alarm should sound, the anti-two-block light should light and the motion of the load handling device should be stopped. Lower the load handling device slightly to eliminate this condition.
3. Slowly lower the boom to create a potential two -block condition. When the load handling device lifts the weight, the audible alarm should sound, the anti-two-block light should light and the boom lowering function should be stopped. Lower the load handling device slightly to eliminate this condition.
4. Slowly extend (telescope) the main boom to create a potential two -block condition. When the load handling device lifts the weight, the audible alarm should sound, the anti-two-block light should light and the boom telescope out function should be stopped. Lower the load handling device slightly to eliminate this condition.
If the light and audible alarm do not function as described and the crane movements are not stopped, the system is
not working properly. The malfunction shall be corrected before operating the crane.
5. If the crane is equipped with a boom extension or jib, repeat the test procedure for the boom extension or jib anti-two-block switch.
6. Check that the display of the main boom length agrees with the actual boom length.
1.15
7. Check that the display of the main boom angle agrees with the actual boom angles.
8. Check that the display of the operating radius of the crane agrees with the actual radius.
9. Check the load display by lifting a load of known weight. The accuracy of the load indication shall be within the tolerance of SAE J159.
OperationAfter being properly programmed, the LMI is operational. Therefore, the operator shall be thoroughlyfamiliar with all controls of the LMI and he shall properly set each switch before operating the crane.All settings shall be checked by lifting a load of known weight and comparing the load to the information displayed on the LMI.
Rated loads include the weight of the hook block, slings, and auxilliary load handling devices. Theircombined weights shall be subtracted from the listed load capacities as stated on the load capacitychart to obtain the net load to be lifted.
WARNING If any of the displays reflect a deviation between displayed and actual values an authorized PAT service representative shall be called for repair of the system or reverification of the crane’s LMI calibration.
WARNING Any structural modifications or changes to the crane shall require reverification of the crane’s LMI calibration.
6. Service and Maintenance
Daily maintenance of the load moment indicator consists of inspecting:1. The electrical wiring connecting the various parts of the system. if electrical wiring is damaged, it shall be replaced immediately.2. If the insulation is worn on the length sensor cable or cable guides are damaged, these parts shall be replaced.3. Check the anti-two-block limit switches for freedom of movement.4. The cable reel shall be under tension to operate properly.5. Check the pressure transducers at the lift cylinder(s) and the connecting hoses for oil leakage.6. Check mechanical installation and electrical connection of force transducer(s) on jibs where applicable.
Other than correcting the problems identified in the Malfunctions Table and replacing faulty mechanicalparts and cables, no other repairs shall be performed by non expert personnel.
1.16
7. Troubleshooting
General
In case of a malfunction of the system, the display (1) will indicate a code which identifies the systemmalfunction.
The error codes listed in the Malfunction Table will identify various faults which can occur with the LMI.Following the Malfunction Table there is information which will explain each fault and describe the actionwhich shall be taken to correct the fault.
Faults within the electronic microprocessor shall be repaired by factory trained service personnel. When these faults occur, the competent service organization shall shall be contacted.
Malfunction Table
Error Code Error E01 Fallen below the radius or above angle range E02 Radius range exceeded or fallen below angle range
E03 Boom position is out of the permissible working area E04 Operating mode not existing
E05 Prohibited length range E06 Radius range exceeded or fallen below jib angle range
NOTE:
If there is any Error Code displayed on the console which is not listed in the Malfunctions Table you shallcall the Local Distributor.
Operating Errors
Malfunctions in the system which are caused by range exceedings or operating errors by the crane operatorhimself are indicated on the display together with an explanation. These error codes are E01, E02, E03, E04,E05 and E06 and they can normally be eliminated by the crane operator himself.
1.17
ERROR 01
E01: FALLEN BELOW RADIUS RANGE RADIUS = 27.4 ft
E01: ABOVE ANGLE RANGE ANGLE = 80.0 o
Cause:Fallen below the minimum radiusor above the angle given in theload capacity chart due to raisingthe boom too far.
Elimination:Lower boom back to a radius or angle given in the load capacitychart.
ERROR 02
E02: RADIUS RANGE EXCEEDED RADIUS = 75.6 ft
E02: BELOW ANGLE RANGE ANGLE = 25.0 o
Cause:The maximum radius or minimumangle given in the load capacitychart was exceeded due to lower-ing the boom too far.
Elimination:Raise boom back to a radius or angle given in the load capacitychart.
E03: NO - LOAD AREA
Cause:Boom position is out of the permis-sible working area (over front)
Elimination:Move boom back to permis- sible working area. See lifting diagram in the load capacity charts.
ERROR 03
1.18
ERROR 04
E04: OPERATING MODENOT AVAILABLE
SEE LOAD CAPACITYCHART * PUSH “INFO”
Cause: 1Operating mode switch in the con-sole set incorrectly.
Elimination:Set operating mode switch cor-rectly to the code assigned to theoperating mode of the crane.
Cause: 2Operating mode is not permissiblewith the actual crane configuration,boom position or area definition.
Elimination:Be sure crane is set up accordingto proper operating configur-ations.
ERROR 05
E05: LENGTH RANGENOT PERMITTED
LENGTH = 75.3 ft
Cause: 1Boom was telescoped too far or notfar enough, i.e. load curves for “onrubber”, you may only operate up to a certain maximum or minimum boom length or with load curvesfor jibs where you have to telescopethe main boom to a certain length.
Elimination:Telescope boom to correct length, given in the load capacitychart.
Cause: 2Length sensor adjustment changedi.e. length sensor cable slid off the length sensor drum.
Elimination:For elimination refer to servicemanual.
1.19
ERROR 06
E06: BELOW JIB ANGLE RANGEJIB ANGLE = 15.0o
E06: RADIUS RANGE EXCEEDED RADIUS = 96.6 ft
Cause:The minimum angle or maximumradius of the luffing fly jib given inthe load capacity chart was exceededdue to lowering the jib too far.
Elimination:Raise jib back to an angle given in the load capacity chart.
Lightbar
The P.A.T. Lightbar is a supplementary indicator for the standard P.A.T. Load Moment Indicator systems.It displays the load moment in form of a bargraph. The lightbar is located in the operator’s cab in front of the operator.
DIMSTOP!
This indicator display how much of the crane capacity is being used. As the crane is moved through its various motions, the bargraph will constantly change.
The range of the bargraph is divided into three areas:- the green area is the normal working area,- the yellow prewarning area shows the remaining portion of the rated load capacity and the bargraph indicates the approach to the overload condition,- the red area shows that the maximum rated load capacity is exceeded.
NOTE: Operating within the red area is not permitted.Brightness adjustment:
In order to adapt the P.A.T. Lightbar’s brightness to the lighting conditions of the environment a DIM-switch is installed on the right hand side of the display. When actuating the DIM-switch the brightness increases. After having exceeded the maximum brightness value the display turns back to the minimum brightness value.
1.20
CONSOLE MEASUREMENT:
CONNECTION BOARD W/VOLTMETER ON X1:30 & X1:33
VOLTMETER SHOULD MEASURE +24V BETWEEN CONNECTIONS X1 - 33 (NEGATIVE) AND X1 - 30 (POSITIVE).
1 3 5
2 4 6
7 9 11 13 15 17 19 21 23 25 27 29
8 10 12 14 16 18 20 22 24 26 2871 72 73 74
49 48 47
59 58 57 56 55 54 53 52 51 50
46 45 44
70 69 68 67 66 65 64 63 62 61 60
80 79 78 77 76 75 43 42 41 40 39 38 37 36 35 34 33 32 31 30
K10LEVER
LOCKOUT K6 K5 K3 K2
K7 K4 K1
K9 K8LMISHUTOFF
A2BSHUTOFF1 2 3 4
X3
X4
F1
F8 F7 F6 F5 F4 F3 F2
R13 R14 R11 R12 R7 R8 R5 R6
R15 R16 R9 R10 R3 R4
R2 R1
X4
H9
V2
H8
V1
X1 X1
X1
X1
X1
X1
X1X1
X1
X1
H7
V11
H4
V8
H1
V5
H6
V10
H5
V9
H3
V7
H2
V6
H10 V3
R17R18
OU
TER
MID
OU
T O
FSE
QU
ENC
E
CEN
TER
MID
4 - W
AY
RO
D
DR
AIN
INN
ERM
ID
OM CM 4W SEQ
ROD
IM
+24.0
1.21
.o.
8079787776757473727170696867666564636261605958575655545352515049
4321
X40(UB)
+UB
GND
LEN.(OA)
ANGLE
+5V
-5VGND
-5V
GND
-5V
+5V
-SIG
-SIGGND
-SIG-5V+9V-9V
-SIG+SIG
UBTXDRXD0 (UB)
SIG0-SIG
0 (UB)A2B
COMPARATOR
DE 1
DE 2
DE 3UB UB
o oo.o oo
K8
K9 0 (UB)
ooo
K10
K10
8586
8787A 30
ooo
F2
87A87
30 85
86K1= NOT USED
ooo
F3
87A87
30 85
86K2 = IM 2 - WAY
ooo
F4
87A87
30 85
86K3 = ROD
DRAIN SOL.
ooo
F5
87A87
30 85
86K4 = TELE OUT
OF SEQ.
ooo
F6
87A87
30 85
86K5 = 4 - WAY
DIREC. VALVE
ooo
F7
87A87
30 85
86K6 = CM 2 - WAY
ooo
F8
87A87
30 85
86K7 = OM / FLY
- 2 WAY
GND
-SIG-5V
DE 4
DE 5
DE 6
4847464544434241403938373635343332313029282726252423
22212019181716151413121110987654321
))))
0 (UB) / GND+24 V
PRESS. SW.BOOM EXT.
PRESS. SW.BOOM RET.
AUTO MODESW. ON
OM / FLYRET. / % SW.
CM / IM RET. SW.
LENGTHRESET SW.
1
2
3
4
5
6
7
8
DATA FROM C.U.
DATA TO C.U.
CONSOLEBY-PASS
KEY
A2B BUTTONBY - PASS
LMI BUTTONBY - PASS
+24V (1)
GND (2)
TXD (3)
RXD (4)
COMM. (5)
A2B (6)
LMI (7)
DI (8)
oo
oo
14
1432
7
6
5
13
LMI BY - PASSKEY
DS350 GraphicConsole to C.P.U.
Connections
1.22
F1 F4F3F2
!
STOP
STOP
! STOP
STOP
PAT DS 350
TARE
LIM
SEL
iCTRL
0335
?
156ft
90.0ft
100% 100% 100%
79.4o
50.8ft
73.5oo02(lbs)MAX
ACT (lbs)
34.900
FIVE SECTION BOOM SERVICE SCREEN(TMS/TTS 870 & RT865BXL)
1 255 1 255 1 255 1 255
0 00 00 00 0
1 2551 2551 2551 255
0 00 00 00 0
38.2 38.2 38.2 38.2 38.2 38.2 38.2 38.2
Ramp Seq. IM Hex Value
CM Hex Value OM/Fly Hex Value
Length of IM
Tot. Length minus IM
To activate service screen press and hold F1 & F4 until screen appears in lower left corner. The ramping value will indicate theramping up and ramping down of the output signal to the solenoids.
1.23
38.238.238.238.238.238.238.238.2
P.A.T. – L.M.IMANUAL
SECTION 2
DS 350 GRAPHIC BCSHYDRAULIC, ELECTRICAL THEORY
& COMPONENT LOCATION
DS350 GRAPHIC with BOOM CONTROL SYSTEM
The DS 350 load moment indicator (LMI) with boom control extension is designed to aidthe crane operator through the crane operations. The DS 350 with boom control extensionis not, and shall not, be a substitute for good operator judgment, experience and use ofaccepted safe crane operating procedure.
2. Warnings
The DS 350 load moment indicator (LMI) with boom control extension is an operationalaid that warns the crane operator when he approaches an overload condition, a two blockcondition and an out of boom sequence condition. The boom control extension controlsthe sequence of the boom during operation. It still remains the operator’s responsibility toselect verify the operation and to select the correct mode during crane operations.
The manual mode is a rigging mode. Lifting loads with manual mode programmed isprohibited.
Should an out of sequence condition occur, the crane operator is responsible to selectmanual mode to return the sections into sequence before he continues the lift.
The responsibility for safe crane operation shall remain with the crane operator who shallensure that all warnings and instructions supplied are fully understood and observed.
Prior to operating the crane, the operator must carefully and thoroughly read andunderstand the information provided by the crane and load moment indicatormanufacturer.
Proper functioning depends upon proper daily inspection and observance of the operatinginstructions provided with the crane and load moment indicator.
2.1
Boom control information flow
Operator movescontrol to extend or
retract position.
Directional pressureswitch transmits signal
to B.C.S.
B.C.S. checks input forAutomode.
Operation in manualmode - no control
output.off
B.C.S. checks input forA mode or B mode and
prepares the controllogic for that mode.
on
B.C.S. checks theretract and % reset
switches on the boomand obtains the length
signals.
Console displayslength and % of each
section.correct
B.C.S. defaults into arigging mode, consoledisplays error code or
dashboard warninglight indicates "out of
sequence".
incorrect
continue on next page
2.2
B.C.S. activates relaysto power up valves.
This enables the oil toflow into the cylinder.
TMS,TTS 870 & RT 865 BXL
B.C.S. switches relayto correct position for
the rod side dumpvalve
TM9150, TM9100
B.C.S. ramps up theanalog output current
for the pressurereducing valves
(proportional valves)
The pressure reducingvalves open linear an
the pilot pressureincreases until
maximum pressure isobtained.
continue on next page
2.3
B.C.S. senses theboom length and
calculates thepercentage of each
section while extendingor retracting.
continuation
B.C.S. starts the ramp downprocess when approaching a
change over point.Theanalog output current
decreases and slows downthe section.
correct
Out of sequencewarning and lock out.
incorrect
At the change over point theB.C.S. changes relay
combination to close the flow tothe actual cylinder and enable
flow to the next cylinder.
TMS/TTS 870 & RT 865 BXL
The B.C.S. ramps up theanalog signal by a linearcurrent increase of the
pressure reducing valves.The section speeds up to
its maximum speed.
TM9150 & TM9100
2.4
Why use electrical boom control ?
Hose reel not required (TMS/TTS 870, RT 865 BXL).
Hydraulic flow is routed internally of the cylinder.Trombone Concept.
Enables selected sequencing of the boom to improve utilization of thecrane.
Mode A:Increased stability. The heavy IM (inner mid section) remains retracted until theCM (center mid section) and OM/Fly (outer mid and fly section) becomes fullyextended. This enables a better load chart for the boom between fully retractedand extended.
Mode B:Increased structural capacity. The stronger sections IM & CM extends in aprogrammed sequence keeping the weaker section OM & Fly fully or partiallyretracted.
Model ModeTM 9150 BTM 9100 A, BTMS 870 A, BTTS 870 A, BRT 865 BXL B
2.5
WHERE ARE THE CONTROLS?
PILOT CONTROLStandard joystick or foot operated treadle valve.
The following switches are located inside, and on the upper right hand side of the cab directly above thewindow.
MANUAL / AUTO (See page 2.7)
AUTO MODE is to be used when lifting loads per the load chart.
MANUAL MODE is used primarily to put the boom back into synchronization or, for rigging andmaintenance purposes. Loads cannot be lifted while on manual mode as the capacity is reduced greatlyby the PAT to limit loads to that which would normally be seen during rigging and / or maintenance.
When changing boom modes, always try to do so with boom full retracted or full extended. This willprevent you from having to select manual mode to desynchronize the boom.
SECTION SELECTOR (See page 2.7)
THE SECTION SELECTOR switch is used to select which section will be extended or retracted, and canonly operate when in manual mode.
INDICATOR LIGHTS (See page 2.7)
THE INDICATOR LIGHTS tell the status when in manual mode as to which boom section has beenselected for operation, and that the electric coils to that section have been energized.
BOOM NOT SYNCHRONIZED LIGHT (See page 2.7)
THE BOOM NOT SYNCHRONIZED LIGHT will illuminate to indicate a boom section. or several boomsections are at least 3% out of synchronization. At this point the load would have to be set down, and themanual controls operated to reset the boom.
2.6
A BB
OO
M
TELE
MO
DE
A U T O M A N U A LB
OO
MM
OD
E
OU
TER
MID
FLY
CEN
TER
MID
INN
ERM
IDB
OO
M T
ELE
SEC
TIO
N S
ELEC
T
BOO
MN
OT
SYN
C
INN
ERM
ID ON
CEN
TER
MID ON
OU
TER
MID
FLY
ON
BOO
MTE
LESC
OPE
SYST
EM
2.7
WHERE ARE THE COMPONENTS LOCATED ?
VALVES S / SPressure reducing valve ( 800 P.S.I. ) and rod side dump lie within the turntable uprights. This is alsowhere the test port is located for settings the pressure reducing valve and the sequence valve.
The 4 - way directional valve and piston dump valve lie outside the turntable uprights on the right side ofthe superstructure.
The Sequence valve lies just below the 4 - way valve , also on the right side of the superstructure.
SWITCHES S / SOn the 4 - way valve are the 3 pressure switches which control the opening of the dump valves and thedirection of movement inputs to the PAT system.
PAT BOX S / SInside the PAT box we have the relays labeled to correspond to the function they control.One item of importance here is the numbers 1 through 7 along the left side of the relays controlling theboom. These numbers indicate the fuse number that corresponds to the valve the relay controls. Whentroubleshooting any problems, it's always a good idea to check these fuses first.
VALVES IN BOOMThe 2 way valves for the inner mid are mounted in the rear of the inner mid as shown. Piston flow is tothe lower left side, while pilot flow is to the upper right.
The 2 way valves for the outer and center mid are mounted in the rear of the center mid.Piston flow for the center mid is to the lower right, while the piston flow to the outer mid is to the upperright.
Pilot flow to the outer mid is to the upper left, while the pilot flow to the center mid is to the lower left.
Wire colors to the valves are shown to the right.
SWITCHES ON BOOMFour Proximity switches are mounted on the left side of the boom. Each of the switches are adjusted toindicate to the PAT system that all the boom sections have been fully retracted.
CABLE REELS ON BOOMThree cable reels are mounted on the left side of the boom. The top reel is the basic L.M.I. reel with thesmall thin cable for A2B.The other two reels have a large cable installed and are primarily used to provide power to the 2 wayvalves inside the boom. They also pickup inputs from two of the proximity switches to send back to thePAT system.
2.8
TMS
/ TTS
870
& R
T865
BX
Lw
ith B
oom
Con
trol
Turn
tabl
e C
ompo
nent
s
2.9
SEQ
UEN
CE
VA
LVE
1000
PSI
TE
LE
EX
TE
ND
X1 TERMINALBOARD A104
DECODERBOARD
A110
DIGITAL INPUTEXTENSION BOARD
A112
DIODE BOARD
A113
VALVE CONTROLBOARD
A111
THIRD WRAP
K11 K12
MH AH
P.A.T. DS350 GRAPHICC.P.U. BOARD LOCATION
TMS870/TTS870(5 section boom)
MAIN BOARD
A101
2.10
DA
TA L
OG
GER
DO
WN
LOA
D R
ECEP
T.(D
ATA
LO
GG
ER O
PTIO
NA
L)
KEY
BY
PASS
SW
ITC
H
FUSE
(2A
)
CRA
NE
INTE
RFA
CE
CA
BLE
FUSE
(10A
)
CA
BLE
ASS
Y T
O B
OO
M
CA
BLE
ASS
Y T
O B
OO
M
CA
BLE
ASS
Y T
O C
ON
SOLE
PRES
. TR
AN
. CA
BLE
ASS
Y (P
ISTO
N)
PRES
. TR
AN
. CA
BLE
ASS
Y (R
OD
)
TMS
/ TTS
870
Cent
ral P
roce
ssin
g U
nit
5 - S
ectio
n Bo
om
(BO
TTO
M V
IEW
OF
C.P
.U.)
2.11
DA
TA L
OG
GER
DO
WN
LOA
D R
ECEP
T.(D
ATA
LO
GG
ER O
PTIO
NA
L)
KEY
BY
PASS
SW
ITC
H
FUSE
(2A
)
CRA
NE
INTE
RFA
CE
CA
BLE
FUSE
(10A
)
CA
BLE
ASS
Y T
O B
OO
M
CA
BLE
ASS
Y T
O B
OO
M
CA
BLE
ASS
Y T
O C
ON
SOLE
PRES
. TR
AN
. CA
BLE
ASS
Y (P
ISTO
N)
PRES
. TR
AN
. CA
BLE
ASS
Y (R
OD
)
RT8
65BX
L Ce
ntra
l Pro
cess
ing
Uni
t
(BO
TTO
M V
IEW
OF
C.P
.U.)
ARE
A D
EF C
AB
LE
2.12
INNER MIDPILOT
INNER MIDCYLINDER
INNER MID
CYL
RED
GREEN
INNER MID
PILOT
BLACK
WHITE
CABLE
OUTER MIDPILOT
CENTER MIDPILOT
OUTER MIDCYLINDER
CENTER MIDCYLINDER
OUTER MID
CYL
RED
GREEN
CENTER MID
CYL
BLACK
WHITE
B
OUTER MID
PILOT
RED
GREEN
CENTER MID
PILOT
BLACK
WHITE
C
2.13
IM le
ngth
sen
sor
LG22
1C
M le
ngth
and
ang
le s
enso
rLW
G22
1
Boom
Con
trol c
ompo
nent
sTM
S/TT
S 87
0 an
d RT
865
BXL
DS3
50 G
raph
ic -
BCS
P A T
P A T
P A T
P A T
P A T
P A T
P A T
P A T
P A T
P A T
P A T
P A T
IM %
rese
tsw
itch
Boo
m le
ngth
sen
sor
LG20
8
OM
retr
act a
nd %
rese
t sw
itch
CM
retr
act a
nd %
rese
t sw
itch
IM re
trac
tsw
itch
See
deta
il“ A
”Se
e de
tail
“ C ”
See
deta
il“ C
”
See
deta
il“ C
”
2.14
P A T
P A T
P A T
P A T
P A T
P A T
P A T
P A T
P A T
P A T
P A T
P A T
1
23
7
5 7
5
8
1PR
E - T
ENSI
ON
(LEN
GTH
SEN
SOR
) SPR
ING
BY
RO
TATI
NG
DR
UM
(16)
REV
OLU
TIO
NS
CO
UN
TER
CLO
CK
WIS
E. T
HEN
UN
SPO
OL
THE
LEN
GTH
CA
BLE
AN
D S
ECU
RE
TO B
USH
ING
ON
TH
E B
OO
M N
OSE
PER
DET
AIL
“A
”. PR
E - T
ENSI
ON
(LEN
GTH
SEN
SOR
) SPR
ING
BY
RO
TATI
NG
DR
UM
(35)
REV
OLU
TIO
NS
CO
UN
TER
CLO
CK
WIS
E. T
HEN
UN
SPO
OL
THE
LEN
GTH
CA
BLE
AN
D S
ECU
RE
TO B
USH
ING
ON
TH
E IN
NER
- M
IDPE
R D
ETA
IL “
A”.
PRE
- TEN
SIO
N (L
ENG
TH S
ENSO
R) S
PRIN
GB
Y R
OTA
TIN
G D
RU
M (3
0) R
EVO
LUTI
ON
S C
OU
NTE
RC
LOC
KW
ISE.
TH
EN U
NSP
OO
L TH
E LE
NG
TH C
AB
LEA
ND
SEC
UR
E TO
BU
SHIN
G O
N T
HE
CEN
TER
- M
IDPE
R D
ETA
IL “
B”
2 3
5R
EMO
VE 1
/4 -
20 N
UTS
ON
BO
TTO
M O
F C
AB
LE G
UID
E.IN
SER
T C
AB
LE G
UID
E SC
REW
S TH
RU
EXI
STIN
G A
NG
LEB
RK
T A
ND
SEC
UR
E IN
PLA
CE
WIT
H 1
/4 -
20 N
UTS
R
EMO
VED
PR
EVIO
USL
Y.
CEN
TER
LIN
E O
F C
AB
LE G
UID
E M
UST
BE
ALI
GN
ED W
/ CEN
TER
LIN
E O
F C
AB
LE R
EEL
DR
UM
.
AFT
ER M
AC
HIN
E IS
CA
LIB
RA
TED
, REM
OVE
PR
OTE
CTI
VE P
APE
RC
OR
RO
SIO
N IN
HIB
TOR
AN
D A
DH
ERE
TO IN
SID
E H
OU
SIN
G C
OVE
RSU
RFA
CE
OF
CA
BLE
REE
L.
7 8
2.15
Boom
Con
trol c
ompo
nent
sTM
S/TT
S 87
0 an
d RT
865
BXL
DS3
50 G
raph
ic -
BCS
PLA
CE
(3) T
IE W
RA
PS, 1
20 D
EGR
EES
APA
RT
AR
OU
ND
BU
SHIN
G. W
RA
P C
AB
LE(8
-10)
REV
OLU
TIO
NS
OVE
R T
HE
TIE
WR
APS
STA
RTI
NG
FR
OM
TH
E O
UTS
IDE
AN
D
WO
RK
ING
INW
AR
D. A
LLO
W A
MPL
E C
AB
LE
TO R
EAC
H J
UN
CTI
ON
BO
X. S
ECU
RE
CA
BLE
WIT
H (2
) AD
DIT
ION
AL
TIE
WR
APS
.
INST
ALL
PR
OXI
MIT
Y SW
ITC
H 0
.44”
FR
OM
TAR
GET
WH
EN B
OO
M S
ECTI
ON
S A
RE
FULL
Y R
ETR
AC
TED
.
THIS
TA
RG
ET IS
ON
LY IN
STA
LLED
IF T
HE
BO
OM
IS E
QU
IPPE
D W
ITH
A B
OO
M
EXTE
NSI
ON
STO
P B
LOC
K.
INST
ALL
PR
OXI
MIT
Y SW
ITC
H 0
.13”
FR
OM
TA
RG
ET W
HEN
BO
OM
SEC
TIO
NS
AR
E FU
LLY
RET
RA
CTE
D.
1.0
DET
AIL
“A
”
To b
e al
igne
dwi
th c
ente
r lin
e
of c
able
reel
dru
m
DET
AIL
“B
”
P A T
P A T
P A T
P A T
See
deta
il“ B
”
See
deta
il“ A
”
0.13
0.44
0.44
0.44
3.94
CEN
TER
LIN
E O
FTA
RG
ETS
&
PRO
XIM
ITY
SW.
184
44
66 16
16
18
DET
AIL
“C
”1.
34
2.16
PAR
TIA
L TO
P VI
EW
19
CEN
TER
LIN
E O
FC
AB
LE R
EEL
DRU
M
INST
ALL
SH
IMS
AS
REQ
UIR
ED T
O A
SSU
RE
CEN
TER
LIN
E O
F C
AB
LE R
EEL
DR
UM
S A
RE
PAR
RA
LLEL
TO
BO
OM
BA
SE S
ECTI
ON
AN
D
PLU
MB
WH
EN C
RA
NE
IS O
N A
LEV
EL \
SUR
FAC
E.
19
CEN
TER
LIN
E O
F C
AB
LE G
UID
ES
CA
BLE
GU
IDES
ON
TH
E B
ASE
& IN
NER
MID
SEC
TIO
NS
ASS
OC
IATE
D W
ITH
TO
P A
ND
M
IDD
LE C
AB
LE R
EEL
MU
ST B
E A
LIG
NED
WIT
HC
ENTE
R O
F C
AB
LE R
EEL
DR
UM
2.17
Boom
Con
trol c
ompo
nent
sTM
S/TT
S 87
0 an
d RT
865
BXL
DS3
50 G
raph
ic -
BCS
HOW DOES THE SYSTEM WORK?
HYDRAULIC
1. Pilot operated 4 way valve provides oil flow to extend and retract the 3 telescoping cylinders. On thisvalve are 2 pressure reducing valves electrically operated by the PAT system. Their function is to reducethe pilot pressure when nearing the point a section must stop in order to slow it down smoothly, then theywill increase the pilot pressure back to normal once the next section begins to move allowing for a smoothtransition.
Directional pressure switches
In each of the pilot pressure lines is a normally open pressure switch, one for extend and one for retract.These pressure switches tell the PAT which direction has been selected by the operator, so it will knowwhich section is next to go out or in and when the pilot pressure is to be reduced and returned to normal.
Third switch pressure
A third pressure switch ( normally closed ) mounted near the top of the 4 way valve monitors joystickpressure directly on the main spool for extend. When no pressure is evident, or the controller is in neutral,the switch is closed , and the piston side dump valve is energized allowing piston side pressure to bereleased through a .078 orifice.
2. Two - way valves control the oil to each telescope cylinder. One for the pilot pressure to the holdingvalve and one for the piston side oil to flow. These are operated in pairs only. When a pair of two-wayvalves are de-energized, that particular telescope cylinder will then operate. The other two pair of twoway - valves must be energized to prevent movement of the other two telescope cylinders. These valvesare also switched on and off by the PAT system when in Automatic mode. They are controlled by anindividual selector switch when in the Manual mode.Two - way valves are normally open, so that in the event of an electrical malfunction, the boom couldalways be telescoped in for repair.
Piston side dump valve
In the piston side, there is a piston side dump valve which allows piston side oil to be released back totank by the way of a .078 orifice. This valve is controlled by the normally closed contacts of the thirdpressure switch and dumps to tank, when the controller is in neutral and pilot pressure has decayed.
Rod side dump valve
In the rod side, there is a rod side dump valve which allows rod side oil to be released back to tank. Thisvalve is electrically operated by the PAT system and is switched on to dump rod side pressure when thecontroller is in neutral.
2.18
Sequence valve
The sequence valve maintains pressure on the rod side to prevent the cylinders from extending whenthe trombone tubes are pressurized.* If the boom sections drift back in momentarily after the controller is released, this is a good indication the sequence valve is defective.* To adjust or check for proper adjustment:
1. Install gauge into test port between pressure reducing valve and sequence valve.2. Select manual mode.3. Select either inner mid or center mid section.
4. Extend the boom section and monitor pressure while boom is extending. If it does not read 1,000 P.S.I., adjust valve accordingly.
Pressure reducing valve
The pressure reducing valve is used to flood the rod side whenever the telescope cylinders firstbegin to extend.* If the boom sections take off with a jump, this is a good indication the pressure reducing valve is defective.* To adjust or check for proper adjustment:
1. Always be sure to check setting of the sequence valve first.2. Gauge should still be in test port from checking sequence valve.3. With manual mode still selected.4. Select either the inner mid or center mid section chosen.5. Extend the section completely until it bottoms out.6. Release controller or treadle valve to neutral (this allows oil to drain off).7. Then operate controller or treadle valve to extend and note pressure reading, it should read 800 P.S.I. if it does not, adjust pressure reducing valve accordingly.
Check valve
The purpose of the check valve, is to prevent high pressure oil from flowing back through the800 P.S.I. pressure reducing valve when trying to retract.
2.19
ELECTRIC
Automatic ModeProportional voltage is sent by the PAT system to the coils on the 4 - way valve, either to the extend orthe retract side as determined by the pressure switches in the joystick lines an the K-5 relay in the PATsystem. The current is applied gradually and removed gradually by the PAT system to assure smoothstarts and transitions between boom section change over.
Extending the inner midThe proportional output building up while extending the inner mid followed by full current and a fullyopen valve while extending, followed by a decrease in current during the change over to the center mid.Once all the 2 way valves for the appropriate sections have changed over and the rod and piston side havedumped momentarily, the current will be reapplied proportionally to allow a smooth start of the centermid. K-5 relay remains energized during the entire process. This is because the operator never left off onthe controller and the extend pressure switch always remained in the on position.
Retracting the inner midWhile retracting the inner mid, followed by full current and a fully open valve while extending, followedby a decrease in current during the change over to the center mid. Once all the 2 way valves for theappropriate sections have changed over the piston side dump valve stayed energized before, during , andafter the change over took place, while the rod side dump valve energized briefly during the change over.This was because we were retracting, and no pilot pressure was seen on the extend side, and therefore ournormally closed pressure switch kept the piston side dump valve energized and K - 5 relay which directsthe proportional voltage never energized. This is a default mode so that if there is an electrical problemcurrent could always be applied to the retract side to bring in the boom in for repairs.Manual Mode
Extending the inner and center midAny time manual mode is selected voltage to the proportional solenoids is at maximum voltage. Thismeans the 4 way valve will respond directly to the input from the controller, without the ramp up andramp down feature as provided when under control by the PAT system. The 2 way valves for theappropriate sections are controlled by the manual switch. Although it is not required to release thecontroller to neutral when changing boom sections, it is preferred. When releasing the controller toneutral the rod side and piston side will drain, which will allow for a smooth transition between boomsections when on manual mode. Note that K-5 relay never energizes, now that we are in manual modeboth coils on the 4 - way valve will remain energized with full voltage.
Retracting the inner and center midAnytime manual mode is selected voltage to the proportional solenoids is at maximum voltage.The two way valves for the appropriate sections are controlled by the manual switch. The rod side valveenergizes briefly as we stop controller input to change sections, and the piston side dump valve is notenergized during retraction.
2.20
.o.
8079787776757473727170696867666564636261605958575655545352515049
4321
X40(UB)
+UB
GND
LEN.(OA)
ANGLE
+5V
-5VGND
-5V
GND
-5V
+5V
-SIG
-SIGGND
-SIG-5V+9V-9V
-SIG+SIG
UBTXDRXD0 (UB)
SIG0-SIG
0 (UB)A2B
COMPARATOR
DE 1
DE 2
DE 3UB UB
o oo.o oo
K8
K9 0 (UB)
ooo
K10
K10
8586
8787A 30
ooo
F2
87A87
30 85
86K1= NOT USED
ooo
F3
87A87
30 85
86K2 = IM 2 - WAY
ooo
F4
87A87
30 85
86K3 = ROD
DRAIN SOL.
ooo
F5
87A87
30 85
86K4 = TELE OUT
OF SEQ.
ooo
F6
87A87
30 85
86K5 = 4 - WAY
DIREC. VALVE
ooo
F7
87A87
30 85
86K6 = CM 2 - WAY
ooo
F8
87A87
30 85
86K7 = OM / FLY
- 2 WAY
GND
-SIG-5V
DE 4
DE 5
DE 6
4847464544434241403938373635343332313029282726252423
22212019181716151413121110987654321
))))
321
X1
0 (UB) / GND+24 V
(((
PRESS. SW.BOOM EXT.
PRESS. SW.BOOM RET.
AUTO MODESW. ON
OM / FLYRET. / % SW.
CM / IM RET. SW.
LENGTHRESET SW.
IM 2-WAYS
CM 2 - WAYS
OM 2 - WAYS
2 A
F1
10 A
F2
)
GND
+24 V
o o
1
2
3
3
2
1
X9 BR14
26COND.
40COND.
X51234 2X SER
IALIN
TERFA
CE
X6
MEA
SUR
EPIN
S
X7
MEM
OR
YEXTEN
SION
X4
DS350 GraphicX1 Terminal Board
SIG. ANALOG OUTPUT BOR.ANALOG SIG. - EXT. VALVEANALOG SIG. - RET. VALVE
TELE OUT OF SEQ.
ROD SIDE DUMP
2.21
))
.078
w
w
ww
w
w
w
w
w
w
w
B A P1 B ARET EXT RETEXT
W W
PRESSURESWITCHEXTEND
PRESSURESWITCHEXTEND
w
W
3800 3000 1500
OPEN
PRESSURESWITCHRETRACT
TELE P2 D LIFT
D P1
PISTONDRAIN
w
P1
P2
w
w
RODDRAIN
TO DUAL RETURN MANIFOLD
TO CASEDRAIN MANIFOLD
w)
)
w
LS
GP
OUT
3650
220-300
49.9GPM
800 PSI
SEQUENCEVALVEWITH CHECK1000 PSI
TEST PORT
TO DRAIN MANIFOLD
w PILOT w
w
w
PILOT w
ww
w
w
~
~ 2.22
)
)
.078
w
w
ww
w
w
w w
w
w
w
B A P1 B ARET EXT RETEXT
W W
PRESSURESWITCHEXTEND
PRESSURESWITCHEXTEND
w
W
3800 3000 1500
PRESSURESWITCHRETRACT
TELE P2 D LIFT
D P1
PISTONDRAIN
w
P1
P2
w
w
RODDRAIN
TO DUAL RETURN MANIFOLD
TO CASEDRAIN MANIFOLD
w)
)
w
LS
GP
OUT
3650
220-300
49.9GPM
800 PSI
SEQUENCEVALVEWITH CHECK1000 PSI
TO DRAIN MANIFOLD
~
~2.23
K3
NCNO
K5
DI 1
K5
DI 2 NO
ww
w
PILOT
CYLINDER FULLY RETRACTED
2.24
2
1
5
1
2
7
8
6
3 t
255
5040
0
0
INNER MID
Proportionalsolenoidvalve 1
Proportional solenoidvalve 2
CENTER MID
Rampingvalue
Length[%]40 47 50 2 sec.
4 sec.
5
3
8
7
6
Maximum Ramping value-valve fully open-
Ramping down
Minimum rampingvalue IM
Change over point-Ramping value 0-
-valve closed-
Minimum rampingvalue CM
Time based ramping upi.e. 12 cycles = 6 seconds
Maximum Ramping value-valve fully open-
DS350 GRAPHIC BOOM CONTROL SYSTEM “B” MODE
RT 865BXLTTS/TMS 870
2.25
OM2 WAYS
CLOSED
OPEN
CM2 WAYS OPEN
CLOSED
IM2 WAYS OPEN
CLOSED
OPEN
RODDRAIN
OPEN
CLOSEDCLOSED
OPENOPEN
PISTONDRAIN
OPEN
CLOSEDCLOSED
OPENOPEN
K5RELAY
EXTEND
START CHANGE OVER STOP
EXTENDINNER MID
EXTENDCENTER MID
PROPORTIONALOUTPUT
PROPORTIONAL VALVE
DS350 GRAPHIC BOOM CONTROL SYSTEMAUTOMATIC MODE
2.26
OM2 WAYS
CLOSED
OPEN
CM2 WAYS OPEN
CLOSED
IM2 WAYS OPEN
CLOSED
OPEN
RODDRAIN
OPEN
CLOSEDCLOSED
OPENOPEN
PISTONDRAIN
K5RELAY
START CHANGE OVER STOP
RETRACTINNER MID
RETRACTCENTER MID
PROPORTIONALOUTPUT
PROPORTIONAL VALVE
DS350 GRAPHIC BOOM CONTROL SYSTEMAUTOMATIC MODE
2.27
DS350 GRAPHIC BOOM CONTROL SYSTEMMANUAL MODE
EXTENDINNER MID
EXTENDCENTER MID
PROPORTIONAL VALVE
START CHANGE OVER STOP
OM2 WAYS
CLOSED
OPEN
CM2 WAYS OPEN
CLOSED
IM2 WAYS OPEN
CLOSED
OPEN
RODDRAIN
OPEN
CLOSEDCLOSED
OPENOPEN
PISTONDRAIN
K5RELAY
OPEN
CLOSEDCLOSED
OPENOPEN
2.28
DS350 GRAPHIC BOOM CONTROL SYSTEMMANUAL MODE
RETRACTINNER MID
RETRACTCENTER MID
PROPORTIONAL VALVE
START CHANGE OVER STOP
OM2 WAYS
CM2 WAYS OPEN
CLOSED
IM2 WAYS OPEN
CLOSED
OPEN
RODDRAIN
OPEN
CLOSEDCLOSED
OPENOPEN
PISTONDRAIN
K5RELAY
2.29
DS350 GRAPHIC (BCS)
Automode control of two way valves
K2 K6 K7 DESCRIPTION0 1 1 IM EXTENDING OR RETRACTING1 0 1 CM EXTENDING OR RETRACTING1 1 0 OM/FLY EXTENDING OR RETRACTING0 0 0 OUT OF SEQUENCE0 0 0 NEUTRAL POSITION
Rod side dump valve logic TMS/TTS 870 and RT 865 BXLNote: K3 is energized in neutral controller position or during the change over transitionwhile both section do not move.
DI 1EXTEND SELECT
DI 2RETRACTSELECT
DI 4OM/FLY
RETRACTED
DI 5IM & CM
RETRACTED
K 3ROD DRAINSOLENOID
0 0 0 0 10 0 0 1 10 0 1 0 10 0 1 1 10 1 0 0 00 1 0 1 00 1 1 0 00 1 1 1 01 0 0 0 01 0 0 1 01 0 1 0 01 0 1 1 0
Analog Outputs
ANALOG CU DESCRIPTIONTERMINAL
1 A111 X1/5 Analog GND for proportional extend or retract solenoid valves.1 A111 X1/6 Analog signal for proportional extend or retract solenoid valves.
2.30
DS350 GRAPHIC (BCS)
Input Output Logic TMS/TTS 870 AND RT 865 BXL
Mode Ext.DI 1
Retr.DI 2
RelayK2
RelayK6
RelayK7
RelayK5
2 wayIM
2 wayCM
2 wayOM
analogoutputboard
Prop.Valveext.
Prop Valveretr.
Ext. auto IM 1 0 0 1 1 1 0 1 1 1 1 0Ret. auto IM 0 1 0 1 1 0 0 1 1 1 0 1Ext. auto CM 1 0 1 0 1 1 1 0 1 1 1 0Ret. auto CM 0 1 1 0 1 0 1 0 1 1 0 1Ext. auto OM 1 0 1 1 0 1 1 1 0 1 1 0Ret. auto OM 0 1 1 1 0 0 1 1 0 1 0 1
Ext. manual IM 1 0 0 0 0 0 0 1 1 0 1 0Ret. manual IM 0 1 0 0 0 0 0 1 1 0 0 1Ext. manual CM 1 0 0 0 0 0 1 0 1 0 1 0Ret. manual CM 0 1 0 0 0 0 1 0 1 0 0 1Ext. manual OM 1 0 0 0 0 0 1 1 0 0 1 0Ret.manual OM 0 1 0 0 0 0 1 1 0 0 0 1
neutral 0 0 0 0 0 0 0 0 0 0 0 0
2.31
DS350 GRAPHIC (BCS)
Boom sequence TMS/TTS 870, RT 865 BXL Main Boom
Mode IM % CM % OM % FLY %AUTO B 0 0 0 0AUTO B 50 0 0 0AUTO B 50 50 0 0AUTO B 75 50 0 0AUTO B 75 75 0 0AUTO B 100 75 0 0AUTO B 100 100 0 0AUTO B 100 100 100 100
AUTO A 0 0 0 0AUTO A 0 100 0 0AUTO A 0 100 100 100AUTO A 100 100 100 100
Boom sequence TMS/TTS 870, RT 865 BXL, TM 9100 AND TM9150 boom extensions
Mode IM % CM % OM % FLY %AUTO 100 0 0 0AUTO 100 100 0 0AUTO 100 100 100 100
2.32
PAT DS350 Graphic (BCS) NOTES1. Tolerance on boom lengths is 3 % before the PAT system recognizes the boom as being out of
sequence.2. Total time between boom section change over that boom sections actually stop moving is two
seconds.
3. Ramping down begins at 10 % prior to change over boom length.
4. Ramping value of 255 is a Pat calibration number, which also equates to 800 milliamps.
5. 800 milliamps at the Proportional coils results in full pilot flow to valve.
6. Wire 239 to the Proportional coils is ground, but must never be grounded to crane ground, as it is alsoan analog signal to the PAT as well.
7. E-07 error code is generated from voltage noise created across the extend and retract pressuresswitches. Suppression diodes have been installed from input to ground(# 38 to # 37 ) to clip the spikes.
8. Resistance of a good proportional coil is 20 ohms, + or - 2 ohms.
9. 4 proximity switches located on left side of boom indicate to the PAT that boom sections are fullyretracted, at which time the PAT will automatically reset the retracted boom length percentage asshown:
OM / Fly 0 % Mid 0 % IM 1 % IM 0 % ( with boom stop pulled down )
10. Pilot pressure switch signal / Analog output signalTwo pressure switches (1-extend & 1-retract) wired through crane interface connector.Extending the boom: Pressure switch signal changes from 0V to +24V, electrical flows to extend.Min. current =0mA, max. current=800mA(measure coil current while extending, meter in serieswire #20 & A 104 X1-63.Retracting the boom: Pressure switch signal changes from 0V to +24V, electrical flows toretract. Min. current =0mA, max. current=800mA(measure coil current while retracting, meter inseries wire #21 & A 104 X1-64.
11. If the PAT will not permit loads to be picked off the first column of the load chart , the problem islikely to be:
a. the inner mid is between fully retracted with the stops out, and fully retracted with the stops in.or
b. the inner mid proximity switches are out of adjustment.
2.33
HELPFUL HINTS
CHECKING THE COILS IN THE TWO WAY VALVES FOR CONTINUITY
1. Select manual mode
2. Select individual sections to operate.
3. If there is continuity in the wiring to the valve, the section lights will illuminate.
CHECKING THE BOOM LENGTH SIGNALS
Three length sensors are located on the side of the boom ,(Overall length, Inner Mid &
Center Mid) the software utilizes the signals to calculate the outer mid & fly section
length.
Disengage the boom stop, retract the boom:
Overall boom length signal -500mV (A 104 X1-10 using MP 15 or X1-8 GND)
Inner Mid length signal -500mV (A 104 X1-24 using same GND)
Center Mid length signal -500mV (A 104 X1-73 using same GND)
CHECKING PROXIMITY SWITCH INPUTS
Four proximity switches are used to tell the system if all sections are fully retracted.
Inner mid retract & percentage reset switch:Reset proximity switch provides +24V signal to A 104 X1-80 when retracted againstboom stop.Center mid retract & percentage reset switch:Reset proximity switch provides +24V signal to A 114 or A 112 X1-9.Outer mid / fly retract & percentage reset switch:Reset proximity switch provides +24V signal to A 104 X1-76.Retract proximity switch provides a +24V signal to A 104 X1-78 when boom stop is disengage.
2.34
P.A.T. – L.M.IMANUAL
SECTION 3
DS 350 GRAPHIC BCSBOOM LENGTH CONNECTIONS
& WIRING DIAGRAMS
.o.
8079787776757473727170696867666564636261605958575655545352515049
4321
X40(UB)
+UB
GND
LEN.(OA)
ANGLE
+5V
-5VGND
-5V
GND
-5V
+5V
-SIG
-SIGGND
-SIG-5V+9V-9V
-SIG+SIG
UBTXDRXD0 (UB)
SIG0-SIG
0 (UB)A2B
COMPARATOR
DE 1
DE 2
DE 3UB UB
o oo.o oo
K8
K9 0 (UB)
ooo
K10
K10
8586
8787A 30
ooo
F2
87A87
30 85
86K1= NOT USED
ooo
F3
87A87
30 85
86K2 = IM 2 - WAY
ooo
F4
87A87
30 85
86K3 = ROD
DRAIN SOL.
ooo
F5
87A87
30 85
86K4 = TELE OUT
OF SEQ.
ooo
F6
87A87
30 85
86K5 = 4 - WAY
DIREC. VALVE
ooo
F7
87A87
30 85
86K6 = CM 2 - WAY
ooo
F8
87A87
30 85
86K7 = OM / FLY
- 2 WAY
GND
-SIG-5V
DE 4
DE 5
DE 6
4847464544434241403938373635343332313029282726252423
22212019181716151413121110987654321
))))
0 (UB) / GND+24 V
PRESS. SW.BOOM EXT.
PRESS. SW.BOOM RET.
AUTO MODESW. ON
OM / FLYRET. / % SW.
CM / IM RET. SW.
LENGTHRESET SW.
1
32
3.1
DS350 GraphicBoom Length to C.P.U.
Connections
3
7
6
5
4
8
9
2
1
10
LG
17 18
R.F.FILTERS
PIN 1 & 5 = GNDPIN 3 & 6 = -5VPIN 2 = LENGTH SIGNAL
LG 208 CABLE REEL(TO NOSE)
1
2
3
1 2 3 4
1
23
AB
4.7K 12
CORESHIELD
BOOM LENGTH SIGNALRETRACTED = -0.500VMAX RANGE = -4.5V
* NOTE - MAX LENGTH SIGNALVARIES WITH BOOMMAX VOLTAGE - 4.5V ISFOR 10 TURNS ON POT.
5
6
1
2
3
1 1 A 1
2 3 B 2
3 4 C 3
5 7 E 5
6 8 F 6
Boom BaseJunction Box
56
TERMINALS :1-2 & 4-5ARE JUMPTOGETHER
.o.
8079787776757473727170696867666564636261605958575655545352515049
4321
X40(UB)
+UB
GND
LEN.(OA)
ANGLE
+5V
-5VGND
-5V
GND
-5V
+5V
-SIG
-SIGGND
-SIG-5V+9V-9V
-SIG+SIG
UBTXDRXD0 (UB)
SIG0-SIG
0 (UB)A2B
COMPARATOR
DE 1
DE 2
DE 3UB UB
o oo.o oo
K8
K9 0 (UB)
ooo
K10
K10
8586
8787A 30
ooo
F2
87A87
30 85
86K1= NOT USED
ooo
F3
87A87
30 85
86K2 = IM 2 - WAY
ooo
F4
87A87
30 85
86K3 = ROD
DRAIN SOL.
ooo
F5
87A87
30 85
86K4 = TELE OUT
OF SEQ.
ooo
F6
87A87
30 85
86K5 = 4 - WAY
DIREC. VALVE
ooo
F7
87A87
30 85
86K6 = CM 2 - WAY
ooo
F8
87A87
30 85
86K7 = OM / FLY
- 2 WAY
GND
-SIG-5V
DE 4
DE 5
DE 6
4847464544434241403938373635343332313029282726252423
22212019181716151413121110987654321
))))
0 (UB) / GND+24 V
PRESS. SW.BOOM EXT.
PRESS. SW.BOOM RET.
AUTO MODESW. ON
OM / FLYRET. / % SW.
CM / IM RET. SW.
LENGTHRESET SW.
3
7
6
5
4
8
9
2
1
10
LG
WG
PIN 1 & 5 = GNDPIN 3 & 6 = -5VPIN 2 = LENGTH SIGNALPIN 4 = ANGLE SIGNAL
LWG 221 CABLE REEL(TO CM)
BOOM LENGTH SIGNALRETRACTED = -0.500VMAX RANGE = -4.5V
ANGLE SIGNAL0 DEG. = -3.125V45 DEG. = -2.50V90 DEG. = -1.875V
* NOTE - MAX LENGTH SIGNALVARIES WITH BOOMMAX VOLTAGE - 4.5V ISFOR 10 TURNS ON POT.
14
3
3.2
DS350 GraphicBoom Length to C.P.U.
Connections
13
17
16
15
14
18
19
12
11
20
13
3
2
1
Boom BaseJunction Box
1 2 A 1
2 10 H 8
3 5 C 3
13 6 D 4
TERMINALS :1-2 & 4-5ARE JUMPTOGETHER
8
TERMINALS FORPROX. SWITCHESSEE PG. 12.1-12.4
.o.
8079787776757473727170696867666564636261605958575655545352515049
4321
X40(UB)
+UB
GND
LEN.(OA)
ANGLE
+5V
-5VGND
-5V
GND
-5V
+5V
-SIG
-SIGGND
-SIG-5V+9V-9V
-SIG+SIG
UBTXDRXD0 (UB)
SIG0-SIG
0 (UB)A2B
COMPARATOR
DE 1
DE 2
DE 3UB UB
o oo.o oo
K8
K9 0 (UB)
ooo
K10
K10
8586
8787A 30
ooo
F2
87A87
30 85
86K1= NOT USED
ooo
F3
87A87
30 85
86K2 = IM 2 - WAY
ooo
F4
87A87
30 85
86K3 = ROD
DRAIN SOL.
ooo
F5
87A87
30 85
86K4 = TELE OUT
OF SEQ.
ooo
F6
87A87
30 85
86K5 = 4 - WAY
DIREC. VALVE
ooo
F7
87A87
30 85
86K6 = CM 2 - WAY
ooo
F8
87A87
30 85
86K7 = OM / FLY
- 2 WAY
GND
-SIG-5V
DE 4
DE 5
DE 6
4847464544434241403938373635343332313029282726252423
22212019181716151413121110987654321
))))
0 (UB) / GND+24 V
PRESS. SW.BOOM EXT.
PRESS. SW.BOOM RET.
AUTO MODESW. ON
OM / FLYRET. / % SW.
CM / IM RET. SW.
LENGTHRESET SW.
1
3
3.3
DS350 GraphicBoom Length to C.P.U.
Connections
3
7
6
5
4
8
9
2
1
10
LG
PIN 1 & 5 = GNDPIN 3 & 6 = -5VPIN 2 = LENGTH SIGNAL
LG 221 CABLE REEL(TO IM)
BOOM LENGTH SIGNALRETRACTED = -0.500VMAX RANGE = -4.5V
* NOTE - MAX LENGTH SIGNALVARIES WITH BOOMMAX VOLTAGE - 4.5V ISFOR 10 TURNS ON POT.
13
17
16
15
14
18
19
12
11
20
3
2
1
Boom BaseJunction Box
TERMINALS :1-2 & 4-5ARE JUMPTOGETHER
TERMINALS FORPROX. SWITCHESSEE PG. 12.1-12.4
1 2 A 1
2 9 G 7
3 5 C 3
7
NO
. OF
TUR
NS
NO
. OF
TUR
NS
"IN
PUT
" SI
GN
AL
AT
"OU
TPU
T" S
IGN
AL
AT
ON
CA
BLE
REE
LO
N L
EN
GT
H P
OT
.T
ERM
. X1-
10 IN
C.U
.M
P 6
TEST
PO
INT
ON
M
AIN
BO
AR
D IN
C.U
.0
0-0
.5V
0.5V
31
-0.9
V0.
9V6
2-1
.30V
1.30
V9
3-1
.70V
1.70
V12
4-2
.10V
2.10
V15
5-2
.50V
2.50
V18
6-2
.90V
2.90
V21
7-3
.30V
3.30
V24
8-3
.70V
3.70
V27
9-4
.10V
4.10
V30
10-4
.50V
4.50
V
PAT
DS3
50G
raph
ic(B
CS)
MA
IN B
OO
M L
EN
GT
H S
IGN
AL
VO
LT
AG
E
(3 T
UR
NS
OF
CA
BLE
REE
L =
1 TU
RN
OF
LEN
GTH
PO
T. =
0.4
V)
CH
AR
T SH
OW
S TY
PIC
AL
VO
LTA
GE
SIG
NA
LS.
THES
E V
OLT
AG
ES A
RE
TO B
E U
SED
AS
A R
EFER
ENC
E O
NLY
, TH
E A
CTU
AL
SIG
NA
L M
AY
VA
RY
SLI
GH
TLY
.FO
R S
PEC
IFIC
BO
OM
LEN
GTH
VO
LTA
GES
, CH
ECK
VO
LTA
GES
AT
MP
6 O
R X
1-10
AN
D C
OM
PAR
E W
ITH
TEST
DA
TA IN
CEN
TRA
L U
NIT
.
CH
ANNE
L #
1
3.4
2 2 10
81 1X1
AMP
3 3 11X1
CABLE REELASS’Y
3 : 1 RATIO
ZERO ADJUSTMENTRETRACTED BOOM - 500MV (-.500V)
“MINIMUM SIGNAL”(RETRACTED BOOM)
- 4.50V“MAXIMUM SIGNAL”
(10 TURNS ON POT)
FIXEDRESISTOR
FIXEDRESISTOR
LENGTH SENSOR10 K /10 TURNSΩ
CABLE REEL TERMINAL
X1CENTRAL UNIT
TERMINAL BOARD
# WIRE NUMBER
TEST POINT ON MAIN BOARD
MP 6TEST POINT
TO A/DCONVERTER
0.0V(GND)
-5V
MP 6 VOLTAGES+ 500MV (.500V) = MIN. SIGNAL
(RETRACTED BOOM)
+4.50V = MAX. SIGNAL(10 TURNS ON POT)
ALL VOLTAGES ARE MEASURED WITHREFERENCE TO GND (TERMINAL X1-8 ON “A104”OR MP 15
ON MAIN BOARD).
P.A.T. DS350 Graphic (BCS) BOOM LENGTH MEASURING CHANNEL
CHANNEL # 1
WORKINGRANGE
E 11
E 21
ERRORCODE
ERRORCODE
.0V
.500V MIN.
4.50V MAX.
5.0V
CH. #1OPERATING
WINDOW
0123456789
10
PRELOAD SPRING 30 REVOLUTIONS
COUNTERCLOCKWISE(CENTER REEL)3.5
1 2 3 4 5 6 7 8 9 10111213 1415 16
-5.00-0.50
LENGTH MEASUREMENT:
CABLE REEL W/VOLTMETER ON 1 & 2 W/VOLTMETER ON 1 & 3 WITH THE BOOM FULLY RETRACTED THE VOLTMETER SHOULD MEASURE -0.50 VOLTS BETWEEN CONNECTIONS 1 (GND) AND 2 (SIGNAL VOLTAGE).
VOLTMTER SHOULD MEASURE -5.0 VOLTS BETWEEN CONNECTIONS 1 (GND) AND 3 (SUPPLY VOLTAGE).
3.6
PATPAT
1 2 3 4 5 6 7 8 9 101112 131415 16
ADJUST TOP OF ANGLE SENSORPARALLEL WITH BOOM.
ADJUST LENGTH POTENIOMETERWITH BOOM FULLY RETRACTED,TURN THE CENTER SCREW COUNTER-CLOCKWISE TO A SOFT STOP.
3.7
LENGTH MEASUREMENT:
CONNECTION BOARD W/VOLTMETER ON X1:8 & X1:11
VOLTMETER SHOULD MEASURE -5.0 VOLTS BETWEEN CONNECTIONSX1 - 8 (NEGATIVE) AND X1 - 11 (POSITIVE).
1 3 5
2 4 6
7 9 11 13 15 17 19 21 23 25 27 29
8 10 12 14 16 18 20 22 24 26 2871 72 73 74
49 48 47
59 58 57 56 55 54 53 52 51 50
46 45 44
70 69 68 67 66 65 64 63 62 61 60
80 79 78 77 76 75 43 42 41 40 39 38 37 36 35 34 33 32 31 30
K10LEVER
LOCKOUT K6 K5 K3 K2
K7 K4 K1
K9 K8LMISHUTOFF
A2BSHUTOFF1 2 3 4
X3
X4
F1
F8 F7 F6 F5 F4 F3 F2
R13 R14 R11 R12 R7 R8 R5 R6
R15 R16 R9 R10 R3 R4
R2 R1
X4
H9
V2
H8
V1
X1 X1
X1
X1
X1
X1
X1X1
X1
X1
H7
V11
H4
V8
H1
V5
H6
V10
H5
V9
H3
V7
H2
V6
H10 V3
R17R18
OU
TER
MID
OU
T O
FSE
QU
ENC
E
CEN
TER
MID
4 - W
AY
RO
D
DR
AIN
INN
ERM
ID
OM CM 4W SEQ
ROD
IM
-5.00
3.8
LENGTH MEASUREMENT:
CONNECTION BOARD W/VOLTMETER ON X1:8 & X1:10
WITH BOOM FULLY RETRACTED THEVOLTMETER SHOULD MEASURE -0.50 VOLTS BETWEEN CONNECTIONS X1 - 8 (NEGATIVE) AND X1 - 10 (POSITIVE).
1 3 5
2 4 6
7 9 11 13 15 17 19 21 23 25 27 29
8 10 12 14 16 18 20 22 24 26 2871 72 73 74
49 48 47
59 58 57 56 55 54 53 52 51 50
46 45 44
70 69 68 67 66 65 64 63 62 61 60
80 79 78 77 76 75 43 42 41 40 39 38 37 36 35 34 33 32 31 30
K10LEVER
LOCKOUT K6 K5 K3 K2
K7 K4 K1
K9 K8LMISHUTOFF
A2BSHUTOFF1 2 3 4
X3
X4
F1
F8 F7 F6 F5 F4 F3 F2
R13 R14 R11 R12 R7 R8 R5 R6
R15 R16 R9 R10 R3 R4
R2 R1
X4
H9
V2
H8
V1
X1 X1
X1
X1
X1
X1
X1X1
X1
X1
H7
V11
H4
V8
H1
V5
H6
V10
H5
V9
H3
V7
H2
V6
H10 V3
R17R18
OU
TER
MID
OU
T O
FSE
QU
ENC
E
CEN
TER
MID
4 - W
AY
RO
D
DR
AIN
INN
ERM
ID
OM CM 4W SEQ
ROD
IM
-0.50
3.9
P.A.T. – L.M.IMANUAL
SECTION 4
DS 350 GRAPHIC BCSPISTON, ROD
CONNECTIONS &WIRING DIAGRAMS
.o.
8079787776757473727170696867666564636261605958575655545352515049
4321
X40(UB)
+UB
GND
LEN.(OA)
ANGLE
+5V
-5VGND
-5V
GND
-5V
+5V
-SIG
-SIGGND
-SIG-5V+9V-9V
-SIG+SIG
UBTXDRXD0 (UB)
SIG0-SIG
0 (UB)A2B
COMPARATOR
DE 1
DE 2
DE 3UB UB
o oo.o oo
K8
K9 0 (UB)
ooo
K10
K10
8586
8787A 30
ooo
F2
87A87
30 85
86K1= NOT USED
ooo
F3
87A87
30 85
86K2 = IM 2 - WAY
ooo
F4
87A87
30 85
86K3 = ROD
DRAIN SOL.
ooo
F5
87A87
30 85
86K4 = TELE OUT
OF SEQ.
ooo
F6
87A87
30 85
86K5 = 4 - WAY
DIREC. VALVE
ooo
F7
87A87
30 85
86K6 = CM 2 - WAY
ooo
F8
87A87
30 85
86K7 = OM / FLY
- 2 WAY
GND
-SIG-5V
DE 4
DE 5
DE 6
4847464544434241403938373635343332313029282726252423
22212019181716151413121110987654321
))))
0 (UB) / GND+24 V
PRESS. SW.BOOM EXT.
PRESS. SW.BOOM RET.
AUTO MODESW. ON
OM / FLYRET. / % SW.
CM / IM RET. SW.
LENGTHRESET SW.
oo
oo
14
13
4.1
DS350 GraphicPiston Pressure
Transducer to C.P.U.Connections
DAVS
D
C
B
A
4
3
2
1
PRESSURE TRANSDUCERPISTON SIDE
1234
PAT
DS3
50G
raph
ic (B
CS)
PIST
ON
PR
ESS
UR
ETR
AN
SDU
CE
RV
OL
TA
GE
SIG
NA
LS
PRE
SSU
RE
"IN
PUT"
SIG
NA
L A
T
"OU
TPU
T"
SIG
NA
L A
T M
P 4
(P.S
.I.)
TER
M. X
1-21
IN
TEST
PO
INT
ON
MA
INC
EN
TRA
L U
NIT
BOA
RD
IN C
.U.
00
MV
.0.
5 V
.14
5-3
3.3
MV
.0.
63 V
.29
0-6
6.6
MV
.0.
77 V
.43
5-9
9.9
MV
.0.
89 V
.58
0-1
33.3
MV
.1.
03 V
.72
5-1
66.6
MV
.1.
17 V
.87
0-1
99.9
MV
.1.
29 V
.10
15-2
33.2
MV
.1.
43 V
.11
60-2
66.6
MV
.1.
53 V
.13
05-2
99.9
MV
.1.
69 V
.14
50-3
33.2
MV
.1.
83 V
.15
95-3
66.5
MV
.1.
97 V
.17
40-3
99.9
MV
.2.
09 V
.18
85-4
33.2
MV
.2.
23 V
.20
30-4
66.5
MV
.2.
36 V
.21
75-4
99.8
MV
.2.
49 V
.23
20-5
33.1
MV
.2.
63 V
.24
65-5
66.5
MV
.2.
76 V
.26
10-5
99.8
MV
.2.
89 V
.27
55-6
33.1
MV
.3.
03 V
.29
00-6
66.4
MV
.3.
16 V
.30
45-6
99.7
MV
.3.
29 V
.31
90-7
33.1
MV
.3.
43 V
.33
35-7
66.4
MV
.3.
56 V
.34
80-7
99.7
MV
.3.
69 V
.36
25-8
33.1
MV
.3.
83 V
.37
70-8
66.3
MV
.3.
96 V
.39
15-8
99.7
MV
.4.
09 V
.40
60-9
32.9
MV
.4.
23 V
.42
05-9
66.3
MV
.4.
36 V
.43
50-9
99.9
MV
.4.
50 V
.
CH
AR
T SH
OW
S TY
PIC
AL
VO
LTA
GE
SIG
NA
LS.
THES
E V
OLT
AG
ES A
RE
TO B
E U
SED
AS
A
REF
EREN
CE
ON
LY, T
HE
AC
TUA
L SI
GN
AL
MA
Y V
AR
Y S
LIG
HTL
Y.
CH
ANNE
L #
2
4.2
P.A.
T. D
S350
Gra
phic
(BCS
)PI
STO
N P
RESS
URE
MEA
SURI
NG
CH
ANN
EL
CHAN
NEL
# 2W
ORK
ING
RA
NG
E
E 12
E 22
ERR
OR
CO
DE
ERR
OR
CO
DE
.0V
.500
V M
IN.
4.50
V M
AX
.
5.0V
CH
. #2
OPE
RA
TIN
G
WIN
DO
W
DA
VS
301
A BCD
300
BA
R M
AX
.(4
410
PSI)
PRES
SUR
E TR
AN
SDU
CER
(PIS
TON
SID
E)
19
20
21
18
4 3 21
OU
TPU
T SI
GN
AL
:ZE
RO P
RESS
UR
E =
0.00
0VM
AX
. PR
ESSU
RE
= -1
.0V
(+ /
- 25
MV
)
AM
P
P4P4
ZER
O P
OIN
TA
DJU
STM
ENT
MP
4TE
ST P
OIN
T
TO A
/DC
ON
VER
TER
MP
4 V
OLT
AG
ES+
500M
V (.
500V
) = M
IN. S
IGN
AL
(ZER
O P
RES
SUR
E)
+4.5
0V =
MA
X. S
IGN
AL
(300
BA
R P
RES
SUR
E)A
LL V
OLT
AG
ES A
RE
MEA
SUR
ED W
ITH
REF
EREN
CE
TO G
ND
(TER
MIN
AL
X1-
19 “
A10
4” O
R M
P 15
ON
MA
IN B
OA
RD
.)
- 5.0
V
0.0V
(GN
D)
+ 5.
0V
~PR
ESSU
REFR
OM
PIS
TON
SID
EO
F LI
FT C
YLI
ND
ERS
X1
CEN
TRA
L U
NIT
TE
RM
INA
L B
OA
RD
#W
IRE
NU
MB
ER
TEST
PO
INT
ON
MA
IN B
OA
RD
X1
X1
4.3
PISTON TRANSDUCER MEASUREMENT:
CONNECTION BOARD W/VOLTMETER ON X1:18 & X1:19 W/VOLTMETER ON X1:20 & X1:19
VOLTMETER SHOULD MEASURE +5.0 VOLTS BETWEEN CONNECTIONSX1:18 (+5.0V) & X1: 19 (GROUND)
VOLTMETER SHOULD MEASURE -5.0 VOLTS BETWEEN CONNECTIONSX1:20 (-5.0V) & X1: 19 (GROUND)
4.4
-5.00
1 3 5
2 4 6
7 9 11 13 15 17 19 21 23 25 27 29
8 10 12 14 16 18 20 22 24 26 2871 72 73 74
K10LEVER
LOCKOUT
K9 K8LMISHUTOFF
A2BSHUTOFF
F1
H9
V2
H8
V1
X1 X1
X1
X1
H4
V8
H1
V5
H10 V3
R17R18
OU
T O
FSE
QU
ENC
E
+5.00
P.A.T. DS350Graphic
E12 ERROR CODE
The following step - by - step procedures, with illustrations,are designed to assist in eliminating error code E12. Sincevarious problems can cause an E12, these procedures willcheck out the complete piston pressure transducer system.
4.5
1 3 5
2 4 6
7 9 11 13 15 17 19 21 23 25 27 29
8 10 12 14 16 18 20 22 24 26 2871 72 73 74
K10LEVER
LOCKOUT
K9 K8LMISHUTOFF
A2BSHUTOFF
F1
R2 R1
H9
V2
H8
V1
X1 X1
X1 X1
X1
H4
V8
H1
V5
H5
V9
H3
V7
H2
V6
H10 V3
R17R18
OU
T O
FSE
QU
EN
CE
4 - W
AY
RO
D
DR
AIN
INN
ER
MID
.000
PISTON PRESSURE TRANSDUCEROUTPUT SIGNAL = .000 VOLT+/- .025V AT ZERO HYDRAULICPRESSURE.
TERMINAL BOARDERROR CODE 12, DRAWING #1
1. LOWER BOOM ALL THE WAY DOWN, SHUT OFF ENGINE. DISCONNECTHYDRAULIC HOSE FROM LIFT CYLINDER TO THE PISTON SIDEPRESSURE TRANSDUCER SO THAT NO HYDRAULIC PRESSURE IS APPLIEDTO TRANSDUCER.
2. CONNECT A DIGITAL VOLTMETER NEGATIVE (-) LEAD TO X1 - 19 ANDPOSITIVE (+) LEAD TO X1 - 21 ON TERMINAL BOARD IN THE P.A.T. CENTRALUNIT VOLTAGE SHOULD BE .000 VOLT +/- .025 VOLT. THIS IS THE OUTPUT SIGNAL FOR THE PISTON PRESSURE TRANSDUCER. RECORD THIS VOLTAGE VDC.
4.6
4.7
1 3 5
2 4 6
7 9 11 13 15 17 19 21 23 25 27 29
8 10 12 14 16 18 20 22 24 26 2871 72 73 74
K10LEVER
LOCKOUT
K9 K8LMISHUTOFF
A2BSHUTOFF
F1
R2 R1
H9
V2
H8
V1
X1 X1
X1 X1
X1
H4
V8
H1
V5
H5
V9
H3
V7
H2
V6
H10 V3
R17R18
OU
T O
FSE
QU
EN
CE
4 - W
AY
RO
D
DR
AIN
INN
ER
MID
DISCONNECTFROM X1 - 21
JUMPER WIRE
TERMINAL BOARDERROR CODE 12, DRAWING #3
5. IF UNABLE TO ADJUST VOLTAGE AT “MP4” TO .500V (500MV) WITH POT“P4”, DISCONNECT THE SIGNAL WIRE FROM TERMINAL X1 - 21 ON TERMINAL BOARD AND CONNECT A JUMPER WIRE BETWEEN TERMINALX1 - 21 AND X1 - 19.
6. TRY READJUSTING POT “P4” FOR .500V (500MV) AT “MP4” WITH JUMPER WIRE IN PLACE. IF STILL UNABLE TO ADJUST VOLTAGE THE MAIN BOARDIS DEFECTIVE. REPLACE MAIN BOARD. IF VOLTAGE CAN BE ADJUSTEDWITH JUMPER WIRE IN PLACE, PRESSURE TRANSDUCER OR CABLE IS DEFECTIVE.
4.8
C
AB
D
PRESSURE TRANSDUCER PLUGERROR CODE 12, DRAWING# 4
7. IF VOLTAGE COULD BE ADJUSTED TO .500V (500 ) MV AT TEST POINT “MP 4” IN STEP 6, REFER TO DRAWING # 4 TO CHECK THE +5 VOLT & -5 VOLT REFERENCE VOLTAGES AT PISTON PRESSURE TRANSDUCER PLUG.
CONNECT DIGITAL VOLT METER NEGATIVE (-) LEAD TO TERMINAL B. CONNECT POSITIVE (+) LEAD TO TERMINAL A, VOLTAGE SHOULD BE +5.00 VDC. CONNECT POSITIVE (+) LEAD TO TERMINAL C, VOLTAGE SHOULD BE -5.00 VDC. IF INCORRECT CHECK CABLE CONNECTIONS IN CENTRAL UNIT AND CHECK CABLE FOR DEFECTS. IF CORRECT REPLACE PRESSURE TRANSDUCER.
. .
4.9
.o.
8079787776757473727170696867666564636261605958575655545352515049
4321
X40(UB)
+UB
GND
LEN.(OA)
ANGLE
+5V
-5VGND
-5V
GND
-5V
+5V
-SIG
-SIGGND
-SIG-5V+9V-9V
-SIG+SIG
UBTXDRXD0 (UB)
SIG0-SIG
0 (UB)A2B
COMPARATOR
DE 1
DE 2
DE 3UB UB
o oo.o oo
K8
K9 0 (UB)
ooo
K10
K10
8586
8787A 30
ooo
F2
87A87
30 85
86K1= NOT USED
ooo
F3
87A87
30 85
86K2 = IM 2 - WAY
ooo
F4
87A87
30 85
86K3 = ROD
DRAIN SOL.
ooo
F5
87A87
30 85
86K4 = TELE OUT
OF SEQ.
ooo
F6
87A87
30 85
86K5 = 4 - WAY
DIREC. VALVE
ooo
F7
87A87
30 85
86K6 = CM 2 - WAY
ooo
F8
87A87
30 85
86K7 = OM / FLY
- 2 WAY
GND
-SIG-5V
DE 4
DE 5
DE 6
4847464544434241403938373635343332313029282726252423
22212019181716151413121110987654321
))))
0 (UB) / GND+24 V
PRESS. SW.BOOM EXT.
PRESS. SW.BOOM RET.
AUTO MODESW. ON
OM / FLYRET. / % SW.
CM / IM RET. SW.
LENGTHRESET SW.
oo
oo
14
13
4.10
DS350 GraphicRod Pressure
Transducer to C.P.U.Connections
DAVS
D
C
B
A
4
3
2
1
PRESSURE TRANSDUCERROD SIDE
1234
PRES
SUR
E"I
NPU
T" S
IGN
AL
AT
"O
UTP
UT
" SI
GN
AL
AT
MP
5(P
.S.I.
)TE
RM
. X1-
16 IN
TE
ST P
OIN
T O
N M
AIN
CE
NT
RA
L U
NIT
BOA
RD
IN C
.U.
00
MV
.0.
5 V
.14
5-3
3.3
MV
.0.
63 V
.29
0-6
6.6
MV
.0.
77 V
.43
5-9
9.9
MV
.0.
89 V
.58
0-1
33.3
MV
.1.
03 V
.72
5-1
66.6
MV
.1.
17 V
.87
0-1
99.9
MV
.1.
29 V
.10
15-2
33.2
MV
.1.
43 V
.11
60-2
66.6
MV
.1.
53 V
.13
05-2
99.9
MV
.1.
69 V
.14
50-3
33.2
MV
.1.
83 V
.15
95-3
66.5
MV
.1.
97 V
.17
40-3
99.9
MV
.2.
09 V
.18
85-4
33.2
MV
.2.
23 V
.20
30-4
66.5
MV
.2.
36 V
.21
75-4
99.8
MV
.2.
49 V
.23
20-5
33.1
MV
.2.
63 V
.24
65-5
66.5
MV
.2.
76 V
.26
10-5
99.8
MV
.2.
89 V
.27
55-6
33.1
MV
.3.
03 V
.29
00-6
66.4
MV
.3.
16 V
.30
45-6
99.7
MV
.3.
29 V
.31
90-7
33.1
MV
.3.
43 V
.33
35-7
66.4
MV
.3.
56 V
.34
80-7
99.7
MV
.3.
69 V
.36
25-8
33.1
MV
.3.
83 V
.37
70-8
66.3
MV
.3.
96 V
.39
15-8
99.7
MV
.4.
09 V
.40
60-9
32.9
MV
.4.
23 V
.42
05-9
66.3
MV
.4.
36 V
.43
50-9
99.9
MV
.4.
50 V
.
PAT
DS3
50G
raph
ic (B
CS)
RO
D P
RES
SUR
ETR
AN
SDU
CE
RV
OL
TA
GE
SIG
NA
LS
CH
AR
T SH
OW
S TY
PIC
AL
VO
LTA
GE
SIG
NA
LS.
THES
E V
OLT
AG
ES A
RE
TO B
E U
SED
AS
A
REF
EREN
CE
ON
LY, T
HE
AC
TUA
L SI
GN
AL
MA
Y V
AR
Y S
LIG
HTL
Y.
CH
ANNE
L #
3
4.11
P.A.
T. D
S350
Gra
phic
(BCS
)RO
D P
RESS
URE
MEA
SURI
NG
CH
ANN
ELCH
ANN
EL #
3WO
RKIN
GR
AN
GE
E 13
E 23
ERR
OR
CO
DE
ERR
OR
CO
DE
.0V
.500
V M
IN.
4.50
V M
AX
.
5.0V
CH
. #3
OPE
RA
TIN
G
WIN
DO
W
DA
VS
301
A BCD
300
BA
R M
AX
.(4
410
PSI)
PRES
SUR
E TR
AN
SDU
CER
(RO
D S
IDE)
14
15
16
13
4 3 21
OU
TPU
T SI
GN
AL
:ZE
RO P
RESS
UR
E =
0.00
0VM
AX
. PR
ESSU
RE
= -1
.0V
(+ /
- 25
MV
)
AM
P
P5P5
ZER
O P
OIN
TA
DJU
STM
ENT
MP
5TE
ST P
OIN
T
TO A
/DC
ON
VER
TER
MP
5 V
OLT
AG
ES+
500M
V (.
500V
) = M
IN. S
IGN
AL
(ZER
O P
RES
SUR
E)
+4.5
0V =
MA
X. S
IGN
AL
(300
BA
R P
RES
SUR
E)A
LL V
OLT
AG
ES A
RE
MEA
SUR
ED W
ITH
REF
EREN
CE
TO G
ND
(TER
MIN
AL
X1-
14 “
A10
4” O
R M
P 15
)O
N M
AIN
BO
AR
D.
- 5.0
V
0.0V
(GN
D)
+ 5.
0V
~PR
ESSU
REFR
OM
RO
D S
IDE
OF
LIFT
CY
LIN
DER
S
X1
CEN
TRA
L U
NIT
TE
RM
INA
L B
OA
RD
#W
IRE
NU
MB
ER
TEST
PO
INT
ON
MA
IN B
OA
RD
X1
X1
4.12
ROD TRANSDUCER MEASUREMENT:
CONNECTION BOARD W/VOLTMETER ON X1:13 & X1:14 W/VOLTMETER ON X1:15 & X1:14
VOLTMETER SHOULD MEASURE +5.0 VOLTS BETWEEN CONNECTIOSX1:13 (+5.0V) & X1: 14 (GROUND)
VOLTMETER SHOULD MEASURE -5.0 VOLTS BETWEEN CONNECTIOSX1:15 (-5.0V) & X1: 14 (GROUND)
-5.001 3 5
2 4 6
7 9 11 13 15 17 19 21 23 25 27 29
8 10 12 14 16 18 20 22 24 26 2871 72 73 74
K10LEVER
LOCKOUT
K9 K8LMISHUTOFF
A2BSHUTOFF
F1
H9
V2
H8
V1
X1 X1
X1
X1
H4
V8
H1
V5
H10 V3
R17R18
OU
T O
FSE
QU
ENC
E
+5.00
4.13
P.A.T. DS350Graphic
E13 ERROR CODE
The following step - by - step procedures, with illustrations,are designed to assist in eliminating error code E13. Sincevarious problems can cause an E13, these procedures willcheck out the complete rod pressure transducer system.
4.14
1 3 5
2 4 6
7 9 11 13 15 17 19 21 23 25 27 29
8 10 12 14 16 18 20 22 24 26 2871 72 73 74
K10LEVER
LOCKOUT
K9 K8LMISHUTOFF
A2BSHUTOFF
F1
R2 R1
H9
V2
H8
V1
X1 X1
X1 X1
X1
H4
V8
H1
V5
H5
V9
H3
V7
H2
V6
H10 V3
R17R18
OU
T O
FSE
QU
EN
CE
4 - W
AY
RO
D
DR
AIN
INN
ER
MID
TERMINAL BOARDERROR CODE 13, DRAWING #1
1. LOWER BOOM ALL THE WAY DOWN, SHUT OFF ENGINE. DISCONNECTHYDRAULIC HOSE FROM LIFT CYLINDER TO THE ROD SIDEPRESSURE TRANSDUCER SO THAT NO HYDRAULIC PRESSURE IS APPLIEDTO TRANSDUCER.
2. CONNECT A DIGITAL VOLTMETER NEGATIVE (-) LEAD TO X1 - 19 ANDPOSITIVE (+) LEAD TO X1 - 16 ON TERMINAL BOARD IN THE P.A.T. CENTRALUNIT VOLTAGE SHOULD BE .000 VOLT +/- .025 VOLT. THIS IS THE OUTPUT SIGNAL FOR THE ROD PRESSURE TRANSDUCER. RECORD THIS VOLTAGE VDC.
.000
ROD PRESSURE TRANSDUCEROUTPUT SIGNAL = .000 VOLT+/- .025V AT ZERO HYDRAULICPRESSURE.
4.15
4.16
1 3 5
2 4 6
7 9 11 13 15 17 19 21 23 25 27 29
8 10 12 14 16 18 20 22 24 26 2871 72 73 74
K10LEVER
LOCKOUT
K9 K8LMISHUTOFF
A2BSHUTOFF
F1
R2 R1
H9
V2
H8
V1
X1 X1
X1 X1
X1
H4
V8
H1
V5
H5
V9
H3
V7
H2
V6
H10 V3
R17R18
OU
T O
FSE
QU
EN
CE
4 - W
AY
RO
D
DR
AIN
INN
ER
MID
DISCONNECTFROM X1 - 16
JUMPER WIRE
TERMINAL BOARDERROR CODE 13, DRAWING #3
5. IF UNABLE TO ADJUST VOLTAGE AT “MP5” TO .500V (500MV) WITH POT“P5”, DISCONNECT THE SIGNAL WIRE FROM TERMINAL X1 - 16 ON TERMINAL BOARD AND CONNECT A JUMPER WIRE BETWEEN TERMINALX1 - 16 AND X1 - 19.
6. TRY READJUSTING POT “P5” FOR .500V (500MV) AT “MP5” WITH JUMPER WIRE IN PLACE. IF STILL UNABLE TO ADJUST VOLTAGE THE MAIN BOARDIS DEFECTIVE. REPLACE MAIN BOARD. IF VOLTAGE CAN BE ADJUSTEDWITH JUMPER WIRE IN PLACE, PRESSURE TRANSDUCER OR CABLE IS DEFECTIVE.
4.17
C
AB
D
PRESSURE TRANSDUCER PLUGERROR CODE 13, DRAWING# 4
7. IF VOLTAGE COULD BE ADJUSTED TO .500V (500 ) MV AT TEST POINT “MP 5” IN STEP 6, REFER TO DRAWING # 4 TO CHECK THE +5 VOLT & -5 VOLT REFERENCE VOLTAGES AT ROD PRESSURE TRANSDUCER PLUG.
CONNECT DIGITAL VOLT METER NEGATIVE (-) LEAD TO TERMINAL B. CONNECT POSITIVE (+) LEAD TO TERMINAL A, VOLTAGE SHOULD BE +5.00 VDC. CONNECT POSITIVE (+) LEAD TO TERMINAL C, VOLTAGE SHOULD BE -5.00 VDC. IF INCORRECT CHECK CABLE CONNECTIONS IN CENTRAL UNIT AND CHECK CABLE FOR DEFECTS. IF CORRECT REPLACE PRESSURE TRANSDUCER.
. .
4.18
P.A.T. – L.M.IMANUAL
SECTION 5
DS 350 GRAPHIC BCSBOOM ANGLE
CONNECTIONS &WIRING DIAGRAMS
.o.
8079787776757473727170696867666564636261605958575655545352515049
4321
X40(UB)
+UB
GND
LEN.(OA)
ANGLE
+5V
-5VGND
-5V
GND
-5V
+5V
-SIG
-SIGGND
-SIG-5V+9V-9V
-SIG+SIG
UBTXDRXD0 (UB)
SIG0-SIG
0 (UB)A2B
COMPARATOR
DE 1
DE 2
DE 3UB UB
o oo.o oo
K8
K9 0 (UB)
ooo
K10
K10
8586
8787A 30
ooo
F2
87A87
30 85
86K1= NOT USED
ooo
F3
87A87
30 85
86K2 = IM 2 - WAY
ooo
F4
87A87
30 85
86K3 = ROD
DRAIN SOL.
ooo
F5
87A87
30 85
86K4 = TELE OUT
OF SEQ.
ooo
F6
87A87
30 85
86K5 = 4 - WAY
DIREC. VALVE
ooo
F7
87A87
30 85
86K6 = CM 2 - WAY
ooo
F8
87A87
30 85
86K7 = OM / FLY
- 2 WAY
GND
-SIG-5V
DE 4
DE 5
DE 6
4847464544434241403938373635343332313029282726252423
22212019181716151413121110987654321
))))
0 (UB) / GND+24 V
PRESS. SW.BOOM EXT.
PRESS. SW.BOOM RET.
AUTO MODESW. ON
OM / FLYRET. / % SW.
CM / IM RET. SW.
LENGTHRESET SW.
oo
oo
14
13
3
7
6
5
4
8
9
2
1
10
LG
WG
17 18
R.F.FILTERS
PIN 1 & 5 = GNDPIN 3 & 6 = -5VPIN 2 = LENGTH SIGNALPIN 4 = ANGLE SIGNAL
CABLE REEL
1
2
3
1 2 3 4
1
23
AB
4.7K 12
CORESHIELD
BOOM LENGTH SIGNALRETRACTED = -0.500VMAX RANGE = -4.5V
ANGLE SIGNAL0 DEG. = -3.125V45 DEG. = -2.50V90 DEG. = -1.875V
* NOTE - MAX LENGTH SIGNALVARIES WITH BOOMMAX VOLTAGE - 4.5V ISFOR 10 TURNS ON POT.
14
32
5.1
DS350 GraphicBoom Angle to C.P.U.
Connections
AC
TUA
L"I
NPU
T"
SIG
NA
L A
T T
ER
M. B
"O
UT
PUT"
SIG
NA
L A
T M
P 8
BO
OM
AN
GL
EIN
CA
NN
ON
PL
UG
AN
DT
EST
POIN
T O
N M
AIN
TER
M. X
1-9
IN C
.U.
BO
AR
D IN
C.U
.90
DE
GS.
-1.8
7+.
4885
DE
GS.
-1.9
3+.
7080
DE
GS.
-2.0
0+.
9275
DE
GS.
-2.0
7+1
.15
70 D
EG
S.-2
.14
+1.3
765
DE
GS.
-2.2
1+1
.60
60 D
EG
S.-2
.28
+1.8
055
DE
GS.
-2.3
5+2
.04
50 D
EG
S.-2
.42
+2.2
645
DE
GS.
-2.4
9+2
.48
40 D
EG
S.-2
.56
+2.7
035
DE
GS.
-2.6
3+2
.92
30 D
EG
S.-2
.70
+3.1
525
DE
GS.
-2.7
7+3
.38
20 D
EG
S.-2
.84
+3.6
015
DE
GS.
-2.9
1+3
.82
10 D
EG
S.-2
.98
+4.0
45
DE
GS.
-3.0
5+4
.27
0 D
EG
S.-3
.12
+4.4
9
PAT
DS3
50G
raph
ic (B
CS)
BOO
M A
NG
LE S
IGN
AL
VO
LTA
GE
CH
AR
T S
HO
WS
TY
PIC
AL
VO
LT
AG
E S
IGN
AL
S.T
HE
SE V
OL
TA
GE
S A
RE
TO
BE
USE
D A
S A
RE
FER
EN
CE
ON
LY
, TH
E A
CT
UA
L S
IGN
AL
MA
Y V
AR
Y S
LIG
HT
LY
.
CH
ANNE
L #
5
5.2
44
9 85
1X
1
AM
P
63
11 X1
MP
8TE
ST P
OIN
T
TO A
/DC
ON
VER
TER
0.0V
(GN
D)
-5V
MP
8 V
OLT
AG
ES+
500M
V (.
500V
) = 9
0o A
NG
LE M
IN. S
IGN
AL
+ 2.
50V
= 4
5o AN
GLE
+4.5
0V =
0o A
NG
LE M
AX
. SIG
NA
LA
LL V
OLT
AG
ES A
RE
MEA
SUR
ED W
ITH
REF
EREN
CE
TO G
ND
(TER
MIN
AL
X1-
8 “A
104”
OR
MP
15O
N M
AIN
BO
AR
D.)
P.A.
T. D
S350
Gra
phic
(BCS
)BO
OM
AN
GLE
MEA
SURI
NG
CH
ANN
ELCH
ANN
EL #
5
WO
RKIN
GR
AN
GE
E 15
E 25
ERR
OR
CO
DE
ERR
OR
CO
DE
.0V
.500
V M
IN.
4.50
V M
AX
.
5.0V
CH
. #5
OPE
RA
TIN
G
WIN
DO
W
“MIN
IMU
M S
IGN
AL
”-1
.875
V =
90o A
NG
LE
“MA
XIM
UM
SIG
NA
L”
-3.1
25V
= 0
o AN
GL
E
FIX
EDR
ESIS
TOR
(PA
RT
OF
THE
AN
GLE
POTE
NTI
OM
ETER
)
CA
BLE
REE
L TE
RM
INA
L
X1
CEN
TRA
L U
NIT
TE
RM
INA
L B
OA
RD
#W
IRE
NU
MB
ER
TEST
PO
INT
ON
MA
IN B
OA
RD
FIX
EDR
ESIS
TOR
(PA
RT
OF
THE
AN
GLE
POTE
NTI
OM
ETER
)
90o
0o
AN
GLE
SEN
SOR
BO
OM
AN
GLE
SEN
SOR
PEN
DU
LUM
A D C
1 4 3
2 56
1 13 3
14 S
OC
KET
PLU
G JU
NC
TIO
N
BO
X B
OO
M B
ASE
TER
MIN
AL
STR
IP
IN J
UN
CTI
ON
BO
X
5.3
P.A.T. – L.M.IMANUAL
SECTION 6
DS 350 GRAPHIC BCSANTI - TWO - BLOCK
CONNECTIONS &WIRING DIAGRAMS
X1 49 48 47 46 3044 45 2 135 34
8 7 16
UB
+24V
810
79
87A
87
30
6 7 6 7
86
V3 85
K10
K9
K8
LM
I OV
ER
LOA
D
F2-1
0A
K9
A2B
ELEC
TRO
NIC
SV
2
OU
TPU
T
+SIG
0- S
IG
UB
+24V
X1
13 14
LMI
BY
PASS
KEY
(CU
)
RED BLU
E
VIO
LET
GR
EY
17 18
14 S
OC
KET
PLU
G
CA
BLE
REE
L
SLIP
RIN
GS
R.F
.FI
LTER
S
FRO
M
CRA
NE
SUPP
LY+2
4V
SHIE
LD
A2B
SWIT
CH
ASS
’Y
WEI
GH
TA
SS’Y
L.M
.I.
A2B
1 3 4 2 2 4 3 1
373
7 6 5 1
6
6
5
5
1
LEV
ER L
OC
KO
UT
SOL
EN
OID
VA
LV
E *
X1
CEN
TRA
L U
NIT
TER
MIN
AL
BOA
RD
- #
-W
IRE
NU
MBE
R
*SO
ME
MO
DE
LS
USE
MU
LT
IPL
E
SOLE
NO
ID V
ALV
ES.
PAT
DS3
50 G
raph
ic L
MI
ANTI
TW
O B
LOCK
&SH
UTO
FF C
KT.
1
2
3
LEN
GTH
CA
BLECO
NSO
LEB
YPA
SS K
EY
1 2
3
4
1
23
A B4.
7K1 2
CO
RE
SHIE
LD
6.1
4.701 2
DRAWING 1:
BOOM TIP JUNCTION BOX W/VOLTMETER ON 1 & 2 TURN POWER OFF OR DISCONNECT X1:35 ON CONNECTION BOARD IN CENTRAL UNIT.
MEASURE THE RESISTANCE BETWEEN TERMINALS 1 & 2.A2B SWITCH CLOSED = 4700 +/- 500 OHMSA2B SWITCH OPEN = GREATER THAN 1 MEGOHM
6.2
DRAWING 2:
TURN POWER OFF OR DISCONNECT X1:35 ON CONNECTION BOARD IN CENTRAL UNIT. MEASURE RESISTANCE BETWEEN X2:RED & X1:BROWN.
A2B SWITCH CLOSED = 4700 (+/-500) OHMSA2B SWITCH OPEN = GREATER THAN 1 MEGAOHM
4.70
X1 : BROWN
X2 : RED
X2 RED SHEILDX1 BROWN CORE
6.3
1 2 3 4 5 6 7 8 9 101112131415 16
4.70
DRAWING 3:
CABLE REEL W/VOLTMETER ON 7 & 8. TURN POWER OFF OR DISCONNECT X1:35 ON CONNECTION BOARD IN CENTRAL UNIT, MEASURE THE RESISTANCE BETWEEN TERMINALS 7 & 8.
A2B SWITCH CLOSED = 4700 (+/- 500) OHMSA2B SWITCH OPEN = GREATER THAN 1 MEGOHM
6.4
1 2 3 4 5 6 7
4.70
DRAWING 4:
BOOM BASE JUNCTION BOX W/VOLTMETER ON 5 & 6 TURN POWER OFF ORDISCONNECT X1:35 ON CONNECTION BOARD IN CENTRAL UNIT.MEASURE THE RESISTANCE BETWEEN TERMINALS 5 & 6.
A2B SWITCH CLOSED = 4700 (+/- 500) OHMSA2B SWITCH OPEN = GREATER THAN 1 MEGAOHM
6.5
1 3 5
2 4 6
7 9 11 13 15 17 19 21 23 25 27 29
8 10 12 14 16 18 20 22 24 26 2871 72 73 74
49 48 47
59 58 57 56 55 54 53 52 51 50
46 45 44
70 69 68 67 66 65 64 63 62 61 60
80 79 78 77 76 75 43 42 41 40 39 38 37 36 35 34 33 32 31 30
K10LEVER
LOCKOUT K6 K5 K3 K2
K7 K4 K1
K9 K8LMISHUTOFF
A2BSHUTOFF
1 2 3 4
X3
X4
F1
F8 F7 F6 F5 F4 F3 F2
R13 R14 R11 R12 R7 R8 R5 R6
R15 R16 R9 R10 R3 R4
R2 R1
X4
H9
V2
H8
V1
X1 X1
X1 X1
X1
X1
X1
X1X1
X1
X1
H7
V11
H4
V8
H1
V5
H6
V10
H5
V9
H3
V7
H2
V6
H10 V3
R17R18
OU
TE
RM
ID
OU
T O
FSE
QU
EN
CE
CE
NT
ER
MID
4 - W
AY
RO
D
DR
AIN
INN
ER
MID
OM CM 4W SEQ
ROD
IM
4.70
DRAWING 5:
CONNECTION BOARD W/VOLTMETER ON X1:34 & X1:35TURN POWER OFF TO CENTRAL UNIT. MEASURE THE RESISTANCEBETWEEN X1:34 & X1:35.
A2B SWITCH CLOSED = 4700 (+/- 500) OHMSA2B SWITCH OPEN = GREATER THAN 1 MEGOHM
6.6
1 3 5
2 4 6
7 9 11 13 15 17 19 21 23 25 27 29
8 10 12 14 16 18 20 22 24 26 2871 72 73 74
49 48 47
59 58 57 56 55 54 53 52 51 50
46 45 44
70 69 68 67 66 65 64 63 62 61 60
80 79 78 77 76 75 43 42 41 40 39 38 37 36 35 34 33 32 31 30
K10LEVER
LOCKOUT K6 K5 K3 K2
K7 K4 K1
K9 K8LMISHUTOFF
A2BSHUTOFF
1 2 3 4
X3
X4
F1
F8 F7 F6 F5 F4 F3 F2
R13 R14 R11 R12 R7 R8 R5 R6
R15 R16 R9 R10 R3 R4
R2 R1
DRAWING 6:
CONNECTION BOARD W/TEMPORARY 4.7k RESISTOR INSTALLEDTURN POWER OFF TO CENTRAL UNIT. INSTALL THE RESISTANCE BETWEENX1:34 & X1:35. TURN POWER ON TO CENTRAL UNIT AND THE A2B ALARMSHOULD BE INACTIVE.
6.7
4.70kΩ
P.A.T. – L.M.IMANUAL
SECTION 7
DS 350 GRAPHIC BCSDIGITAL INPUTS
DS350 GRAPHIC (BCS)
Digital Inputs
INPUT CU DESCRIPTION NOTESTERMINAL
1 A104X1/38
TELE EXTEND (+24V) GROVE PRESSURE SWITCH SIGNAL
2 A104X1/40
TELE RETRACT (+24V) GROVE PRESSURE SWITCH SIGNAL
3 A104X1/42
AUTO MODE SELECTED (+24V) GROVE SELECTOR SWITCH SIGNAL
4 A104X1/76
PROX. SWITCH OM/FLY RETRACTED& OM/FLY % RESET (+24V)
PAT SWITCH ON CM - SIGNAL VIA CMCABLE REEL
5 A104X1/78
PROX. SWITCH CM/IM RETRACTED(+24V)
PAT SWITCH ON BOOM BASE
6 A104X1/80
PROX. SWITCH IM % RESET (+24V) PAT SWITCH ON BOOM BASE
E1 A112/A114X1/1
HOUSE LOCK PIN SWITCH SIGNAL GROVE LIMIT SWITCH (RT865BXL ONLY)
E2 A112/A114X1/3
AUTO MODE A = ONAUTO MODE B = OFF
GROVE SELECTOR SWITCH SIGNAL (NOTFOR RT865BXL)
E3 A112/A114X1/6
FRONT O/R OVERLOAD(GROUND SIGNAL)
GROVE FRONT O/R SWITCH SIGNAL (NOTFOR RT865BXL)
E4 A112/A114X1/7
AREA DEFINATION SWITCHON RUBBER
SWIVEL LIMIT SWITCH (RT865BXL ONLY)
E5 A112/A114X1/9
PROX. SWITCH CM RETRACTED &CM % RESET (+24V)
PAT SWITCH ON IM - SIGNAL VIA IMCABLE REEL
7.1
P.A.T. – L.M.IMANUAL
SECTION 8
DS 350 GRAPHIC BCSCENTRAL UNIT,
P.C. BOARD LAYOUT& CONNECTIONS
P.A.T. DS350 Graphic (BCS)5 - Section Boom - Main Board
8.1
Power Supply Test Points:MP 1 = +5V E-1MP 2 = -5V E-4MP 11 = Ground H-4MP 12 = +5V B-7MP 13 = Digital Ground B-7MP 15 = Analog Ground E-1MP 19 = -5V E-1
Analog Measuring Channels / Test Points:Ch. 1 Boom Length - MP 6 / P6(Do Not Adjust) G-3Ch. 2 Piston Pressure - MP 4 / P4 G-4Ch. 3 Rod Pressure - MP 5 / P5 G-3Ch. 5 Bom Angle - MP 8 / P8(Do Not Adjust) G-2
DS350 GRAPHIC BCSX1 Terminals A104 Board
1,2 24V Battery - Input3,4 GND () Battery - Input 5 F1 (2 amp) GND 6 F1 (2 amp) Load Side ub 7 GND (Inner Shield Connection) 8 GND 9 Boom Angle Signal 10 Boom Length Signal 11 -5Volt Supply/Length/Angle Transducer 12 GND (Inner Shield Connection) 13 +5Volt Supply/Piston Pressure Transducer 14 GND 15 -5Volt/Rod Pressure Transducer 16 Rod Pressure Signal 17 GND (Inner Shield Connection) 18 +5Volt Supply/Piston Pressure Transducer 19 GND 20 -5Volt Supply/Piston Pressure Transducer 21 Piston Pressure Signal 22 GND (Inner Shield Connection) 24 Length (I/M) Signal 25 -5Volt Supply / Length Sensor 26 +9 Volt Supply/Force Transducer 27 -9 Volt Supply/Force Transducer 28 + Force Signal 29 - Force Signal 30 24V (ub) 31 TXD Data Transmit to Console 32 RXD Data Received from Console33,36 GND (oub) 34 0 Signal A2B 35 A2B Signal 37 Digital Input 1 (-) 38 Digital Input 1 (+) Tele Ext. Press. SW. 39 Digital Input 2 (-) 40 Digital Input 2 (+) Tele Retr. Press. SW. 41 Digital Input 3 (-) 42 Digital Input 3 (+) Auto Mode
43 +C/M Prox. Switch44 LMI Shut-off Signal
(LMI By Pass Key)45 +24V (ub) from F1 (2amp)
(LMI By Pass Key)46 A2B Shut off Signal
(A2B By Pass Key)47 +24V Battery from F2 (10 amp)48 Output to Lever Lockout49 K10 LMI Lockout Alarm50,51,52 Not Used53 K2 +24V54 K2 (NO) I/M 2 way valve55 Not Used56 K3 +24V57 K3 (NO) Tele Rod Drain Sol.58 Not Used59 K4 +24V60 Not Used61 K4 (NO) Tele out of Seq. Sol.62 K5 +24V63 K5 (NO) Extend64 K5 (NC) Retract65 K6 +24V66 K6 (NO) C/M 2 way valve67 Not Used68 K7 +24V69 K7 (NO) O/M - Fly 2 way valve70,71,72 Not Used73 Length Signal C/M74 -5V75 Digital Input 4 GND76 Digital Input 4 Prox. Switch
O/M Fly Retract77 Digital Input 5 GND78 Digital Input 5 Prox. Switch
CM/IM Retract79 Digital Input 6 GND80 Digital Input 6 Prox. Switch
Length Reset
X1 TERM. DESCRIPTION X1 TERM. DESCRIPTION
8.2
1 3 5
2 4 6
7 9 11 13 15 17 19 21 23 25 27 29
8 10 12 14 16 18 20 22 24 26 2871 72 73 74
49 48 47
59 58 57 56 55 54 53 52 51 50
46 45 44
70 69 68 67 66 65 64 63 62 61 60
80 79 78 77 76 75 43 42 41 40 39 38 37 36 35 34 33 32 31 30
K10LEVER
LOCKOUT K6 K5 K3 K2
K7 K4 K1
K9 K8LMISHUTOFF
A2BSHUTOFF
1 2 3 4
X3
X4
F1
F8 F7 F6 F5 F4 F3 F2
R13 R14 R11 R12 R7 R8 R5 R6
R15 R16 R9 R10 R3 R4
R2 R1
X4
H9
V2
H8
V1
X1 X1
X1 X1
X1
X1
X1
X1X1
X1
X1
H7
V11
H4
V8
H1
V5
H6
V10
H5
V9
H3
V7
H2
V6
H10 V3
R17R18
OU
TER
MID
OU
T O
FSE
QU
ENC
E
CEN
TER
MID
4 - W
AY
RO
D
DR
AIN
INN
ERM
ID
OM CM 4W SEQ
ROD
IM
P.A.T. DS350 Graphic (BCS)5 - Section Boom - X1 Terminal Board (A104)
8.3
DS350 GRAPHIC (BCS)
Relay Outputs
INPUT CU DESCRIPTION NOTESTERMINAL
K1 A104X1/52
NOT USED NONE
K2 A104X1/54
2 - WAY IM SOLENOID VALVES (2)PILOT PRESSUREPISTON SIDE PRESSURE
OFF = IM EXTENDS OR RETRACTS ON = IM ISNOT ALLOWED TO MOVE REFER TO TRUTHTABLE 1
K3 A104X1/57
TELE ROD DRAIN VALVE OFF = BOOM IS EXTENDING OR RETRACTINGAND IS NOT FULLY RETRACTEDON = BOOM IS IN NEUTRAL POSITION OR FULLYRETRACTED
K4 A104X1/61
TELE OUT OF SEQUENCE PROVIDES SIGNAL TO GRV WARNING LIGHT
K5 A104X1/62
ANALOG OUTPUT SIGNAL FROMANALOG BOARD
ANALOG OUTPUT TO PROPORTIONAL SOLENOIDVALVES, EXTEND & RETRACT, RELAY K5SELECTS EXTEND OR RETRACT
K5 A104X1/63
ANALOG OUTPUT SIGNAL TOPROPORTIONAL EXTEND SOLENOIDVALVE
MAXIMUM 800mA TO EXTEND VALVE ONEVALVE FOR ALL SECTIONS
K5 A104X1/64
ANALOG OUTPUT SIGNAL TOPROPORTIONAL RETRACT SOLENOIDVALVE
MAXIMUM 800mA TO RETRACT VALVE ONEVALVE FOR ALL SECTIONS
K6 A104X1/66
2 - WAY CM SOLENOID VALVES (2)PILOT PRESSUREPISTON SIDE PRESSURE
OFF = CM EXTENDS OR RETRACTS ON = CM ISNOT ALLOWED TO MOVE
K7 A104X1/69
2 - WAY OM/FLY SOLENOID VALVES(2) PILOT PRESSURE PISTON SIDEPRESSURE
OFF = OM/FLY EXTENDS OR RETRACTS ON =OM/FLY IS NOT ALLOWED TO MOVE
K8 A104X1/44
LMI CUT OFF INTERNAL RELAY CONNECT LMI BYPASS VIA DIODE ASSEMBLYFROM GRAPHIC CONSOLE AND CU KEY SWITCH
K9 A104X1/46
A2B CUT OFF INTERNAL RELAY CONNECT A2B BYPASS FROM GRAPHICCONSOLE
K10 A104X1/48
LMI UNLOCK RELAY OUTPUT POWERS THE LMI UNLOCK SOLENOID WHEN NOOVERLOAD, A2B OR ERROR CONDITION
K10 A104X1/49
EXTERNAL ALARM OUTPUT USED FOR EEC UNITS ONLY
8.4
P.A.T. DS350 Graphic (BCS)5 - Section Boom - Diode Board(A113)
XD1 XC1 XB1 XA112 11 10 9 8 7 6 5 4 3 2 1
X1 X1
24 000 35 0003PAT BS Z:E
P.A.T. DS350 Graphic (BCS)5 - Section Boom - Valve Control Board (A111)
..X2 X3
MP1
F1
MP11
...J3
1
3
MP10
X1
.. .
13J2
J1
MP4 MP5 MP6 MP7
MP3
MP2
MP8
8.5
P.A.T. DS350 Graphic (BCS)5 - Section Boom - Digital Input
Extention Board (A112)
X2/IN X3/OUT
H16 H15 H14 H13 H12 H11 H10 H9 H8 H7 H6 H5 H4 H3 H2 H1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
30 25 20 15 10 5 3 2
1
MP4 MP3
MP6
GND
MP0C11 C12
MP1
+5V
MP5
MP2
8.6
DS350 GRAPHIC (BCS)
PAT - GROVE Interface
Grove wirenumber
Interfaceconnector
Description
71 A POWER SUPPLY +24V
51 B CRANE GND
73 C LMI UNLOCK SOLENOID (RELAY OUTPUT)
387 D TELE EXTEND PRESSURE SWITCH (INPUT)
388 E TELE RETRACT PRESSURE SWITCH (INPUT)
239 F HIGH = AUTO MODE, LOW = MANUAL MODE (INPUT)
242 G SELECT OM / FLY IN MANUAL MODE (INPUT)
243 H SELECT CM IN MANUAL MODE (INPUT)
244 J SELECT IM IN MANUAL MODE (INPUT)
[507] K 3RD WRAP CUT OFF MAIN HOIST RT ONLY
[505] L 3RD WRAP CUT OFF AUX. HOIST RT ONLY
[338] M 3RD WRAP WARNING LIGHT (GND) RT ONLY
323 N TELE OUT OF SEQUENCE SIGNAL (RELAY OUTPUT)
[74] O ADDITIONAL EXTERNAL ALARM (RT ONLY EEC)
[744] P HOUSE LOCK PIN SWITCH - PICK & CARRY
240 Q AUTO MODE A = HIGH, AUTO MODE B = LOW (INPUT)
147 R FRONT OUTRIGGER OVERLOAD (INPUT)
238 S PROPORTIONAL TELE - SOLENOID GND.
1083 T TELE ROD DRAIN SOLENOID VALVE SIGNAL
255 U PROPORTIONAL TELE - SOLENOID (EXTEND)
257 V PROPORTIONAL TELE - SOLENOID (RETRACT)WX
8.7
HIG
H=A
UTO
/ N
ON
E=M
AN
UA
L
+24V
GN
D
LMI U
NLO
CK S
OLS
TELE
EX
T. P
RESS
. SW
.
TELE
RET
RA
CT P
RESS
. SW
.
OM
/FLY
TEL
E
CM T
ELE
IM T
ELE
TELE
OU
T O
F SE
Q.
HIG
H S
IGN
AL
= A
UTO
MO
DE
A
NO
SIG
NA
L =
AU
TO M
OD
E B
FRO
NT
O/R
OV
ERLO
AD
TELE
PRO
P A
NA
LOG
GN
D
TELE
RO
D D
RA
IN S
OL
TELE
EX
T PR
OP
SOL
TELE
RET
RA
CT P
ROP
SOL
1 2 3 4 5 6 A111X1 3 4 5 6 9 10 A114
X1 22 47 53 54 65 66 68 69 56 57 1 2 3 4 48 38 40 42 36 37 39 41 75 77 79 59 61 49 62 63 64
IS +24V
K2
(CO
M) +
24V
DI E
2+2
4=M
OD
E A
0V
=MO
DE
BD
I E2
GN
D[
DI E
3 (+
24V
)D
I E3
(GN
D=F
RO
NT
O/R
OL)
DI E
5 (+
24V
=CM
RET
)D
I E5
GN
D
K2
(NO
) +24
V T
O IM
2-W
AY
SO
LS
K6
(CO
M) +
24V
K6
(NO
) +24
V T
O C
M 2
-WA
Y S
OLS
K7
(CO
M) +
24V
K7
(NO
) +24
V T
O O
M/F
LY 2
-WA
Y S
OLS
K3
(CO
M) +
24V
K3
(NO
) +24
V T
O T
ELE
RO
D D
RA
IN+2
4V+2
4VG
ND
GN
DK
10 (N
O) +
24V
TO
LM
I UN
LOC
K S
OLS
DI 1
(+24
V=T
ELE
EXT
PRES
SW
)D
I 2 (+
24V
=TEL
E RE
T PR
ES S
W)
DI G
ND
DI 1
GN
D
DI 3
(+24
V=A
UTO
MO
DE
DI 2
GN
DD
I 3 G
ND
DI 4
GN
DD
I 5 G
ND
DI 6
GN
D
K4
(CO
M) +
24V
K4
(NC)
+24
V T
O T
ELE
OU
T O
F SE
QK
10 (N
C) +
24V
TO
LM
I L/O
ALA
RM
K5
(CO
M)
K5
(NO
) OU
TPU
T TO
EX
T PR
OP
K5
(NC)
OU
TPU
T TO
RET
PRO
P
+24V
+24V
GN
D
GN
DA
GN
DA
1 (P
RO
P)
DI EXTENSION BOARD24 350 300 301
4 5 6 7 8 9 10 11 12 A113X1
1 2 3 4 5 6 9
9
1 4 6 9 8 10 8
8
7
7
2 3 5 7 11 12 13 14
12
19 10 11 12 13 14 15 20 21 18 16 17 22 23 24 25
IS
A B C D E F G H J K L M N O P Q R S T U V W X A B C D E F G H J K L M N O P Q R S T U V W X
1 2 3 4 5 6 7 8 9 101112 13 14 15 16 17 1819 20 2122 23 24 25
71 51 73 387
388
239
242
243
244
323
240
147
238
1083
255
257
23 -
SOCK
ET R
ECEP
TS/
S H
ARN
ESS
(REF
)
LMI - CRANE INTERFACE23 - PIN PLUG
TMS/TTS 870INTERFACE
8.8
B
CO
NT
INU
ED
FR
OM
PA
GE
12.1
To Boom BaseJunction Box
P.A.T. – L.M.IMANUAL
SECTION 9
DS 350 GRAPHIC BCSBASIC ADJUSTMENTS
& CHECKS
MODEL: S/N:
PAT DS35O Graphic (BCS)"BASIC ADJUSTMENTS AND VOLTAGE CHECKS"
1. Crane Supply Voltage @ Xl -1 ( + ) & Xl -4(GND) = VDC
2. Supply Voltage to Main Board @ Xl -1 ( + ) & Xl -3 (GND) = VDC
3. Main Board Power Supply ( Reference Voltages +/- 50 MV) : (For MP Locations Refer To Page 8.33 )
+ 9V @ MP 14= VDC MP 15 Ground - Force Transducer - 9V @ MP 16= VDC MP 15 Ground - Force Transducer+ 5V @ MP 17= VDC MP 15 Ground - Internal to Board - 5V @ MP 19= VDC MP 15 Ground - Internal to Board +5V @ MP 1= VDC MP 15 Ground - Internal to Board
-5V @ MP 2= VDC MP 15 Ground - Jib Angle, Length / Angle Rod, Piston +5V @ MP 18= VDC MP15 Ground - Piston & Rod Pressure +5V @ MP 12 = VDC MP 13 Ground - Internal to Board +12V @ MP 21= VDC MP 15 Ground - Internal to Board + 6V @ MP 20 = VDC MP 15 Ground - Internal to Board
4. Boom Length: (MP 15 Ground for Meter)Fully Retracted Ft. VDC @ X1-10 VDC @ MP 6Fully Extended Ft. VDC @ X1-10 VDC @ MP 6- 5 Volt Reference Voltage VDC @ X1-11
5. Boom Angle: (MP 15 Ground for Meter)Minimum Angle Degs. VDC @ X1-9 VDC @ MP 8Maximum Angle Degs. VDC @ X1-9 VDC @ MP 8- 5 Volt Reference Voltage VDC @ X1 -11
6. Pressure Transducers: (MP 15 Ground for Meter)Piston Zero Point VDC @ X1-21 VDC @ MP 4Rod Zero Point VDC @ X1-16 VDC @ MP 5+5 Volt Reference Voltage @ X1-13 & 18- 5 Volt Reference Voltage @ X1-15 & 20
9.1
P.A.T. DS350 Graphic (BCS)5 - Section Boom - Main Board (A101)
9.2
Power Supply Test Points:MP 1 = +5V E-1MP 2 = -5V E-4MP 11 = Ground H-4MP 12 = +5V B-7MP 13 = Digital Ground B-7MP 15 = Analog Ground E-1MP 19 = -5V E-1
Analog Measuring Channels / Test Points:Ch. 1 Boom Length - MP 6 / P6(Do Not Adjust) G-3Ch. 2 Piston Pressure - MP 4 / P4 G-4Ch. 3 Rod Pressure - MP 5 / P5 G-3Ch. 5 Bom Angle - MP 8 / P8(Do Not Adjust) G-2
P.A.T. – L.M.IMANUAL
SECTION 10
DS 350 GRAPHIC BCSMAIN BOARD & TRANSDUCERREPLACEMENT PROCEDURE
P.AT DS350 GraphicTMS/TTS 870 & RT865BXL
Instructions for replacement of the Main P.C. Board, Pressure Transducer.
A digital voltmeter is required to make adjustments on the main board.Voltmeter should be set on a range that will display three digits to the rightof the decimal point (i.e. 2VDC).
When the main board in the central unit or pressure transducers are replaced,the zero point for rod and piston pressure transducer channels must bechecked and readjusted with no hydraulic pressure applied to the pressuretransducers
A. Check the zero pressure output signals for the rod and the piston pressure transducer on the terminal board inside central
processing unit. Terminal X1/16 for rod signal and terminalX1/21 for piston signal. Signal voltage should be .000 volt+/- .025 volts.
B. Refer to instructions on pages 10.3 and 10.4 for adjustment ofpressure channel zero points.
If the main board is replaced, the data and system EPROM must be removedfrom the old board and installed on the new board. Refer to page 10.5 forEPROM location.
10.1
1 3 5
2 4 6
7 9 11 13 15 17 19 21 23 25 27 29
8 10 12 14 16 18 20 22 24 26 2871 72 73 74
K10LEVER
LOCKOUT
K9 K8LMISHUTOFF
A2BSHUTOFF
F1
R2 R1
H9
V2
H8
V1
X1 X1
X1 X1
X1
H4
V8
H1
V5
H5
V9
H3
V7
H2
V6
H10 V3
R17R18
OU
T O
FSE
QU
EN
CE
4 - W
AY
RO
D
DR
AIN
INN
ER
MID
.000
.000
ROD PRESSURE TRANSDUCEROUTPUT SIGNAL = .000 VOLT+/- .025V AT ZERO HYDRAULICPRESSURE.
PISTON PRESSURE TRANSDUCEROUTPUT SIGNAL = .000 VOLT+/- .025V AT ZERO HYDRAULICPRESSURE.
TERMINAL BOARD
10.2
10.3
10.4
10.5
P.A.T. – L.M.IMANUAL
SECTION 11
DS 350 GRAPHIC BCSTROUBLESHOOTING
GUIDE
GENERAL FLOWCHART
This section explains how to handle a problem that may arise with the P.A.T. Load MomentIndicator System - P.A.T. DS350. The procedures are easy to follow and are given in flowcharts on the following pages. Start with general flowchart below which will guide youto one of the more detailed flowcharts shown on pages 11.2-11.40.
START
What’s Wrong?
Lever LockoutActivated
Length Cable Problem No Display
No FunctionAnti-Two-Block
Go to Page 11.2 Go to Page 11.3 Go to Page 11.4 Go to Page 11.7
Wrong LengthDisplayed
Go to Page 11.10
Wrong Angle Displayed
Go to Page 11.32
Error CodeDisplayed
Go to Page 11.41
Bad Data Transfer - Console/CPU
Go to Pages 11. 38
Interface Problem
Go to Page 11.40
Wrong Load Displayed
Go to Page 11.35
11.1
LEVER LOCKOUT ACTIVATED
PROBLEMThe lever lockout system of the crane is activated.Crane movements “hoist up”, telescope out”, and
“boom down” are stopped. Crane is not in overloador two-block condition.
START
Set the override key switch in central unit into upperposition to override LMI.
fixed?
Does light in console indicateAnti-Two-Block warning?
Fault in crane electricor hydraulic system.
If console display is blank, fault is locatedin power supply, wiring or fuses.
Fault in Anti-TwoBlock system.
If Load Moment LimitLight (7) displays fault
is located in LMI,cables, wiring, fuses or
console.
Check lever lockoutsystem in crane
Go to Page 11.4 Go to Page 11.7 Read error code dis-played on console
display (1) and go toPage11.41.
YESNO
NO YES
11.2
BROKEN LENGTH CABLE
PROBLEMDamaged or broken length cable.
STEP ACTION
1 Cut old cable at cable drum.
2 Open cable reel cover and disconnect wiring from terminal block. Pull 7- conductor cable out of strain relief.
3 Remove cable reel from mounting brackets.
4 Remove damaged length cable, which is mounted to the slip rings in the cable reel, from Terminal X1 and X2. Refer to Drawing on Page 11.49.
5 Turn the cable reel and open the stain relief attached to the axle in the center of the drum. Pull existing length cable out of the cable reel.
6 Disconnect damaged length cable from Anti-Two-Block switch receptacle at the boom nose.
7 Pull new length cable through the hole, pipe and strain relief and push it through the axle of the reeling drum. Tighten strain relief to ensure sealing.
8 Dismantle length cable near slip ring and reconnect shield to terminal No. X2 and center to No. X1. Refer to Drawing on Page 11.49.
9 Remount cable reel to the boom. Turn reeling drum clockwise to get rest of new cable onto the drum.
10 Set preload on cable reel by turning the drum counter-clockwise (see page 2.15 - pre-tension).
11 Reconnect new cable to Terminal No. 1 (center) and ground terminal (shield) of receptacle at the boom nose.
12 Reset length potentiometer in length angle transducer (screw is located in center of white gear): with boom fully retracted, turn potentiometer carefully counter-clockwise until it stops. Check function of Anti-Two-Block switch. Recheck length and angle display. Refer to drawing 6 on page 11.53.
11.3
NO DISPLAY
PROBLEMBlank console display.
No warninglight shown.Crane movements stopped.
START
Check fuses on CPU box.
correct?
Measure crane voltage on terminal board (ter-minal block X1) between Pin 2 (+24V) and
Pin 4 (ground). Refer to Drawing 3, “Terminal Board”, on page 11.50.
Note: If crane voltage is measured below 18Vsystem will switch off.
correct?
Measure crane voltage on terminal board (ter-minal block X4) between Pin 2 (+24V) and
Pin 3 (ground). Refer to Drawing 3, “Terminal Board”, on page 11.50.
Replace fuses.
correct?
NEXT PAGE
Defect on terminal board. Diode D4, inductance L1 or capacitor C1 is faulty. These items can’t be replaced, change
terminal board. Refer to Drawing 3, “Terminal Board” on page 11.50.
Check crane power supply for faulty crane electric or if power supply is too low.
NO
YES
YES
YES
NO
NO
11.4
NO DISPLAYcontinued
PREVIOUS PAGE
Measure crane voltage on main board (terminal block X1) between Pin 1 (+24V) and Pin 3 (ground).
Refer to Drawing 4, “Main Board”,on page 11.51.
correct?
Faulty wiring or connectorsbetween terminal board and main board. Check wiring and connections.
Measure voltages out of power supply between:
MP 15 = ground (analog) and MP 1 = +5VMP 15 = ground (analog) and MP 2 = -5VMP 13 = ground (digital) and MP 12 = +5VMP 15 = ground (analog) and MP 18 = +5VMP 15 = ground (analog) and MP 19 = -5VMP= Measuring Points on Main Board. Refer to Drawing 4, “Main Board”, on page 11.51.
correct?
NEXT PAGE
NO
YES
NO
YES
11.5
Short circuit in externalwiring. Check external
wiring of system for defects.
NO DISPLAYcontinued
PREVIOUS PAGE
Fault in wiring between terminalblock X1 and console board.Check wiring. Refer to Drawing 5,“Console Board”, on page 11.52.
correct?
END
NOcorrect?
YES
NO
YES
Disconnect ribbon cables from X2 and X3of main board. Measure voltages out of power supply between:MP 15 = ground (analog) and MP 1 = +5VMP 15 = ground (analog) and MP 2 = -5VMP 13 = ground (digital) and MP 12 = +5VMP 15 = ground (analog) and MP 18 = +5VMP 15 = ground (analog) and MP 19 = -5VMP= Measuring Points on Main Board. Refer to Drawing 4, “Main Board”, on page 11.51.
Measure voltage at console terminal block between Pin 1 = (+24V) and Pin 2 = (crane ground). Refer to Drawing 5, “Console Board”, on page 11.52.
Replace console board.
Defective power supply onmain board. Replace main board and reset pressure channels - see Section 10.
11.6
ANTI-TWO-BLOCK PROBLEM
START
Check to see whether or not crane is in two-block condition.
correct? Lower hook down in safe position.
Check if jumper / dummy plug isplugged into receptacle at boom nose.
correct?Plug appropriate plug into
socket of junction box.
NO
YES
NO
YES
correct? Replace Anti-Two-Block switch.
NEXT PAGE
NO
YES
PROBLEMFunction of Anti-Two-Block System is faulty.
Remove jumper / dummy plug and checkfunction of anti-two-block switch withohmmeter between terminals 1 and 2 in the receptacle.Switch closed=4700 + 500 Ohms(weight installed) Switch open => 1 Megaohm (weight removed)Safe Condition = 0 ohmBlock-To-Block = > 1 megaohm
11.7
ANTI-TWO-BLOCK PROBLEM
PREVIOUS PAGE
Disconnect wire from terminal block X1, Pin 35 incentral unit. Measure between Pin 1 and Pin 2 ofreceptacle at boom nose with ohmmeter.Switch closed = 0 OhmSwitch open = >1 Megohm
correct?Fault in wiring cable from Anti-Two-Block switch to junction box at boom nose or short circuit in length cable. Check wiring.
For next measurement reconnect jumper / dummyplug, then disconnect length cable from slip rings7 / 8 in cable reel. With ohmmeter, measurebetween center and shield of length cable.Anti-Two-Block switch open = > 1 megohmAnti-Two-Block switch closed = 4700 Ohms+ 500 Ohms.Reconnect length cable to slip ring.
Faulty wiring between receptacle atboom nose and cable reel or damaged length cable. Check out wiring. In case of damaged length cable,replace length cable
correct?
NEXT PAGE
NO
YES
NO
YES
11.8
ANTI-TWO-BLOCK PROBLEM
PREVIOUS PAGE
correct?
END
Check Anti-Two-Block signal in central unit.With ohmmeter measure between wire discon-nected from terminal block X1, Pin 35 and Pin 34.Anti-Two-Block switch closed = 4700 Ohms+ 500 OhmsAnti-Two-Block switch open = > 1 Megohm.
Faulty wiring between cable reel and central unit. Check Ten Pin Receptacle,
using same measurements as in previous step. See cranes specific wiring diagramfor wires # 5 (+) and # 6 (-). If fault is
found check cable.
Check main board function by installing a temporary resistor, 4700 Ohms, at terminnal block X1 between 35 and 34 in central. With resistor connected alarm should be inactive.
If problem still exist, replace main board and reset pressure channel. correct?
NO
YES
NO
YES
11.9
BOOM LENGTH PERCENTAGE PROBLEMA. Boom Length Percentage Error
Boom lengthpercentage error
Keep the boom stop blocklatched. Switch to ManualMode and retract the boomcompletely.
Is thepercentage reading (1%, 0%, 0%)?
Yes
NoContinue to Page 11.15
The LMI does not recognize the one ormore reset switch signals. Check
proximity switch target adjustment , If damage is visible install new switch.
Measure voltage supply to IM switch atterminal 1 or 2 (+24V) and 5 or 6 (GND)in the junction box at the front of theboom base.
Is theVoltageCorrect? No
Yes
Keep the inner mid section retracted.Measure the inner mid reset switch signal Faulty voltage supply wiring toat terminal 3 (24V) and 5 (GND) in the switch. Replace defectivejunction box at the front of the boom base cables. section.
Next Page 11.10
BOOM LENGTH PERCENTAGE PROBLEMPrevious Page
Is thevoltagecorrect ? No
Yes
Measure the IM reset switch signal at Defective IM reset switch. terminal 5 (24V) and 9 (GND) in the length Replace proximity switch.sensor LG221.
Is the VoltageCorrect ? No
Yes
Measure the IM reset switch signal at Faulty wiring in cableterminal 15 (24V) and 14 (GND) in the connecting the junction box
boom base junction box. with the length sensor.
Is thevoltagecorrect? No
Yes
Measure the IM reset switch signal at central unit Faulty wiring in cable connecting terminal A104 80 (24V) and A 101 36 (GND). the length sensor LG221 and the
boom base junction box.
Is thevoltagecorrect? No
Yes
Measure the CM reset switch signal at Defective CM reset switch terminal 10 (24V) and 9 (GND) in the length Replace proximity switch. sensor LG221.
Next Page11.11
BOOM LENGTH PERCENTAGE PROBLEMPrevious Page
Is the voltage correct ? No
Yes
Measure the CM reset switch signal at Faulty wiring in cable connectingterminal 30 (24V) and 14 (GND) in the the junction box with the length
boom base junction box. sensor.
Is the voltage correct ? No
Yes
Measure the CM reset switch signal at Faulty wiring in cablecentral unit terminal Al14-9 (24V) and connecting the boom baseA l04-36 (GND). junction box with the LG221.
Is the voltage correct ? No
Yes
Measure voltage supply to OM switch at Faulty wiring in cable connectingterminal 11 (+24V) and 9 (GND) in the center the central unit and the boom mid junction box. base junction box.
Is the voltage correct ? No
Yes
Measure voltage supply to CM switch at Faulty wiring in cableterminal 7 (+24V) and 5 (GND) in the inner connecting the central unit andmid junction box. the boom base junction box.
Next Page 11.12
BOOM LENGTH PERCENTAGE PROBLEM
Previous Page
Is the voltage correct ? No
Yes
Keep the outer mid (OM) section retracted. Measure the OM reset switch signal at terminal Faulty voltage supply wiring to switch. 10 (24V) and 9 (GND) in the center mid junction Replace defective cables. box .
Is the voltage correct ? No
Yes
Measure the CM reset switch signal at Faulty wiring in cable terminal 10 (24V) and 9 (GND) in the connecting the center mid junctionlength- angle sensor LWG221. box and the LWG 221.
Is the voltage
correct ? No
Yes
Measure the OM reset switch signal at Faulty wiring in cable connectingterminal 17 (24V) and 14 (GND) in the the junction box with the length
boom base junction box. sensor.
Next Page
11.13
BOOM LENGTH PERCENTAGE PROBLEM
Previous Page
Is the voltage correct ? No
Yes
Measure the OM reset switch signal at Faulty wiring in cablecentral unit terminal Al04-78 (24V) and connecting the boom base Al04-36 (GND). junction box with the LWG 221.
Is the voltage
correct ?
Defective digital input 4, 5 on main board or Faulty wiring in cable connectingdigital input 5 on extension board. Contact the central unit and the boom
service dealer to obtain replacement base junction box.instructions.
11.14
BOOM LENGTH PERCENTAGE PROBLEMB. Main Boom Length Error
Main boom length error
In manual mode retract allboom sections. Pull the boomstop and retract the inner mid
section completely.
Is the main boom length
indicated correctly? Yes
No
CAUTION: High tension on cable reel drum! ContinueCAUTION: To avoid length potentiometer damage. do not with *turn the length potentiometer past the stop. on page 11.17
Is the length cable spooled properly on the LG 208 No drum ?
Yes
With all sections completely retracted, un-spool the length cable carefully. Let the drum
Reset the length potentiometer. rewind slowly and spool the cable manually back on the
drum. Check the roller guides for correct adjustment.
Has the adjustment corrected the boom length indication. Yes
Continue with * No on page 11.17. Next Page
11.15
BOOM LENGTH PERCENTAGE PROBLEM Previous Page
Check the power supply to the length sensor. Measure the power supply voltage at central unit terminal Al04
Xl /l1(-5V) and Al04 Xl/8(GND).
Is the voltagecorrect (-5V) ? No
Yes
Possible short or wiring fault between Main board component defective central unit and cable reel. Measure with Contact authorized service dealer the DVM at the length transducer (LG 208) for the board replacement procedure. terminal 1(GND) and 3 (-5V)
Is the voltagecorrect (-5V) ? No
Yes
Verify the length sensor signal. Faulty wiring between Measure the voltage at the length central unit and length
transducer (LG 208) terminal 1 (GND) transducer. Checkand 2 (-500mV) with fully retracted wiring, junction boxes boom. and connectors for faulty wiring.
Is the voltage correct ? No
(-500mV)
Yes
Check the length signal in the central unit. Defective length potentiometer. Measure the signal at central unit terminal Replace length potentiometerA104 Xl/10(-5OOmV) and Al 04 Xl/8(GND) assembly. For instruction how to with fully retracted boom. change the length potentiometer assembly refer to Section 3.
Next Page
11.16
BOOM LENGTH PERCENTAGE PROBLEM
Previous Page
Is the voltage correct ? (-500mV) Yes
No
Check the wiring that connects the Main board component defective. LG 208 with the central unit. Inspect the Contact authorized service dealer for cable and connectors. the board replacement procedure.
Have you found any wiring faults ? Yes
No
Connect the voltmeter central unit Correct the wiring problem.terminal A104 X1/10 (signal) and A104 Xl/8 (GND). Use a small screwdriver to turn the lengthpotentiometer carefully clockwise. * The voltage should decrease from -500mV to -4.5V.
Is the voltage decreasing from -500mV to Yes -4.5V ?
No
Check the wiring that connects the Main board component defective. LG 208 with the central unit. Inspect the Contact authorized service dealer for cable and connectors. the board replacement procedure.
Next Page
11.17
BOOM LENGTH PERCENTAGE PROBLEM
Previous Page
Have you found any wiring faults ? Yes
No
Connect the voltmeter central unit Correct the wiring problem.terminal 2 (signal) and terminal 1 (GND). Use a small in the
cable reel. Carefully turn the length potentiometer clockwise. The voltage should decrease from -500mV to -4.5V.
Is the voltage correct? (0 turns = -500mV 10 turns = -4.5 V) Yes
No
Defective length potentiometer assembly. Reset length transducer.Replace and adjust length potentiometer. Continue with section 14.
11.18
BOOM LENGTH PERCENTAGE PROBLEM
C. Inner Mid Length Error
In manual mode retract allboom sections. Pull the boomstop and retract the inner mid
section completely.
Is the inner mid boom length
indicated correctly?
Continuewith *
on page 11.21
Is thelength cable
spooled properly onthe 221drum?
Yes
No
CAUTION : High tension on cable reel drum !CAUTION : To avoid length potentiometer damage,do not turn the length potentiometer past the stop.
Reset the length potentiometer.
With all sections completelyretracted, un - spool the lengthcable carefully. Let the drumrewind slowly and spool thecable manually back on the
drum. Check the roolerguidesfor correct adjustment.
No
Yes
Hasthe adjustment
corrected the inner midlength indication?
Continuewith *
on page 11.21
Check the power supply to the length sensor. Measurethe power supply voltage at central unit terminal A104
X1/11 (-5V) and A104 X1/8 (GND)
Next Page
11.19
BOOM LENGTH PERCENTAGE PROBLEM
Previous Page
Is the voltagecorrect (-5V)?
Possible short or wiring fault betweencentral unit and cable reel. Measure with
the DVM at the length transducers (LG 221)terminal 1 (GND) and 3 (-5V)
Main board component defective.Contact authorized service dealer
for the board replacementprocedure.
Is the voltagecorrect (-5V)?
Verify the length sensor signal.Measure the voltage at the length
transducer (LG 221) terminal 1 (GND)and 2 (-500mV) with fully retracted
boom.
Faulty wiring between central unit and length
transducer. Checkwiring, junction boxes
and connectors forfaulty wiring.
No
Yes
No
Yes
Is the voltagecorrect (-500mV)?
No
Yes
Check the length signal in the central unit.Measure the signal at central unit terminal
A104 X1-24 (-500mV) and A104 X1-8(GND) with fully retracted boom.
Defective length potentiometer.Replace length potentiometer
assembly.
Next Page
11.20
Previous Page
Is the voltagecorrect (-500mV)?
No
Yes
BOOM LENGTH PERCENTAGE PROBLEM
Check the wiring that connects theLG 221 with the central unit. Inspect the
cable and the connections.
Main board component defective.See section 10 for replacement procedure.
Have you found any wiring faults?
Yes
No
Connect the voltmeter to central unitterminal A104 X1-24 (signal) and
A104 X1-8 (GND).Turn potentiometer clockwise
0 turns = -500mV, 10 turns = -4.5V.
Correct the wiring problem.
*Is
the voltagedecreasing from
-500mV to- 4.5V?
Check the wiring between lengthtransducer LG 221 and central unit
Inspect cable connectors and junctionboxes.
Main board component defective.See section 10 for replacement procedure.
Yes
No
Next Page
11.21
Previous Page
Have you foundany wiring faults?
No
Yes
BOOM LENGTH PERCENTAGE PROBLEM
Connect the voltmeter to terminal 2 (signal)and terminal 1 (GNU) in the cable reel.Turn length potentiometer clockwise.0 turns = - 500mV, 10 turns = -4.5V
Correct the wiring problem.
Is the voltage correct?
0 turns = -500mV10 turns = - 4.5V
Defective length potentiometerassembly. Replace and adjust length
potentiometer.
Reset lengthtransducer. Possible main board defect.
Yes
No
11.22
BOOM LENGTH PERCENTAGE PROBLEM
D. Center Mid Length Error
In manual mode retract all boom sections. Pull the boom stop and retract the inner mid
section completely.
Is thecenter mid
length indicatedcorrectly?
Is the length cable
spooled properly onthe LWG 221
drum?
Continuewith *
on page 11.25
Yes
No
Reset the length potentiometer.
CAUTION: High tension on cable reel drum.CAUTION: To avoid length potentiometer damage, do not
turn the length potentiometer past the stop.No
YesWith all sections completely
retracted, un-spooled the lengthcable carefully. Let the drum
rewind slowly and spool the cablemanually back on the drum. Check the roller guides for
correct adjustment.
Hasthe adjustment
corrected the center midlength indication?
Continuewith *
on page 11.25
Yes
Check the power supply to the length sensor. Measurethe power supply voltage at central unit terminal A 104
X1-11 (-5V) and A104 X1-8 (GND).
No
Next Page
11.23
BOOM LENGTH PERCENTAGE PROBLEM
Previous Page
Is the voltagecorrect (-5V)?
Possible short or wiring fault betweencentral unit and cable reel. Measure at
the length transducer, terminal 1(GND) and 3 (-5V).
Main board component defective.Follow board replacement procedure.
Is the voltagecorrect (-5V)?
Verify the length sensor signal.Measure the voltage at the length
transducer, terminal 1 (GND)and 2 (-500mV) with fully
retracted boom.
Faulty wiring between centralunit and length transducer.
Check wiring, junction boxes andconnectors for faulty wiring.
Is the voltagecorrect (-500mV)?
No
Yes
No
Yes
No
Yes
Measure the signal at central unit terminalA 104 X1-73 (-500mV) and A 104 X1-8
(GND) with fully retracted boom.
Defective length potentiometer.Replace length potentiometer
assembly.
Next Page
11.24
Is the voltagecorrect (-500mV)?
BOOM LENGTH PERCENTAGE PROBLEM
Previous Page
No
Check the wiring that connects theLG 221 with the central unit. Inspect the
cable and the connections.
Main board component defective.See section 10 for replacement procedure.
Yes
Have you foundany wiring faults?
Yes
No
Connect the voltmeter central unit terminalA 104 X1-73 (signal) and A 104 X1-8 (GND).
Turn length potentiometer clockwise.0 turns = -500mV, 10 turns = -4.5V.
Correct the wiring problem.
*
Isthe voltage
decreasing from-500mV to
-4.5V?
Check the wiring that connects theLG 221 with the central unit. Inspect the
cable and the connections.
Main board component defective.See section 10 for
replacement procedure.
Yes
No
Next Page
11.25
BOOM LENGTH PERCENTAGE PROBLEM
Previous Page
Have you foundany wiring faults?
Yes
No
Connect the voltmeter to terminal 2(signal) and terminal 1 (GND) in the
cable reel. Turn the length potentiometerclockwise. 0 turns = -500mV, 10 turns = -4.5V.
Correct the wiring problem.
Is the voltage correct?
0 turns = -500mV10 turns = - 4.5V
Defective length potentiometerassembly. Replace and adjust length
potentiometer.
Possible main board defect.Follow main board replacement procedure.
Yes
No
11.26
BOOM LENGTH PERCENTAGE PROBLEM
E. No Extend or Retract Function in Automode
Switch to manual mode and extendor retract the boom manually.
Does theboom extend or
retract?
Switch to automode. Start the engine and operate theextend control. Measure the voltage at central unit
terminal A 104 X1-38 (24V) and A 104 X1-37 (GND)while operating the extend control.
Defect in crane electric or hydraulic circuit.Reset crane fuse breaker. Check LMI fuses
in the central unit enclosure.
No
Yes
Is thevoltagecorrect?
Faulty wiring to extend pressure switch ordefective pressure switch. Correct the
wiring and replace the switch if defective.
Switch to automode. Start the engine and operate theretract control. Measure the voltage at central unit
terminal A 104 X1-40 (24V) and A 104 X1-39 (GND)while operating the extend control.
No
Yes
Is thevoltagecorrect?
No
Yes
Select the service screen on the consoleby pressing the two outer keys (F1 & F4)
simultaneously. The ramping value for the selectedsection shall increase from 0 to 255. The ramping
value remains 0 in the neutral position.
Faulty wiring to retract pressure switch ordefective pressure switch. Correct the wiring
and replace the switch if defective.
Next Page
11.27
BOOM LENGTH PERCENTAGE PROBLEM
Previous Page
Is the ramping value
increasing?
No
Yes
Continue to troubleshoot the wiring tothe 2 way value and the hydraulic
circuit.
Check ribbon cable connection incentral unit and wiring in the central unit.
11.28
BOOM LENGTH PERCENTAGE PROBLEM
F. Out of Sequence WarningBoom sections are out of sequence
(Automode)
Follow instructions in section A.
Is theproblem
corrected?
End
Yes
No
Follow instructions in section B.
Is theproblem
corrected?
End
Yes
No
Follow instructions in section C.
Is theproblem
corrected?
End
Yes
No
Follow instructions in section D.
Is theproblem
corrected?
End
Yes
No
Next Page11.29
BOOM LENGTH PERCENTAGE PROBLEM
Previous Page
With outer mid section completely retractedcheck the adjustment for the OM retract switch
target.
Is theswitch and
target adjustedcorrectly?
No
Yes
Measure the switch signalat central unit.
A 104 X1-76 (24V) andA 104 X1-36 (GND)
Adjust OM retractswitch and target.
Is thevoltagecorrect?
Yes
No
Main board component defective.See main board replacement
procedure.
Faulty wiring. Check the voltage at terminal17 (24V) and 13 (GND) in the boom base
junction box.
Have youfound afault in
the wiring?
Yes
No
Next Page
Correct the wiringbetween boom base
junction box and centralunit.
11.30
BOOM LENGTH PERCENTAGE PROBLEM
Previous Page
Measure switch signal at LWG 221 terminal 10(24V) and 9 (GND)
Is thevoltagecorrect?
Yes
No
Correct the wiring between LWG 221and boom base junction box. Refer to
section 9 and 11.
Check the signal at terminal 10 (24V) and9 (GND) in CM junction box. Refer to
section 9.1 and 11.
Is the voltagecorrect?
No
Yes
Retract all boom section inmanual mode and let the system
reset boom percentage.Recheck.
Defective OM retract switch.Replace proximity switch.
Refer to section 9 & 11.
End
11.31
ANGLE READING PROBLEM
PROBLEMAngle Reading Incorrect
Crane is not in “Out of Load Chart” condition.
START
Check levelness of the angle sensor in cable reelwith main boom at horizontal remove cover from the cable reel. Refer to Page 11.53, Angle / Length Sensor Adjustment Procedure.
Readjust the angle sensor to the correct position by loosening the mounting screws and moving the angle sensor. Refer to Page 11.53, Angle / Length Sensor Adjustment Procedure.
Check power supply to anglesensor on Terminal Board, Terminal X1, Pin 8 (ground)and Pin 11 (-5V) +/- 50mv.Refer to Drawing 3 “TerminalBoard” on page 11.50.
NEXT PAGE
Main board defective. replace main board andreset pressure channel. Refer to Section 10 ofthis Manual.Note: Consult factory before replacing mainboard for further troubleshooting steps.
correct?NO
YES
correct?NO
YES
11.32
Remove wire # 4 from Terminal, in thecablereel, and recheck the boom angle signal voltages at terminal # 4 in cable reel.If the signal is correct the problem is in the wiring between the cable reel and the central unit or the main board is defective.If the signal is incorrect the angle sensor is defective. Replace the angle sensor and adjustaccording to instructions on page 11.53
correct?NO
YES
Measure supply to angle sensor in cablereel at terminal between Pin 5 (ground)and Pin 6 (-5V) +/- 50mv.Refer to Drawing 6, Length / Angle Tran-sducer on page 11.53.
ANGLE READING PROBLEM
PREVIOUS PAGE
Measure signal from angle sensor in cablereel at terminal between Pin 4 (signal) andPin 5 (ground).Boom Angle Signal Voltages: 0 Degrees -3.12 Volts 45 Degrees -2.49 Volts 75 Degrees -2.07 VoltsFor more detailed signal voltages referto : Boom Angle Signal Voltage Chartin Section 5.
NEXT PAGE
Faulty wiring between central unit andangle sensor. Check wiring.correct?
NO
YES
11.33
ANGLE READING PROBLEM
PREVIOUS PAGE
Faulty wiring between central unit andcable reel. Check wiring.correct?
NO
YES
Measure signal from angle sensor in cablereel at terminal between Pin # 9 (signal) andPin # 8 (ground).Boom Angle Signal Voltages: 0 Degrees -3.12 Volts 45 Degrees -2.49 Volts 75 Degrees -2.07 VoltsFor more detailed signal voltages referto : Boom Angle Signal Voltage Chartin Section 5.
Measure angle signal of amplified output onmain board between test point MP 15(ground)and MP 8 (angle signal).Note: Negative signal at terminal X1 Pin 9will be converted into positive signal at MP 8.Boom Angle Signal Voltages: 0 Degrees +4.49 Volts 45 Degrees +2.48 Volts 75 Degrees +1.15 VoltsFor more detailed signal voltages referto : Boom Angle Signal Voltage Chartin Section 5.
Main board defective. replace main board andreset pressure channel. Refer to Section 10 ofthe System Manual.Note: Consult factory before replacing mainboard for further troubleshooting steps.
correct?NO
YES
END
11.34
LOAD READING PROBLEMPROBLEM
Load reading incorrect.
START
Check selected operating mode(codeon operating mode switch).
correct?NO
YES
Select operating mode switch to correct position(see operating mode in load chart).
Check boom length reading on display.
correct?NO
YES
Reset length potentiometer. With fully retractedboom, turn potentiometer axle counterclockwiseuntil it stops
Measure radius and check with the displayed radius.
Check if mechanical adjustment of angle transduceris correct. Angle transducer box should in line withboom and adjusted to actual boom angle.
correct?NO
YES
Check power supply to pressure transducer (rodside). Unplug transducer cable from transducer.Measure on terminal board at terminal block X1.Measure between Pin 14 (ground) and Pin 15(-5V). Measure between Pin 14 (ground) and Pin13 (+5V).
Power supply on main board defected. Checkpower supply out and measure between testpoint MP15 = ground and MP18 = +5V andbetween test point MP15 = ground and MP2 =-5V. If incorrect, replace main board and resetpressure channel.
correct?NO
YES
NEXT PAGE
11.35
LOAD READING PROBLEM
PREVIOUS PAGE
Check power supply to pressure transducer(piston side). Unplug transducer cable fromtransducer. Measure on terminal board at ter-minal block X1. Measure between Pin 19 (ground) and Pin 20 (-5V). Measure betweenPin 19 (ground) and Pin 18 (+5V).
correct?NO
YES
Power supply on main board defective. Checkpower supply and measure between test pointMP 15 = ground and MP 18 = +5V and betweentest point MP 15 = ground and MP 2 = -5V. Ifincorrect, replace main board and reset pressurechannels.
Check power supply at transducer plugs. Mea-sure between B = ground and A = +5V. Meas-ure between B = ground and C = -5V.
correct?NO
YES
Faulty wiring. Check wiring (pressure transducer cable).
Plug transducer cable back into transducer.Check out signal from transducer. Measurebetween B = ground and D = signal in transducer plug. Signal = 0 to -1V (+/- 20mV).
correct?NO
YES
Transducer defective - replace transducer.
NEXT PAGE
11.36
PREVIOUS PAGE
LOAD READING PROBLEM
Plug transducer cables back into transducer.Check transducer signals in central unit. Dis-connect wire # 4 of transducer cable from terminal block X1, Pin 21 (signal piston side).Disconnect wire # 4 of transducer cable from terminal block X1, Pin 16 (signal rod side).Measure transducer signals (0....-1V) betweenPin 19 (ground) and wire # 4 (piston and rodside transducer cable).
correct?NO
YES
Faulty wiring. Check wiring (pressure transducercable). Transducer defective-replace transducerand reset pressure channel as described below.
Reconnect wire # 4 from transducer cablesback to terminal X1, Pin 16 (rod side) andterminal X1, Pin 21 (piston side).Without pressure in hoses, check 0 pointadjustment on main board by disconnectinghydraulic hoses from transducer. Measure between test point MP 15 (ground) and test point MP 4. Signal should be 0.50V (piston side). Measure between test point MP 15 (ground) and test point MP 5. Signal should be 0.50V (rod side).
correct?NO
YES
Measure voltage between test point MP 15(ground) and test point MP 4 and reset with P4 to 0.50V (piston side).Measure voltage between test point MP 15(ground) and test point MP 5 and reset with P5 to 0.50V (rod side).If not resettable, replace transducer.
END
11.37
BAD DATA TRANSFER BETWEEN CONSOLE & CENTRAL UNIT
PROBLEMError Code “E93 / E94”
No data transfer to and from console.
START
Make sure that Data EPROM is plugged intomain board socket D5 and System EPROM isplugged into main board socket D4. Checkthat EPROMS are inserted with notch on EPROM to matching notch on socket.
correct?NO
YES
Place EPROM in correct socket.
Check supply crane voltage for console in central unit at terminal board (block X1) between Pin 33(ground) and Pin 30 (+24V). Make sure externaland internal power supply is correct.
correct?NO
YES
Defective internal power supply. Replace main board and reset pressure channel. orDefect in terminal board. Replace terminal board.
NEXT PAGE
11.38
PREVIOUS PAGE
BAD DATA TRANSFER BETWEEN CONSOLE & CENTRAL UNIT
Check power supply to console between consoleterminal # 2 = ground (KM) and terminal # 1 =+24V.
correct?NO
YES
Faulty wiring in cable from central unit to console. Replace cable.
Ensure that wires are properly connected be-tween terminal block X1 Pin 31 and consoleterminal Pin 4 and between terminal block X1 Pin 32 and console terminal Pin 3.
correct?NO
YES
Defective electronic components on main boardand / or console board. Replace console boardand / or replace main board.
END
11.39
INTERFERENCE PROBLEMPROBLEM
Interference from crane electric.Error Code “E93 / E94” intermittent.
Frozen console displays.
START
Check system out; Pg. 11.38&39 - Bad DataTransfer Between Console & Central Unit.
correct?NO
YES
Replace or repair part which is defective.
Check if additional ground like between main board terminal X9 and central unit box mountingbracket is in place.
Install ground link - single cable minimum ofAWG14 (2.0mm2) between terminal X9/1 andcentral unit box mounting bracket. correct?
NO
YES
Ensure that cable shields are connected correctly.Refer to connections and wiring diagrams.
Make correct shield connection.Refer to connection and wiring diagrams.correct?
NO
YESFind out which component of the crane electricis spiking out (e.g. dump valve, outrigger relay).Install a diode or varistor across terminals of spiking component. Diode type such as 1N 4001can be used (watch + and - connection for diode).
END
11.40
ERROR CODE DISPLAY
PROBLEMError code displayed. Lever lockout activated.
Warning lights on.
ERRORDISPLAY ERROR CAUSE ACTION
E 01* Below radius or above angle Fallen below the minimum Lower boom back to a radius range. radius or above the angle given or angle given in the load
in the load chart due to raising chart.the boom too far.
E 02* Beyond radius or below The maximum radius or Raise boom back to a radiusangle range. minimum angle given in the or angle given in the load
load chart was exceeded due chart.to lowering the boom too far.
E 03* Prohibited slewing range. Slewing range prohibited Slew back into admissible(no load area) with load. range.
E 04* Operating mode not available. Operating mode switch in the Set operating mode switchconsole set incorrectly. correctly to the code assignedOperating mode is not per- to the operating mode of themissible with actual crane crane.configuration.
E 05* Length range not permitted. Boom was telescoped too Telescope boom to correctfar or not far enough. length given in the load chart.
Length sensor adjustment See Section No. 3changed; i.e. length sensorcable slid off the cable drum.
E 06* Fallen below angle range with Fallen below the minimum jib Luff in the jib to a radius orluffing jib operation. angle specified in the angle specified in the load
respective load chart due to chart.luffing out the jib too far.
* This error can be corrected by the operator.
11.41
ERROR CODE DISPLAY ERROR
DISPLAY ERROR CAUSE ACTION
E 07 No acknowledgment signal Overload relay is stuck, Replace relay.from overload relay (K8). defective or not being selected.
E 08 No acknowledgment signal Anti-Two-Block switch relay Replace relay.from Anti-Two-Block switch is defective or not beingrelay (K9). selected.
E 11 Fallen below lower limiting Cable from central unit to length sensor Check cable. Replace ifvalue for the measuring defective, not connected or water in the necessary. See Section 3.
channel "length". connectors
Length potentiometer defective. Replace and reset lengthpotentiometer. See Section 3.
Electronic component in the Replace main board andmeasuring channel defective on reset pressure channels.main board. See Section 10.
E 12 Fallen below lower limiting Cable from central unit to Check cable as well as plug.value for the measuring the pressure transducer Replace if necessary.channel "pressure piston side". defective, loose or water in See Section 10.
the plug.
Pressure transducer on Replace pressure transducerpiston side defective. and reset pressure channel.
See Section 10.
Electronic component in the Replace main board andmeasuring channel defective reset pressure channels.on main board. See Section 10.
E 13 Fallen below lower limiting Cable from central unit to Check cable as well as plug.value for the measuring the pressure transducer Replace if necessary.channel "pressure rod side". defective, loose or water in See Section 10.
in the plug.
Pressure transducer on rod Replace pressure transducerside defective. and reset pressure channel.
See Section 10.
Electronic component in Replace main board andthe measuring channel defective reset pressure channels.on main board. See Section 10.
E 14 Fallen below upper limit value Cable from central unit to Check cable as well as plugs,in measuring channel "Force". force measuring point defective replace if need be.
or water inside the plugs. Force transducer defective. Replace force transducer.
Electronic component in the Replace main board and resetmeasuring channel defective. pressure channels. Section 10
11.42
ERROR CODE DISPLAY
ERROR DISPLAY ERROR CAUSE ACTION
E 15 Fallen below lower limiting Cable from central unit to the length/ Check cable.value for the measuring angle sensor defective or loose or Replace if necessary.channel "angle main boom". water inside plug. See Section 5.
Angle sensor defective. Replace angle sensor.and reset adjustment.
Electronic component in the Replace main board andmeasuring channel defective. reset pressure channels.
See Section 10.
E 16 Fallen below lower limit Cable from central unit Check cable as well as plug,value for measuring channel to angle sensor defective replace if need be."Luffing Jib Angle". or disconnected or water
inside the plug.
Angle sensor defective. Replace angle sensor.
Electronic component in the Replace main board and resetmeasuring channel defective. pressure channels.
See Section 10.
E 18 Front Stabilizer overloaded Exceeding capacities allowed for over Achieve a safe working areathe front. Immediately.
E 19 Error in the reference voltage. Electronic component on Replace main board and resetthe main board defective. pressure channels.
+5 volt supply See Section 10.
E 20 Error in the reference voltage. Bad power supply on Check wiring, replace ifmain board. need be.
-9 volt supplyBad force transducer Check force transducer cable,wiring, (external). replace if need be.
E 21 Upper limiting value for the Cable from central unit to the Check cable. Replace ifmeasuring channel "length" length/angle sensor defective necessary. See Section 3.exceeded. or loose.
Length potentiometer Replace and reset lengthdefective. potentiometer.
Electronic component in the Replace main board andmeasuring channel defective reset pressure channels.on main board. See Section 10.
11.43
ERROR CODE DISPLAY
ERRORDISPLAY ERROR CAUSE ACTION
E 22 Upper limiting value for the Cable from central unit to the Check cable as well as plug.measuring channel "pressure pressure transducer defective, Replace if necessary.piston side” exceeded. loose or water in the plug. See Section 10.
Pressure transducer on piston Replace pressure transducerside defective. and reset pressure channels.
See Section 10.
Electronic component in the Replace main board andmeasuring channel defective reset pressure channels.on main board. See Section 10.
E 23 Upper limiting value for the Cable from central unit to the Check cable as well as plug.measuring channel "pressure pressure transducer defective, Replace if necessary.rod side" exceeded. loose or water in the plug. See Section 10.
Pressure transducer on rod Replace pressure transducerside defective. and reset pressure channels.See Section 10.
Electronic component in the Replace main board andmeasuring channel defective. reset pressure channels.on main board. See Section 10.
E 24 Upper limit value in measuring Cable between central unit and Check cable as well as plug,channel "Force" exceeded. force measuring point defective replace if need be.
or water inside the plug.
Force sensor defective. Replace force sensor.
Electronic component in the Replace main board and resetmeasuring channel defective. pressure channels.See Section 7.
E 25 Upper limiting value for the Cable from central unit to the Check cable.measuring channel "angle length/angle sensor defective Replace if necessary.main boom" exceeded. or loose. See Section 5.
Angle sensor defective. Replace angle sensor and resetmechanical adjustment.Electronic component in the Replace main board and resetmeasuring channel defective pressure channels.on main board. See Section 10.
E 26 Upper limit value for See Error E 16. See Error E 16.measuring channel "LuffingJib Angle" exceeded.
11.44
ERROR CODE DISPLAY
ERRORDISPLAY ERROR CAUSE ACTION
E 29 Error in the reference Supply and Reference voltages on Check supply voltages. voltage. MP10 is more than 3.3V Electronic component on Replace main board and reset
-5 volt supply the main board defective. pressure channels.See section 10.
E 31 Error in system program EPROM with system Replace EPROM with systemprogram defective. program.
Electronic component on Replace main board and resetthe main board defective. pressure channels.
See section 10.E 37 Error in program run EPROM with system program Replace system program
defective. EPROM.Electronic component on the main Replace main board and resetboard defective. pressure channels.
See section10.
E 38 Incorrect system program. CPU is equipped with an Equip main board withincorrect version of system correct version of systemprogram. EPROM.
E 41 Error in the external RAM. RAM in the CPU on the Replace CPU Chip No. main board defective. 80C31. Replace main
board and reset pressurechannels. See Section 10.
E 42 Error in the external write/ Internal defect in Exchange write/read memoryread memory (RAM). digital part of CPU. (CMOS-RAM).
Replace main board and resetpressure channels.See Section 10.
E 45 Error in internal Defective electronic Replace main board andcommunications. component. reset pressure channels.
See Section 10.E 47 Malfunction in the Internal defect in Replace main board and reset
monitored write/read in digital part of CPU pressure channels.memory. See Section 10.
E 48 Malfunction in the monitored Inter defect in digital part of CPU Replace main board and resetpressure channels.See section 10
E 51 Error in data memory. Data EPROM on the main Replace Data EPROM.board defective. Make sure BR3 on the main
board is installed.See Drawing 4 on page 11.51.
11.45
ERROR CODE DISPLAY
ERRORDISPLAY ERROR CAUSE ACTION
E 60 Error in EPROM DATA-EPROM is not plugged into Properly install DATA-EPROMthe correct socket or location is not See page 11.51programmed correctly in the EPROM.
E 70 Error in return signal No or wrong return signal from digital Ribbon cable defective or badinput extension module to processor. Connection. Replace cable.
Digital input circuit defective.Replace module.Decoder circuit defective.Replace decoder module.
E 71 Incorrect acknowledgment of the A2B relay is stuck or defective. Replace K9 relay. See pageA2B Relay on A101 Term. board. 11.50
A2B relay is not being selected due to Check terminal board, maina break on the terminal board, main board and ribbon cables as wellboard or ribbon cable. as replace defective part, if
necessary.
E 72 – E 77 Analogous to E 71 for relays Analogous to E 71 for relays Analogous to E 71 for relaysK2 – K7 K2 – K7 K2 – K7
E 80 Error in return signal No or wrong return signal from analog Ribbon cable defective or badoutput extension module to processor. Connection. Replace cable.(for inner mid) Analog output circuit defective.
Replace module.Decoder circuit defective.Replace decoder module.
E 83 Boom not synchronized. The outer mid and fly section are not Select manual mode, manuallyfully retracted while the center mid retract the outer mid and flysection or the inner mid section section until fully retracted.retracts or extends. Return to auto mode.
Check fly section cable adjustment. The fly section
shall not be extended whencenter mid section is fullyretracted.
11.46
ERROR CODE DISPLAY
ERRORDISPLAY ERROR CAUSE ACTION
E 89 Change of the operating code The operating mode switch in the Lower the load and set theduring lifting a load. console was used during lifting operating mode switch correctly
a load. to the code assigned to theactual operating mode of the crane.
E 91 No data transmission from 24V supply of console Check 24V at terminal Xl ofconsole to central unit. interrupted. console electronics.(See page 11.38 - 11.40)
Interruption or accidental Check the connection betweenground in the line from console electronics andconsole electronics to central unit. If you find ancentral unit. accidental ground, the
transmitter module in theconsole electronics can bedamaged. You should, therefore, replace the console electronics.
Transmitter / receiver module Replace console electronics defective. or main board respectively.
E 92 Error in the data transmission Defective data line Check the connection betweenfrom console to central unit. from console electronics to console electronics and central(See page 11.38 - 11.40) central unit. unit.
Transmitter / receiver Replace console electronicsmodule defective. or main board respectively.
E 93 Error in the data transmission Defective contact in the line Check the line to the console.from central unit to console. from central unit to console.(See page 11.38 - 11.40) Transmitter / receiver Replace console electronics
module defective. or main board respectively.
E 94 No data transmission from Interruption or accidental Check the line to the consolecentral unit to console. ground in the data line from (in case of accidental ground(See page 11.38 - 11.40) central unit to console. also replace console
electronics).5V supply for the computer Check the connection to thein the central unit is missing. power supply.5V supply voltage too low. Replace power supply module.Transmitter / receiver Replace console electronics module defective. or main board respectively.
Data EPROM defective. Check data EPROM.
Computer module defective. Replace main board.
Electromagnetic interference’s Eliminate interference source(e.g. when switching by inverse diodes or varistors.contactors or valves).
11.47
ERROR CODE DISPLAY
ERRORDISPLAY ERROR CAUSE ACTION
E 95 Error in the crane data EPROM Data EPROM defective. Replace data EPROM.Position of jumper for the selection Check the jumper position.of the type of EPROM is wrong.Electronic component on main board Replace main board and resetdefective. pressure channels.
E 96 Error in the internal RAM of the CPU or main board of the console Replace console main board.CPU of the console. defective.
E 97 Error in the external RAM of the External RAM of the console Replace console main board.CPU of the console. defective.
Electronic component on the main Replace console main board.board defective.
E 98 Wrong jumper position in the The jumper position BR9/BR10 in the Check the jumper position.console. console does not correspond to the
actual type of central unit.Electronic component on the main Replace console main board.board defective.
11.48
1 2
X1 : BROWN
X2 : RED
3 4
Drawing 1 : Slip Ring Unit
Drawing 2 : Boom Nose Junction Box
11.49
1 3 5
2 4 6
7 9 11 13 15 17 19 21 23 25 27 29
8 10 12 14 16 18 20 22 24 26 2871 72 73 74
49 48 47
59 58 57 56 55 54 53 52 51 50
46 45 44
70 69 68 67 66 65 64 63 62 61 60
80 79 78 77 76 75 43 42 41 40 39 38 37 36 35 34 33 32 31 30
K10LEVER
LOCKOUT K6 K5 K3 K2
K7 K4 K1
K9 K8LMISHUTOFF
A2BSHUTOFF
1 2 3 4
X3
X4
F1
F8 F7 F6 F5 F4 F3 F2
R13 R14 R11 R12 R7 R8 R5 R6
R15 R16 R9 R10 R3 R4
R2 R1
X4
H9
V2
H8
V1
X1 X1
X1 X1
X1
X1
X1
X1X1
X1
X1
H7
V11
H4
V8
H1
V5
H6
V10
H5
V9
H3
V7
H2
V6
H10 V3
R17R18
OU
TER
MID
OU
T O
FSE
QU
ENC
E
CEN
TER
MID
4 - W
AY
RO
D
DR
AIN
INN
ERM
ID
OM CM 4W SEQ
ROD
IM
Drawing 3 : Terminal Board
11.50
Power Supply Test Points:MP 1 = +5V E-1MP 2 = -5V E-4MP 11 = Ground H-4MP 12 = +5V B-7MP 13 = Digital Ground B-7MP 15 = Analog Ground E-1MP 19 = -5V E-1
Analog Measuring Channels / Test Points:Ch. 1 Boom Length - MP 6 / P6(Do Not Adjust) G-3Ch. 2 Piston Pressure - MP 4 / P4 G-4Ch. 3 Rod Pressure - MP 5 / P5 G-3Ch. 5 Bom Angle - MP 8 / P8(Do Not Adjust) G-2
Drawing 4 : Main Board
11.51
Drawing 5 :Console Board
11. 52
1 2 3 4 5 6 7 8 1 2 3 4
MP 2+7V
MP 5+5V
MP 0GND
MP 3-24V
MP 4-24V
MP 6
MP 7
MP 1+UB
J5
J4
J3
J1
J2
X1
X5
PAT
PAT
1 2 3 4 5 6 7 8 9 101112 131415 16
ADJUST LENGTH POTENIOMETERWITH BOOM FULLY RETRACTED,TURN THE CENTER SCREW COUNTER-CLOCKWISE TO A SOFT STOP.
Drawing 6 : Length / Angle Transducer
11.53
(BOTTOM VIEWOF C.P.U.)
FUSE (2A)
FUSE (10A)
Drawing 8 : Central Unit Box
OUT IN
NORMALOPERATION
L/OOVERRIDE
+ _
COMPONENTCAUSING
INTERFERENCE
SUPPRESSOR DIODE
CAUTION: Make sure that + and - diode connections aremade as shown to ensure proper polarity.
Drawing 7 : Suppressor Diode
OVERRIDEKEY SWITCH
11.54
P.A.T. – L.M.IMANUAL
SECTION 11APPENDIX
DS 350 GRAPHIC BCSBOOM LENGTH
TROUBLESHOOTINGPROCEDURE
5 Section Boom
Problem :Outer Mid section and Fly will not extend.
Reason:Center Mid section indicates 96% - 97% extention on the PAT even though boom Section is fullyextended.
Findings:Cable reels are spooling properly.
Switch to manual mode and retract all sections with the boom stop pulled.Boom percentages should indicate a 0% - 0% - 0%
If not check the proximity switchesProximity switches are all four being made when boom is fully retracted to reset zero point withswingaway stop pulled down.Proxy switch Terminal to check in reference to Ground( X1/ 36)OM/Fly Retracted A 104 X 1/76CM Retracted A 114 X 1/9IM+CM Retracted A 104 X 1/78 The red LED will be illuminated when switch is on.IM % Reset A 104 X 1/80 All four should have a minimum of
20 volts
If still not correctReset the length potentiometers by turning them counterclockwise until they stop with the boom fullyretracted.
If still not correctPress the outer two keys simultaneously ( F1& F4 on the PAT console) to obtain the length indication forthe inner mid and center mid.With the boom stop disengaged the total length retracted should be 35.4 and extended 137.8With the inner mid extended it should read 61.0With the inner mid and the center mid extended it should read 86.6
If still not correctCheck the voltage on terminal #6, #7 and #9 on the main board for .495 to .500 volts with the boom fullyretracted. If off, reset per the calibration papers inside the box.Ch. #3 - Force transducer not usedCh. #4 - Rod transducer - Do not touchCh. #5 - Piston transducer-Do not touchCh. #6 - Total Overall Length - (top reel)Ch. #7 - Center mid / Inner mid - (middle reel)Ch. #8 - Angle transducer - Do not touchCh. #9 - Inner mid - Bottom reel
Appendix 1
TMS / TTS 870 BOOM CONTROL SYSTEM ( M4XT V2.3 C )
A. Testing boom length calibration and boom percentage.
Caution: Elevate the boom to a permissible load chart radius.
Switch to Manual mode and retract all sections with the boom stop pulled.Boom percentage indication on console shall read 0% - 0% - 0%.Select Manual mode and IM and extend IM fully. Indication 100% (+ / - 1 %) - 0% - 0%.Select Manual mode and CM and extend CM fully.Indication 100% (+ / - 1 %) -100% (+ / - 1 %) - 0%.Select Manual mode and OM / Fly and extend OM / Fly fully.Indication 100 % (+ / - 1 %) - 100 % (+ / - 1 %) - 100 % (+ / - 1 %)
Should indication differ ensure that boom stop was pulled, when fully retracted and all sections aremechanically extended.
If still not correct go to step B.
B. Correcting boom length and % indication.
Caution: Elevate the boom to a permissible load chart radius.
Switch to Manual mode and use the section selector switches in the cab for the duration of the followingprocedure.Retract the boom fully with the boom stop pulled.Reset carefully the potentiometer inside the length and length angle sensors counter clockwise until stop.
Repeat test A. If still not corrected proceed below.
On the horizontal line of the graphic console press the two outer keys simultaneous to obtain the lengthindication for IM and CM in a test picture.With the boom stop disengaged calibrate the total length to retracted 35.4 and extended 137.8. Read theboom length on the graphic console.With the boom stop disengaged calibrate the IM length to retracted 35.4 and extended 61.0. Read theboom length on the graphic console in the test picture.With the boom stop disengaged calibrate the IM + CM length to retracted 35.4 and .extended 86.6. Readthe boom length on the graphic console.Transfer data into Eprom and check out length indication as described above.
Repeat test A. If still not corrected proceed with test C.
Appendix 2
C. Testing the retract and boom % reset switches
Switch to Manual mode.
With the boom stop engaged retract boom fully.Lower the retracted boom in order to reach the switches.Switch the engine of but leave the electrical power on.
The Red LED on the proximity switch shall be switched on for the OM / Fly, CM, IM + CM retract andIM % reset switch. If not adjust the targets to the correct position. If still not check the power supply toeach switch using the wiring diagram.
If all LEDs are switched on check the signal voltage returning to the central unit terminal. The voltageshall not be lower than 20 Volts with reference to crane GND ( Xl - 36 ) for
OM / Fly retract A104 X 1 / 76 CM retract A l 14 X 1 / 9 IM + CM retract A 104 X 1 / 78 IM % reset A 104 X1 / 80
Once identified which circuit is not powered use the wiring diagram to locate the wiring problem.
Note: With the boom stop engaged and the IM reset switch signal on the system is programmed toindicate 1 % extension for the IM section. To read 0 % you must pull the boom stop down and pass thetarget.
The IM reset target must be adjusted with the boom stop engaged and the boom fully retracted onto theboom stop. The IM + CM retract switch has two targets providing the boom is equipped with boom stopretracted against boom stop and another target for retracted against base section. Do not attempt to adjusttargets if the two positions are not met. Incorrect adjustment could cause cylinder damage.
D. Boom does not extend or retract while Auto mode is selected.
Switch to manual mode and retract the boom.
When fully retracted select a legal operating mode on graphic console.
Switch to auto mode and to mode A or B.
Ensure that no other LMI error, A2B or overload exists.
Have the operator start the engine and push the extend control.
Measure extend pressure switch signal on terminal A 104 Xl / 38 in the CU ( approx. 24 Volt referencecrane GND ).
Appendix 3
If not use the electrical diagram to identify the cause. Measure signal of pressure switchlocated on the right, inside the valve bank compartment. Disconnect wire 387 from the switch andmeasure voltage on switch output terminal.
Have the operator start the engine and push the retract control.
Measure retract pressure switch signal on terminal A l 04 Xl / 40 in the CU( approx. 24 Volt reference crane GND ).
If not, use the electrical diagram to identify the cause. Measure signal of pressure switch located on thecontrol valve. Disconnect wire 388 from switch and measure voltage on switch output terminal.
Replace switch or rectify the wiring problem.
If signals are correct and problem is not resolved go to E.
E. Testing the boom control signals
Retract the boom.
Switch to Manual mode.
Switch to IM and measure on Al 04 -Xl / 54, 66, 69 in CU. No voltage.
Measure at the cathode of the diodes which are connected to terminal 54, 66, 69 or at the cathode terminalof the diode matrix board. Should measure, crane voltage ( 24 Volt on cathode of diode connected to 66,69 and no voltage on the cathode of the diode connected to 54.
Switch to CM and measure on Al 04 -Xl / 54, 66, 69 in CU. No voltage.
Measure at the cathode of the diodes which are connected to - terminal 54, 66, 69 or at the cathodeterminal of the diode matrix board. - Should measure crane voltage ( 24 Volt on cathode of diodeconnected to 54, 69 and no voltage on the cathode of the diode connected to 66.Switch to OM / Fly and measure on Al 04 - X l / 54, 66, 69 in CU. No voltage.
Measure at the cathode of the diodes which are connected to terminal 54, 66, 69 or at the cathode terminalof the diode matrix board. Should measure crane voltage 24 Volt on cathode of diode connected to 54,66 and no voltage on the cathode of the diode connected to 69.
If any of the above Xl terminals has crane voltage replace diode or diode matrix board. If the voltagesequence is incorrect on the cathode of the diodes refer to the Grove electrical documentation and checkwiring.
Switch to Auto mode and measure crane voltage an terminal Al 04 -Xl / 42.No voltage should be measured on the terminals 54, 66, 69 or on the cathode of the diodes.
Appendix 4
Switch to mode A and measure crane voltage 24 Volt on terminal Al 14 -Xl / 3 ( DI extension board ) . Switch to mode B and measure no crane voltage on terminal Al 14 - Xl / 3 ( DI extension board ).
Start the engine and have the operator slowly push the tele out controls. Carry out the following test.
Be sure: boom is fully retracted and B mode selected.
A 104 X1 / 54 = NO VOLTAGE A 104 X1 / 66 = 24 VOLT A 104 X1 / 69 = 24 VOLT When the IM has reached 50% the system switches to extend the CM. Measure:
A104 Xl / 54 = 24 Volt A104 Xl / 66 = NO VOLTAGE A104 Xl / 69 = 24 Volt
When the IM and the CM have reached 100 % the system switches to extend the OM / Fly, Measure:
A104 X1 / 54 = 24 Volt A104 X1 / 66 = 24 Volt A104 X1 / 69 = NO VOLTAGE
If one of above measurements is incorrect check the fuses F3, F7, F8 for relay contacts K2, K6, K7on the terminal board.
Check relay K2, K6, K7.
Connect an Amp meter in series with wire 20 and terminal Al 04 Xl / 63. When extending the boom inAuto mode the ramping value should climb up to a 800 mA with fully open solenoid valve.
Connect an Amp meter in series with wire 21 and terminal Al 04 Xl / 64. When retracting the boom inAuto mode the ramping value should climb up to a 800 mA with fully open solenoid valve.
If one of above fails check fuse F6 and relay K5 on the terminal board inside CU. Connect an Amp meter in series with the black wire removed from terminal A111 X1 / 6 and
terminal A111 X1 / 6. When extending or retracting ( depends on the direction controlled by theoperator) the boom in Auto mode the ramping value should climb up to a 800 mA with fully opensolenoid valve.
Should the measurement fail check for complete solenoid circuit - Check solenoid coil resistance forcontinuity. Check for good analog ground from A111 board to solenoid. Connect Ohm meter to theremoved wire ends of terminal A111 Xl / 5 and 6 and test closed circuit. Note that you will not measureany electrical current when the circuit is interrupted.Rectify wiring or solenoid coil failure and test again.
Appendix 5
Changes in the boom control circuit
Obsolete the 3- way valves for IM, CM & OM in the boom.
A pair of 2 - way valves for each cylinder. De-energize the pair to allow operation of the particulartelescope cylinder. Energize the other 2 pairs to prevent movement of the other telescope cylinder.
Instead of 3 separate proportional valves for each section - now use two proportional valves ( retract andextend ). Signal extend from NO contact of K5. Signal retract from NC contact of K5. The current toopen the valve fully is now 800 mA.
A CM retract switch is added to monitor CM fully retracted. The signal is used to monitor CM fullyretracted and CM % reset to 0.
The OM / Fly retract switch is additionally used as OM / Fly % reset switch.
An additional rod drain valve is added. See below.
All relays controlling the 2 way valves are de-energized in manual mode. The two way valves arecontrolled manually by switches in the cab.
All relays controlling the 2 way valves are de-energized in neutral.
Appendix 6
Test Procedure
PAT DS350 Boom Control System
RT865BXL, TMS / TTS870 With 5 Section Boom
A. Purpose:This procedure is designed to be an aid in verifying the operation and defining the proper test methods forthe wiring and control circuitry of the PAT DS350 Boom Control System.
B. Personnel required to perform these tests:
2
C. Equipment and Tools required to perform these tests: a. Digital multimeter b. Central unit key c. Medium flat blade screwdriver d. Medium philips screwdriver e. 10mm socket or nut driver f. Small flat blade screwdriver
D. Sub Assembly Description:
Reference Number Part Number ( PAT ) Descriptiona. A104 024 - 350 - 300 - 092 Extension Boardb. A111 024 - 350 - 300 - 135 ( B ) Analog Control Boardc. A114 024 - 350 - 300 - 301 Digital Extension Board
E. System description ( basic ): The PAT DS350 Boom Control System ( designated as System Under Test or SUT ) it is amicroprocessor controlled system that optimizes the boom configuration during lift operations. Tounderstand the basic theory of the system, one must think in terms of action - reaction, i.e. for every actionthere is a controlled reaction.The following description assumes that the boom is fully retracted, the boom extension stop block is dis -engaged, Auto Mode is selected, and that an extend operation is to be performed. The reverse of thisdiscussion is true for retract operations. The sequence of events that must occur for the boom to startmoving is as follows:
1. The SUT detects whether the operator has selected Automatic mode or Manual mode, and in Automode, whether Mode A or Mode B is selected. The Auto / Manual switch toggles a digital input onA104 - X1 - P42. If Auto is selected, this signal will be high ( from here on out, all signal levels will bespecified as either high or low. A high signal being crane voltage, 24 V, and low being near groundlevel ), if Manual is selected, the signal is low. Mode A or B operations are controlled with a switchlocated in the cab. This switch controls the A114 - X1 - P3 input. A high signal indicates Mode A, a lowindicates Mode B. If the Auto mode is selected, the status of Mode A / B switch can be readily seen onthe A114 board by looking at the H2 LED. If the LED is illuminated, Mode A is selected, if it is not thenMode B is selected.
Appendix 7
2. The SUT senses that the foot pedal has been depressed by the output of a pressure switch. There are two( 2 ) pressure switch’s built into the foot pedal circuitry, one is for boom extend and the other is for boomretract operations. The output of these switches are piped into the SUT as digital inputs. These switchesare normally open and switch crane voltage ( 24V ) on or off. Assuming that an extend operation is beingperformed, A104 - X1 - P38 ( DI - 1 ) will go high and A104 - X1 - P39 ( DI - 2 ) will be low.
3. Once DI - 1 is detected, the A104 relay K - 5 is energized applying a veritable voltage signal ontoX1 - P63. This analog control is generated from the A114 board, A114 - X1 - P6, and is a variable voltageoutput that is determined by a digital code supplied by the microprocessor. This code is determined by theposition of each section of the boom and the mode of operation.
4. There are three ( 3 ) control signals that are supplied by the SUT that determine which section of theboom will be selected. The logic of these signals are such that to select a section the signal level to thatsections control valves must go low. Each section has two ( 2 ) control valves, for a total of six ( 6 ) thatmust be de - energized in tandem. One valve is pilot pressure and the other is the main flow valve. TheSUT supplies control from the following terminals:
Inner Mid ( IM ) A104 - X1 - P54 to boom base junction box P - 19 and P - 24 Center Mid ( CM ) A104 - X1 - P66 to boom base junction box P - 20 and P - 26 Outer Mid / Fly ( OM/F A104 - X1 - P69 to boom base junction box P - 28 and P - 29
If no boom operations are selected, all of these signals will be low, but whenever an extend / retractoperation is selected, these signals become active and control the flow of hydraulic oil. The logic table forthese valves is as follows:
IM CM OM /F
A104 - X1 - P54 0 1 1A104 - X1 - P66 1 0 1A104 - X1 - P69 1 1 0
( NOTE : 1 = high, 0 = low )
5. Flow control of hydraulic oil for the IM is as follows:a. A104 - X1 - P54 stays low as A104 - X1 - P66 and A104 - X1 - P69 go high. This initializesboth the IM 2 - way valves for hydraulic flow.b. The analog board, A111 - X1 - P6, generates the control voltage for voltage for theproportional valves. This signal is directed to either the extend or retract sections of theproportional valve by the action relay K5 located on the A104 board, A104 - X1 - P63 for extend,A104 - X1 - P64 for retract. The proportional valve, located in the superstructure, will control thepressure of fluid to the cylinder depending on the current output from the A111 board, 800mAyields full flow, 0mA yields full restriction of fluid.c. An extend signal is generated from the SUT, A104 - X1 - P63, that energizes the piston side ofthe cylinder. This will allow fluid to enter the piston side to extend.
6. The sequencing of the sections are determined by the mode selected and are detailed on the attachedsheet. The IM will extend at full speed until the cross over point is reached, 50% in mode B. At this pointthe speed of the section will ramp down and then stop, then the CM will start to extend under the sameconditions as the IM.
Appendix 8
TMS /TTS870 Boom Sequence, Auto Mode A and B
Mode ( A / B ) IM % CM % OM / Fly % A 0 0 0 A 0 100 0 A 0 100 100 A 100 100 100 B 0 0 0 B 50 0 0 B 50 50 0 B 75 50 0 B 75 75 0 B 100 75 0 B 100 100 0 B 100 100 100
7. During the retract sequence, the operation is the same with the exception of the presence of theproximity switches. These switches are used to detect when the applicable boom section is fully retracted.If the OM / Fly section is being retracted, the OM / Fly switch must turn on or an E - 83 error will appear.This will not lock out the system but will make the telescope out of sequence light to illuminate. If theCM is being retracted, the CM switch must turn on when fully retracted before the IM will start to retract.If this fails to happen, the IM will not retract and the telescope out of sequence light will illuminate.Testing of these switches will be detailed in the test section.
F. Preliminary Adjustments
1. Using the 10 mm nutdriver, remove the lids from each of the cable reels.2. Verify that all boom sections are fully retracted and that the stop block is disengaged.3. Preset each of the length sensors to the minimum by turning the slot in the gear wheel fullycounter clockwise until it comes to a soft stop.
G. Testing the SUT:
1. Start the crane. 2. Program the PAT console to the correct operating mode. 3. Place the Auto / Manual switch in the Manual position.
OK_______ 1. Verify that the maximum load on the console is approximately 2000 lb.
OK_______ 2. Place the boom select switch into the IM position, verify that the IM lamp illuminates.
OK_______ 3. Extend the IM about 2 ft. to verify that the IM does extend, then completely retract the IM.
OK_______ 4. Place the boom select switch into the CM position, verify that the CM lamp illuminates.
OK_______ 5. Extend the CM about 2 ft. to verify that the CM does extend, then completely retract theCM.
Appendix 9
OK_______ 6. Place the boom select switch into the OM / Fly position, verify that the OM / Fly lampilluminates.
OK_______ 7. Extend the OM / Fly about 2 ft. to verify that the OM / Fly does extend, then completelyretract the OM / Fly.
4. Open the central unit and the boom base junction box.
OK_______ 8. Verify that wires 11 and 12 from the 19 pin cannon plug are wired to pins L and M.
OK_______ 9. Using the meter, monitor the Manual / Auto input signal on A104 - X1 - P42, using thechassie as ground. Verify that the signal level in Manual mode is low and high in Automode.
OK_______ 10. Using the meter, monitor the telescope extend pressure switch input, A104 - X1 - P38.Extend the boom to verify that the signal goes high.
OK_______ 11. Using the meter, monitor the telescope retract pressure switch input, A104 - X1 - P39.Retract the boom with the stop block engaged to verify the signal goes high.
OK_______ 12. Select Auto mode and monitor the input at A114 - X1 - P3 to verify that the signal goeshigh when in the A code, and low in the B code.
OK_______ 13. Select Auto mode A, and monitor the extend analog voltage control signal,A104 - X1 - P63, Extend the boom to verify that the signal goes to a higher level, around25 volts. Retract the boom with the stop block engaged.
Record Voltage ____________
OK_______ 14. Disconnect wire 20 from A104 - X1 - P63 on the extension board. Set the meter tomeasure current, 10 amp setting. Connect the black lead to A104 - X1 - P63 and the redlead to wire 20. Extend the boom to verify that the current is between 750 mA and 850mA. Reconnect wire 20.
Record Current ____________
OK_______ 15. Select Auto mode A, using the meter monitor the retract analog voltage control signal,A104 - X1 - P64. Extend the boom about 10 ft., then retract the boom to verify that thesignal goes to a higher voltage level, around 25 volts.
Record Voltage ____________
OK_______ 16. Disconnect wire 21 from A104 - X1 - P64 on the extension board. Set the meter tomeasure current, 10 amp setting. Connect the black lead to A104 - X1 - P64 and the redlead to wire 21. Extend the boom about 10 ft., then retract the boom to verify that thecurrent measurement is between 750 mA and 850 mA.
Record Voltage ____________
Appendix 10
OK_______17. Select Manual mode, and ensure the boom is fully retracted with the stop blockdisengaged. Verify that the boom is fully retracted onto the base section.
OK_______ 18. Using the meter, monitor the signal from proximity switch 1, OM / Fly retract signal onA104 - X1 - P76 and verify a high signal.
OK_______ 19. Using the meter, monitor the signal from proximity switch 2, CM / IM retract signal onA104 - X1 - P78 and verify a high signal.
OK_______ 20. Using the meter, monitor the signal from proximity switch 3, length reset signal onA104 - X1 - P80 and verify a low signal.
OK_______ 21. Using the meter, monitor the signal from proximity switch 4, CM retract signal onA114 - X1 - P9 and verify a high signal and H5 LED is illuminated.
5. Extend all boom sections about 5 ft.
OK_______ 22. Using the meter, monitor each proximity switch signal, each should be low.
OK_______ 23. Using the meter, monitor the OM / Fly proximity retract switch input signal onA104 - X1 - P76. While retracting the OM / Fly verify the signal changes from low tohigh, until the sections bottoms out.
OK_______ 24. Using the meter, monitor the CM proximity retract switch input signal onA114 - X1 - P3. While retracting the CM verify the signal changes from low to high,until the section bottoms out.
OK_______ 25. Using the meter, monitor the CM / IM proximity retract switch input signal onA104 - X1 - P78. While retracting the CM - IM verify the signal changes from low tohigh, until section bottoms out.
OK_______ 26. Using the meter, monitor the length reset proximity switch signal on A104 - X1 - P80 toverify the signal is high.
OK_______ 27. Fully retract all boom sections and switch to Auto mode. Using the meter, monitor thetelescope out of sequence signal on A104 - X1 - P61 to verify the signal is low.
OK_______ 28. Telescope the boom out approximately 5 ft. in mode B. Switch to Manual mode andtelescope the CM out about 5 ft. Switch to Auto mode and verify the signal level onA104 - X1 - P81 is high and the telescope out of sequence light is illuminated.
OK_______ 29. Using the meter, monitor the front outrigger overload signal on A111 - X1 - P6. Duringnormal operation, this should stay high. Disconnect wire17 from from this terminal.Install a jumper wire from ground, A111 - X1 - P4, to the front outrigger overload inputsignal, A111 - X1 - P6. Verify that the console displays E - 18 error code. Remove thejumper wire and install wire 17 to A111 - X1 - P6.
Appendix 11
OK_______ 30. Fully retract all boom sections and select Auto mode. Using the meter, monitor thetelescope rod drain signal on A104 - X1 - P57 and verify the signal is low.
OK_______ 31. While telescoping out, monitor the signal on A104 - X1 - P57 to verify the signal stayslow.
OK______ 32. While monitoring the telescope rod drain signal on A104 - X1 - P57, stop extending theboom at about 5 ft., when the extend operation stops and boom comes to a rest, verifythat the signal goes high.
NOTE:Ensure that all safety precautions are performed
before performing the following steps. Ensure that theoutriggers are fully extended and jacks are down, and
properly set.
OK_______ 33. Fully retract all boom sections with the boom stop block engaged. Select Auto mode Aand raise the boom to approximately 60 degrees.
OK_______ 34. Fully extend the boom and verify that each section sequence as listed on the attachedsheet.
OK_______ 35. Retract the boom and verify the sequence is the inverse of extend.
OK_______ 36. Fully retract all boom sections with the boom stop block engaged. Select Auto mode Band raise the boom to approximately 60 degrees.
OK_______ 37. Retract the boom and verify the sequence is the inverse of extend.
G. FinalIf all these tests pass, the system is operational and ready for calibration. Provide the crane model number,serial number, the PAT CPU part number, serial number, sign and date this page and return to ProductSupport Service Department.
Crane Model Number: ___________________ S /N:_______________
PAT CPU Part Number:__________________ S / N_______________
Signature:____________________ Date:_______________
Appendix 12
TMS870,TTS870 & RT865B 5 Section Boom Drift Test
PURPOSE:
To determine the cause of the telescope cylinder drift.
TEST DESCRIPTION:
The boom shall be loaded with each section extended approximately 1- 1/2’ to 2’ to determine the cause of suspected leakage in the telescope cylinder or hold valve. The boom is only partially extended to reduce the effects of thermal contraction of the oil in the cylinders. TEST PREPARATION:
1 Reeve the machine with a minimum of two parts line. 2 Fully retract boom and extend each section (in manual mode) from 18” to 24” and mark off 1” increments for 6” on the Inner, center and outer mid sections. 3 Select a load (including hook block) between 20,000 to 25,000 pounds and position it at a 25’ to 30’ radius.
TEST PROCEDURE:
1 Switch boom control system to automatic mode. (Note: Boom will be out of sequence.)
2 Hoist load approximately 2’ off of the ground with the boom nose positioned over the load. Keep the engine running or the ignition switch on during the test.
3 Observe the marks on the boom sections for 30 minutes to determine which section(s) are retracting. A slight compression of the oil is normal when the load is picked. Approximately 1” per section would be expected. The sections should extend back to the original position when the load is lowered to the ground.
4 Hoist the load to the ground, observe and record the movement of the marks on the boom sections.
5 Determine which section(s) are retracting and reposition the boom sections to there original positions.
6 Switch boom control system to manual mode and select a section that is not retracting. This Will help to determine if the hold valve is leaking or if the cylinder has an internal leak.
Appendix 13
TMS870,TMS870 & RT865B Hold Valve Drift Test – continued
7 Repeat steps 2 through 5. If the section(s) do not retract in the manual mode, the hold valve is most likely leaking. If the section retracts, the cylinder may have an internal leak or both the hold valve and the two way valve on the piston side are leaking. NOTE: The piston side two way valves located inside the boom are N.O. valves connected in-line with the hold valves. When in the Automatic Mode with the telescope controller in the neutral position and the power on, the piston side two way valves are not powered shut. This permits any leakage past the hold valve to drain through the piston side drain valve and the .078 in line orifice. When in the Manual Mode under the same conditions, the two way valves are powered shut on the sections not selected. This should block any leakage from the hold valve and prevent the cylinder from retracting. Prior to assuming that the cylinder has a leak, the two way valve should be checked to ensure that 24 volts are present at the valve with the system in manual mode with an other section selected. Thermal contraction will cause a cylinder to retract as the fluid in the cylinder cools. The change in length of the cylinder is proportional to the extended length of the cylinder and the change of the temperature of the oil in the cylinder. The coefficient of expansion for API Group 1 oil is approximately 0.00043/ 0F. A cylinder that is extended 25’ which has had the oil cool 100 F would retract about 13 “as the oil cools. A cylinder that is extended 2’ which has had the oil cool 100 Degrees F will retract about 1” due to the thermal contraction. Testing the boom almost fully refracted greatly reduces the effect of thermal contraction and ensures a proper diagnosis of the system.
Appendix 14
P.A.T. – L.M.IMANUAL
SECTION 12
DS 350 GRAPHIC BCSELECTRICAL DIAGRAMS
A 104 X1 12 13 14 15 16 17 18 19 20 21 28 29 30 31 32 33 44 46 7 8 10 11 9 35 34 24 73 43 36 80 78 76
1 2 3 4
A B C DA B C D
PRES. TRANS.(ROD)
1 2 3 4
A B C DA B C D
PRES. TRANS.(PISTON)
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10 11 12 13 14
14 SOCKET PLUG
14 PIN PLUG
A B C D E F G H I J K L M N
A B C D E F G H I J K L M N
X1 1 2 3 4 5 6 7 8
+24V
GND TX
DR
XDC
OM
.A
2B LMI
DI
X7 1 2 3 4
X812
1 2 3 4 5 6 7 8 9 10 11 12 13 14
+24VGND CONSOLE
1 2 3 4 IS 1 2 3 4 IS
11 12
13 14+24V
1 4 3 2 5 6 7 8 9 GN
/YL
12.1
To page 12.2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 IS
To Boom BaseJunction Box
TMS/TTS 870WIRING CONNECTIONS
A
IS +5V
AG
ND
-5V
PRES
S. R
OD
SIG
.IS +5
VA
GN
D-5
VPR
ESS.
PIS
TON
SIG
.
+24V
TXD
RX
DG
ND
LMI B
YPA
SSA
2B B
YPA
SS
IS AG
ND
LEN
GTH
(O.A
. BO
OM
)
-5V
AN
GLE
A2B
SIG
NA
LA
2B G
ND
LEN
GTH
(IM
)LE
NG
TH (C
M)
PRO
XY
(+)
GN
DD
I 6 (P
RO
XY
3 L
ENG
TH R
ESET
)D
I 5 (P
RO
XY
2 C
M/IM
RET
RA
CT)
DI 4
(PRO
XY
1 O
M/F
LY R
ETRA
CT)
HIG
H=A
UTO
/ N
ON
E=M
AN
UA
L
+24V
GN
D
LMI U
NLO
CK S
OLS
TELE
EX
T. P
RESS
. SW
.
TELE
RET
RA
CT P
RESS
. SW
.
OM
/FLY
TEL
E
CM T
ELE
IM T
ELE
TELE
OU
T O
F SE
Q.
HIG
H S
IGN
AL
= A
UTO
MO
DE
A
NO
SIG
NA
L =
AU
TO M
OD
E B
FRO
NT
O/R
OV
ERLO
AD
TELE
PRO
P A
NA
LOG
GN
D
TELE
RO
D D
RA
IN S
OL
TELE
EX
T PR
OP
SOL
TELE
RET
RA
CT P
ROP
SOL
1 2 3 4 5 6 A111X1 3 4 5 6 9 10 A114
X1 22 47 53 54 65 66 68 69 56 57 1 2 3 4 48 38 40 42 36 37 39 41 75 77 79 59 61 49 62 63 64
IS +24V
K2
(CO
M) +
24V
DI E
2+2
4=M
OD
E A
0V
=MO
DE
BD
I E2
GN
D[
DI E
3 (+
24V
)D
I E3
(GN
D=F
RO
NT
O/R
OL)
DI E
5 (+
24V
=CM
RET
)D
I E5
GN
D
K2
(NO
) +24
V T
O IM
2-W
AY
SO
LS
K6
(CO
M) +
24V
K6
(NO
) +24
V T
O C
M 2
-WA
Y S
OLS
K7
(CO
M) +
24V
K7
(NO
) +24
V T
O O
M/F
LY 2
-WA
Y S
OLS
K3
(CO
M) +
24V
K3
(NO
) +24
V T
O T
ELE
RO
D D
RA
IN+2
4V+2
4VG
ND
GN
DK
10 (N
O) +
24V
TO
LM
I UN
LOC
K S
OLS
DI 1
(+24
V=T
ELE
EXT
PRES
SW
)D
I 2 (+
24V
=TEL
E RE
T PR
ES S
W)
DI G
ND
DI 1
GN
D
DI 3
(+24
V=A
UTO
MO
DE
DI 2
GN
DD
I 3 G
ND
DI 4
GN
DD
I 5 G
ND
DI 6
GN
D
K4
(CO
M) +
24V
K4
(NC)
+24
V T
O T
ELE
OU
T O
F SE
QK
10 (N
C) +
24V
TO
LM
I L/O
ALA
RM
K5
(CO
M)
K5
(NO
) OU
TPU
T TO
EX
T PR
OP
K5
(NC)
OU
TPU
T TO
RET
PRO
P
+24V
+24V
GN
D
GN
DA
GN
DA
1 (P
RO
P)
DI EXTENSION BOARD24 350 300 301
4 5 6 7 8 9 10 11 12 A113X1
1 2 3 4 5 6 9 8
9
1 4 6 9 8 1 0
8
7
7
2 3 5 7 11 12 13 14
12
19 10 11 12 13 14 15 20 21 18 16 17 22 23 24 25
IS
A B C D E F G H J K L M N O P Q R S T U V W X A B C D E F G H J K L M N O P Q R S T U V W X
1 2 3 4 5 6 7 8 9 101112 13 14 15 1617 1819 20 2122 23 24 25
71 51 73 387
388
239
242
243
244
323
240
147
238
1083
255
257
23 -
SOCK
ET R
ECEP
TS/
S H
ARN
ESS
(REF
)
LMI - CRANE INTERFACE23 - PIN PLUG
TMS/TTS 870INTERFACE
12.2
B
CO
NT
INU
ED
FR
OM
PA
GE
12.1
To Boom BaseJunction Box
12.3
SIG
. A
GN
D-5
V
AG
ND
SIG
.-5
V
1 14 2 3 4 5 6 7 8 9 10 11 12 13 IS
A B C D E F G H J K L M N P
14 SOCKET PLUG
A
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14
9 10 11 12 13 14 15 16 17 18
A B C D E F G H J K L M N P
19 20 21 22 23 24 25 26 27 28 29 30 31
A B C D E F G H J K L M N P R S T U V
A B C D E F G H J K L M N P R S T U V
1 2 3 4 5 6 7 8 9 10 11 12 13 14 IS
1 2 3 4 5 6 7 8 9 10 11 12 14
B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7
LENGTHTRANSDUCER
LG208 (TO NOSE)
BRN
RED
1 2 3 4
VV
V V
A B A B
4.7K
1 2
321
3=RED2=BRN1=BLKCORE
SHEI
LD
001 2 3
4.7K
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
AG
ND
SIG
.-5
V
LENGTHTRANS.
ANGLETRANS.
BRN
RED
OR
GY
ELG
RN
BLU
VIO
GR
AW
HT
BLK
WH
T/BL
K
1 2 3 4 5 6 7 8 9 10 11
1 2 3 13 8 6 4 9 14 12 7 5 10 11
1 2 3 4 5 6 7 8 9 10 11 12
BRN
RED
OR
GY
ELG
RN
BLU
VIO
GR
AW
HT
BLK
WH
T/BL
K
SHD
WH
TB
RN
GR
NC
RE
BLK
RED PN
KY
EL BLU
VIO GR
A
LENG
TH/A
NG
LELWG
221 (TOC
M)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
AG
ND
SIG
.-5
V
LENGTHTRANS.
BRN
RED
OR
GY
ELG
RN
BLU
VIO
GR
AW
HT
BLK
WH
T/BL
K
1 2 3 4 5 6 7 8 9 10 11
1 2 3 6 7 12 4 9 10 5 8 11
1 2 3 4 5 6 7 8 9 10 11 12
BRN
RED
OR
GY
ELG
RN
BLU
VIO
GR
AW
HT
BLK
WH
T/BL
K
SHD
WH
TB
RN
GR
NC
RE
BLK
RED PN
KY
EL BLU
VIO
GR
A
LENG
TH/A
NG
LE LG221 (TO
IM)
C D
2 4 31
1342 E
1 7 2 3 4 5 6
13 3 1 2 4 6 7 5 8 9 10 11 12 14
31
1 3 2 4 5 9 6 7 13 8 10 11 14 12
TMS/TTS870WIRING
CONNECTIONS
RED 1
BLK 1
GRN 1
WHT 1
12.4
C
123456789
1011
VIOYELPNKREDBLKGRABLUCRESHD
WHTBRNGRN
341
2
TIE WRAPUSED TO IDENTIFY CABLE
RED
BLK
GRN
WHT
RED 1 = CM CYL (+)RED = CM PILOT (+)BLK 1 = OM CYL (+)BLK = OM PILOT (+)GRN 1 = CM CYL (-)GRN = CM PILOT (-)WHT 1= OM CYL (-)WHT = OM PILOT (-)
IS
1234
567
SHDWHTBRNGRN
REDYELBLUVIOGRABLKCREPNK
D 341
2
1423
1423
IS
IS
(+)NONC(-)
OO
OO
REDBLKGRNWHT
RED = IM CYL (+)BLK = IM PILOT (+)GRN = IM CYL (-)WHT = IM PILOT (-)
JUNCTION BOX (IM)
PROXY SW 4(CM RETR)
1423
1423
IS
(+)NONC(-)
OO
OO
PROXY SW 1(OM/FLY RETR)
JUNCTION BOX (CM)
654321
3
42
1
1423
1423
IS
(+)NONC(-)
OO
OO
PROXY SW 3 (TOP)(LENGTH RESET)
E
1423
1423
IS
(+)NONC(-)
OO
OO
PROXY SW 2 (BOTTOM)(CM/IM RETR. 2-POSITIONS)
23
4
11
4
3
2JUNCTION BOXBOOM BASE
TMS/TTS 870WIRING CONNECTIONS
A 104 X1 12 13 14 15 16 17 18 19 20 21 28 29 30 31 32 33 44 46 7 8 10 11 9 35 34 24 73 43 36 80 78 76
1 2 3 4
A B C DA B C D
PRES. TRANS.(ROD)
1 2 3 4
A B C DA B C D
PRES. TRANS.(PISTON)
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10 11 12 13 14
14 SOCKET PLUG
14 PIN PLUG
A B C D E F G H I J K L M N
A B C D E F G H I J K L M N
X1 1 2 3 4 5 6 7 8
+24V
GND TX
DR
XDC
OM
.A
2B LMI
DI
X7 1 2 3 4
X812
1 2 3 4 5 6 7 8 9 10 11 12 13 14
+24VGND CONSOLE
1 2 3 4 IS 1 2 3 4 IS
11 12
13 14+24V
1 4 3 2 5 6 7 8 9 GN
/YL
12.5
To page 12.6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 IS
To Boom BaseJunction Box
RT865BXLWIRING CONNECTIONS
A
IS +5V
AG
ND
-5V
PRES
S. R
OD
SIG
.IS +5
VA
GN
D-5
VPR
ESS.
PIS
TON
SIG
.
+24V
TXD
RX
DG
ND
LMI B
YPA
SSA
2B B
YPA
SS
IS AG
ND
LEN
GTH
(O.A
. BO
OM
)
-5V
AN
GLE
A2B
SIG
NA
LA
2B G
ND
LEN
GTH
(IM
)LE
NG
TH (C
M)
PRO
XY
(+)
GN
DD
I 6 (P
RO
XY
3 L
ENG
TH R
ESET
)D
I 5 (P
RO
XY
2 C
M/IM
RET
RA
CT)
DI 4
(PRO
XY
1 O
M/F
LY R
ETRA
CT)
HIG
H=A
UTO
MO
DE/
NO
NE=
MA
NU
AL
MO
DE
+24V
GN
D
LMI U
NLO
CK S
OLS
TELE
EX
T. P
RESS
. SW
.
TELE
RET
RA
CT P
RESS
. SW
.
OM
/FLY
TEL
E
CM T
ELE
IM T
ELE
TELE
OU
T O
F SE
Q.
TELE
PRO
P A
NA
LOG
GN
D
TELE
RO
D D
RA
IN S
OL
TELE
EX
T PR
OP
SOL
TELE
RET
RA
CT P
ROP
SOL
1 2 3 4 5 6 A111X1 1 2 7 8 9 10 A114
X1 22 47 53 54 65 66 68 69 56 57 1 2 3 4 48 38 40 42 36 37 39 41 75 77 79 59 61 49 62 63 64
IS +24V
K2
(CO
M) +
24V
DI E
1 (+
24V
HO
USE
PIN
EN
GA
GED
)
DI E
1 G
ND
DI E
4 (+
24V
AR
EA D
EF.)
DI E
4 (G
ND
=FR
ON
T O
/R O
L)
DI E
5 (+
24V
=CM
RET
)D
I E5
GN
D
K2
(NO
) +24
V T
O IM
2-W
AY
SO
LS
K6
(CO
M) +
24V
K6
(NO
) +24
V T
O C
M 2
-WA
Y S
OLS
K7
(CO
M) +
24V
K7
(NO
) +24
V T
O O
M/F
LY 2
-WA
Y S
OLS
K3
(CO
M) +
24V
K3
(NO
) +24
V T
O T
ELE
RO
D D
RA
IN+2
4V+2
4VG
ND
GN
DK
10 (N
O) +
24V
TO
LM
I UN
LOC
K S
OLS
DI 1
(+24
V=T
ELE
EXT
PRES
SW
)D
I 2 (+
24V
=TEL
E RE
T PR
ES S
W)
DI G
ND
DI 1
GN
D
DI 3
(+24
V=A
UTO
MO
DE
DI 2
GN
DD
I 3 G
ND
DI 4
GN
DD
I 5 G
ND
DI 6
GN
D
K4
(CO
M) +
24V
K4
(NC)
+24
V T
O T
ELE
OU
T O
F SE
QK
10 (N
C) +
24V
TO
LM
I L/O
ALA
RM
K5
(CO
M)
K5
(NO
) OU
TPU
T TO
EX
T PR
OP
K5
(NC)
OU
TPU
T TO
RET
PRO
P
+24V
+24V
GN
D
GN
DA
GN
DA
1 (P
RO
P)
DI EXTENSION BOARD24 350 300 301
4 5 6 7 8 9 10 11 12 A113X1
1 2 3 4 5 6 9 8
9
1 4 6 9 8 10
8
7
7
2 3 5 7 11 12 13 14
12
19 10 11 12 13 14 16 20 21 18 15
IS
A B C D E F G H J K L M N O P Q R S T U V W X A B C D E F G H J K L M N O P Q R S T U V W X
1 2 3 4 5 6 7 8 9 101112 13 14 15 1617 18 19 20 2122 23 24 25
71 51 73 387
388
239
242
243
244
323
238
1083
255
257
23 -
SOCK
ET R
ECEP
TS/
S H
ARN
ESS
(REF
)
LMI - CRANE INTERFACE23 - PIN PLUG
RT865BXLINTERFACE
12.6
B
CO
NT
INU
ED
FR
OM
PA
GE
12.5
To Boom BaseJunction Box
17 22 23 24 25
1 2 3 4
LMI L
/O A
LARM
74H
OU
SE L
OCK
PIN
SW
ITCH
744
1 2 3 4
A B C D EA B C D E
12o
348o
NO
NCCOM
CRANE 12o AREADEFINITION SWITCH INELECTRICAL SWIVEL
SWIV
EL H
ARN
ESS
5 PI
N R
ECEP
TACL
EA
REA
DEF
. IN
TERF
ACE
5 SO
CKET
PLU
G
SIG
. A
GN
D-5
V
AG
ND
SIG
.-5
V
1 14 2 3 4 5 6 7 8 9 10 11 12 13 IS
A B C D E F G H J K L M N P
14 SOCKET PLUG
A
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14
9 10 11 12 13 14 15 16 17 18
A B C D E F G H J K L M N P
19 20 21 22 23 24 25 26 27 28 29 30 31
A B C D E F G H J K L M N P R S T U V
A B C D E F G H J K L M N P R S T U V
1 2 3 4 5 6 7 8 9 10 11 12 13 14 IS
1 2 3 4 5 6 7 8 9 10 11 12 14
B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7
LENGTHTRANSDUCER
LG208 (TO NOSE)
BRN
RED
1 2 3 4
VV
V V
A B A B
4.7K
1 2
321
3=RED2=BRN1=BLKCORE
SHEI
LD
001 2 3
4.7K
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
AG
ND
SIG
.-5
V
LENGTHTRANS.
ANGLETRANS.
BRN
RED
OR
GY
ELG
RN
BLU
VIO
GR
AW
HT
BLK
WH
T/BL
K
1 2 3 4 5 6 7 8 9 10 11
1 2 3 13 8 6 4 9 14 12 7 5 10 11
1 2 3 4 5 6 7 8 9 10 11 12
BRN
RED
OR
GY
ELG
RN
BLU
VIO
GR
AW
HT
BLK
WH
T/BL
K
SHD
WH
TB
RN
GR
NC
RE
BLK
RED PN
KY
EL BLU
VIO GR
A
LENG
TH/A
NG
LELWG
221 (TOC
M)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
AG
ND
SIG
.-5
V
LENGTHTRANS.
BRN
RED
OR
GY
ELG
RN
BLU
VIO
GR
AW
HT
BLK
WH
T/BL
K
1 2 3 4 5 6 7 8 9 10 11
1 2 3 6 7 12 4 9 10 5 8 11
1 2 3 4 5 6 7 8 9 10 11 12
BRN
RED
OR
GY
ELG
RN
BLU
VIO
GR
AW
HT
BLK
WH
T/BL
K
SHD
WH
TB
RN
GR
NC
RE
BLK
RED PN
KY
EL BLU
VIO
GR
A
LENG
TH/A
NG
LE LG221 (TO
IM)
C D
2 4 31
1342 E
1 7 2 3 4 5 6
13 3 1 2 4 6 7 5 8 9 10 11 12 14
31
1 3 2 4 5 9 6 7 13 8 10 11 14 12
RT865BXLWIRING
CONNECTIONS
12.7
RED 1
BLK 1
GRN 1
WHT 1
12.8
C
123456789
1011
VIOYELPNKREDBLKGRABLUCRESHD
WHTBRNGRN
341
2
TIE WRAPUSED TO IDENTIFY CABLE
RED
BLK
GRN
WHT
RED 1 = CM CYL (+)RED = CM PILOT (+)BLK 1 = OM CYL (+)BLK = OM PILOT (+)GRN 1 = CM CYL (-)GRN = CM PILOT (-)WHT 1= OM CYL (-)WHT = OM PILOT (-)
IS
1234
567
SHDWHTBRNGRN
REDYELBLUVIOGRABLKCREPNK
D 341
2
1423
1423
IS
IS
(+)NONC(-)
OO
OO
REDBLKGRNWHT
RED = IM CYL (+)BLK = IM PILOT (+)GRN = IM CYL (-)WHT = IM PILOT (-)
JUNCTION BOX (IM)
PROXY SW 4(CM RETR)
1423
1423
IS
(+)NONC(-)
OO
OO
PROXY SW 1(OM/FLY RETR)
JUNCTION BOX (CM)
654321
3
42
1
1423
1423
IS
(+)NONC(-)
OO
OO
PROXY SW 3 (TOP)(LENGTH RESET)
E
1423
1423
IS
(+)NONC(-)
OO
OO
PROXY SW 2 (BOTTOM)(CM/IM RETR. 2-POSITIONS)
23
4
11
4
3
2JUNCTION BOXBOOM BASE
RT865BXLWIRING CONNECTIONS
P.A.T. – L.M.IMANUAL
SECTION 13
DS 350 GRAPHIC BCSSERVICE BULLETINS &
MISCELLANEOUSINFORMATION
P.A.T. GRAPHIC CONSOLE JUMPER CONNECTION
The jumpers J1 and J2 must be inserted according to the type of central unit to which this console is connected
or an Error code 91 occurs.
Central Unit with DS350 modular or DS150 mainboard or compatible
interface like 24 350 30 0128( J1 = closed / J2 = 1 -2)
X1 L1
J1 J2
1
Central Unit with DS350G mainboard orcompatible interface like 24 350 30 0127
( J1 = open / J2 = 2-3)
X1 L1
J1 J2
1
13.1
P.A.T. – L.M.IMANUAL
SECTION 14
DS 350 Graphic ModularCONSOLE CONNECTIONS
& WIRING DIAGRAM
1 2
3 4
5 6
7 8
1
2 3
4
MP
2+7
V
MP
5+5
VM
P 0
GN
D
MP
3-2
4V
MP
4-2
4V
MP
6
MP
7
MP
1+U
B
J5 J4
J3
J1J2
X1
X5
VIE
W O
F BA
CK
SID
EO
F G
RA
PHIC
CO
NSO
LE
14.1
51 52 3 4 5 6 7 8 9 10
+UB
GN
D+U
B
+UB
GN
DR
XD
TXD
A2B
BY
PASS
A2B
BY
PASS
LMI B
YPA
SS
8 9 1 2 3 4 5 6 7 10 11 12 13 14
CENTRAL UNITMAIN BOARD
1 2 3 4 5 6 7 10 8 9 11 12 13 14
1 2 3 4 5 6 7 8 X1 +U
B
GN
D
TXD
RX
DA
2B
LOA
D
A2B D
I
X7 1 2 3 4
+UB
SIG
+SI
G -
GN
D X812
+UBGND
A B C D
1 2 3 4LIGHTBAR
CONSOLE (1318)
ELECTRICAL WIRING FROMCENTRAL UNIT TO CONSOLE
14.2
P.A.T. – L.M.IMANUAL
SECTION 15
DS 350 Graphic ModularCENTRAL UNIT,
P.C. BOARD LAYOUT& CONNECTIONS
PAT DS350 Graphic ModularCENTRAL UNIT TERMINAL BOARD CONNECTIONS
X1 TERM. DESCRIPTION
1,3 +12V Battery - Input
2,4 GND ( ) Battery-Input
6 Data Transmit to Console
7 A2B Bypass
8 A2B Bypass
9 LMI Bypass
10 + 12V (ub)
11 +UBR
12 LMI Lockout Solenoid
13 Ext. Hor. # 1
14 +UBS
15 GND
16 Digital Input # 1
18 Digital Input # 3
19 Digital Input # 4
20 +UB Piston Pressure Transducer
21 Piston Pressure Signal
22 GND (Inner Shield Connection)
23 +UB Rod Pressure Transducer
24 Rod Pressure Signal
25 GND (Inner Shield Connection)
26 +UB Length Transducer
X1 TERM. DESCRIPTION
27 Length Signal
28 GND
29 Angle Signal
30 Force Signal
31 A2B Signal
32 A2B Ground
33,34,35,36 Not Used
51 +UB
52 GND
53 Fuse (4 AMP)
54 Fuse (4 AMP)
57 Not Used
58 Not Used
60 +UBS
61 Fuse (10AMP)
62 Fuse (10 AMP)
64 UB
65 GND
66,67,68,69 Not Used
76 +UB
77 GND
5 Data Received from Console
17 Digital Input # 2
15.1
+
+
F1 +UBS+12V
+UB
+0V
+UBS0VRXDTXD
STOP
+
DINDIN
K10A
K9
K8A2B-OA2B-I
10
LOAD-I
+ +UBS
K10B
10AF2-REL -MREL -A
REL -R+ +UBS
+ +UBS
DE 1DE 2DE 3DE 4
IU DAV1
+ +UBSI
U DAV2
+ +UBSI
U LG 1
IU WG 1
IU LG 1
+ +UBSI
U S1 DHG 1
IU S2 DHG 2
+ +UB
SI - OUTSI - IN
F1 - 4A
A2B-0A2B-I
LOAD-I+ +UBS F2-10A
SI-RELSI-REL+ +UBS
DE 5
DE 6
+ +UBS
1
0V
0V
0V
0V
0V
0V
0V
0V
23456789
1112131415161718192021222324252627282930313233343536515253545758596061626465666768697677
12V
CONSOLE
LOAD SWITCH
REL
+UBS
DE 1-4
DAV 1
DAV 2
LWG 1
LG 2HES
DHG S1
S2
12V
SI-UB
LOAD KEY
SWITCH
SI-REL
DE 5,6
+UBS
AD
DITIO
NA
L TERM
S
A107
MEM
OR
YEX
TENTIO
N
A101 M
AIN
BO
AR
D D
S350M
OD
ULA
R/C
UR
REN
T IN
A106 A
NA
LOG
G IN
PUT
A105 SER
IAL
EXTEN
SION
A104 D
IGITA
LO
UTPU
T
A103
DA
TEN-
MO
DU
LE
A102
CPU
-M
OD
ULE
X11
X12
X3
X3
24 352 31 0001
15.2
X1 1 2 12 11 51 52 3 4 5 6 7 8 9 10 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 53 54 59 60 61 62
1 2 3 8 9 1 2 3 4 5 6 7 10 11 12 13 14GN
/YL
1 2 3
GN
/YL
71 (+
UB
)51
(GND
)73 (LM
I UN
LOC
K SO
L.)
1 3
1
2
1 2 3 4 5 6 7 8 X1
1 2 3 4 5 6 7 10 8 9 11 12 13 14
X812
X7 1 2 3 4
+UBEGND
+UB
GN
DTX
DR
XD A2B A2B
LOAD D
1
+UB
ESI
G+
SIG
-G
ND
1 2 3 4
A B C D
1 2 3 4
LIGHTBAR
V VV V
VV
V
V
V
V
V
V
V
V
3
21
NO
NC
C
NO
NC
C
over fronton rubber
on outriggers
1 2 3 4
V
V
AA
V
V
BB
V
V
CC
V
V
DD
V
V
EE
1 3 4 2
1 2 3 4
V
V
AA
V
V
BB
V
V
CC
1
2
pres. trans.(piston)
1 2 3 4
V
V
AA
V
V
BB
V
V
CC
1
2
pres. trans.(rod)
1 2 3 4 1 2 3 4
1 2 3 4 5 6 7
V V V V V V
1 2 3 4 5 6TO MAIN BOOM
CONNECTOR
6 PI
N P
LUG
1 2 3 4 7 5 6
1
2
4 AMPFUSE
IN OU
T
10 AMPFUSE
IN OU
T
4 3
2 1
LMI BYPASSKEY SWITCH
CONSOLE (1318)
DS350GRAPHIC MODULAR
CENTRAL UNIT
+UB
GN
DLM
I UN
LOC
K S
.
+UB
R
+UB
GN
D+U
BG
ND
RXD TX
DA
2B B
YPA
SSA
2B B
YPA
SSLM
I BYP
ASS
+UB
EXT.
HO
R. *1
+UB
SG
ND
DI1
DI2
DI3 DI4
+UB
PIST
ON
GN
D
+UB
RO
DG
ND
+UB
LEN
GTH
GN
DA
NG
LE
FORC
EA
2B S
IGNA
L
A2B
GR
OU
ND
NO
T U
SED
NO
T U
SED
NO
T U
SED
NO
T U
SED
FUSE
(4 a
mp)
FUSE
(4 a
mp)
LMI B
YPA
SS+U
BS
FUSE
(10
amp)
FUSE
(10
amp)
CRANE SYSTEM AREADEF. SWITCH ELEC. SWIVEL
5 PINDEUTSCH
PLUG
1 OUTER SHIELD GROUNDED AT STRAINRELIEF CONNECTOR.
2 INNER SHIELD CUT AND INSULATED
3 INSULATE OUTER SHIELD AND CONNECT TO CHASIS GND.
*1) OPTIONAL FOR EXTERNAL HORN (EEC UNITS ONLY)
NOTES:
15.3
P.A.T. DS350 Graphic Modular MAIN BOARD
15.4
MP25
+UBMP1
KGND
KG
ND
F1
X1
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
69 68 67 66 65 64 62 61 60 59 58 57 55 54 52 51
F2
J4J3J2J1 31
- +
KG
ND
H9
A2B
X1
KGND
J103 24 1 MP29
+5V/RS232
A2BK9
LMIK8
LOA
D
LEVERLOCKOUT
K10
KG
ND
+UB
KGND
+UB
1 +UB
H12
TXD
H10
MA
INO
N/O
FF
H1 H
2 H3 H
4 H5 H
6
X13
DI 1- D
I 6 =>D
I 1D
I 6
X14
KGND
+UB
1
V10H
11V11
MP41
MP40
PFAIL+U
B1
power o.k.
GND
+5V
+6V
+9V
KG
ND
AG
ND
X16
AG
ND
CC
MP42PWM DC
- G1 +
MP24+BATT
MP23
VBAT
X15
KG
ND
GND
AG
ND
KG
ND
KG
ND
X12
X17
GND
MP21
SP5
X11J11
A B C D E F G H I J K L M
A B C D E F G H I J K L M
1
2
3
4
5
6
7
8
9
10
11
12
13
1
2
3
4
5
6
7
8
9
10
11
12
13
77 76
MP 26
MP 4
MP 9
MP 8
LOCATIONS :
MP 1 - zone M13 = KGND.MP 25 - zone M13 = +UBS CONSOLE, SENSORS, DI’sMP 8 - zone M2 = +9VMP 9 - zone M2 = +6VMP 4 - zone M1 = +5V MP 26 - zone M1 = GND.MP 23 - zone A2 = VBATT MP 24 - zone D2 = +BATTMP 40 - zone M4 = +UB
MP 41 - zone M4 = POWER FAILMP 42 - zone G1 = +5VMP 21 - zone E5 = +5VMP 29 - zone D10 = +5VH1-H6 - zone I5 = DI 1-6
LED’S
H 8 - zone M3 - LOADH 9 - zone E11 - A2BH 10 - zone G9 - MAIN IN/OUTH 11 - zone M3 - POWERH 12 - zone I11 - TXD
EJECT
MP2MP6
MP5
BR6
BR5
X3
J12
J8 J9 MP3 J6
SYSTEMD10
D1
MP4 X2X1
J13
MP7
P1
J1J2
J10
J11 J1
4
J15
J7
A102 CPU
BR
4 3 2 1
J6
J2J1
J5J3
DATAD1
TLKD3
A103 DATEN
X1
D3
D2
D14
D13
D6
D17
D21D7D15
D9
D20
D18
D19
D11
D12
P.A.T. DS350 Graphic Modular EXTENSION BOARDS
15.5
Ensure the notch is in the correct direction ( to the right ) The EPROMS must be installed completely to the left,leaving blank holes to the right.
X16
1216
X17
1240
+ ++ +
- +
MP12
J2
MP13
P7P6
P5P4
P3P2
P1
MP11
J1 MP9
MP10
MP17
- +MP0MP8
P8
MP7 - M
P1->7 6 5 4 3 2 1
VREFA
MP14
BR1
AG
ND AGND
AGNDAGND
MP16
1612
120
1240
DS350 Graphic ModuleAnalog Input Module
BOARD P/N 9-333-103290
X1:1-7 ADC INPUT 0.5 V … 4.5 V, Note: If channel adjustments are made throughthe software and graphic console, DO NOT adjust offset with P1 - P7
X1:8 = TEMP (0.5V + 10mV/oC)X1:9 = VREFA = 5.000V referenceX1:10 = AGND (reference GND)X1:11 = VREF+ = 5.0V power ADCX1:12-15 = CH01-04, DIN 1-4 / 10X1:16 = CH05, +UBS / 10X1:17 = CH06, HESIN(A2B) *4X1:18 = CH07, +9V *4X1:19 = CH08, VREFA / 2 = 2.500VX1:20 = UKLEMM, app. VREFA, limits ADC input to 5.0V
X1
15.6
MP 1 = AGNDMP 8 = + 5VMP 1 - 7 = Input channels 1 - 7 - 0.5V/ 4mA 2.5V/20mAMP 14 = + 13V REF 02MP 16 = HESIN input voltageMP 17 = app 5.4V clamp for inputs
MODEL: S/N:
PAT DS35O Graphic Modular“BASIC ADJUSTMENTS AND VOLTAGE CHECKS”
1. Crane Supply Voltage @ Xl -1 ( + ) & Xl -4(GND) = VDC
2. Main Board Power Supply ( Reference Voltages +/- 50 MV) : (For MP Locations Refer To Page 15.4 )
+12/+24V @ MP 25= VDC MP 1 Ground + 9V @ MP 8= VDC MP 1 Ground+5V @ MP 4= VDC MP 1 Ground
+6V @ MP 9= VDC MP 1 Ground +5V @ MP 42= VDC MP 1 Ground
+5V @ MP 29= VDC MP 1 Ground+12/+24V @ MP 40= VDC MP 1 Ground
3. Boom Length:
Fully Retracted Ft. mA @ X1-27Fully Extended Ft. mA @ X1-27Fully Retracted Ft. VDC @ MP X1-3(A106), MP 0 (GND)Fully Extended Ft. VDC @ MP X1-3(A106), MP 0 (GND)+12/+24V Volt Reference Voltage VDC @ X1-26 (X1-28 GND)
4. Boom Angle:Minimum Angle Degs. mA @ X1-29 Maximum Angle Degs. mA @ X1-29Minimum Angle Degs. VDC @ MP X1-4(A106), MP 0 (GND)
Maximum Angle Degs. VDC @ MP X1-4(A106), MP 0 (GND) +12/+24V Volt Reference Voltage VDC @ X1-26 (X1-28 GND)
5. Pressure Transducers:Piston Zero Point mA @ X1-21 / VDC @ X1-1(A106), MP0 (GND)Rod Zero Point mA @ X1-24 / VDC @ X1-2(A106), MP0 (GND)
Piston +12/+24 Volt Reference Voltage VDC @ X1-20 (X1-22 GND)Rod +12/+24 Volt Reference Voltage VDC @ X1-23 (X1-25 GND)
6. Analog Input Module (A106):+5V @ MP8 = VDC MP 0 Ground+5V @ MP17= VDC MP 0 Ground+5V @ MP16= VDC MP 0 Ground
15.7
P.A.T. – L.M.IMANUAL
SECTION 16
DS 350 Graphic ModularBOOM LENGTH CONNECTIONS
& WIRING DIAGRAMS
5 3 1 5 3 1
GN
D1
OU
T+U
B
GN
D1
OU
T+U
B
5 3 15 3 1X3X4
X1
7 8
12345678S
SHIELD 1
CORE 2
1 2 3 4 5 6 7
1 2 3 4 5 6
1 2 3 4 5 6 7
123456
7
26 2827
+UB
LEN
GTH
(GN
D)
X1
A
1 2 3Current Based AmplifierAll sensing devices used for Analog Inputs now have a
current output. (min. signal 4mA, max. signal 20mA)This circuit is measured in series.
- +
MP12
J2
MP13P7 P6 P5 P4 P3 P2 P1
MP11
J1
MP9
MP1
0
MP1
7
- +
MP0
MP8
P8
MP7 - MP1->
VRE
FA
MP1
4
BR1
AGND
AG
ND
AG
ND
AG
ND
MP16 1612
120 1240
X1
Channel # 1OPERATING WINDOW
E11
E21
WORKINGRANGE
.0V
.500v MIN.
4.50v MAX.
5.0V
ERRORCODE
ERRORCODE
X2
6 Pin Connector
6 Pin Plug
VOLTAGESX1 3 ANALOG INPUT MODULE
+ 500MV (.500V) = MIN. SIGNAL (RETRACTED BOOM)+ 4.50V = MAX. SIGNAL (10 TURNS ON POT)
ALL VOTAGES ARE MEASURED WITHREFERENCE TO GND (TERMINAL X1 - 28) ON MAIN BOARD.
* THESE MEASUREMENTS ARE MADE IN PARALLEL
DS350 GRAPHIC MODULARBOOM LENGTH MEASURING CHANNEL
CHANNEL # 1
16.1
E11 / E21 (measurements in cable reel)
Measure Voltage - Length transducer at X1 1(+) & 3 (-)Range 10V to 30V
Measure Voltage - Length transducer at X1 2(+) & 3 (-)Range 1V to 5.6V
Measure Amps - Length transducer at X1 2(+) & (-) WIRE 2. Range 4 mA to 20 mA
-
+
NO. OF TURNS ON CABLE
REEL
NO. OF TURNS ON LENGTH
POT
SIGNAL AT X1 TERM. PIN #27 ON C.P.U.
TERMINAL
SIGNAL ON ANALOG MODULE AT X1-3
(X1-28 GND.)0 0 4 mA .5 V3 1 5.5 mA .9 V6 2 7.2 mA 1.3 V9 3 8.7 mA 1.7 V12 4 10.4 mA 2.1 V15 5 12.0 mA 2.5 V18 6 13.6 mA 2.9 V21 7 15.2 mA 3.3 V24 8 16.8 mA 3.7 V27 9 18.4 mA 4.1 V30 10 20 mA 4.5 V
16.2
DS350 Graphic ModularBoom Length Signal
( 3 TURNS OF CABLE REEL = 1 TURN OF LENGTH POT.)CHART SHOWS TYPICAL MILLI-AMP AND VOLTAGE SIGNALS. THESE VOLTAGES ARE TO BE USED AS A REFERENCE ONLY, THE ACTUAL SIGNAL MAY VARY SLIGHTLY.
CHANNEL # 1
24.0
X3123
135
XA2
X2 L
123
135
XB2
AX2
1 2 3 4 5 6 7 8
12345678S
X1
X27 (9)8 (10)
9333103309
X4
MEASURE VOLTAGE IN LENGTH TRANSDUCERAT X1 - 1 (+) & X1 - 3 (-)… RANGE = 10V - 30V.
16.3
1.0
X3123
135
XA2
X2 L
123
135
XB2
AX2
1 2 3 4 5 6 7 8
12345678S
X1
X27 (9)8 (10)
9333103309
X4
MEASURE VOLTAGE IN LENGTH TRANSDUCERAT X1 - 2 (+) & X1 - 3 (-)… RANGE = 1V - 5.6V.
16.4
4.00
X3123
135
XA2
X2 L
123
135
XB2
AX2
1 2 3 4 5 6 7 8
12345678S
X1
X27 (9)8 (10)
9333103309
X4
MEASURE AMPERAGE IN LENGTH TRANSDUCERAT X1 - 2 (+) & WIRE #2 (-)… RANGE = 4mA - 20mA.
16.5
P.A.T. – L.M.IMANUAL
SECTION 17
DS 350 Graphic ModularPISTON, ROD
CONNECTIONS &WIRING DIAGRAMS
GRAPHIC CONSOLE
SPECIAL FUNCTION 0 - SETTING OF TRANSDUCER INPUT
0 - SETTING OF PRESSURE AND FORCE INPUTS
The 0 - setting consists of calculating an appropriate 0 - point offset, which, when added to the transducer measurement, allows the real physical pressure of force to be calculated. To achievethis, a procedure has been developed, allowing the 0 - setting to be performed and visualized in a simple manner.
ACTIVATING THE 0 - SETTING FUNCTION
To activate the 0 - Setting Function, press the INFO key to activate the Info Function. Now pressthe CTRL key. At this point, a five digit Authorization Number must be entered. Only authorizedpersonnel may adjust the 0 - point settings.Example : 6 4 3 5 6
0 - SETTING THE TRANSDUCER INPUTS
Now, having successfully entered a valid password, the piston - side 0 - point setting functionis activated.
The display shows which transducer (piston-side, rod-side or force) is being zeroed and a horizontaldial marks the present pressure (or force) difference in %. By pressing the + key, the input pressure(or force) is adjusted upwards, and by pressing the - key, the input value is adjusted downwards.When the + and - keys are pressed simultaneously, the 0 - setting occurs automatically. Manualadjustments may be performed using + or -.
The return key toggles between the piston - side, the rod - side, and the force 0 - setting.
When the operator is finished, pressing the EXC or INFO key returns the console back to the normaldisplay.
17.1
1 2 3
20 2221
+UB
(GN
D)
X1
A
OU
TPU
T SI
GN
AL
(PIS
TON
)
4
1 2 3 4
AA
BB
CC
PRESS. TRANS.(PISTON)
DS350 GRAPHIC MODULARPISTON PRESSURE MEASURING CHANNEL
CHANNEL # 2
Current Based AmplifierAll sensing devices used for Analog Inputs now have a
current output. (min. signal 4mA, max. signal 20mA)This circuit is measured in series.
Channel # 2OPERATING WINDOW
E12
E22
WORKINGRANGE
.0V
.500v MIN.
4.50v MAX.
5.0V
ERRORCODE
ERRORCODE
- +
MP12
J2
MP13P7 P6 P5 P4 P3 P2 P1
MP11
J1
MP9
MP1
0
MP1
7
- +
MP0
MP8
P8
MP7 - MP1->
VRE
FA
MP1
4
BR1
AGND
AG
ND
AG
ND
AG
ND
MP16 1612
120 1240
X1
VOLTAGESX1 1 ANALOG INPUT MODULE
+ 500MV (.500V) = MIN. SIGNAL (ZERO PRESSURE)+ 4.50V = MAX. SIGNAL (300 BAR PRESSURE)
ALL VOTAGES ARE MEASURED WITHREFERENCE TO GND (TERMINAL X1 - 22) ON MAIN BOARD.
* THESE MEASUREMENTS ARE MADE IN PARALLEL17.2
E12 / E22 (measurements at transducer)
Measure Voltage - (Elec) Piston transducer at A (+) & C (-)Range 10V to 30V
Measure Voltage - (Elec) Piston transducer at B (+) & C (-)Range 0V
Measure resistance - (Hyd) Piston transducer at B (+) & C (-)Range 200 - 300 Ohm
-
+
1 2 3
23 2524
+UB
(GN
D)
X1
A
OU
TPU
T SI
GN
AL
(RO
D)
4
1 2 3 4
AA
BB
CC
PRESS. TRANS.(ROD)
DS350 GRAPHIC MODULARROD PRESSURE MEASURING CHANNEL
CHANNEL # 3
Current Based AmplifierAll sensing devices used for Analog Inputs now have a
current output. (min. signal 4mA, max. signal 20mA)This circuit is measured in series.
Channel # 3OPERATING WINDOW
E13
E23
WORKINGRANGE
.0V
.500v MIN.
4.50v MAX.
5.0V
ERRORCODE
ERRORCODE
- +
MP12
J2
MP13P7 P6 P5 P4 P3 P2 P1
MP11
J1
MP9
MP1
0
MP1
7
- +
MP0
MP8
P8
MP7 - MP1->
VRE
FA
MP1
4
BR1
AGND
AG
ND
AG
ND
AG
ND
MP16 1612
120 1240
X1
VOLTAGESX1 2 ANALOG INPUT MODULE
+ 500MV (.500V) = MIN. SIGNAL (ZERO PRESSURE)+ 4.50V = MAX. SIGNAL (300 BAR PRESSURE)
ALL VOTAGES ARE MEASURED WITHREFERENCE TO GND (TERMINAL X1 - 25) ON MAIN BOARD.
* THESE MEASUREMENTS ARE MADE IN PARALLEL17.3
E13 / E23 (measurements at transducer)
Measure Voltage - (Elec) Rod transducer at A (+) & C (-)Range 10V to 30V
Measure Voltage - (Elec) Rod transducer at B (+) & C (-)Range 0V
Measure resistance - (Hyd) Rod transducer at B (+) & C (-)Range 200 - 300 Ohm
-
+
DS350 Graphic ModularPRESSURE TRANSDUCER PLUG
PISTON AND ROD
CONNECT DIGITAL VOLT METER NEGATIVE (-) LEAD TO TERMINAL C. CONNECT POSITIVE (+) LEAD TO TERMINAL A, VOLTAGE SHOULD BE +24.0 VDC (SUPPLY VOLTAGE).
CONNECT POSITIVE (+) LEAD TO TERMINAL B, AND NEGATIVE (-) LEAD TO TERMINAL C, VOLTAGE SHOULD BE 0 VDC. IF INCORRECT CHECK CABLE CONNECTIONS IN CENTRAL UNIT AND CHECK CABLE FOR DEFECTS. IF CORRECT REPLACE PRESSURE TRANSDUCER.
17.4
C
B
A
+24.0 +0.
MEASURING RESISTANCE BETWEEN B (+) AND C (-) RANGE 200 - 300 Ohm.
P.A.T. – L.M.IMANUAL
SECTION 18
DS 350 Graphic ModularBOOM ANGLE
CONNECTIONS &WIRING DIAGRAMS
GN
D1
OU
T+U
B
5 3 1 5 3 1
GN
D1
OU
T+U
B
5 3 15 3 1X3X4
X1
7 8
12345678S
SHIELD 1
CORE 2
1 2 3 4 5 6 7
1 2 3 4 5 6
1 2 3 4 5 6 7
123456
7
26 2928
+UB
AN
GLE
(90o
TO 0
o )
(GN
D)
X1
A
1 3 4Current Based AmplifierAll sensing devices used for Analog Inputs now have a
current output. (min. signal 4mA, max. signal 20mA)This circuit is measured in series.
- +
MP12
J2
MP13P7 P6 P5 P4 P3 P2 P1
MP11
J1
MP9
MP1
0
MP1
7
- +
MP0
MP8
P8
MP7 - MP1->
VRE
FA
MP1
4
BR1
AGND
AG
ND
AG
ND
AG
ND
MP16 1612
120 1240
X1
Channel # 5OPERATING WINDOW
E15
E25
WORKINGRANGE
.0V
.500v MIN.
4.50v MAX.
5.0V
ERRORCODE
ERRORCODE
X2
6 Pin Connector
6 Pin Plug
VOLTAGESX1 4 ANALOG INPUT MODULE
+ 500MV (.500V) = 90o ANGLE MIN. SIGNAL+ 2.50V = 45o ANGLE
+ 4.5 V = 0o ANGLE MAX. SIGNALALL VOTAGES ARE MEASURED WITH
REFERENCE TO GND (TERMINAL X1 - 28) ON MAIN BOARD.* THESE MEASUREMENTS ARE MADE IN PARALLEL
DS350 GRAPHIC MODULARBOOM ANGLE MEASURING CHANNEL
CHANNEL # 5
18.1
E15 / E25(measurements in cable reel)
Measure Voltage - Angle transducer at X1 1(+) & 3 (-)Range 10V to 30V
Measure Voltage - Angle transducer at X1 2(+) & 3 (-)Range 1V to 5.6V
Measure Amps - Angle transducer at X1 4(+) & (-) WIRE 4. Range 4 mA to 20 mA
-
+
ACTUAL BOOM ANGLE
IN DEGS.
SIGNAL AT X1 TERM. PIN #29 ON C.P.U.
TERMINAL
SIGNAL ON ANALOG MODULE AT X1-4
(X1-28 GND.)90o 4.0 mA 0.48
85o 4.9 mA + .70
80o 5.7 mA + .92
75o 6.6 mA + 1.15
70o 7.4 mA + 1.37
65o 8.3 mA + 1.60
60o 9.2 mA + 1.80
55o 10.2 mA + 2.04
50o 11.2 mA + 2.26
45o 12.1 mA + 2.48
40o 12.9 mA + 2.70
35o 13.7 mA + 2.92
30o 14.7 mA + 3.15
25o 15.6 mA + 3.38
20o 16.5 mA + 3.60
15o 17.3 mA + 3.82
10o 18.0 mA + 4.04
5o 19.2 mA + 4.27
0o 20 mA + 4.49
DS350 Graphic ModularBoom Angle Signal
CHART SHOWS TYPICAL MILLI-AMP AND VOLTAGE SIGNALS.THESE VALUES ARE TO BE USED AS A REFERENCE ONLY, THE ACTUAL SIGNAL MAY VARY SLIGHTLY.
CHANNEL #5
18.2
24.0
X3
1 2 3
1 3 5
XA
2
X2
L 1 2 3
1 3 5
XB2
AX
2
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 S
X1
X2
7 (
9)8
(10)
9333
1033
09
X4
MEA
SUR
E VO
LTA
GE
IN A
NG
LE T
RA
NSD
UC
ERA
T X1
- 1
(+) &
X1
- 3 (-
)… R
AN
GE
= 10
V - 3
0V.
18.3
1.0
X3
1 2 3
1 3 5
XA
2
X2
L 1 2 3
1 3 5
XB2
AX
2
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 S
X1
X2
7 (
9)8
(10)
9333
1033
09
X4
MEA
SUR
E VO
LTA
GE
IN A
NG
LE T
RA
NSD
UC
ERA
T X1
- 2
(+) &
X1
- 3 (-
)… R
AN
GE
= 1V
- 5.
6V.
18.4
20.0
X3
1 2 3
1 3 5
XA
2
X2
L 1 2 3
1 3 5
XB2
AX
2
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 S
X1
X2
7 (
9)8
(10)
9333
1033
09
X4
MEA
SUR
E A
MPE
RA
GE
IN A
NG
LE T
RA
NSD
UC
ERA
T X1
- 4
(+) &
WIR
E #4
(-)…
RA
NG
E =
4mA
- 20
mA
.
18.5
DDDDSSSS333355550000GGGGrrrraaaapppphhhhiiiiccccMMMMoooodddduuuullllaaaarrrr
SSSSlllleeeewwwwiiiinnnngggg AAAAnnnngggglllleeee
18-6
1 2 3 4
X1 1 2 12 11 13 51 52 3 4 5 6 7 8 9 10 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 30 33 34 35 59 60 61 62
1 2 3 4 5 6 8 9 1 2 3 4 5 6 7 10 11 12 13 14GN
/YL
1 2 3 4 5 6
GN
/YL
71 (+
UB
)51
(GN
D)
73 (LM
I UN
LOC
K S
OL.
)
1 312
1 2 3 4 5 6 7 8 X1
1 2 3 4 5 6 7 10 8 9 11 12 13 14
X812
+UBEGND
+UB
GN
DTX
DR
XD A2B
A2B
LOAD D
1V VV V
VV
X7 1 2 3 4
+UB
ESI
G+
SIG
-G
ND
1 2 3 4
A B C D
1 2 3 4LIGHTBAR
V
V
V
V
V
V
V
V
1 2 3 4
V
V
AA
V
V
BB
V
V
CC
12
pres. trans.(piston)
1 2 3 4
V
V
AA
V
V
BB
V
V
CC
12
pres. trans.(rod)
1 2 3 4 1 2 3 4
1 2 3 4 5 6 7
V V V V V V
1 2 3 4 5 6TO MAIN BOOM
CONNECTOR
6 PI
N P
LUG
1 2 3 4 5 6
12
4 AMPFUSE
IN OU
T
10 AMPFUSE
IN OU
T
4 3
2 1
LMI BYPASSKEY SWITCH
CONSOLE (1318)
DS350GRAPHIC MODULAR
with SLEWINGPOTINTIOMETER
+UB
GN
DLM
I UN
LOC
K S
.
+UB
R K
10 C
OM
+UB
GN
D+U
BG
ND
RXD TX
DA2
B B
YPAS
SA2
B B
YPAS
SLM
I BYP
ASS
+UB
EXT.
HO
R. *
1K
10 N
C
+UB
SD
I GN
DD
I1D
I2
DI3 DI4 +U
BPI
STO
NG
ND
+UB
RO
DG
ND
+UB
LEN
GTH
GN
DAN
GLE
A2B
SIG
NAL
A2B
GR
OU
ND
FUSE
(4 a
mp)
FUSE
(4 a
mp)
LMI B
YPAS
S+U
BS
FUSE
(10
amp)
FUSE
(10
amp)
1 OUTER SHIELD GROUNDED AT STRAINRELIEF CONNECTOR.
2 INNER SHIELD CUT AND INSULATED
3 INSULATE OUTER SHIELD AND CONNECT TO CHASIS GND.
*1) OPTIONAL FOR EXTERNAL HORN(EEC UNITS ONLY)
NOTES:
53 54
D.O.Module
X2/1 1 2 3
GN
D
VV
LMI L
ocko
ut A
larm
Rea
r Axl
e O
scil.
Rel
ay
1 2 5 3
2 1 3 4
SLEW
1+
12 V
SLEW
2G
ND
12
2
VV
VV
18-7
1
2 4
3
3335
30+UB
(GND)
X1 A
SLEW ANGLE 1
1
2
3
4
Cur
rent
Bas
ed A
mpl
ifier
All s
ensi
ng d
evic
es u
sed
for A
nalo
g In
puts
now
hav
e a
curr
ent o
utpu
t. (m
in. s
igna
l 4m
A, m
ax. s
igna
l 20m
A)Th
is c
ircui
t is
mea
sure
d in
ser
ies.
OPE
RA
TIN
G W
IND
OW
E1A
E2A
WO
RK
ING
RAN
GE
.0V
.500
v M
IN.
4.50
v M
AX.
5.0V
ERR
OR
CO
DE
ERR
OR
CO
DE
-+
MP1
2
J2MP1
3P7
P6P5
P4P3
P2P1
MP1
1
J1MP9
MP10
MP17
-+ MP0MP8
P8 MP7
-M
P1->
VREFA
MP14
BR1
AG
NDAGND
AGND
AGND
MP1
616
1 21
201 2
40
X1
VOLT
AGES
X1 5
AN
ALO
G IN
PUT
MO
DU
LE+
500M
V (.5
00V)
= M
IN. S
IGN
AL B
OO
M O
VER
FR
ON
T+
4.50
V =
MAX
. SIG
NAL
BO
OM
OVE
R R
EAR
ALL
VOTA
GES
AR
E M
EASU
RED
WIT
HR
EFER
ENC
E TO
GN
D (M
P 0)
ON
AN
ALO
G B
OAR
D.
* TH
ESE
MEA
SUR
EMEN
TS A
RE
MAD
E IN
PAR
ALLE
L
- +
1
2
5
3R
W
Y
B
SLEW ANGLE 2
4 m
A.5
00V
(A10
6)O
PEN
4.5V
(A10
6)
12 m
A2.
5V (A
106)
12 m
A2.
5V (A
106)
DS3
50G
RA
PHIC
MO
DU
LAR
SL
EW A
NG
LE#1
18-8
1
3 4
2
3335
34+UB
(GND)
X1 A
SLEW ANGLE 2
1
2
3
4
Cur
rent
Bas
ed A
mpl
ifier
All s
ensi
ng d
evic
es u
sed
for A
nalo
g In
puts
now
hav
e a
curr
ent o
utpu
t. (m
in. s
igna
l 4m
A, m
ax. s
igna
l 20m
A)Th
is c
ircui
t is
mea
sure
d in
ser
ies.
OPE
RA
TIN
G W
IND
OW
E1B
E2B
WO
RK
ING
RAN
GE
.0V
.500
v M
IN.
4.50
v M
AX.
5.0V
ERR
OR
CO
DE
ERR
OR
CO
DE
-+
MP1
2
J2MP1
3P7
P6P5
P4P3
P2P1
MP1
1
J1MP9
MP10
MP17
-+ MP0MP8
P8 MP7
-M
P1->
VREFA
MP14
BR1
AG
NDAGND
AGND
AGND
MP1
616
1 21
201 2
40
X1
VOLT
AGES
X1 6
AN
ALO
G IN
PUT
MO
DU
LE+
500M
V (.5
00V)
= M
IN. S
IGN
AL B
OO
M O
VER
FR
ON
T+
4.50
V =
MAX
. SIG
NAL
BO
OM
OVE
R R
EAR
ALL
VOTA
GES
AR
E M
EASU
RED
WIT
HR
EFER
ENC
E TO
GN
D (M
P 0)
ON
AN
ALO
G B
OAR
D.
* TH
ESE
MEA
SUR
EMEN
TS A
RE
MAD
E IN
PAR
ALLE
L
- +
1
2
5
3R
W
Y
B
SLEW ANGLE 1
12 m
A2.
5V (A
106)
12m
A2.
5V (A
106)
OPE
N4.
5V (A
106)
4 m
A.5
00V
(A10
6)
DS3
50G
RA
PHIC
MO
DU
LAR
SL
EW A
NG
LE#2
18-9
DS350 Graphic ModularSlewing Potentiometer Components
Slewing PotentiometerElectrical Slip ring Assembly
Printed Circuit Slewing Board
18-10
Printed Circuit Slewing Board(showing X1 Terminal Board)
Slew Potentiometer Installation &Adjustment Procedure
These instructions are applicable for installing direct drive parts (if required)to the slew potentiometer mounted in the top of the slip ring assembly.
Potentiometer
Collar set fastened to shaft by two (2) set screws.
18-11
Slotted Clutch Plate
Collar
Potentiometer
Slotted Clutch Plate
Collar
Plug to the Slip ring Circuit Board
18-12
Note: These four (4) washersmust be installed before proceeding to the next step.
Plastic Shield installedon top of four washers .
18-13
Clutch plate installed on top of slip ring assembly.
Position the collar so there is between 1/32” to 1/16” clearance to the bottom of the potentiometer.
Tighten set screws.18-14
Install the aluminum plate with potentiometer over mounting posts. Turn shaft in the center of potentiometer with screwdriver until drive pin seats in the slot in the clutch plate.
Collar with drive pin seated in the slot in clutch plate.
18-15
Use a torpedo level to assure plate is level.
18-16
These instructions are applicable to cranes using a top mountedslew potentiometer inside the slip ring assembly.
1. Position the superstructure over the front and engage the house lock pin.
2. Set the Console to read Slewing Angle:A. Complete the LMI console setup according to the crane’s current
operating configuration.B. Press limits “LMI”.C. Press 4 for Slew Angle/virtual wall limits.D. Press 1 for Slew Angle.E. Press 2 or 3 to display Slewing Angle.
NOTE: Refer to the P.A.T. Load Moment Indicator Operator’s Handbookfor detailed instructions.
18-17
3. Remove the Slip Ring cover.
4. Loosen the three screws that secure the potentiometer.
DO NOT ATTEMPT TO ROTATE THIS SLOTTED SHAFT.
18-18
5. Disengage the house lock pin and swing approximately 10 deg. to the right (clockwise). Slowly swing back to the left and engage the house lock pin*. Rotate the body of the slew potentiometer until the slew angle indicates 0.6 deg. (+/- 0.1 deg.). NOTE: This value may not be obtainable due to limited wire length on the slew potentiometer, or the electrical terminals interferance with one of the mounting screws, if this occurs,reposition the collar set screwed to the potentiometer shaft and repeat step 5.
6. Disengage the house lock pin and swing approximately 10 deg. to the left (counterclockwise). Slowly swing back to the right and engage the house lock pin*. If the angle indicated on the console does not exceed +/- 1.0 deg., proceed to step 7. If the indicated angle exceeds +/- 1.0 deg. Return to step 5.
7. Tighten the three screws that secure the slew potentiometer to the mounting plate. Install the slip ring cover.
8. Disengage the house lock pin and swing approximately 10 deg. to the right (clockwise). Slowly swing back to the left and engage the house lock pin*. If the angle indicated on the console does not exceed +/- 1.0 deg., proceed to step 9. If it does exceed +/- 1.0 return to step 4.
9. Disengage the house lock pin and swing approximately 10 deg. to the left (counterclockwise). Slowly swing back to the right and engage the house lock pin*. Verify the angle indicated on the console does not exceed +/- 1.0 deg. If the angle exceeds +/- 1.0 deg., Return to step 4.* IF THE SUPERSTRUCTURE SWINGS PAST THE HOUSE LOCK PIN ENGAGED POSITION, THE PROCEDURE MUST BE REPEATED.
18-19
P.A.T. – L.M.IMANUAL
SECTION 19
DS 350 Graphic ModularANTI - TWO - BLOCK
CONNECTIONS &WIRING DIAGRAMS
GN
D 1
OU
T+U
B
5 3 1 5 3 1
GN
D 1
OU
T+U
B
5 3 15 3 1X3X4
X1
7 8
12345678S
SHIELD 1
CORE 2
1 2 3 4 5 6 7
1 2 3 4 5 6
1 2 3 4 5 6 7
123456
7
X2
6 Pin Connector
6 Pin Plug
To Central Unit
1 2 3
ANTI - TWO BLOCK SWITCH
1
2
3SHIELD
CO
RE
123456
6 PI
N
C
ON
NEC
TOR
6 PI
N D
UM
MY
PLU
G
4.7KRESISTOR
ΩΩΩΩ
ANTI - TWO - BLOCK WIRING DIAGRAM
NOTES: OUTER SHIELD GROUNDED AT STRAIN RELIEF CONNECTOR
CUT AND INSULATE INNER SHIELD
SWITCH PREWIRED AND POTTED
IMPORTANT CHANGE
1
2
1
!
1
1 1
2
2
1
!
19.1
GN
D 1
OU
T+U
B
5 3 1 5 3 1
GN
D 1
OU
T+U
B
5 3 15 3 1X3X4
X1
7 8
12345678S
SHIELD 1
CORE 2
1 2 3 4 5 6 7
1 2 3 4 5 6
1 2 3 4 5 6 7
123456
7
X2
6 Pin Connector
6 Pin Plug
To Central Unit
ANTI - TWO BLOCK SWITCH
6 PIN DUMMY PLUG
4.7KRESISTOR
ΩΩΩΩ
ANTI - TWO - BLOCK WIRING DIAGRAM
NOTES: OUTER SHIELD GROUNDED AT STRAIN RELIEF CONNECTOR
CUT AND INSULATE INNER SHIELD
SWITCH PREWIRED AND POTTED
IMPORTANT CHANGE
1
2
1
!
1 1
2
2
! AB
1 2 3
1
23
SHIELD
CO
RE
12
1
1
1 2 3 4
1 2 3
1 2 3
12
1
1
1 2 3
AB
A B
19.2
AUX. BOOM NOSEANTI - TWO BLOCK SWITCH
1
2
3
4
5
6
NO. PART NO. QTY DESCRIP.
1 9-333-102764 1 COMP. ASSEM.2 9-333-102717 1 2-POLE JUMPER BAR3 9-333-102666 1 TAGS, TERMINAL STRIP4 9-333-102663 4 BLOCK, TERMINAL STRIP5 9-333-102230 1 SWITCH A2B, WITH RETAINER
CRIMP6 9-333-102765 1 COMP. ASSEM., DUMMY PLUG
3 4
2 1
Auxiliary Boom Nose
NO. PART NO. QTY DESCRIPTION
1 9-333-102238 1 SWITCH, A2B W/O CRIMP2 9-333-102235 1 CONDUIT 10 FEET
(MUST CUT TO LENGTH)3+ 9-333-102767 1 JUNCTION BOX ASSEM.4 9-333-102687 2 SCREW
19.3
Auxiliary Boom NoseJUNCTION BOX ASSEMBLY
NO. PART NO. QTY DESCRIPTION
1 9-333-102758 1 Junction Box 2 9-333-102793 1 Strain Relief (90o) 3 9-333-101984 1 Locknut4 9-333-102759 1 Mounting rail, terminal strip5 9-333-102663 3 Block, terminal strip 6 9-333-102664 1 End plate, terminal strip7 9-333-102665 2 End bracket, terminal strip8 9-333-102666 1 Tags, terminal strip9 9-333-102760 1 Connector, cannon 2-pin male recp.10 9-333-102482 1 Gasket11 9-333-102612 1 Cover, dust12 9-333-102669 4 Screw #413 9-333-102266 4 Lockwasher #414 9-333-102480 4 Nut #4
Complete Assembly # 9-333-102767
A2B CABLE
(BLACK)
(BROWN)
(RED)
1
2
3
1
2
3
A
B
1
2
19.4
Fixe
d Sw
inga
way
Ext
ensi
on
NO
.
P
AR
T N
O.
Q
TY
DE
SCR
IPT
ION
1
9-33
3-10
2238
1Sw
itch,
A2B
W/O
Crim
p2
7-11
0-15
1205
2C
apsc
rew
39-
333-
1022
351
Con
duit
10 fe
et(m
ust c
ut to
leng
th)
4 +
9-33
3-10
2690
1Ju
nctio
n bo
x as
sem
bly
59-
333-
1026
872
Scre
w
19.5
Fixed SwingawayJUNCTION BOX ASSEMBLY
NO. PART NO. QTY DESCRIPTION
1 9-333-102758 1 Junction Box 2 9-333-102674 1 Strain Relief 3 9-333-102759 1 Mounting rail, terminal strip4 9-333-102663 3 Block, terminal strip 5 9-333-102664 1 End plate, terminal strip6 9-333-102665 2 End bracket, terminal strip7 9-333-102666 1 Tags, terminal strip8 9-333-102760 1 Connector, cannon 2-pin male recp.9 9-333-102482 1 Gasket10 9-333-102612 1 Cover, dust11 9-333-102669 4 Screw #412 9-333-102266 4 Lockwasher #413 9-333-102480 4 Nut #4
Complete Assembly # 9-333-102690
A2B CABLE
(BLACK)
(BROWN)
(RED)
1
2
3
1
2
3
A
B
1
2
19.6
P.A.T. – L.M.IMANUAL
SECTION 20
DS 350 Graphic ModularTROUBLESHOOTING
GUIDE
General Flowchart 20.2Lever Lockout Activated 20.3Broken Length Cable 20.4No Display 20.5Anti - Two - Block 20.7Length Reading Problem 20.10Angle Reading Problem 20.13Load Reading Problem 20.16Bad Data Transfer Between Console & Central Unit 20.18Error Code Displayed 20.20
20.1
PAT DS350 Graphic ModularLOAD MOMENT INDICATOR
TROUBLESHOOTING
GENERAL FLOWCHART
This section explains how to handle a problem that may arise with the P.A.T. Load MomentIndicator System - P.A.T. DS350 Graphic Modular. The procedures are easy to follow and are given in flowcharts on the following pages. Start with general flowchart below which will guide you to one of the more detailed flowcharts shown on pages 20.3 through 20.19.
START
What’s Wrong?
Lever LockoutActivated
Length Cable Problem No Display
No FunctionAnti-Two-Block
Go to Page 20.3 Go to Page 20.4 Go to Page 20.5 Go to Page 20.7
Wrong LengthDisplayed
Wrong Load Displayed
Error CodeDisplayed
Go to Page 20.10 Go to Page 20.16 Go to Page 20.20
20.2
Wrong AngleDisplayed
Go to Page 20.13
Bad Data Transfer
Go to Page 20.18
LEVER LOCKOUT ACTIVATED
PROBLEMThe lever lockout system of the crane is activated.Crane movements “hoist up”, telescope out”, and
“boom down” are stopped. Crane is not in overloador two-block condition.
START
Set the override key switch in central unit into upperposition to override LMI.
fixed?
Does the console indicateAnti-Two-Block warning?
Fault in crane electricor hydraulic system.
If console displays isblank, fault is located
in power supply, wiring or fuses.
Fault in Anti-TwoBlock system.
If Load Moment LimitLight is lit, the faultis located in LMI,
cables, wiring, fuses orconsole.
Check lever lockoutsystem in crane
Go to page 20.5 Go to page 20.7 Read error code dis-played on console
and go to page20.20.
YESNO
NO YES
20.3
BROKEN LENGTH CABLE
PROBLEMDamaged or broken length cable.
STEP ACTION
1 Cut old cable at cable drum.
2 Open cable reel cover and disconnect wiring from terminal block. Pull 7- conductor cable out of strain relief.
3 Remove cable reel from mounting brackets.
4 Remove damaged length cable, which is mounted to the slip rings in the cable reel, from Terminal X1 and X2 See drawing 1 on page 20.28.
5 Turn the cable reel and open the stain relief attached to the axle in the center of the drum. Pull existing length cable out of the cable reel.
6 Disconnect damaged length cable from Anti-Two-Block switch receptacle at the boom nose.
7 Pull new length cable through the hole, pipe and strain relief and push it through the axle of the reeling drum. Tighten strain relief to ensure sealing.
8 Dismantle length cable near slip ring and reconnect shield to terminal No. X1 and center to No. X2 See drawing 1 on page 20.28.
9 Remount cable reel to the boom. Turn reeling drum clockwise to get rest of new cable onto the drum.
10 Set preload on cable reel by turning the drum counter-clockwise 5 to 8 turns.
11 Reconnect new cable to Terminal No. 1 (center) and ground terminal (shield) of receptacle at the boom nose.
12 Reset length potentiometer in length angle transducer (screw is located in center of white gear): with boom fully retracted, turn potentiometer carefully counter-clockwise until it stops. Check function of Anti-Two-Block switch. Recheck length and angle display.
20.4
NO DISPLAY
PROBLEMBlank console display.
No warninglight shown.Crane movements stopped.
START
Check fuses on CPU box.
correct?
Measure crane voltage on main board terminal strip between X1-1(+12/24V) andX1-2 (ground).
This is an imput voltage from crane Note: If crane voltage is measured below
10V system will switch off.
correct?
Measure crane voltage on main board terminal strip between X1-3(+12/24V) and X1-4 (ground). This is a output voltage to
the console.
Replace fuses.
correct?
NEXT PAGE
Defect on main board. Replace main board, see replacement
procedure.
Check crane power supply for faulty crane electric or if power supply is too low.
NO
YES
YES
YES
NO
NO
20.5
NO DISPLAYcontinued
PREVIOUS PAGE
Measure voltage in the console between X1-1 (+12/24V) and
X1-2 (ground). Refer to Drawing 6 on page20.32 .
correct?
Check connections of thecable between console andcentral unit. Replace cable
if necessary.
Display is defective. Replace the console.
END
NO
YES
20.6
ANTI-TWO-BLOCK PROBLEM
START
Check to see whether or not crane is in two-block condition.
correct? Lower hook down in safe position.
Turn power off or disconnectwire from X1-31 in central unit.
correct?Plug appropriate plug into
socket of junction box.
NO
YES
NO
YES
correct? Replace Anti-Two-Block switch.
NEXT PAGE
NO
YES
PROBLEMFunction of Anti-Two-Block System is faulty.
20.7
Measure the resistance at the boom nosebox between terminals 1 and 6 with ohmmeter. This checks the function of the Anti-Two-Block switch.See drawing 2 on page 20.28.Switch Closed = 4700 +/- 500 OhmsSwitch Open = > 1 Megaohm
ANTI-TWO-BLOCK PROBLEM
PREVIOUS PAGE
Measure the A2B signal in the cable reel betweenX1:Brown and X2:Red wires on the slip ring withan ohmmeter. See drawing 1 on page 20.28.Switch closed = 4700 +/- 500 OhmsSwitch open = >1 MegohmReconnect slip ring wires.
correct?Fault in wiring cable from junction box at boom nose to cable reel or short circuit in length cable. Check wiring.
Measure the A2B signal in the cable reel between7 and 8 with an ohmmeter.See drawing 1 on page 20.28.Anti-Two-Block switch open = > 1 megohmAnti-Two-Block switch closed = 4700 Ohms+ 500 Ohms.Reconnect length cable to slip ring.
Fault in 7 conductor cable between cable reel and boom base box.correct?
NEXT PAGE
NO
YES
NO
YES
correct?
NO
YESReplace slip ring.
Measure the A2B signal in the boom basebox between terminal 5 and 6 with an ohmeter.Anti-Two-Block switch open = > 1 megohmAnti-Two-Block switch closed = 4700 Ohms
+ 500 Ohms.Reconnect length cable to slip ring.
20.8
ANTI-TWO-BLOCK PROBLEM
PREVIOUS PAGE
END
correct?
correct?
Turn system power off. Check Anti-Two-Block signal in central unit with ohmmeter measure between X1-31 and X1-32.Anti-Two-Block switch closed = 4700 Ohms+ 500 OhmsAnti-Two-Block switch open = > 1 Megohm.
Faulty wiring between cable reel and central unit. Check Ten Pin Receptacle,
using same measurements as in previous step. See cranes specific wiring diagramfor wires # 5 (+) and # 6 (-). If fault is
found check cable.
Disconnect X1-31 and X1-32.Check main board function by installing a temporary resistor, 4700 Ohms, between X1-31 and X1-32 in central unit. With resistor connected alarm should be inactive.
NO
YES
NO
Connect wire # 5 back to terminal X1-31 on themain board.
Defect on main board. Replace mainboard and reset pressure channel.
Reconnect wire #5 to X1-31 and wire #6 to X1-32.
20.9
Check out clutch in big gear wheel of length transducer. Extend and retract boom to ensure that clutch is not slipping on potentiometer axle. See drawing 7 on page 20.33.
correct?
Check power supply to length transducer on main board, terminal X1-28 (ground) and X1-26 (+12/24V). See drawing 3 on page 20.29.
YES
NO
LENGTH READING PROBLEMPROBLEM
Length reading incorrect.Crane is not in “out of load chart” condition.
START
Check mechanical adjustment of length potentiometer in cable reel. When main boom is fully retracted, adjust length potentiometer counter-clockwise until it stops.See drawing 7 on page 20.33.
Replace the gearwheel, clean potentiometeraxle. Reset length potentiometer.
Main board defective. Replace main board and reset pressure channel. correct?
NEXT PAGE
NO
YES
20.10
LENGTH READING PROBLEM
PREVIOUS PAGE
Measure supply to length transducer in cable reel at terminal between Pin 1 (ground) and Pin 3 (+12/24V). See drawing 7 on page 20.33.
correct?Faulty wiring between central unit and length transducer. Check wiring.
Measure signal from length transducerin cable reel at X1-2 and wire #2, the return signal is a current output. Measure-ment should be in series.Retracted Boom = 0 Potentiometer Turns = 4mA 10 Potentiometer Turns = 20mA
Replace length potentiometer assembly. Removeslip ring body from shaft and remove gear wheelfrom potentiometer axle. Unscrew mounting plateand remove potentiometer assembly from mounting plate. Remove assembly wires from terminal block. Connect new assembly to terminal block.Reinstall mounting plate, gear wheel and slip rings.Reset potentiometer with fully retracted boom, turncounterclockwise until it stops. See drawing 7 on page 20.33.
correct?
Measure signal from length transducer in central unit. The return signal is a currentoutput and must be measured in series.Connect meter between wire #2 and X1-27. 0 Potentiometer Turns = 4mA 10 Potentiometer Turns = 20mA
correct?Faulty wiring between central unitand length transducer. Check wiring.
NEXT PAGE
NO
NO
NO
YES
YES
YES
See drawing 3 on page 20.29.
20.11
LENGTH READING PROBLEM
PREVIOUS PAGE
Measure length signal of amplified output on analoginput module between test point MP0 and X1-3.The measurement should be between 0.5V-4.5V.
Refer to Drawing 5 on page 20.31.
Main board defective. Replace main board.Reset pressure channel. correct?
END
0 Potentiometer Turns = 0.5 V (500mV)10 Potentiometer Turns = 4.5 V
20.12
YES
NO
Analog Input Module is defective. Replace module.
ANGLE READING PROBLEM
PROBLEMAngle Reading Incorrect
Crane is not in “Out of Load Chart” condition.
START
Check levelness of the angle sensor in cable reelwith main boom at horizontal remove cover from the cable reel. See drawing 7 on page 20.33.
Readjust the angle sensor to the correct position by loosening the mounting screws and moving the angle sensor. See drawing 7 on page 20.33.
Place the boom at 0 o. Check power supply to angle sensor on main board between X1-26 (+12/24V) and X1-28 (GND)
Refer to Drawing 3 on page 20.29.
NEXT PAGE
Main board defective. replace main board andreset pressure channel. Note: Consult factory before replacing mainboard for further troubleshooting steps.
correct?NO
YES
correct?NO
YES
20.13
Replace angle sensor.correct?NO
YES
Measure supply to angle sensor in cablereel at terminal between X1-1 (+12/24V)and X1-3 (GND).See drawing 7 on page 20.33.
ANGLE READING PROBLEM
PREVIOUS PAGE
Measure signal in series from angle sensor in cable reel, one lead to wire #4 and the other lead X1-4. Boom Angle Signal : 0 Degrees 20 mA 45 Degrees 12 mA 90 Degrees 4 mA
NEXT PAGE
Faulty wiring between central unit andangle sensor. Check wiring.correct?
NO
YES
20.14
ANGLE READING PROBLEM
PREVIOUS PAGE
Faulty wiring between central unit andcable reel. Check wiring.correct?
NO
YES
Measure signal from angle sensor in centralunit. Measurement should be taken in seriesat X1-29 and wire #4.Boom Angle Signal : 0 Degrees 20 mA 45 Degrees 12 mA 90 Degrees 4 mA
Measure angle signal analog input modulebetween test point MP0 and X1-4. The measure-ment should be between 0.5 - 4.5V.Boom Angle Signal : 0 Degrees 0.5 Volt 45 Degrees 2.48 Volts 90 Degrees 4.5 VoltsSee drawing 5 on page 20.31.
Faulty analog input module or CPU module incentral unit.correct?
NO
YES
END
20.15
LOAD READING PROBLEMPROBLEM
Load reading incorrect.
START
Check selected operating mode(codeon operating mode switch).
correct?NO
YES
Select operating mode switch to correct position(see operating mode in load chart).
Check boom length reading on display.
correct?NO
YES
Reset length potentiometer. With fully retractedboom, turn potentiometer axle counterclockwiseuntil it stops .See drawing 7 on page 20.33.
Measure radius and check with the displayed radius.
Check if mechanical adjustment of angle transduceris correct. Angle transducer box should in line withboom and adjusted to actual boom angle. See drawing 7 on page 20.33.
correct?NO
YES
Check power supply to pressure transducer (rodside). Unplug transducer cable from transducer.Measure voltage at the cable connection betweenA (+12/24V) and C (ground).
Check power supply at main board betweenX1-20 (+12/24V) and X1-22 (ground) for pistonand X1-23 (+12/24V) and X1-25 (ground) forrod side. See drawing 3 on page 20.29.
correct?NO
YES
NEXT PAGE
Fault in pressure transducer.
Replace the main in central unit. Refer to Drawingon page 15.3.
correct?
NO
YES
20.16
LOAD READING PROBLEM
PREVIOUS PAGE
Measure in series piston side signal, in centralunit, remove wire #2 from X1-21. Connect onelead to wire #2 and the other to X1-21. The measurement should be between 4-20mA (4mA at 0 PSI to 20mA at 4410 PSI). Rod side, remove wire #2 from X1-24. Referto Drawing9 &10 on pages 20.35 & 20.36.
correct?NO
YES
correct?NO
YES
END
20.17
Measurement is not within 4-20mA.Fault in pressure transducer cable.Refer to Drawing 9&10, page 20.35 & 20.36.
Measurement within 4-20mA, but 4mAdoes not equal 0 PSI. Adjust zero point on pressure transducers at console. Referto page 17.1.
If transducer(s) are not adjustable,replace pressure transducer(s) andadjust zero point. Refer to page 17.1.
4-20mA
NO
YES
Measure pressure transducer signals on the analog input module between testpoints, (Piston side, MP0 (GND) and X1-1) (Rod side, MP0 (GND) and X1-2).The measurement should be between 0.5V - 4.5V at 0 PSI to 4.5V at 4410PSI.Refer to Drawing 5 on page 20.31.
Replace the analog input module board incentral unit.
BAD DATA TRANSFER BETWEEN CONSOLE & CENTRAL UNIT
PROBLEMError Code “E93 / E94”
No data transfer to and from console.
START
Make sure that EPROMS are correct and plugged intoEPROM MODULE is on main board. Refer to Drawing4 on page 20.30.
correct?NO
YES
Place EPROM S in correct socket.Refer to Drawing 4 on page 20.30
Measure process voltage on the main board in thecentral unit between MP24 (+5V) and MP0 (GND).Refer to Drawing 3 on page 20.29.
correct?NO
YES
Make sure external and internal power supply iscorrect. Refer to page 20.5.
NEXT PAGE20.18
Check the H12 (TXD) LED on the main board ON/OFF.Refer to Drawing 3 on page 20.29.
On
Turn off system power. Check the continuityof the receive (RXD) and transfer (TXD) wires.
Check continuity between: X1-5 main board and X1-3 consoleX1-6 main board and X1-4 console
Refer to Drawings 3&6 on pages 20.29,20.32.
Off
correct?NO
YES
Check connections and replace cable from centralunit to console, if necessary. Refer to Drawing 8on page 20.34.
PREVIOUS PAGE
BAD DATA TRANSFER BETWEEN CONSOLE & CENTRAL UNIT
20.19
Check if additional ground link between main board terminal X9 and central unit box mountingbracket is in place. Refer to Drawing 3 on page20.29.
Install ground link - single cable minimum ofAWG14 (2.0mm2) between terminal X9/2 andcentral unit box mounting bracket. correct?
NO
YES
Ensure that cable shields are connected correctly.Refer to connections and wiring diagrams.
Make correct shield connection.Refer to connection and wiring diagrams,correct?
NO
YESFind out which component of the crane electricis spiking out (e.g. dump valve, outrigger relay).Install a diode or varistor across terminals of spiking component. Diode type such as 1N 4001can be used (watch + and - connection for diode).
END
INTERFERENCE PROBLEM
PROBLEMInterference from crane electric.
Error Code “E93 / E94” intermittent.Frozen console displays.
START
Check system out; refer to Section 8 - Bad DataTransfer Between Console & Central Unit.
correct?NO
YES
Replace or repair part which is defective.
Check if additional ground like between main board terminal X9 and central unit box mountingbracket is in place. Refer to Drawing 4, “MainBoard”, in Section 11.
Install ground link - single cable minimum ofAWG14 (2.0mm2) between terminal X9/1 andcentral unit box mounting bracket. Refer toDrawing 4, “Main Board”, in Section 11.
correct?NO
YES
Ensure that cable shields are connected correctly.Refer to connections and wiring diagrams, Draw-ings 9A,B,C in Section 11.
Make correct shield connection.Refer to connection and wiring diagrams,Drawings 9A,9B and 9C in Section 11.
correct?NO
YESFind out which component of the crane electricis spiking out (e.g. dump valve, outrigger relay).Install a diode or varistor across terminals of spiking component. Diode type such as 1N 4001can be used (watch + and - connection for diode).Refer to Drawing 7, “Suppressor Diode”, in Sec-tion 11.
END
20.20
ERROR CODE DISPLAY
PROBLEMError code displayed. Lever lockout activated.
Warning lights on.
ERRORDISPLAY ERROR CAUSE ACTION
E 01* Below radius or above angle Fallen below the minimum Lower boom back to a radius range. radius or above the angle given or angle given in the load
in the load chart due to raising chart.the boom too far.
E 02* Beyond radius or below The maximum radius or Raise boom back to a radiusangle range. minimum angle given in the or angle given in the load
load chart was exceeded due chart.to lowering the boom too far.
E 03* Prohibited slewing range. Slewing range prohibited Slew back into admissible(no load area) with load. range.
E 04* Operating mode not available. Operating mode switch in the Set operating mode switchconsole set incorrectly. correctly to the code assignedOperating mode is not per- to the operating mode of themissible with actual crane crane.configuration.
E 05* Length range not permitted. Boom was telescoped too Telescope boom to correctfar or not far enough. length given in the load chart.
Length sensor adjustment See page 20.33.changed; i.e. length sensorcable slid off the cable drum.
E 06* Fallen below angle range with Fallen below the minimum jib Luff in the jib to a radius orluffing jib operation. angle specified in the angle specified in the load
respective load chart due to chart.luffing out the jib too far.
* This error can be corrected by the operator.
20.21
ERROR CODE DISPLAY ERROR
DISPLAY ERROR CAUSE ACTION
E 07 No acknowledgement signal Overload relay is stuck,from overload relay (K8). defective or not being selected.
E 08 No acknowledgement signal Anti-Two-Block switch relayfrom Anti-Two-Block switch is defective or not beingrelay (K9). selected.
E 11 Fallen below lower limiting Cable from central unit to length sensor Check cable. Replace ifvalue for the measuring defective, not connected or water in the necessary. See page 20.33.
channel "length". connectors
Length potentiometer defective. Replace and reset lengthpotentiometer. See page 20.33.
Electronic component in the Replace main board andmeasuring channel defective on reset pressure channels.main board.
E 12 Fallen below lower limiting Cable from central unit to Check cable as well as plug.value for the measuring the pressure transducer Replace if necessary.channel "pressure piston side". defective, loose or water in
the plug.
Pressure transducer on Replace pressure transducerpiston side defective. and reset pressure channel.
Electronic component in the Replace main board andmeasuring channel defective reset pressure channels.on main board.
E 13 Fallen below lower limiting Cable from central unit to Check cable as well as plug.value for the measuring the pressure transducer Replace if necessary.channel "pressure rod side". defective, loose or water in
in the plug.
Pressure transducer on rod Replace pressure transducerside defective. and reset pressure channel.
Electronic component in Replace main board andthe measuring channel defective reset pressure channels.on main board.
E 14 Fallen below upper limit value Cable from central unit to Check cable as well as plugs,in measuring channel "Force". force measuring point defective replace if need be.
or water inside the plugs. Force transducer defective. Replace force transducer.
Electronic component in the Replace main board and resetmeasuring channel defective. pressure channels.
20.22
ERROR CODE DISPLAY ERROR DISPLAY ERROR CAUSE ACTION E 15 Fallen below lower limiting Cable from central unit to the length/ Check cable. value for the measuring angle sensor defective or loose or Replace if necessary. channel "angle main boom". water inside plug. See page 20.37. Angle sensor defective. Replace angle sensor. and reset adjustment. Electronic component in the Replace main board and measuring channel defective. reset pressure channels. E 16 Fallen below lower limit Cable from central unit Check cable as well as plug, value for measuring channel to angle sensor defective replace if need be. "Luffing Jib Angle". or disconnected or water inside the plug. E 17 Angle sensor defective. Replace angle sensor. Electronic component in the Replace main board and reset measuring channel defective. pressure channels. E 18 Front Stabilizer overloaded Exceeding capacities allowed for over Achieve a safe working area the front. Immediately. E 19 Error in the reference voltage. Electronic component on Replace main board and reset the main board defective. pressure channels. +5 volt supply E 1A Below limiting value for slewing Cable from central unit to the slewing Check wiring, replace if angle 1. angle sensor defective or loose. necessary. E 1B Below limiting value for slewing Slewing angle pot. defective. Replace and reset slewing angle angle 2. wiring, (external). potentiometer. Electronic component in the measuring Replace main board and reset channel defective on main board. pressure channels. E 21 Upper limiting value for the Cable from central unit to the Check cable. Replace if measuring channel "length" length/angle sensor defective necessary. See page 20.37. exceeded. or loose. Length potentiometer Replace and reset length defective. potentiometer. See page 20.33. Electronic component in the Replace main board and measuring channel defective reset pressure channels. on main board.
20.23
ERROR CODE DISPLAY ERROR DISPLAY ERROR CAUSE ACTION E 22 Upper limiting value for the Cable from central unit to the Check cable as well as plug. measuring channel "pressure pressure transducer defective, Replace if necessary. piston side” exceeded. loose or water in the plug. Pressure transducer on piston Replace pressure transducer side defective. and reset pressure channels. Electronic component in the Replace main board and measuring channel defective reset pressure channels. on main board. E 23 Upper limiting value for the Cable from central unit to the Check cable as well as plug. measuring channel "pressure pressure transducer defective, Replace if necessary. rod side" exceeded. loose or water in the plug. Pressure transducer on rod Replace pressure transducer side defective. and reset pressure channels. Electronic component in the Replace main board and measuring channel defective. reset pressure channels. on main board. E 24 Upper limit value in measuring Cable between central unit and Check cable as well as plug, channel "Force" exceeded. force measuring point defective replace if need be. or water inside the plug. Force sensor defective. Replace force sensor. Electronic component in the Replace main board and reset measuring channel defective. pressure channels. E 25 Upper limiting value for the Cable from central unit to the Check cable. measuring channel "angle length/angle sensor defective Replace if necessary. main boom" exceeded. or loose. Angle sensor defective. Replace angle sensor and reset mechanical adjustment. Electronic component in the Replace main board and reset measuring channel defective pressure channels. on main board. E 26 Upper limit value for See Error E 16. See Error E 16. measuring channel "Luffing Jib Angle" exceeded.
20.24
ERROR CODE DISPLAY ERROR DISPLAY ERROR CAUSE ACTION E 27 Upper limit value for the measur- Cable from central unit to the Check cable. channel 7 exceeded. Sensor of channel 7 defective Replace if necessary. or loose. Sensor of channel 7 defective. Replace angle sensor and reset mechanical adjustment. Electronic component in the Replace main board and reset measuring channel 7 defective. pressure channels. E 29 Error in the reference Supply and Reference voltages on Check supply voltages. voltage. MP10 is more than 3.3V. Electronic component on Replace main board and reset -5 volt supply the main board defective. pressure channels. A/D converter defective. E 2A Above limiting value for slewing Cable from central unit to the slewing Check wiring, replace if angle 1. angle sensor defective or loose. necessary. E 2B Above limiting value for slewing Slewing angle pot. defective. Replace and reset slewing angle angle 2. wiring, (external). potentiometer. Electronic component in the measuring Replace main board and reset channel defective on main board. pressure channels. E 31 Error in system program EPROM with system Replace EPROM with system program defective. program. Electronic component on Replace main board and reset the main board defective. pressure channels.
E 37 Error in program run EPROM with system program Replace system program defective. EPROM. Electronic component on the main Replace main board and reset board defective. pressure channels. E 38 Incorrect system program. CPU is equipped with an Equip main board with incorrect version of system correct version of system or program. Data EPROM. E 39 Incorrect system program. CPU is equipped with an Equip main board with incorrect version of system correct version of system or program. TLK EPROM. E 41 Error in the external RAM. RAM in the CPU on the Replace CPU Chip No. main board defective. 80C31. Replace main board and reset pressure channels. E 42 Error in the external write/ Internal defect in Exchange write/read memory read memory (RAM). digital part of CPU. (CMOS-RAM). Replace main board and reset pressure channels.
20.25
ERROR CODE DISPLAY ERROR DISPLAY ERROR CAUSE ACTION E 42 Error in the external Internal defect in digital part Exchange write/read memory write/read memory of CPU. (CMOS-RAM). Replace main (RAM) part 1. Board and reset pressure channels. E 43 Error in the external Internal defect in digital part Exchange write/read memory write/read memory of CPU. (CMOS-RAM). Replace main (RAM) part 2. Board and reset pressure channels. E 45 Error in internal Defective electronic Replace main board and communications. component. reset pressure channels. E 46 Error in A/D Defective electronic Replace main board and conversion component. reset pressure channels. E 47 Malfunction in the Internal defect in Replace main board and reset monitored write/read in digital part of CPU pressure channels. memory.
E 48 Malfunction in the monitored Inter defect in digital part of CPU Replace main board and reset pressure channels. E 51 Error in data memory. Data EPROM on the main Replace Data EPROM. board defective. Make sure BR3 on the main Eprom Module not bridge correctly. board is installed. E 52 Error in TLK memory. TLK EPROM on the main Replace main board and reset Pressure channels. E 56 Error in crane data EEPROM Memory module wrongly bridged. Bridge memory module acc. To memory type. Crane data EEPROM defective. Replace EPROM module and reset pressure channels. E 57 Error in serial crane data EEPROM Serial crane data EEPROM does not Write data on serial crane data contain valid data. EEPROM (by means of test program or on line function), then restart the LMI Memory module defective. Replace EPROM module and reset pressure channels. E 58 Error in the serial analog data No valid data in the serial analog Same action as E 57 EEPROM data EEPROM. LMI main board defective. Replace main board. E 61 Serial communicate problem Green cable in Buss ext. or module Check connections itself. Replace module. E 63 Digital inputs on buss extension Replace buss extension E 69 Error in serial crane data Memory module wrongly bridged. Bridge memory module acc. EEPROM to memory type. The number of the selected Load chart EPROM defective. Replace load chart EPROM. EPROM base and the programming values are not identical.
20.26
ERROR CODE DISPLAY ERROR DISPLAY ERROR CAUSE ACTION E 71 Incorrect acknowledgment a.Anti two block relay is stuck or Replace main board. of the 1 relay on the main board. defective console to central unit. b. Two block relay is not being selected due to a break on the main board. E 72 - Analogous to E 71 for the relays. Analogous to E 71 for the relays Analogous to E 71 for the relays E 77 K2…K7 K2…K7 K2…K7. E 80 Wipers for slewing potentiometer Replace potentiometer. out of tolerance. E 84 Wrong rigging condition. The selected rigging condition is not Select another rigging condition contained in the data EPROM. Check the programming in the data EPROM. E 85 Error in the radius determination. The computed radius is too small Check the programming in the ( negative deflection ) data eprom. E 89 Changed of the operating code The mode switch was changed Lower the load and set the during lifting a load. during lifting a load. switch to the correct operating configuration of the crane. E 91 No data transmission from the a. Supply voltage of console a. Check voltage at terminal X1 console to central unit. interrupted. console electronics. b. Interruption or ground in the line b. Check connection between from console to central unit. console and central unit. c. Transmitter/receiver module c. If accidental ground occurs, defective. The transmitter module in the console electronics can be damaged. Replace the console electronics or main board. E 92 Error in the data transmission a. Temporary interruption of the a. Check connection between from console to central unit. data line from console electronics console and central unit. to central unit. b. Transmitter/receiver module defective. E 93 Error in the data transmission a. Temporary interruption of the a. Check connection between from central unit data line from console electronics console and central unit. to central unit. b. Replace console electronics b. Transmitter/receiver module or main board respectively. defective. 20.27
ERROR CODE DISPLAY ERROR DISPLAY ERROR CAUSE ACTION E 94 No data transmission from a. Interruption or accidental ground a. Check connection between console to central unit. in the line from console to CU. Console electronics and central
unit. If you find an accidental ground, the transmitter module in the console
electronics can be damaged. Replace the console electronics.
b. Transmitter/receiver module b. Replace console electronics defective. Or main board respectively. c. Data-EPROM defective. c. Check data EPROM. d. CPU defective. d. Replace CPU module. e. Electromagnetic interference e. Eliminate interference (when switching contractors or source by inverse diodes or valves). Varistor.
E 95 Error in the crane data EPROM Data EPROM defective. Replace data EPROM. Position of jumper for the selection Check the jumper position. of the type of EPROM is wrong. Electronic component on main board Replace main board and reset defective. pressure channels. E 96 Error in the internal RAM of the CPU or main board of the console Replace console main board. CPU of the console. defective. E 97 Error in the external RAM of the External RAM of the console Replace console main board. CPU of the console. defective. Electronic component on the main Replace console main board. board defective. E 98 Wrong jumper position in the The jumper position BR9/BR10 in the Check the jumper position. console. console does not correspond to the actual type of central unit. Electronic component on the main Replace console main board. board defective.
EAB Short circuit in the anti - two Short circuit in the anti - two block Replace two block switch block switch circuit switch. Short circuit in the cable to the two Replace cable to the two block block switch switch Electronic component on the analog Check analog input module input module defective Replace if necessary Note: If an error message is displayed which is not contained in above list, please con Grove or PAT service departments.
20.28
MP 25
+UBSMP1
KGND
KG
ND
F1
X1
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54
F2
J4J3J2J1 31
- +
KG
ND
H9
A2B
X1
KGND
J103 24 1 MP29
+5V/RS232
A2BK9
LMIK8
LOAD
LEVERLOCKOUT
K10
KG
ND
+UB
KGND
+UB
1 +UB
H12
TXD
H10
MAIN
ON
/OFF
H1 H
2 H3 H
4 H5 H
6
X13
DI 1-D
I 6 =>D
I 1D
I 6
X14
KGND
+UB
1
V10H
11V11
MP41
MP40
PFAIL+UB
1pow
er o.k.
GND
+5V
+6V
+9V
KG
ND
AGN
D
X16
AGN
D
C
C
MP42PWM DC
- G1 +
MP24+BATT
MP23
VBAT
X15
KG
ND
GND
AGN
DK
GN
D
KG
ND
X12
X17
GND
MP21
SP5
X11J11
A B C D E F G H I J K L M
A B C D E F G H I J K L M
1
2
3
4
5
6
7
8
9
10
11
12
13
1
2
3
4
5
6
7
8
9
10
11
12
13
20.29
Drawing 3 : Main Board
77 76
MP 26
MP 4
MP 9
MP 8
LOCATIONS :
MP 1 - zone M13 = GND.MP 25 - zone M13 = +UBSMP 8 - zone M2 = +9VMP 9 - zone M2 = +6VMP 4 - zone M1 = +5V MP 26 - zone M1 = GND.MP 23 - zone A2 = VBATT MP 24 - zone D2 = +BATTMP 40 - zone M4 = +UB
MP 41 - zone M4 = POWER FAILMP 42 - zone G1 = +5VMP 21 - zone E5 = +5VMP 29 - zone D10 = +5VH1-H6 - zone I5 = DI 1-6
LED’S
H 8 - zone M3 - LOADH 9 - zone E11 - A2BH 10 - zone G9 - MAIN IN/OUTH 11 - zone M3 - POWERH 12 - zone I11 - TXD
EJECT
MP2MP6
MP5
BR6
BR5
X3
J12
J8 J9 MP3 J6
SYSTEMD10
D1
MP4
X2X1
J13
MP7
P1
J1J2
J10
J11 J1
4
J15
J7
A102 CPU
BR
4 3 2 1
J6
J2J1
J5J3
DATAD1
TLKD3
A103 DATEN
X1
D3
D2
D14
D13
D6
D17
D21D7D15
D9
D20
D18
D19
D11
D12
20.30
Drawing 4 : CPU and Daten EPROM boards
Ensure the notch is in the correct direction ( to the right )The EPROMS must be installed completely to the left, leavingblank holes to the right
X16
1216
X17
1240
+ ++ +
- +
MP12
J2
MP13
P7P6
P5P4
P3P2
P1
MP11
J1 MP9
MP10
MP17
- +MP0MP8
P8
MP7 -M
P1->7 6 5 4 3 2 1
VREFA
MP14
BR1
AG
ND AGND
AGNDAGND
MP16
1612
120
1240
BOARD P/N 9-333-103290
The analog input module converts the sensor signals on channels 1 - 7 to signals that will beprocessed at the CPU and software. The incoming signal measured at the measuring points( MP ) will be 0.5V/4mA …. 2.5V/20mA. The analog input module then converts the channelsignals to 0.5V…. 4.5V, which can be measured on X1:1 through X1:7. The signal voltage canbe measured at either point using ground and signal input.
X1
20.31
Drawing 5 : Analog Input Module
1 2
3 4
5 6
7 8
1
2 3
4
MP
2+7
V
MP
5+5
VM
P 0
GN
D
MP
3-2
4V
MP
4-2
4V
MP
6
MP
7
MP
1+U
B
J5 J4
J3
J1J2
X1
X5
Dra
win
g 6
:VIE
W O
F BA
CK
SID
EO
F G
RA
PHIC
CO
NSO
LE
20.32
AD
JUST
LEN
GTH
PO
TEN
IOM
ETER
WIT
H B
OO
M F
ULL
Y R
ETR
AC
TED
,TU
RN
TH
E C
ENTE
R S
CR
EW
CO
UN
TER
CLO
CK
WIS
E TO
A S
OFT
ST
OP.
Dra
win
g 7
: Len
gth
/ Ang
leT
rans
duce
r
X3
1 2 3
1 3 5
XA
2
X2
L 1 2 3
1 3 5
XB2
AX
2
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 SX
1
X2
7 (
9)8
(10)
9333
1033
09
20.33
51 52 3 4 5 6 7 8 9 10
+UB
GN
D+U
B
+UB
GN
DR
XD
TXD
A2B
BY
PASS
A2B
BY
PASS
LMI B
YPA
SS
8 9 1 2 3 4 5 6 7 10 11 12 13 14
CENTRAL UNITMAIN BOARD
1 2 3 4 5 6 7 10 8 9 11 12 13 14
1 2 3 4 5 6 7 8 X1 +U
B
GN
D
TXD
RX
DA
2B
LOA
D
A2B D
I
X7 1 2 3 4
+UB
SIG
+SI
G -
GN
D X812
+UBGND
A B C D
1 2 3 4LIGHTBAR
CONSOLE (1318)
Drawing 8 :ELECTRICAL WIRING FROM CENTRAL UNIT TO CONSOLE
20.34
20 2
1 2
2
X1
1
2 1
2 1
1
CEN
TR
AL
UN
ITM
AIN
BO
AR
D
GN/YL
1 2
3
1
2
3
4
1
2 3
GN/YL
71 (+UB)
51 (GND)
73(LMI UNLOCK SOL.)
A
B
C
1 2
3
4
A
B
C
PRE
SS. T
RA
NS.
(PIS
TO
N)
Dra
win
g 9
:EL
EC
TRIC
AL
WIR
ING
FR
OM
C
ENT
RA
L U
NIT
TO
PR
ESSU
RE
TRA
NSD
UC
ER
(PIS
TON
)
+UBGND
LMI UNLOCK S.
+UBR
+UB
PISTON
GND
20.35
23 2
4 2
5
X1
1
2 1
2 1
1
CEN
TR
AL
UN
ITM
AIN
BO
AR
D
GN/YL
1 2
3
1
2
3
4
1
2 3
GN/YL
71 (+UB)
51 (GND)
73(LMI UNLOCK SOL.)
A
B
C
1 2
3
4
A
B
C
PRE
SS. T
RA
NS.
(RO
D)
+UBGND
LMI UNLOCK S.
+UBR
+UB
ROD
GND
Dra
win
g 10
:ELE
CTR
ICA
L W
IRIN
G F
RO
M
CE
NT
RA
L U
NIT
TO
PR
ESSU
RE
TRA
NSD
UC
ER (R
OD
)
20.36
26 2
7 2
8 2
9 3
0 3
1 3
2 3
3 3
4 3
5 3
6 5
3 5
4
+UBLEN(GND) 0.0VANGLEFORCEA2B SIG.A2B GROUNDNOT USEDNOT USEDNOT USEDNOT USEDFUSE (4 AMP)FUSE (4 AMP)
CEN
TRA
L U
NIT
MA
IN B
OA
RD
1 2
3
4
7
5
6
1 2
3 4
5
6 7
1 2
3 4
5
6
1 2
3 4
5
6 7
6 SO
CK
ET
PL
UG
6 PI
N R
ECEP
TAC
LE
78
53
15
31
S8
76
54
32
1
53
15
31
GND
ANGLE SIG.
+UB
GND
LENGTH SIG.
+UB
X2
X4
X3
X1
6
5
4
3
2
1
7
X1
X2
BRN
RED
SHIE
LD
CO
RE
CA
BLE
REE
L > > > > > >
> > > > > >
1 2 3 4 5 6
1
2
3
123
SHIE
LD
CO
RE
6 PI
N R
ECEP
TAC
LE
4.
7KR
ESIS
TOR
Dra
win
g 11
:ELE
CTR
ICA
L W
IRIN
G F
RO
M
CE
NT
RA
L U
NIT
TO
CA
BLE
REE
L/A
NTI
-TW
O B
LOC
K
20.37
20-38
20-39
P.A.T. – L.M.IMANUAL
SECTION 21
DS 350 Graphic Modular (BCS)Console Connections,
Wiring Diagrams
DATA FROM C.U.DATA TO C.U.
LMI
A2B
CONSOLE BY - PASS
KEY
+
+
F1 +UBS+24V
+UB
+0V
+UBS0VRXDTXD
STOP
+
K10A
K9
K8A2B-OA2B-I
10LOAD-I
+ +UBS
K10B
10AF2-REL -MREL -AREL -R + +UBS
+ +UBS
DE 1DE 2DE 3DE 4
IU DAV1
+ +UBSI
U DAV2
+ +UBSI
U LG 1
IU WG 1
IU LG 1
+ +UBSI
U S1 DHG 1
IU S2 DHG 2
+ +UB
SI - OUTSI - IN
F1 - 4A
A2B-0A2B-I
LOAD-I
+ +UBS F2-10ASI-RELSI-REL+ +UBS
DE 5
DE 6
+ +UBS
1
0V
0V
0V
0V
0V
0V
0V
0V
23456789
1112131415161718192021222324252627282930313233343536515253545758596061626465666768697677
W # 73A
24 VOLTS
GND
LEVER LOCKOUTSOLENOIDS
W # 71K =
W # 51AJ =
A
B
C
1
2
3
12
3
4A
10A
4D
5E
LMI L/O ALARM (EEC)
HOUSE LOCK PIN SWITCH
4
5
13
14
LMI BYPASSKEY SWITCH
8
6
5
4
2
7
6
5
4
3
2
1
(GND)
1 (+24 V)
34
34
AB
GRAPHIC CONSOLE
7
3
1234567
+
X1
X212345678
BU
S EX
TE
NSIO
N
X4123456
BRN
BRN
WHT
WHT
GRN
GRNYEL
YEL
PNK
GRA
GRA
PNK
BRN
WHTBRN
WHT
PNK
GRA
GRA
PNK
GRN
YELGRN
YEL
DS350 Graphic Modular BCSConsole to C.P.U. Connections
= WIRES AREGROUPEDTOGETHER
= CONNECTED
3-PairTwistedCable
MAIN
BO
ARD
21.1
F1 F4F3F2
!
STOP
STOP
! STOP
STOP
PAT DS 350
TARE
LIM
SEL
iCTRL
0335
?
156ft
90.0ft
100% 100% 100%
79.4o
50.8ft
73.5oo02(lbs)MAX
ACT (lbs)
34.900
FIVE SECTION BOOM SERVICE SCREEN(RT865BXL - BCS)
1 2551 2551 2551 255
0 00 00 00 0
1 2551 2551 2551 255
0 00 00 00 0
38.238.238.238.238.238.238.238.2
Ramp Seq. IM Hex Value
CM Hex Value OM/Fly Hex Value
Length of IM
Tot. Length minus IM
To activate service screen press and hold F1 & F4 until screen appears in lower left corner. The ramping value will indicate theramping up and ramping down of the output signal to the solenoids.
21.2
38.238.238.238.238.238.238.238.2
P.A.T. – L.M.IMANUAL
SECTION 22
DS 350 Graphic Modular (BCS)System Theory &
Component Location
CAB
LER
EEL
CR
ANE
INTER
FACE
CO
NN
ECTO
R
BOOMCONTROL BUS
EXTENSION
DIGITALINPUT
DIGITALOUTPUT
ANALOGOUTPUT
ANALOGINPUT
CENTRALUNIT
ANALOG INPUT
DIGITAL INPUTS
CR
ANE
INTER
FACE
CO
NN
ECTO
R
ON RUBBER - OVER FRONTHOUSE PIN SWITCHPRESS. SW. EXTEND PILOT PRESS.PRESS. SW. RETRACT PILOT PRESS.AUTOMODE SWITCH IN CAB
PROX. SW. ON CM SECTIONPROX. SW. ON IM SECTIONPROX. SW. ON BASE SECTIONPROX. SW. ON BASE SECTION
BOOM EXTEND
BOOM RETRACT
AUTOMODE ONOM / FLY RET.CM RET. & % RESETIM RET.IM % RESET
OUT OF SEQ. WARNING LIGHT IN CAB
PROP. PRESS. REDUCING VALVE EXT.
PROP. PRESS. REDUCING VALVE RET.
IM - 2 WAY SOLENOID VALVE
CM - 2 WAY SOLENOID VALVE
OM - 2 WAY SOENOID VALVE
OUT OF SEQ. WARN.
PROP. EXT.
PROP. RET.
IM 2 WAY SOL.
CM 2 WAY SOL.
OM 2 WAY SOL.
CENTER MID LENGTH SENSORINNER MID LENGTH SENSOR
MAIN BOOM LENGTH SENSORANGLE SENSORROD PRESS. TRANS.PISTON PRESS. TRANS.
P1 P2 A1 L1
AI 1
AI 2
AO1
K4K5 NO
K5 NC
K2
K6
K7K5
DI 1DI 2DI 3DI 4DI 5DI 6DI 7
LMI CONSOLE
RxDTxD
ON RUBBER OVER FRONTHOUSE PIN ENGAGED
PROP.
DS350 Graphic Modular (BCS)SYSTEM THEORY
22.1
HOW DOES THE SYSTEM WORK?
HYDRAULIC
1. Pilot operated 4 way valve provides oil flow to extend and retract the 3 telescopingcylinders. On this valve are 2 pressure reducing valves electrically operated by the PATsystem. Their function is to reduce the pilot pressure when nearing the point a sectionmust stop in order to slow it down smoothly, then they will increase the pilot pressureback to normal once the next section begins to move allowing for a smooth transition.
Directional pressure switches
In each of the pilot pressure lines is a normally open pressure switch, one for extend andone for retract. These pressure switches tell the PAT which direction has been selectedby the operator, so it will know which section is next to go out or in and when the pilotpressure is to be reduced and returned to normal.
Third switch pressure
A third pressure switch ( normally closed ) mounted near the top of the 4 way valvemonitors joystick pressure directly on the main spool for extend. When no pressure isevident, or the controller is in neutral, the switch is closed , and the piston side dumpvalve is energized allowing piston side pressure to be released through a .078 orifice.
2. Two - way valves control the oil to each telescope cylinder. One for the pilotpressure to the holding valve and one for the piston side oil to flow. These are operatedin pairs only. When a pair of two-way valves are de-energized, that particular telescopecylinder will then operate. The other two pair of two way - valves must be energized toprevent movement of the other two telescope cylinders. These valves are also switchedon and off by the PAT system when in Automatic mode. They are controlled by anindividual selector switch when in the Manual mode.Two - way valves are normally open, so that in the event of an electrical malfunction,the boom could always be telescoped in for repair.
Piston side dump valve
In the piston side, there is a piston side dump valve which allows piston side oil to bereleased back to tank by the way of a .078 orifice. This valve is controlled by thenormally closed contacts of the third pressure switch and dumps to tank, when thecontroller is in neutral and pilot pressure has decayed.
Rod side dump valve
In the rod side, there is a rod side dump valve which allows rod side oil to be releasedback to tank. This valve is electrically operated by the PAT system and is switched on todump rod side pressure when the controller is in neutral.
22.2
Sequence valve
The sequence valve maintains pressure on the rod side to prevent the cylinders from extendingwhenthe trombone tubes are pressurized.* If the boom sections drift back in momentarily after the controller is released, this is a goodindication the sequence valve is defective.* To adjust or check for proper adjustment:
1. Install gauge into test port between pressure reducing valve and sequence valve.2. Select manual mode.3. Select either inner mid or center mid section.
4. Extend the boom section and monitor pressure while boom is extending. If it does not read 1,000 P.S.I., adjust valve accordingly.
Pressure reducing valve
The pressure reducing valve is used to flood the rod side whenever the telescope cylinders firstbegin to extend.* If the boom sections take off with a jump, this is a good indication the pressure reducing valve is defective.* To adjust or check for proper adjustment:
1. Always be sure to check setting of the sequence valve first.2. Gauge should still be in test port from checking sequence valve.3. With manual mode still selected.4. Select either the inner mid or center mid section chosen.5. Extend the section completely until it bottoms out.6. Release controller or treadle valve to neutral (this allows oil to drain off).7. Then operate controller or treadle valve to extend and note pressure reading, it should read 800 P.S.I. if it does not, adjust pressure reducing valve accordingly.
Check valve
The purpose of the check valve, is to prevent high pressure oil from flowing back through the800 P.S.I. pressure reducing valve when trying to retract.
22.3
HELPFUL HINTS
CHECKING THE COILS IN THE TWO WAY VALVES FOR CONTINUITY
1. Select manual mode
2. Select individual sections to operate.
3. If there is continuity in the wiring to the valve, the section lights will illuminate.
CHECKING THE BOOM LENGTH SIGNALS
Three length sensors are located on the side of the boom ,(Overall length, Inner Mid &
Center Mid) the software utilizes the signals to calculate the outer mid & fly section length.
Disengage the boom stop, retract the boom and measure all with meter in series:
Overall boom length signal 4 mA (A 101 Main X1-27)
Inner Mid length signal 4mA (A 101 Bus X1-63 )
Center Mid length signal 4 mA (A 101 Bus X1-64 )
CHECKING PROXIMITY SWITCH INPUTS
Four proximity switches are used to tell the system if all sections are fully retracted.
Inner mid retract & percentage reset switch:Reset proximity switch provides +24V signal to A 101 Bus X1-41 when retracted against boom stop.Center mid retract & percentage reset switch:Reset proximity switch provides +24V signal to A 101 Bus X1 - 37.
Outer mid / fly retract & percentage reset switch:Reset proximity switch provides +24V signal to A 101 Bus X1-35.
Retract proximity switch provides a +24V signal to A 101 X1-39 when boom stop is disengage.
22.4
VIEW A - A
BYP
ASS
KEY
SW
ITC
H
FUSE
( 4A
)
FUSE
( 10
A)
CAB
LE A
SSY.
TO
BO
OM
3 -P
AIR
CAB
LE B
US
EXTE
NSI
ON
CAB
LE A
SSY.
TO
CO
NSO
LE
CAB
LE T
O C
RA
NE
INTE
RFA
CE
CAB
LE A
SSY.
TO
PR
ESS.
TR
ANSD
UC
ER (
RO
D )
CAB
LE T
O A
REA
DEF
INIT
ION
CAB
LE A
SSY.
TO
PR
ESS.
TR
ANSD
UC
ER (
PIST
ON
)
VIEW B - B
CAB
LE A
SSY.
TO
BO
OM
CAB
LE A
SSY.
TO
BO
OM
3 -P
AIR
CAB
LE T
O C
ENTR
AL U
NIT
SS C
ABLE
TO
CR
AN
E IN
TER
FAC
E
A A PATB B
19 - pin plug
14 - pin plug
7 - pin plug
RT865BXL
CRANE ELECTRICINTERFACE CONNECTION
CENTRAL UNIT BOOM CONTROLBUS EXTENSION
CONNECTIONS FORTURNTABLE HARDWARE
TO BOOM HARDWARE
P.A.T. - LMI RT865 BXL (BCS)
TURNTABLE COMPONENTS
22.5
RT865BXL (BCS)Central Processing Unit
K10K8K9
4 AMP 10 AMP
LMI BYPASS
KEY SWITCH
FERRITEFILTER
A 102 CPUMODULE
A 103 E-PROMMODULE
A 106 ANALOGINPUT MODULE
A 101 MAINBOARD
A 105 SERIALEXTENSION
MODULE
X1 TERMINALSTRIP
SYSTEME-PROM
DATA E-PROM
TLK E-PROM
SYS
DATATLK
RELAYS
RT865BXL (BCS)Bus Extension
A102 CPUMODULE
A 104 PVEXTENSION
MODULE
X1 TERMINAL
X2TERMINAL
A 105 ANALOG INPUT
MODULE
A 101 BUSEXTENSION
2 AMP FUSE
K1-K8RELAYS
4 AMPFUSEX1
TERMINAL
22.6
4
25 26 27 28
MP8
DS350 Graphic ModularBUS EXTENSION BOARDS
THIS BOARD IS NOT USED - RT865BXL (BCS)
A 101Bus Extension
A 102 CPUModule
A 105 AnalogInput Module
A 104 PVExtensionModule
22.7
RT865BXLwith Boom Control
Turntable Components
22.8
INPUT CU DESCRIPTION NOTESTERMINAL
K1 A101 BUS X1/3
NOT USED NONE
K2 A101 BUS X1/5
2 - WAY IM SOLENOID VALVES (2) PILOT PRESSURE PISTON SIDE PRESSURE
OFF = IM EXTENDS OR RETRACTS ON = IM IS NOT ALLOWED TO MOVE
K3 A101 BUS X1/8
TELE ROD DRAIN VALVE
OFF = BOOM IS EXTENDING OR RETRACTING AND IS NOT FULLY RETRACTED ON = BOOM IS IN NEUTRAL POSITION OR FULLY RETRACTED
K4 A101 BUS X1/12
TELE OUT OF SEQUENCE PROVIDES SIGNAL TO GRV WARNING LIGHT
K5 A101 BUS X1/13
ANALOG OUTPUT SIGNAL FROM ANALOG BOARD
ANALOG OUTPUT TO PROPORTIONAL SOLENOID VALVES, EXTEND & RETRACT, RELAY K5 SELECTS EXTEND OR RETRACT
K5A101 BUS
X1/14
ANALOG OUTPUT SIGNAL TO PROPORTIONAL EXTEND SOLENOID VALVE
MAXIMUM 800mA TO EXTEND VALVE ONE VALVE FOR ALL SECTIONS
K5A101 BUS
X1/15
ANALOG OUTPUT SIGNAL TO PROPORTIONAL RETRACT SOLENOID VALVE
MAXIMUM 800mA TO RETRACT VALVE ONE VALVE FOR ALL SECTIONS
K6A101 BUS
X1/17
2 - WAY CM SOLENOID VALVES (2) PILOT PRESSURE PISTON SIDE PRESSURE
OFF = CM EXTENDS OR RETRACTS ON = CM IS NOT ALLOWED TO MOVE
K7 A101 MAIN X1/20
2 - WAY OM/FLY SOLENOID VALVES (2) PILOT PRESSURE PISTON SIDE PRESSURE
OFF = OM/FLY EXTENDS OR RETRACTS ON = OM/FLY IS NOT ALLOWED TO MOVE
K8A101 MAIN
X1/9LMI CUT OFF INTERNAL RELAY
CONNECT LMI BYPASS VIA DIODE ASSEMBLY FROM GRAPHIC CONSOLE AND CU KEY SWITCH
K9A101 MAIN
X1/8A2B CUT OFF INTERNAL RELAY
CONNECT A2B BYPASS FROM GRAPHIC CONSOLE
K10A101 MAIN
X1/12LMI UNLOCK RELAY OUTPUT
POWERS THE LMI UNLOCK SOLENOID WHEN NO OVERLOAD, A2B OR ERROR CONDITION
K10 A101 MAIN X1/13
EXTERNAL ALARM OUTPUT USED FOR EEC UNITS ONLY
RT865BXL (BCS)Relay Outputs
22.9
22.10
DS350 Graphic Modular (BCS)Relay Diagram
X1123456789
10111213141516171819202122232425262728
2A - F1>>>
K1
2A - F2>>>
K2
2A - F3>>>
K3
2A - F4>>>
K4
2A - F5>>>
K5
2A - F6>>>
K6
2A - F7>>>
K7
2A - F8>>>
K8
+
+UB10 - 35V
KGND
H17
H18
H19
H20
H21
H22
H23
H24
BUS EXTENSION
9IM TELE +24V IM 2WAYS
16TELE ROD DRAIN
13TELE OUT OF SEQUENCE
17TELE EXT. PROP. SOL.
18TELE RET. PROP. SOL.
8CM TELE
7OM / FLY TELE
+24V TELE ROD DRAIN SOL.
TELE SEQUENCE
NO PROP. EXT.NC PROP. RET.
+24V CM 2WAYS
+24V OM 2WAYS
A104X11234
TELEPROP.
ANALOGGND.
ANALOG SIGNAL
K2 K6 K7 DESCRIPTION0 1 1 IM EXTENDING OR RETRACTING1 0 1 CM EXTENDING OR RETRACTING1 1 0 OM/FLY EXTENDING OR RETRACTING0 0 0 OUT OF SEQUENCE0 0 0 NEUTRAL POSITION
ANALOG CU DESCRIPTIONTERMINAL
1 A104 X1/2 Analog GND for proportional extend or retract solenoid valves.1 A104 X1/1 Analog signal for proportional extend or retract solenoid valves.
ModeExt. DI 1
Retr. DI 2
Relay K2
Relay K6
Relay K7
Relay K5
2 way IM
2 way CM
2 way OM
analog output
Prop. val. EXT.
Prop. val. RETR.
Auto IM 1 0 0 1 1 1 0 1 1 1 1 0Auto IM 0 1 0 1 1 0 0 1 1 1 0 1Auto CM 1 0 1 0 1 1 1 0 1 1 1 0Auto CM 0 1 1 0 1 0 1 0 1 1 0 1Auto OM 1 0 1 1 0 1 1 1 0 1 1 0Auto OM 0 1 1 1 0 0 1 1 0 1 0 1
Man. IM 1 0 0 0 0 0 0 1 1 0 1 0Man. IM 0 1 0 0 0 0 0 1 1 0 0 1Man. CM 1 0 0 0 0 0 1 0 1 0 1 0Man. CM 0 1 0 0 0 0 1 0 1 0 0 1Man. OM 1 0 0 0 0 0 1 1 0 0 1 0Man. OM 0 1 0 0 0 0 1 1 0 0 0 1
Neutral 0 0 0 0 0 0 0 0 0 0 0 0
Mode IM% CM% OM% FLY%B - Mode 0 0 0 0B - Mode 50 0 0 0B - Mode 50 50 0 0B - Mode 75 50 0 0B - Mode 75 75 0 0B - Mode 100 75 0 0B - Mode 100 100 0 0B - Mode 100 100 100 100
RT865BXL (BCS) DS350Graphic Modular
Automode control of two way valves
Analog Outputs
Input / Output Logic RT865BXL (BCS)
Boom sequence RT865BXL (BCS)
22.11
Logic 1 ON - 0 OFF
P.A.T. – L.M.IMANUAL
SECTION 23
DS 350 Graphic Modular (BCS)Boom Length Connections
& Wiring Diagrams
P A TP A TP A TP A TP A TP A TP A TP A T
P A TP A TP A TP A T
1
23
7
57
5
8
1 PRE - TENSION (LENGTH SENSOR) SPRINGBY ROTATING DRUM (10) REVOLUTIONS COUNTERCLOCKWISE. THEN UNSPOOL THE LENGTH CABLEAND SECURE TO BUSHING ON THE BOOM NOSEPER DETAIL “A”.
PRE - TENSION (LENGTH SENSOR) SPRINGBY ROTATING DRUM (30) REVOLUTIONS COUNTERCLOCKWISE. THEN UNSPOOL THE LENGTH CABLEAND SECURE TO BUSHING ON THE INNER - MIDPER DETAIL “A”.
PRE - TENSION (LENGTH SENSOR) SPRINGBY ROTATING DRUM (25) REVOLUTIONS COUNTERCLOCKWISE. THEN UNSPOOL THE LENGTH CABLEAND SECURE TO BUSHING ON THE CENTER - MIDPER DETAIL “B”
2
3
5 REMOVE 1/4 - 20 NUTS ON BOTTOM OF CABLE GUIDE.INSERT CABLE GUIDE SCREWS THRU EXISTING ANGLEBRKT AND SECURE IN PLACE WITH 1/4 - 20 NUTS REMOVED PREVIOUSLY.
CENTER LINE OF CABLE GUIDE MUST BE ALIGNED W/ CENTERLINE OF CABLE REEL DRUM.
AFTER MACHINE IS CALIBRATED, REMOVE PROTECTIVE PAPERCORROSION INHIBTOR AND ADHERE TO INSIDE HOUSING COVERSURFACE OF CABLE REEL.
7
8
Boom Control componentsRT 865BXL
DS350 Graphic Modular - BCS
23.1
IM length sensor LG321
CM length sensorLG321
Boom Control componentsRT 865BXL
DS350 Graphic Modular - BCS
P A TP A TP A TP A TP A TP A TP A TP A T
P A TP A TP A TP A T
IM % resetswitch
Boom length & angle sensorLWG309
OM retract and %reset switch
CM retract and %reset switch
IM retractswitch
See detail“ A ” See detail
“ C ” See detail“ C ”
See detail“ C ”
23.2
PLACE (3) TIE WRAPS, 120 DEGREES APART AROUND BUSHING. WRAP CABLE(8-10) REVOLUTIONS OVER THE TIE WRAPSSTARTING FROM THE OUTSIDE AND WORKING INWARD. ALLOW AMPLE CABLE TO REACH JUNCTION BOX. SECURE CABLEWITH (2) ADDITIONAL TIE WRAPS.
INSTALL PROXIMITY SWITCH 0.44” FROMTARGET WHEN BOOM SECTIONS AREFULLY RETRACTED.
THIS TARGET IS ONLY INSTALLED IF THE BOOM IS EQUIPPED WITH A BOOM EXTENSION STOP BLOCK.
INSTALL PROXIMITY SWITCH 0.13” FROM TARGET WHEN BOOM SECTIONS ARE FULLY RETRACTED.
1.0
DETAIL “A”
To be alignedwith center line
of cable reel drum
DETAIL “B”
P A TP A TP A TP A T
See detail“ B ”
See detail“ A ”
0.13
0.44
0.44
0.44
3.94CENTER LINE OF
TARGETS & PROXIMITY SW.
18
4
4
4
66
16
16
18
DETAIL “C” 1.34
23.3
PARTIAL TOP VIEW
19
CENTER LINE OFCABLE REEL DRUM
INSTALL SHIMS AS REQUIRED TO ASSURE CENTER LINE OF CABLE REEL DRUMS AREPARRALLEL TO BOOM BASE SECTION AND PLUMB WHEN CRANE IS ON A LEVEL \SURFACE.
19
CENTER LINE OF CABLE GUIDES
CABLE GUIDES ON THE BASE & INNER MIDSECTIONS ASSOCIATED WITH TOP AND MIDDLE CABLE REEL MUST BE ALIGNED WITHCENTER OF CABLE REEL DRUM
Boom Control componentsRT 865BXL
DS350 Graphic Modular - BCS
23.4
5 3 1 5 3 1
GN
D1
OU
T+U
B
GN
D1
OU
T+U
B
5 3 15 3 1X3X4
X1
7 8
12345678S
SHIELD 1
CORE 2
1 2 3 4 5 6 7
1 2 3 4 5 6
1 2 3 4 5 6 7
123456
7
26 2827
+UB
LEN
GTH
(GN
D)
X1
A
1 2 3Current Based AmplifierAll sensing devices used for Analog Inputs now have a
current output. (min. signal 4mA, max. signal 20mA)This circuit is measured in series.
-+
MP12
J2
MP13P7 P6 P5 P4 P3 P2 P1
MP11
J1
MP9
MP1
0
MP1
7
-+
MP0
MP8
P8
MP7 - MP1->
VRE
FA
MP1
4
BR1
AGND
AG
ND
AG
ND
AG
ND
MP16 16 12
120 1240
X1
Channel # 1 OPERATING WINDOW
E11
E21
WORKING RANGE
.0V
.500v MIN.
4.50v MAX.
5.0V
ERRORCODE
ERRORCODE
X2
6 Pin Connector
6 Pin Plug
VOLTAGESX1 3 ANALOG INPUT MODULE
+ 500MV (.500V) = MIN. SIGNAL (RETRACTED BOOM)+ 4.50V = MAX. SIGNAL (10 TURNS ON POT)
ALL VOTAGES ARE MEASURED WITHREFERENCE TO GND (TERMINAL X1 - 28) ON MAIN BOARD.
* THESE MEASUREMENTS ARE MADE IN PARALLEL
DS350 GRAPHIC MODULARBOOM LENGTH MEASURING CHANNEL
CHANNEL # 1
E11 / E21 (measurements in cable reel)
Measure Voltage - Length transducer at X1 1(+) & 3 (-)Range 10V to 30V
Measure Voltage - Length transducer at X1 2(+) & 3 (-)Range 1V to 5.6V
Measure Amps - Length transducer at X1 2(+) & (-) WIRE 2. Range 4 mA to 20 mA
-
+
23.5
1234
56
7
LG
1
2
3
1 2 3 4
1
3
AB
4.7K 12
CORESHIELD
* NOTE - MAX LENGTH SIGNALVARIES WITH BOOM, MAX. SIGNAL=20mA IS FOR 10 TURNS ON POT.
5
6
123
7 - PIN PLUG
3
7
6
5
4
8
2
1
X1
5
3
1
7
8X2
5
3
1
X4
X3
WG
GND
SIG.
+24V
GND
SIG.
+24V
2
X1BRN
X2RED
SHEILD
CORE
7
1 1 A 1
2 2 B 2
3 3 C 3
4 4 D 4
5 5 E 5
6 6 F 6
7 7 G 7
GND
SIG
IS = CUT&INSULATE
IS = CUT&INSULATELWG309 L/A TRANSDUCER
DS350 Graphic Modular BCSBoom Length to C.P.U.
Connections
IS = CUT&INSULATE
OS Connectedto strain relief
insert
BOOM LENGTH SIGNALRETRACTED = 4mAMAX RANGE = 20 mA
BOOM ANGLE SIGNAL90o = 4mA0o = 20 mA
W # 73A
24 VOLTS
GND
LEVER LOCKOUTSOLENOIDS
W # 71K =
W # 51AJ =
A
B
C
1
2
3
4D
5E
LMI L/O ALARM (EEC)
HOUSE LOCK PIN SWITCH
+
+
F1 +UBS+24V
+UB
+0V
+UBS0VRXDTXD
STOP
+
K10A
K9
K8A2B-OA2B-I
10LOAD-I
+ +UBS
K10B
10AF2-REL -MREL -AREL -R + +UBS
+ +UBS
DE 1DE 2DE 3DE 4
IU DAV1
+ +UBSI
U DAV2
+ +UBSI
U LG 1
IU WG 1
IU LG 1
+ +UBSI
U S1 DHG 1
IU S2 DHG 2
+ +UB
SI - OUTSI - IN
F1 - 4A
A2B-0A2B-I
LOAD-I
+ +UBS F2-10ASI-RELSI-REL+ +UBS
DE 5
DE 6
+ +UBS
1
0V
0V
0V
0V
0V
0V
0V
0V
23456789
1112131415161718192021222324252627282930313233343536515253545758596061626465666768697677
12
3
4A
10A
4
5
13
14
LMI BYPASSKEY SWITCH
X1
X212345678
BU
S EX
TE
NSIO
N
X4123456
BRN
BRN
WHT
WHT
GRN
GRNYEL
YEL
PNK
GRA
GRA
PNK
BRN
WHTBRN
WHT
PNK
GRA
GRA
PNK
GRN
YELGRN
YEL
= WIRES AREGROUPEDTOGETHER
= CONNECTED
CH #1CH #5
3-PairTwistedCable
MAIN
BO
ARD
23.6
P A TP A TP A TP A TP A TP A TP A TP A T
P A TP A TP A TP A T
X3123
135
XA2
X2 L
123
135
XB2
AX2
1 2 3 4 5 6 7 8
12345678S
X1
X27 (9)8 (10)
9333103309
X4
RT865BXL (BCS)Cable Reel LWG309
ADJUST LENGTH POTENIOMETER WITH BOOM FULLY RETRACTED, TURN THE CENTER SCREW COUNTERCLOCKWISE TO A SOFT STOP.
Ratio = 3.75 to 1(PRE - TENSION ON CABLE REEL = 10 REVOLUTIONS COUNTERCLOCKWISE)
Complete Assembly 9-333-103394Board, Terminal w/ filters 1 9-333-103309Angle Sensor WG103/0007 1 9-333-103303Length Potentiometer 1 9-333-103308Length Cable -(single core, 63M - 206 ft.) 9-333-102382Slip Ring Assem. 2-pole 1 9-333-102732
23.7
NO. OF TURNS ON CABLE
REEL
NO. OF TURNS ON LENGTH
POT
SIGNAL AT X1 TERM. PIN #27 ON C.P.U.
TERMINAL
SIGNAL ON ANALOG MODULE AT X1-3
(X1-28 GND.)0 0 4 mA .5 V
3.75 1 5.5 mA .9 V7.5 2 7.2 mA 1.3 V
11.25 3 8.7 mA 1.7 V15 4 10.4 mA 2.1 V
18.75 5 12.0 mA 2.5 V22.5 6 13.6 mA 2.9 V
26.25 7 15.2 mA 3.3 V30 8 16.8 mA 3.7 V
33.75 9 18.4 mA 4.1 V37.5 10 20 mA 4.5 V
DS350 Graphic ModularBoom Length Signal LWG 309
( 3.75 TURNS OF CABLE REEL = 1 TURN OF LENGTH POT.)CHART SHOWS TYPICAL MILLI-AMP AND VOLTAGE SIGNALS. THESE VOLTAGES ARE TO BE USED AS A REFERENCE ONLY, THE ACTUAL SIGNAL MAY VARY SLIGHTLY.
23.8
CHANNEL # 1
P A TP A TP A TP A TP A TP A TP A TP A T
P A TP A TP A TP A T
RT865BXL (BCS)Cable Reel LG321
171819
111213141516171819
X3123
135
XA2
X2 L
123
135
XB2
AX2
1 2 3 4 5 6 7 8
12345678S
X1
X27 (9)8 (10)
9333103309
X4
X1111213
141516
ADJUST LENGTH POTENIOMETER WITH BOOM FULLY RETRACTED, TURN THE CENTER SCREW COUNTERCLOCKWISE TO A SOFT STOP.
Ratio = 2 to 1(PRE - TENSION ON CABLE REEL = 25 REVOLUTIONS COUNTERCLOCKWISE)
Complete Assembly 9-333-103621Board, Terminal w/ filters 1 9-333-101777Length Potentiometer 1 9-333-101617Length Cable -(eleven core, 25 M - 86 ft.) 9-333-102490Slip Ring Assem. 11 pole 1 9-333-102737Junction Box 1 9-333-101778Gear Wheel 1 9-333-103752
(CUT CABLE TO SPECIFIED LENGTH)
23.9
BOOM LENGTH SIGNALRETRACTED = 4 mAMAX RANGE = 20 mA* NOTE - MAX LENGTH SIGNALVARIES WITH BOOM, MAX SIGNAL20 mA IS FOR 10 TURNS ON POT.
3
7
6
5
4
8S
2
1
10
LG 321 CABLE REEL(TO IM)
13
17
16
15
14
18
19
12
11
20
321
X1
X1
LG
531
X3
X2
20191817161514131211
87
12
6
49
145
7
1113
14
BRNBRN
REDRED
ORGORG
YELYEL
GRNGRN
BLUBLU
VIOVIO
GRAGRA
WHTWHT
BLKBLK
WHT/BLKWHT/BLK
21
11
10
9
8
7
6
5
4
3
123456789101112131415161718192021222324252627282930313233343536373839404142434445464748495051525354555657585960616263646566
X1
1234
A104X1
PV E
XT
EN
SIO
N
35910
2
X4123456
BRN
WHT
GRN
YEL
PNK
GRA
BRN
WHT
GRN
YEL
GRA
PNK
BRN
WHT
GRA
PNK
X212345678
BRN
WHT
PNK
GRA
GRN
YEL GRN
YEL
MAIN
BO
ARD
K2 COM ( +24V )K2 NO ( +24V TO IM 2-WAY SOLS. )
K3 COM ( +24V )K3 NO ( +24V TELE ROD DRAIN SOL. )K3 NCK4 COMK4 NOK4 NC ( TELE OUT OF SEQUENCE )K5 COMK5 NO ( PROP EXT )K5 NC ( PROP RET )K6 COM ( + 24V )K6 NO ( +24V TO CM 2-WAY SOLS. )K6 NC K7 COM ( +24V )K7 NO ( +24V TO OM 2-WAY SOLS. )K7 NC
+24V+24VGNDGNDDI 1 ( +24V = TELE EXT. PRESS. SW. )DI 1 GNDDI 2 ( +24V = TELE RET. PRESS. SW. )DI 2 GNDDI 3 ( +24V = AUTO MODE )DI 3 GNDDI 4 ( +24V = OM / FLY RET )DI 4 GNDDI 5 ( +24V = CM RET & % RESET )DI 5 GNDDI 6 ( +24V = IM RET )DI 6 GNDDI 7 ( +24V = IM % RESET )DI 7 GND
ANALOG INPUT 1 (IM LEN.)ANALOG INPUT 2 (CM LEN.)
BU
S EXTENSIO
N
TO JUCTIONBOX - IM
DS350 Graphic Modular BCSInner Mid Cable Reel to
Bus Extension Connections
10
8
1 3 2 4
TO JUCTION
BOX - BOOM BASE
VUTSRPNMLKJHGFEDCBA
1413121110987654321
1413121110987654321
14 - SOCKET PLUG
811
14
6
7
12
1314
1
3
= Outer sheild connected to strainrelief insert.
= Inner sheild cut and insulate.
11
3 31 1
3 3
23.10
P A TP A TP A TP A TP A TP A TP A TP A T
P A TP A TP A TP A T
RT865BXL (BCS)Cable Reel LG321
171819
111213141516171819
X3123
135
XA2
X2 L
123
135
XB2
AX2
1 2 3 4 5 6 7 8
12345678S
X1
X27 (9)8 (10)
9333103309
X4
X1111213
141516
ADJUST LENGTH POTENIOMETER WITH BOOM FULLY RETRACTED, TURN THE CENTER SCREW COUNTER-CLOCKWISE TO A SOFT STOP.
Ratio = 1 to 1(PRE - TENSION ON CABLE REEL = 30 REVOLUTIONS COUNTERCLOCKWISE)
Complete Assembly 9-333-103620Board, Terminal w/ filters 1 9-333-101777Length Potentiometer 1 9-333-101617Length Cable -(eleven core, 33.5 M - 110 ft.) 9-333-102490Slip Ring Assem. 11 pole 1 9-333-102737 Junction Box 1 9-333-101778Gear Wheel 1 9-333-102982
(CUT CABLE TO SPECIFIED LENGTH)
23.11
MANUAL
SECTION 24
DS 350 Graphic Modular (BCS)Piston & Rod Connections
& Wiring Diagrams
P.A.T. – L.M.I
W # 73A
24 VOLTS
GND
LEVER LOCKOUTSOLENOIDS
W # 71K =
W # 51AJ =
A
B
C
1
2
3
4D
5E
LMI L/O ALARM (EEC)
HOUSE LOCK PIN SWITCH
+
+
F1 +UBS+24V
+UB
+0V
+UBS0VRXDTXD
STOP
+
K10A
K9
K8A2B-OA2B-I
10LOAD-I
+ +UBS
K10B
10AF2-REL -MREL -AREL -R + +UBS
+ +UBS
DE 1DE 2DE 3DE 4
IU DAV1
+ +UBSI
U DAV2
+ +UBSI
U LG 1
IU WG 1
IU LG 1
+ +UBSI
U S1 DHG 1
IU S2 DHG 2
+ +UB
SI - OUTSI - IN
F1 - 4A
A2B-0A2B-I
LOAD-I
+ +UBS F2-10ASI-RELSI-REL+ +UBS
DE 5
DE 6
+ +UBS
1
0V
0V
0V
0V
0V
0V
0V
0V
23456789
1112131415161718192021222324252627282930313233343536515253545758596061626465666768697677
12
3
4A
10A
4
5
13
14
LMI BYPASSKEY SWITCH
X1B
US E
XT
EN
SION
X212345678
X4123456
BRN
BRN
WHT
WHT
GRN
GRNYEL
YEL
PNK
GRA
GRA
PNK
BRN
WHTBRN
WHT
PNK
GRA
GRA
PNK
GRN
YELGRN
YEL
= WIRES AREGROUPEDTOGETHER
= CONNECTED
123123
PISTON TRANSDUCER
ROD TRANSDUCER
DS350 Graphic Modular BCSPiston & Rod Transducers
to C.P.U. Connections
OS Connectedto strain relief
insert
IS = CUT& INSULATE1
1
1
DA
VS 314
A
B
C
1
2
31
CH #2
CH #3
DA
VS 314
A
B
1
2
31
C
3-PairTwistedCable
MAIN
BO
ARD
24.1
1 2 3
20 2221
+UB
(GN
D)
X1
A
OU
TPU
T SI
GN
AL
(PIS
TON
)
4
1 2 3 4
AA
BB
CC
PRESS. TRANS.(PISTON)
DS350 GRAPHIC MODULARPISTON PRESSURE MEASURING CHANNEL
CHANNEL # 2
Current Based AmplifierAll sensing devices used for Analog Inputs now have a
current output. (min. signal 4mA, max. signal 20mA)This circuit is measured in series.
Channel # 2 OPERATING WINDOW
E12
E22
WORKING RANGE
.0V
.500v MIN.
4.50v MAX.
5.0V
ERRORCODE
ERRORCODE
-+
MP12
J2
MP13P7 P6 P5 P4 P3 P2 P1
MP11
J1
MP9
MP1
0
MP1
7
-+
MP0
MP8
P8
MP7 - MP1->
VRE
FA
MP1
4
BR1
AGND
AG
ND
AG
ND
AG
ND
MP16 16 12
120 1240
X1
VOLTAGESX1 1 ANALOG INPUT MODULE
+ 500MV (.500V) = MIN. SIGNAL (ZERO PRESSURE)+ 4.50V = MAX. SIGNAL (300 BAR PRESSURE)
ALL VOTAGES ARE MEASURED WITHREFERENCE TO GND (TERMINAL X1 - 22) ON MAIN BOARD.
* THESE MEASUREMENTS ARE MADE IN PARALLEL
E12 / E22 (measurements at transducer)
Measure Voltage - (Elec) Piston transducer at A (+) & C (-)Range 10V to 30V
Measure Voltage - (Elec) Piston transducer at B (+) & C (-)Range 0V
Measure resistance - (Hyd) Piston transducer at B (+) & C (-)Range 200 - 300 Ohm
-
+
24.2
1 2 3
23 2524
+UB
(GN
D)
X1
A
OU
TPU
T SI
GN
AL
(RO
D)
4
1 2 3 4
AA
BB
CC
PRESS. TRANS.(ROD)
DS350 GRAPHIC MODULARROD PRESSURE MEASURING CHANNEL
CHANNEL # 3
Current Based AmplifierAll sensing devices used for Analog Inputs now have a
current output. (min. signal 4mA, max. signal 20mA)This circuit is measured in series.
Channel # 3 OPERATING WINDOW
E13
E23
WORKING RANGE
.0V
.500v MIN.
4.50v MAX.
5.0V
ERRORCODE
ERRORCODE
-+
MP12
J2
MP13P7 P6 P5 P4 P3 P2 P1
MP11
J1
MP9
MP1
0
MP1
7
-+
MP0
MP8
P8
MP7 - MP1->
VRE
FA
MP1
4
BR1
AGND
AG
ND
AG
ND
AG
ND
MP16 16 12
120 1240
X1
VOLTAGESX1 2 ANALOG INPUT MODULE
+ 500MV (.500V) = MIN. SIGNAL (ZERO PRESSURE)+ 4.50V = MAX. SIGNAL (300 BAR PRESSURE)
ALL VOTAGES ARE MEASURED WITHREFERENCE TO GND (TERMINAL X1 - 25) ON MAIN BOARD.
* THESE MEASUREMENTS ARE MADE IN PARALLEL
E13 / E23 (measurements at transducer)
Measure Voltage - (Elec) Rod transducer at A (+) & C (-)Range 10V to 30V
Measure Voltage - (Elec) Rod transducer at B (+) & C (-)Range 0V
Measure resistance - (Hyd) Rod transducer at B (+) & C (-)Range 200 - 300 Ohm
-
+
24.3
DS350 Graphic ModularPRESSURE TRANSDUCER PLUG
PISTON AND ROD
CONNECT DIGITAL VOLT METER NEGATIVE (-) LEAD TO TERMINAL C.CONNECT POSITIVE (+) LEAD TO TERMINAL A, VOLTAGE SHOULD BE+24.0 VDC (SUPPLY VOLTAGE).
CONNECT POSITIVE (+) LEAD TO TERMINAL B, AND NEGATIVE (-) LEAD VOLTAGE SHOULD BE 0 VDC. IF INCORRECT CHECK CABLE CONNECTIONS IN CENTRAL UNIT AND CHECK CABLE FOR DEFECTS. IF CORRECT REPLACE PRESSURE TRANSDUCER.
24.4
C
B
A
+24.0+ 0
MEASURING RESISTANCE BETWEEN B ( + ) AND C ( - )RANGE 200 - 300 Ohm.
GRAPHIC MODULAR CONSOLESPECIAL FUNCTION 0 - SETTING OF TRANSDUCER INPUT
The 0 - setting consists of calculating an appropriate 0 - point offset, which, when added to the transducer measurement, allows the real physical pressure of force to be calculated. To achievethis, a procedure has been developed, allowing the 0 - setting to be performed and visualized in a simple manner.
To activate the 0 - Setting Function, press the INFO key (1) to activate the Info Function. Now pressthe CTRL key (2). At this point, a five digit Authorization Number must be entered. Only authorized personnel may adjust the 0 - point settings.Example : 6 4 3 5 6
F1 F4F3F2
!
STOP
STOP
! STOP
STOP
PAT DS 350
TARE
LIM
SEL
iCTRL
(1)
(2)
ENTER YOURSERVICE CODE
5 5 5 5 5
+ >
F1 F4F3F2
!
STOP
STOP
! STOP
STOP
PAT DS 350
TARE
LIM
SEL
iCTRL+ESC
AUTO0
0
-4% -2% 0% +2% +4%
0
Now, having successfully entered a valid password, the piston - side 0 - point setting functionis activated.
The display shows which transducer (piston-side, rod-side or force) is being zeroed and a horizontaldial marks the present pressure (or force) difference in %. By pressing the + key, the input pressure(or force) is adjusted upwards, and by pressing the - key, the input value is adjusted downwards.When the + and - keys are pressed simultaneously, the 0 - setting occurs automatically. Manualadjustments may be performed using + or -.
The return key toggles between the piston - side, the rod - side, and the force 0 - setting.
When the operator is finished, pressing the EXC or INFO key returns the console back to the
The first step is to lower the boom all the way down(blocking the boom), shut the engine off then disconnecthydraulic hose from the piston or rod side pressuretransducer.
24.5
MANUAL
SECTION 25
DS 350 Graphic Modular (BCS)Boom Angle Connections
& Wiring Diagrams
P.A.T. – L.M.I
1234
56
7
LG
1
2
3
1 2 3 4
1
3
AB
4.7K 12
CORESHIELD
* NOTE - MAX LENGTH SIGNALVARIES WITH BOOM, MAX. SIGNAL=20mA IS FOR 10 TURNS ON POT.
5
6
123
7 - PIN PLUG
3
7
6
5
4
8
2
1
X1
5
3
1
7
8X2
5
3
1
X4
X3
WG
GND
SIG.
+24V
GND
SIG.
+24V
2
X1BRN
X2RED
SHEILD
CORE
7
1 1 A 1
2 2 B 2
3 3 C 3
4 4 D 4
5 5 E 5
6 6 F 6
7 7 G 7
GND
SIG
IS = CUT&INSULATE
IS = CUT&INSULATELWG309 L/A TRANSDUCER
DS350 Graphic Modular BCSBoom Angle to C.P.U.
Connections
IS = CUT&INSULATE
OS Connectedto strain relief
insert
BOOM LENGTH SIGNALRETRACTED = 4mAMAX RANGE = 20 mA
BOOM ANGLE SIGNAL90o = 4mA0o = 20 mA
W # 73A
24 VOLTS
GND
LEVER LOCKOUTSOLENOIDS
W # 71K =
W # 51AJ =
A
B
C
1
2
3
4D
5E
LMI L/O ALARM (EEC)
HOUSE LOCK PIN SWITCH
+
+
F1 +UBS+24V
+UB
+0V
+UBS0VRXDTXD
STOP
+
K10A
K9
K8A2B-OA2B-I
10LOAD-I
+ +UBS
K10B
10AF2-REL -MREL -AREL -R + +UBS
+ +UBS
DE 1DE 2DE 3DE 4
IU DAV1
+ +UBSI
U DAV2
+ +UBSI
U LG 1
IU WG 1
IU LG 1
+ +UBSI
U S1 DHG 1
IU S2 DHG 2
+ +UB
SI - OUTSI - IN
F1 - 4A
A2B-0A2B-I
LOAD-I
+ +UBS F2-10ASI-RELSI-REL+ +UBS
DE 5
DE 6
+ +UBS
1
0V
0V
0V
0V
0V
0V
0V
0V
23456789
1112131415161718192021222324252627282930313233343536515253545758596061626465666768697677
12
3
4A
10A
4
5
13
14
LMI BYPASSKEY SWITCH
X1
X212345678
BU
S EX
TE
NSIO
N
X4123456
BRN
BRN
WHT
WHT
GRN
GRNYEL
YEL
PNK
GRA
GRA
PNK
BRN
WHTBRN
WHT
PNK
GRA
GRA
PNK
GRN
YELGRN
YEL
= WIRES AREGROUPEDTOGETHER
= CONNECTED
CH #1CH #5
3-PairTwistedCable
MAIN
BO
ARD
25.1
GN
D1
OU
T+U
B
5 3 1 5 3 1
GN
D1
OU
T+U
B
5 3 15 3 1X3X4
X1
7 8
12345678S
SHIELD 1
CORE 2
1 2 3 4 5 6 7
1 2 3 4 5 6
1 2 3 4 5 6 7
123456
7
26 2928
+UB
ANG
LE(9
0o T
O 0
o )
(GN
D)
X1
A
1 3 4Current Based AmplifierAll sensing devices used for Analog Inputs now have a
current output. (min. signal 4mA, max. signal 20mA)This circuit is measured in series.
-+
MP12
J2
MP13P7 P6 P5 P4 P3 P2 P1
MP11
J1
MP9
MP1
0
MP1
7
-+
MP0
MP8
P8
MP7 - MP1->
VRE
FA
MP1
4
BR1
AGND
AG
ND
AG
ND
AG
ND
MP16 16 12
120 1240
X1
Channel # 5 OPERATING WINDOW
E15
E25
WORKING RANGE
.0V
.500v MIN.
4.50v MAX.
5.0V
ERRORCODE
ERRORCODE
X2
6 Pin Connector
6 Pin Plug
VOLTAGESX1 4 ANALOG INPUT MODULE
+ 500MV (.500V) = 90o ANGLE MIN. SIGNAL+ 2.50V = 45o ANGLE
+ 4.5 V = 0o ANGLE MAX. SIGNAL ALL VOTAGES ARE MEASURED WITH
REFERENCE TO GND (TERMINAL X1 - 28) ON MAIN BOARD.* THESE MEASUREMENTS ARE MADE IN PARALLEL
DS350 GRAPHIC MODULARBOOM ANGLE MEASURING CHANNEL
CHANNEL # 5
E15 / E25(measurements in cable reel)
Measure Voltage - Angle transducer at X1 1(+) & 3 (-)Range 10V to 30V
Measure Voltage - Angle transducer at X1 2(+) & 3 (-)Range 1V to 5.6V
Measure Amps - Angle transducer at X1 4(+) & (-) WIRE 4. Range 4 mA to 20 mA
-
+
25.2
DS350 Graphic ModularBoom Angle Signal
CHART SHOWS TYPICAL MILLI-AMP AND VOLTAGE SIGNALS.THESE VALUES ARE TO BE USED AS A REFERENCE ONLY, THE ACTUAL SIGNAL MAY VARY SLIGHTLY.
ACTUAL BOOM ANGLE
IN DEGS.
SIGNAL AT X1 TERM. PIN #29 ON C.P.U.
TERMINAL
SIGNAL ON ANALOG MODULE AT X1-4
(X1-28 GND.)90o 4.0 mA 0.48
85o 4.9 mA + .70
80o 5.7 mA + .92
75o 6.6 mA + 1.15
70o 7.4 mA + 1.37
65o 8.3 mA + 1.60
60o 9.2 mA + 1.80
55o 10.2 mA + 2.04
50o 11.2 mA + 2.26
45o 12.1 mA + 2.48
40o 12.9 mA + 2.70
35o 13.7 mA + 2.92
30o 14.7 mA + 3.15
25o 15.6 mA + 3.38
20o 16.5 mA + 3.60
15o 17.3 mA + 3.82
10o 18.0 mA + 4.04
5o 19.2 mA + 4.27
0o 20 mA + 4.49CHANNEL #5
25.3
P A TP A TP A TP A TP A TP A TP A TP A T
P A TP A TP A TP A T
RT865BXL (BCS)Cable Reel LWG309
TO SET ANGLE TRANSDUCER, ENSURE THE CRANE IS LEVEL AND SET THE BOOM AT 0 o(using a level on top of base as shown in the above drawing). LOOSEN THE FOUR ALLEN HEAD BOLTS (A) AND WITH A LEVEL ON THE TRANSDUCER (see drawing to right) ENSURE THAT BOTH LEVELS ARE READING THE SAME. TIGHTEN BOLTS.
COMPLETE ASSEMBLY 9-333-103303
25.4
MANUAL
SECTION 26
DS 350 Graphic Modular (BCS)Anti - Two - Block Connections
& Wiring Diagrams
P.A.T. – L.M.I
GN
D1
OU
T+U
B
5 3 1 5 3 1
GN
D1
OU
T+U
B
5 3 15 3 1X3X4
X1
7 8
12345678S
SHIELD 1
CORE 2
1 2 3 4 5 6 7
1 2 3 4 5 6
1 2 3 4 5 6 7
123456
7
X2
6 Pin Connector
6 Pin Plug
To Central Unit
ANTI - TWO BLOCK SWITCH
6 PIN DUMMY PLUG
4.7KRESISTOR
ΩΩΩΩ
ANTI - TWO - BLOCK WIRING DIAGRAM
NOTES:OUTER SHIELD GROUNDED ATSTRAIN RELIEF CONNECTOR
CUT AND INSULATE INNER SHIELD
SWITCH PREWIRED AND POTTED
IMPORTANT CHANGE
1
2
1
!
1 1
2
2
! AB
1 2 3
1
23
SHIELD
CO
RE
12
1
1
1 2 3 4
1 2 3
1 2 3
12
1
1
1 2 3
AB
A B
26.1
AUX. BOOM NOSEANTI - TWO BLOCK SWITCH
1
2
3
4
5
6
NO. PART NO. QTY DESCRIP.
1 9-333-102764 1 COMP. ASSEM.2 9-333-102717 1 2-POLE JUMPER BAR3 9-333-102666 1 TAGS, TERMINAL STRIP4 9-333-102663 4 BLOCK, TERMINAL STRIP5 9-333-102230 1 SWITCH A2B, WITH RETAINER
CRIMP6 9-333-102765 1 COMP. ASSEM., DUMMY PLUG
DATA FROM C.U.DATA TO C.U.
LMI
A2B
CONSOLE BY - PASS
KEY
+
+
F1 +UBS+24V
+UB
+0V
+UBS0VRXDTXD
STOP
+
K10A
K9
K8A2B-OA2B-I
10LOAD-I
+ +UBS
K10B
10AF2-REL -MREL -AREL -R + +UBS
+ +UBS
DE 1DE 2DE 3DE 4
IU DAV1
+ +UBSI
U DAV2
+ +UBSI
U LG 1
IU WG 1
IU LG 1
+ +UBSI
U S1 DHG 1
IU S2 DHG 2
+ +UB
SI - OUTSI - IN
F1 - 4A
A2B-0A2B-I
LOAD-I
+ +UBS F2-10ASI-RELSI-REL+ +UBS
DE 5
DE 6
+ +UBS
1
0V
0V
0V
0V
0V
0V
0V
0V
23456789
1112131415161718192021222324252627282930313233343536515253545758596061626465666768697677
W # 73A
24 VOLTS
GND
LEVER LOCKOUTSOLENOIDS
W # 71K =
W # 51AJ =
A
B
C
1
2
3
12
3
4A
10A
4D
5E
LMI L/O ALARM (EEC)
HOUSE LOCK PIN SWITCH
4
5
13
14
LMI BYPASSKEY SWITCH
8
6
5
4
2
7
6
5
4
3
2
1
(GND)
1 (+24 V)
34
34
AB
GRAPHIC CONSOLE
7
3
1234567
+
X1
X212345678
BU
S EX
TE
NSIO
N
X4123456
BRN
BRN
WHT
WHT
GRN
GRNYEL
YEL
PNK
GRA
GRA
PNK
BRN
WHTBRN
WHT
PNK
GRA
GRA
PNK
GRN
YELGRN
YEL
DS350 Graphic Modular BCSAnti - Two Block Connections
= WIRES AREGROUPEDTOGETHER
= CONNECTED
3-PairTwistedCable
MAIN
BO
ARD
26.2
3
2 1
Auxiliary Boom Nose
NO. PART NO. QTY DESCRIPTION
1 9-333-102238 1 SWITCH, A2B W/O CRIMP2 9-333-102956 1 CONDUIT 3 FEET
(MUST CUT TO LENGTH)3+ 9-333-102768 1 JUNCTION BOX ASSEM.
26.3
Auxiliary Boom NoseJUNCTION BOX ASSEMBLY
NO. PART NO. QTY DESCRIPTION
1 9-333-102758 1 Junction Box 2 9-333-102764 1 Strain Relief 3 9-333-101984 1 Locknut4 9-333-102759 1 Mounting rail, terminal strip5 9-333-102663 3 Block, terminal strip 6 9-333-102664 1 End plate, terminal strip7 9-333-102665 2 End bracket, terminal strip8 9-333-102666 1 Tags, terminal strip9 9-333-102760 1 Connector, cannon 2-pin male recp.10 9-333-102482 1 Gasket11 9-333-102612 1 Cover, dust12 9-333-102669 4 Screw #413 9-333-102266 4 Lockwasher #414 9-333-102480 4 Nut #4
Complete Assembly # 9-333-1027678
A2B CABLE
(BLACK)
(BROWN)
(RED)
1
2
3
1
2
3
A
B
1
2
26.4
Folding Extension
NO. PART NO. QTY DESCRIPTION 1 9-333-102230 1 Switch, A2B W/O Crimp2 9-333-102956 1 Conduit 10 feet
(must cut to length)3 + 9-333-102996 1 Junction box assembly4 + 9-333-102766 1 Junction box assembly
1
2 34
26.5
Folding ExtensionJUNCTION BOX ASSEMBLY
NO. PART NO. QTY DESCRIPTION
1 9-333-102758 1 Junction Box 2 9-333-101995 1 Strain Relief 3 9-333-102759 1 Mounting rail, terminal strip4 9-333-102663 3 Block, terminal strip 5 9-333-102664 1 End plate, terminal strip6 9-333-102665 2 End bracket, terminal strip7 9-333-102666 1 Tags, terminal strip8 9-333-102760 1 Connector, cannon 2-pin male recp.9 9-333-102482 1 Gasket10 9-333-102612 1 Cover, dust11 9-333-102669 4 Screw #412 9-333-102266 4 Lockwasher #413 9-333-102480 4 Nut #4
Complete Assembly # 9-333-102766
A2B CABLE
(BLACK)
(BROWN)
(RED)
1
2
3
1
2
3
A
B
1
2
26.6
NO. PART NO. QTY DESCRIPTION
1 9-333-102758 1 Junction Box 2 9-333-101995 1 Strain Relief 3 9-333-101984 1 Locknut4 9-333-102664 1 Mounting Rail5 9-333-102663 3 Block, terminal strip 6 9-333-102664 1 End plate, terminal strip7 9-333-102665 2 End bracket, terminal strip8 9-333-103044 1 Tags, terminal strip9 9-333-102792 1 Connector, cannon 2-pin male recp. 10 9-333-102482 1 Gasket11 9-333-102612 1 Cover, dust12 9-333-102669 4 Screw #413 9-333-102266 4 Lockwasher #4 14 9-333-102480 4 Nut #4
Complete Assembly # 9-333-102996
Folding ExtensionJUNCTION BOX ASSEMBLY
26.7
MANUAL
SECTION 27
DS 350 Graphic Modular (BCS)Digital Inputs
P.A.T. – L.M.I
INPUT CU DESCRIPTION NOTESBUS EXT. TERMINAL
1 A101 BUS X1/29
TELE EXTEND (+24V) GROVE PRESSURE SWITCH SIGNAL
2 A101 BUS X1/31
TELE RETRACT (+24V) GROVE PRESSURE SWITCH SIGNAL
3 A101 BUS X1/33
AUTO MODE SELECTED (+24V) GROVE SELECTOR SWITCH SIGNAL
4 A101 BUS X1/35
PROX. SWITCH OM/FLY RETRACTED & OM/FLY % RESET (+24V)
PAT SWITCH ON CM - SIGNAL VIA CM CABLE REEL
5 A101 BUS X1/37
PROX. SWITCH CM RETRACTED & RESET %(+24V) PAT SWITCH ON BOOM BASE
6 A101 BUS X1/39
PROX. SWITCH IM RETRACT(+24V) PAT SWITCH ON BOOM BASE
7 A101 BUS X1/41
PROX. SWITCH IM % RESET (+24V) PAT SWITCH ON BOOM BASE
INPUT MAIN
2 A101 MAIN X1/17
AREA DEFINATION SWITCH ON RUBBER SWIVEL LIMIT SWITCH
3 A101 MAIN X1/18
HOUSE LOCK PIN SWITCH SIGNAL GROVE LIMIT SWITCH
RT865BXL (BCS)MAIN & BUS EXTENSION
DIGITAL INPUTS
27.1
X1
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
6027.2
+
+UB10 - 35V
KGND
>>
DE 1
> DE 2
> DE 3
> DE 4
> DE 5
> DE 6
> DE 7
> DE 8
> DE 9
> DE 10
> DE 11
> DE 12
> DE 13
> DE 14
> DE 15
> DE 16
H11
H1
H2
H3
H4
H5
H6
H7
H8
H9
H10
H12
H13
H14
H15
H16
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
+24V TELEEXT.PRESS. SW.
+24V TELERET.PRESS. SW.
+24V AUTO MODE
+24V OM / FLY RET.
+24V CM RET. & % RESET.
+24V IM RET.
+24V IM % RESET.
4TELE EXT. PRESS. SW.
5TELE RET. PRESS. SW.
6HIGH=AUTO / NONE=MANUAL MODE
6PROXY SW.1 OM / FLY RET.
PROXY SW.4 CM RET & % RESET.
7PROXY SW. 2 IM RET. (2 POSITIONS)
6PROXY SW.3 IM RESET %. (TOP)
DS350 Graphic Modular (BCS)Digital Input Diagram
12
23 pin plug
19 pin plug
14 pin plug
* TERMINAL # 25 IS + 24V TO PROXYSWITCHES 1,2,3 & 4.
* TERMINAL # 27 IS GND. TO PROXYSWITCHES 1,2,3 & 4.
MANUAL
SECTION 28
DS 350 Graphic Modular (BCS)Central Unit P.C. Modular
Board Layout
P.A.T. – L.M.I
P.A.T. DS350 Graphic Modular MAIN BOARD
28.1
MP 25
+UBSMP1
KGND
KG
ND
F1
X1
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54
F2
J4J3J2J1 31
- +
KG
ND
H9
A2B
X1
KGND
J103 24 1 MP29
+5V/RS232
A2BK9
LMIK8
LOAD
LEVERLOCKOUT
K10
KG
ND
+UB
KGND
+UB
1 +UB
H12
TXD
H10
MAIN
ON
/OFF
H1 H
2 H3 H
4 H5 H
6
X13
DI 1-D
I 6 =>D
I 1D
I 6
X14
KGND
+UB
1
V10H
11V11
MP41
MP40
PFAIL+UB
1pow
er o.k.
GND
+5V
+6V
+9V
KG
ND
AGN
D
X16
AGN
D
C
C
MP42PWM DC
- G1 +
MP24+BATT
MP23
VBAT
X15
KG
ND
GND
AGN
DK
GN
D
KG
ND
X12
X17
GND
MP21
SP5
X11J11
A B C D E F G H I J K L M
A B C D E F G H I J K L M
1
2
3
4
5
6
7
8
9
10
11
12
13
1
2
3
4
5
6
7
8
9
10
11
12
13
77 76
MP 26
MP 4
MP 9
MP 8
LOCATIONS :
MP 1 - zone M13 = GND.MP 25 - zone M13 = +UBS CONSOLE, SENSORS, DI’sMP 8 - zone M2 = +9VMP 9 - zone M2 = +6VMP 4 - zone M1 = +5V MP 26 - zone M1 = GND.MP 23 - zone A2 = VBATT MP 24 - zone D2 = +BATTMP 40 - zone M4 = +UB
MP 41 - zone M4 = POWER FAILMP 42 - zone G1 = +5VMP 21 - zone E5 = +5VMP 29 - zone D10 = +5VH1-H6 - zone I5 = DI 1-6
LED’S
H 8 - zone M3 - LOADH 9 - zone E11 - A2BH 10 - zone G9 -MAIN IN/ OUTH 11 - zone M3 - POWERH 12 - zone I11 - TXD
EJECT
MP2MP6
MP5
BR6
BR5
X3
J12
J8 J9 MP3 J6
SYSTEMD10
D1
MP4
X2X1
J13
MP7
P1
J1J2
J10
J11 J1
4
J15
J7
A102 CPU
BR
4 3 2 1
J6
J2J1
J5J3
DATAD1
TLKD3
A103 DATEN
X1
D3
D2
D14
D13
D6
D17
D21D7D15
D9
D20
D18
D19
D11
D12
P.A.T. DS350 Graphic Modular EXTENSION BOARDS
28.2
Ensure the notch is in the correct direction ( to the right )The EPROMS must be installed completely to the left, leavingblank holes to the right.
X16
1216
X17
1240
+ ++ +
- +
MP12
J2
MP13
P7P6
P5P4
P3P2
P1
MP11
J1 MP9
MP10
MP17
- +MP0MP8
P8
MP7 -M
P1->7 6 5 4 3 2 1
VREFA
MP14
BR1
AG
ND AGND
AGNDAGND
MP16
1612
120
1240
DS350 Graphic ModuleAnalog Input Module
BOARD P/N 9-333-103290X1:1-7 = ADC INPUT 0.5V… 4.5 V, Note: If channel adjustments are made through
the software and graphic console, DO NOT adjust offset with P1 - P7X1:8 = TEMP (0.5V + 10mV/oC)X1:9 = VREFA = 5.000V referenceX1:10 = AGND (reference GND)X1:11 = VREF+ = 5.0V power ADCX1:12-15 = CH01-04, DIN 1-4 / 10X1:16 = CH05, +UBS / 10X1:17 = CH06, HESIN(A2B) *4X1:18 = CH07, +9V *4X1:19 = CH08, VREFA / 2 = 2.500VX1:20 = UKLEMM, app. VREFA, limits ADC input to 5.0V
X1
28.3
MP 1 = AGNDMP 8 = + 5VMP 1 - 7 Input channels 1 - 7 - 0.5V / 4 mA
2.5V / 20mAMP 14 = + 13V REF 02MP 16 = HESIN input voltageMP 17 = app 5.4V clamp for inputs
+UB1KGND
MP11
F42A
F52A
MP3MP4
1 2 3 4 5 6123456
MP15
MP10
MP0
GN
D
MP1
C30
MP16
H3
H1 H2
MP1
DS350 Graphic Modular (BCS) A 105 Serial Extension Module
Part No. 9-333-103292
A 101 Bus Extension Module Part No. 9-333-103717
X4
F1
H17
K1F2
H18
K2F3
H19
K3F4
H20
K4F5
H21
K5F6
H22
K6F7
H23
K7F8
H24
K8
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
53 54 55 56 57 58 59 60
61 62 63 64 65 66
F25
25 26 27 28
MP 8UREL
MP9
H1
DI 1
H2
H3
H4
H5
H6
H7
H8
DI 8
H16H15H14H13H12H11H10H9
DI 9
DI 16
C27
MP14ADC
C93
KG
ND
MP
0
AGN
D
MP
1
+ UB MP
2
+ 7V MP
3
+5V
MP4
+14V
MP5
-14V
MP6
+REF
MP7
+REX
MP1
0-10V
MP1
1USI
N
MP1
2
RIP
P
MP1
3
1 2 3 4 5 6 7 8
2A
X2
28.4
MP0 MP1 MP3
MP2
J1C33
C38 C37
C32
J3
X4
MP4
H1
SLAVEE - PROM
DS350 Graphic Modular (BCS) A 102 CPU Module
Part No. 9-333-103718
X2
X1
A 105 Analog Input Module Part No. 9-333-103719
1 2 3 4
MP6MP7MP3MP2
MP0
P11P12
X2
MP5 MP4
MP1
H1
A 104 PV Extension Module Part No. 9-333-103720
28.5
Grove wire Interfacenumber connector
71H A POWER SUPPLY +24V51AK B CRANE GND
C387A D TELE EXTEND PRESSURE SWITCH (INPUT)388 E TELE RETRACT PRESSURE SWITCH (INPUT)
239B F HIGH = AUTO MODE, LOW = MANUAL MODE (INPUT)242B G SELECT OM / FLY IN MANUAL MODE (INPUT)243B H SELECT CM IN MANUAL MODE (INPUT)244B J SELECT IM IN MANUAL MODE (INPUT)
[507] K 3RD WRAP CUT OFF MAIN HOIST RT ONLY[505] L 3RD WRAP CUT OFF AUX. HOIST RT ONLY[338] M 3RD WRAP WARNING LIGHT (GND) RT ONLY323A N TELE OUT OF SEQUENCE SIGNAL (RELAY OUTPUT)
OPQR
238A S PROPORTIONAL TELE - SOLENOID GND.1083 T TELE ROD DRAIN SOLENOID VALVE SIGNAL255A U PROPORTIONAL TELE - SOLENOID (EXTEND)257A V PROPORTIONAL TELE - SOLENOID (RETRACT)
WX
Grove wire Interfacenumber connector
71K A POWER SUPPLY +24V51AJ B CRANE GND73A C LMI UNLOCK SOLENOIDS74 D LMI LOCK OUT ALARM
744 E HOUSE LOCK PIN SWITCHFGH
RT865BXL (BCS)BUS EXTENSION
INTERFACE
RT865BXL (BCS)MAIN BOARD
INTERFACE
28.6
+
+
F1 +UBS+24V
+UB
+0V
+UBS0VRXDTXD
STOP
+
K10A
K9
K8A2B-OA2B-I
10LOAD-I
+ +UBS
K10B
10AF2-REL -MREL -AREL -R + +UBS
+ +UBS
DE 1DE 2DE 3DE 4
IU DAV1
+ +UBSI
U DAV2
+ +UBSI
U LG 1
IU WG 1
IU LG 1
+ +UBSI
U S1 DHG 1
IU S2 DHG 2
+ +UB
SI - OUTSI - IN
F1 - 4A
A2B-0A2B-I
LOAD-I
+ +UBS F2-10ASI-RELSI-REL+ +UBS
DE 5
DE 6
+ +UBS
1
0V
0V
0V
0V
0V
0V
0V
0V
23456789
1112131415161718192021222324252627282930313233343536515253545758596061626465666768697677
12
3
4A
10A
W # 73A
24 VOLTS
GND
LEVER LOCKOUTSOLENOIDS
W # 71K =
W # 51AJ =
A
B
C
1
2
3
4D
5E
LMI L/O ALARM (EEC)
HOUSE LOCK PIN SWITCH
4
5
13
14
LMI BYPASSKEY SWITCH
X1
X212345678
BU
S EX
TE
NSIO
N
X4123456
BRN
BRN
WHT
WHT
GRN
GRNYEL
YEL
PNK
GRA
GRA
PNK
BRN
WHTBRN
WHT
PNK
GRA
GRA
PNK
GRN
YELGRN
YEL
DS350 Graphic Modular BCSCrane Interface to Main Board
= WIRES AREGROUPEDTOGETHER
= CONNECTED
3-PairTwistedCable
MAIN
BO
ARD
28.7
123456789101112131415161718192021222324252627282930313233343536373839404142434445464748495051525354555657585960616263646566
X1
1234
A104X1
PV E
XT
EN
SIO
N
X4123456
BRN
WHT
GRN
YEL
PNK
GRA
BRN
WHT
GRN
YEL
GRA
PNK
BRN
WHT
GRA
PNK
X212345678
BRN
WHT
PNK
GRA
GRN
YEL GRN
YEL
MAIN
BO
ARD
K2 COM ( +24V )K2 NO ( +24V TO IM 2-WAY SOLS. )
K3 COM ( +24V )K3 NO ( +24V TELE ROD DRAIN SOL. )K3 NCK4 COMK4 NOK4 NC ( TELE OUT OF SEQUENCE )K5 COMK5 NO ( PROP EXT )K5 NC ( PROP RET )K6 COM ( + 24V )K6 NO ( +24V TO CM 2-WAY SOLS. )K6 NC K7 COM ( +24V )K7 NO ( +24V TO OM 2-WAY SOLS. )K7 NC
+24V+24VGNDGNDDI 1 ( +24V = TELE EXT. PRESS. SW. )DI 1 GNDDI 2 ( +24V = TELE RET. PRESS. SW. )DI 2 GNDDI 3 ( +24V = AUTO MODE )DI 3 GNDDI 4 ( +24V = OM / FLY RET )DI 4 GNDDI 5 ( +24V = CM RET & % RESET )DI 5 GNDDI 6 ( +24V = IM RET )DI 6 GNDDI 7 ( +24V = IM % RESET )DI 7 GND
ANALOG INPUT 1 (IM LEN.)ANALOG INPUT 2 (CM LEN.)
BU
S EXTENSIO
N
1
456789
TELE EXTEND PRESSURE SW.TELE RETRACT PRESSURE SW.HIGH = AUTO MODE / NONE = MANUAL MODEOM / FLY TELECM TELEIM TELE
A AB BC CD DE EF FG GH HJ JK KL LM MN NO OP PQ QR RS ST TU UV VW WX X
71H51AK
387A388239B242B243B244B
323A
238A1083255A257A
+ 24VGND
TELE OUT OF SEQUENCE
TELE PROP. ANALOG GND.TELE ROD DRAIN SOLENOIDTELE EXTEND PROP. SOLENOIDTELE RETRACT PROP. SOLENOID
S/S HARNESS23 - SOCKET RECEPT
LMI - CRANE INTERFACE23 - PIN PLUG
15161718
13
12
9
15
16
13
1718
8
7
1
24
5
6
= WIRES AREGROUPEDTOGETHER
DS350 Graphic Modular BCSCrane Interface to Bus Extension
28.8
MANUAL
SECTION 29
DS 350 Graphic Modular (BCS)Troubleshooting Guide
P.A.T. – L.M.I
General Flowchart 29.2Lever Lockout Activated 29.3Broken Length Cable 29.4No Display 29.5Anti - Two - Block 29.7Length Reading Problem 29.10Angle Reading Problem 29.37Load Reading Problem 29.40Bad Data Transfer Between Console & Central Unit 29.42Error Code Displayed 29.45
29.1
PAT DS350 Graphic Modular (BCS)LOAD MOMENT INDICATOR
TROUBLESHOOTING
GENERAL FLOWCHART
This section explains how to handle a problem that may arise with the P.A.T. Load MomentIndicator System - P.A.T. DS350 Graphic Modular (BCS). The procedures are easy to follow and are given in flowcharts on the following pages. Start with general flowchart below whichwill guide you to one of the more detailed flowcharts shown on pages 35.3 through 35.45.
START
What’s Wrong?
Lever LockoutActivated
Length Cable Problem No Display
No FunctionAnti-Two-Block
Go to Page 29.3 Go to Page 29.4 Go to Page 29.5 Go to Page 29.7
Wrong LengthDisplayed
Wrong Load Displayed
Error CodeDisplayed
Go to Page 29.10 Go to Page 29.40 Go to Page 29.45
29.2
Wrong AngleDisplayed
Go to Page 29.37
Bad Data Transfer
Go to Page 29.42
LEVER LOCKOUT ACTIVATED
PROBLEMThe lever lockout system of the crane is activated.Crane movements “hoist up”, telescope out”, and
“boom down” are stopped. Crane is not in overloador two-block condition.
START
Set the override key switch in central unit into upperposition to override LMI.
fixed?
Does the console indicateAnti-Two-Block warning?
Fault in crane electricor hydraulic system.
If console displays isblank, fault is located
in power supply,wiring or fuses.
Fault in Anti-TwoBlock system.
If Load Moment LimitLight is lit, the faultis located in LMI,
cables, wiring, fuses orconsole.
Check lever lockoutsystem in crane
Go to page 29.5 Go to page 29.7 Read error code dis-played on console
and go to page29.45.
YESNO
NO YES
29.3
BROKEN LENGTH CABLE
PROBLEMDamaged or broken length cable.
STEP ACTION
1 Cut old cable at cable drum.
2 Open cable reel cover and disconnect wiring from terminal block. Pull conductor cable out of strain relief.
3 Remove cable reel from mounting brackets.
4 Remove damaged length cable, which is mounted to the slip rings in the cable reel, from Terminal X1 and X2 See drawing 1 on page 29.53.
5 Turn the cable reel and open the stain relief attached to the axle in the center of the drum. Pull existing length cable out of the cable reel.
6 Disconnect damaged length cable from Anti-Two-Block switch receptacle at the boom nose.
7 Pull new length cable through the hole, pipe and strain relief and push it through the axle of the reeling drum. Tighten strain relief to ensure sealing.
8 Dismantle length cable near slip ring and reconnect shield to terminal No. X1 and center to No. X2 See drawing 1 on page 29.53.
9 Remount cable reel to the boom. Turn reeling drum clockwise to get rest of new cable onto the drum.
10 Set preload on cable reel by turning the drum counter-clockwise.
11 Reconnect new cable to Terminal No. 1 (center) and ground terminal (shield) of receptacle at the boom nose.
12 Reset length potentiometer in length angle transducer (screw is located in center ofwhite gear): with boom fully retracted, turn potentiometer carefully counter-clockwise until it stops. Check function of Anti-Two-Block switch. Recheck length and angle display.
29.4
NO DISPLAY
PROBLEMBlank console display.
No warninglight shown.Crane movements stopped.
START
Check fuses on CPU box.
correct?
Measure crane voltage on main board terminal strip between X1-1(+12/24V) andX1-2 (ground).
This is an imput voltage from crane Note: If crane voltage is measured below
10V system will switch off.
correct?
Measure crane voltage on main board terminal strip between X1-3(+24V) and
X1-4 (ground). This is a output voltage to the console.
Replace fuses.
correct?
NEXT PAGE
Defect on main board. Replace main board, see replacement
procedure.
Check crane power supply for faulty crane electric or if power supply is too low.
NO
YES
YES
YES
NO
NO
29.5
NO DISPLAYcontinued
PREVIOUS PAGE
Measure voltage in the consolebetween X1-1 (+24V) and
X1-2 (ground). Refer to Drawing 6 on page29.57 .
correct?
Check connections of thecable between console andcentral unit. Replace cable
if necessary.
Display is defective. Replace the console.
END
NO
YES
29.6
ANTI-TWO-BLOCK PROBLEM
START
Check to see whether or not crane is in two-block condition.
correct? Lower hook down in safe position.
Turn power off or disconnectwire from X1-31 in central unit.
correct?Plug appropriate plug into
socket of junction box.
NO
YES
NO
YES
correct? Replace Anti-Two-Block switch.
NEXT PAGE
NO
YES
PROBLEMFunction of Anti-Two-Block System is faulty.
29.7
Measure the resistance at the boom nosebox between terminals 1 and 6 with ohmmeter. This checks the function of the Anti-Two-Block switch.See drawing 2 on page 29.53.Switch Closed = 4700 +/- 500 OhmsSwitch Open = > 1 Megaohm
ANTI-TWO-BLOCK PROBLEM
PREVIOUS PAGE
Measure the A2B signal in the cable reel betweenX1:Brown and X2:Red wires on the slip ring withan ohmmeter. See drawing 1 on page 29.53.Switch closed = 4700 +/- 500 OhmsSwitch open = >1 MegohmReconnect slip ring wires.
correct?Fault in wiring cable from junction box at boom nose to cable reel or short circuit in length cable. Check wiring.
Measure the A2B signal in the cable reel between7 and 8 with an ohmmeter. See drawing 1 on page 20.28.Anti-Two-Block switch open = > 1 megohmAnti-Two-Block switch closed = 4700 Ohms+ 500 Ohms.Reconnect length cable to slip ring.
Fault in 7 conductor cable between cable reel and boom base box.correct?
NEXT PAGE
NO
YES
NO
YES
correct?NO
YESReplace slip ring.
Measure the A2B signal in the boom basebox between terminal 5 and 6 with an ohmeter.Anti-Two-Block switch open = > 1 megohmAnti-Two-Block switch closed = 4700 Ohms
+ 500 Ohms.Reconnect length cable to slip ring.
29.8
ANTI-TWO-BLOCK PROBLEM
PREVIOUS PAGE
END
correct?
correct?
Turn system power off. Check Anti-Two-Block signal in central unit with ohmmeter measure between X1-31 and X1-32.Anti-Two-Block switch closed = 4700 Ohms+ 500 OhmsAnti-Two-Block switch open = > 1 Megohm.
Faulty wiring between cable reel and central unit. Check Ten Pin Receptacle,
using same measurements as in previous step. See cranes specific wiring diagramfor wires # 5 (+) and # 6 (-). If fault is
found check cable.
Disconnect X1-31 and X1-32.Check main board function by installing a temporary resistor, 4700 Ohms, between X1-31 and X1-32 in central unit. With resistor connected alarm should be inactive.
NO
YES
NO
Connect wire # 5 back to terminal X1-31 on the main board.
Defect on main board. Replace mainboard and reset pressure channel.
Reconnect wire #5 to X1-31 and wire #6 to X1-32.
29.9
LENGTH READING PROBLEMPROBLEM
Length reading incorrect.Crane is not in “out of load chart” condition.
START
NEXT PAGE
29.10
Boom length percentage problem
Switch to Manual Mode and retract the boomcompletely against the stop block.
Check the Percentage indication (1%, 0 %, 0 %)
Wrong?
IM and/ or CM retract signal not recognized. Checkproximity switch target adjustment. Refer to Drawingon page 23.3. If damage is visible install new switch.
Continue to page 29.17
Correct?
Measure the voltage supply to IM switch at terminal1 (+24V) and 3 (GND) in the length transducer LG321.
Adjust the target and switchSee page 23.3
A. Boom Length Percentage Problem
No
Yes
No
Yes
LENGTH READING PROBLEM
PREVIOUS PAGE
NEXT PAGE29.11
A. Boom Length Percentage Problem Cont.
Measure the voltage at terminal25 (+24V) and terminal 27 (GND)in the bus extension.
Failure in bus extension.Check connectors, fuses andbus extension power supply.
Faulty wiring between busextension and LG 321. Checkwiring.
Correct?
Correct?
Yes
No
No
Yes
Measure voltage at terminal 1 or 2 (+24V) and 5 or 6 (GND) in the switch junction box. See page 29.5.
Correct?
Measure voltage at terminal 1 (+24V) and 5(GND) in the IM junction box. Behind drum.
Faulty wiring between lengthtransducer and LG 321 and switchjunction box. Check wiring.
Correct?
Faulty wiring between lengthtransducer and LG 321 and IMjunction box. Check wiring.
Yes
No
Yes
No
LENGTH READING PROBLEM
PREVIOUS PAGE
29.12
A. Boom Length Percentage Problem Cont.
Measure the IM reset switch signal at terminal 3(+ 24V) and 5 (GND) in the proximity switch junction box on base boom. See page 29.5.
Correct?
Yes
No
Measure the IM reset switch signal at wire 2(+ 24)(fast-on connector) and terminal 3 (GND)in the length transducer LG321. See page 29.4.
Faulty switch wiring or defectiveswitch. Replace IM reset proximity switch. Adjust switch and target.
Correct?
Yes
No
Measure the IM retract switch signal at terminal 4(+ 24) and terminal 5 (GND) in the length switch junction box on base boom. See page 29.5.
Faulty wiring between lengthtransducer and LG 321 and switchjunction box. Check wiring.
NEXT PAGE
LENGTH READING PROBLEM
A. Boom Length Percentage Problem Cont.
PREVIOUS PAGE
Correct?
Yes
No
Measure the IM reset switch signal at wire 4(+ 24)(fast-on connector) and 3 (GND)in the length transducer LG321. See page 29.4
Faulty switch. Replace IM retractproximity switch. Adjust switchand target.
Correct?
Yes
No
Measure the CM retract switch signal at terminal 6 (+ 24) and terminal 5 (GND) in the IM junction box. See page 29.5
Faulty wiring between lengthtransducer and LG 321 and switchjunction box. Check wiring.
Measure the CM retract switch signal at terminal 8 (+ 24) and terminal 3 (GND) in the LG321. See page 29.4
Correct?
Yes
No
Defective switch. Replace CMretract proximity switch. Adjustswitch and target
NEXT PAGE
29.13
LENGTH READING PROBLEM
A. Boom Length Percentage Problem Cont.
PREVIOUS PAGE
Correct?
Yes
No
Measure the IM retract switch signal at terminal 39(+24V) and 27 (GND) in the bus extension. See page 29.3
Faulty wiring between lengthtransducer LG321 and switchjunction box. Check wiring.
Correct?
Yes
No
Measure the IM reset switch signal at terminal 41(+24V) and 27 (GND) in the bus extension. See page 29.3
Faulty wiring between bus extension and length transducer LG321 and switch junction box. Check wiring.
Correct?
Yes
No
Measure the CM retract switch signal at terminal 37(+24V) and 27 (GND) in the bus extension. See page 29.3
Faulty wiring between bus extension and length transducer LG321 and switch junction box. Check wiring.
Correct?
Yes
No
NEXT PAGE
29.14
LENGTH READING PROBLEM
A. Boom Length Percentage Problem Cont.
PREVIOUS PAGE
Measure OM retract switch power supply at terminalX1/11 (+24V) and X1/7 (GND) in the LG 321 (CM).See page 29.4
Correct?
Yes
No
Faulty wiring between bus extension and length transducer LG321 and switch junction box. Check wiring.
Measure at CM junction box terminal 11 (+24V)and 9 (GND). See page 29.5
Correct?
Yes
No
Measure OM retract switch signal at CM junction box terminal 10 (+24V) and 9 (GND). See page 29.5
Faulty wiring between CM box and length transducer LG321 (CM). Check wiring.
Correct?
Yes
No
Measure signal at terminal X1/8 (+24V) and X1/7 (GND) in the LG 321 (CM). See page 29.4
Faulty wiring between bus extension and length transducer LG321 (CM). Check wiring.
NEXT PAGE
29.15
LENGTH READING PROBLEM
A. Boom Length Percentage Problem Cont.
PREVIOUS PAGE
Correct?
Yes
No
Measure signal at bus extension terminal X1/35(+24V) and X1/27 (GND). See page 29.3
Faulty wiring between CM box and length transducer LG321 (CM). Check wiring.
Correct?
Yes
No
Digital input defective on bus extention. CheckLED’s on bus extension. Follow replacement procedures.
Faulty wiring between bus extension and length transducer LG321 (CM). Check wiring.
END
29.16
LENGTH READING PROBLEM
B. Boom Out Of Sequence In Automode
START
Problem:In Automode the boom becomes out of
sequence, the warning light is on.
Select manual mode. With no load suspended retractthe boom completely. Disengage the boom stop block and retract the boom completely. Check the percentageindication. ( 0%, 0%, 0%)
Correct?
Yes
No
Inspect the spooling of the length cable on all three drums. Continue with section A.
Correct?
Yes
No
Remove the lid from the length transducers LWG 309and both LG 321. Carefully reset the length transducerpotentiometer. Repeat testing the boom sequence in automode.
Correct the spooling manually.CAUTION
Drum is under tension.
NEXT PAGE
29.17
LENGTH READING PROBLEM
B. Boom Out Of Sequence In Automode Cont.
PREVIOUS PAGE
Failed?
Yes
No
In manual mode retract the boom. Disengage the boom stop blockto retract all section completely. Re-check the length potentiometeradjustment.
END
Correct?
Yes
No
Remove lid from LG321 (IM length) and measuresupply voltage at terminal X1/1 (+24V) and X1/3(GND). See page 29.4
Adjust gear assembly and checkO-ring in gear wheel. ReplaceO-ring if wear is visible.
NEXT PAGE
Correct?
Yes
No Measure the voltage at terminal X1/25(+24V) and terminal X1/27 (GND) inbus extension.
Correct?
Yes
NoFailure in bus extension.Check connectors, fusesand bus extension powersupply.
Faulty wiring between bus extensionand LG 321 (IM). Check wiring.
29.18
LENGTH READING PROBLEM
B. Boom Out Of Sequence In Automode Cont.
PREVIOUS PAGE
Turn the length poteniometer in the LG 321 (IM)counter clockwise to a soft stop. Measure the voltageat terminal X1/2 (1V) and terminal X1/3 (GND).See page 29.4
Correct?
Yes
NoSwitch power off. Remove wire 2 fromLG 321 terminal X1/2. Switch power on.Measure electrical current at terminal X1/2(+ 4mA). Meter - in series.
Correct?
Yes
No
Switch power off.Re-connect wire 2 toterminal X1/2. Faulty
length sensor unit. Replacelength sensor unit.
Switch power off. Re-connect wire 2to terminal X1/2.
Faulty wire between length transducer LG 321 and bus extension. Check wiring.
Turn the length poteniometer in the LG 321 (IM)clockwise to a soft stop(10 turns). Measure the voltageat terminal X1/2 (5.6V) and terminal X1/3 (GND). See page 29.4
NEXT PAGE
29.19
LENGTH READING PROBLEM
B. Boom Out Of Sequence In Automode Cont.
PREVIOUS PAGE
Correct?
Yes
NoSwitch power off. Remove wire 2 fromLG 321 terminal X1/2. Switch power on.Measure electrical current at terminal X1/2(+ 20mA). Meter - in series.
Correct?
Yes
No
Switch power off.Re-connect wire 2 toterminal X1/2. Faulty
length sensor unit. Replacelength sensor unit.
Switch power off. Re-connect wire 2to terminal X1/2.
Faulty wire between length transducer LG 321 and bus extension. Check wiring.
Remove lid from LG 321 (CM) and measure supply voltage at terminalX1/1 (+24V) and X1/3 (GND).
Correct?
Yes
No
Faulty wire between length transducer LG 321 (CM) and bus extension. Check wiring.
NEXT PAGE
29.20
LENGTH READING PROBLEM
B. Boom Out Of Sequence In Automode Cont.
PREVIOUS PAGE
Turn the length poteniometer in the LG 321 (CM)counter clockwise to a soft stop. Measure the voltageat terminal X1/2 (1V) and terminal X1/3 (GND).See page 29.4
Correct?
Yes
NoSwitch power off. Remove wire 2 fromLG 321 (CM) terminal X1/2. Switch power on. Measure electrical current at terminal X1/2 (+ 4mA). Meter - in series
Correct?
Yes
No
Switch power off.Re-connect wire 2 toterminal X1/2. Faulty
length sensor unit. Replacelength sensor unit.
Switch power off. Re-connect wire 2to terminal X1/2.
Faulty wire between length transducer LG 321 (CM) and bus extension. Check wiring.
Turn the length poteniometer in the LG 321 (CM)clockwise to a soft stop(10 turns). Measure the voltageat terminal X1/2 (5.6V) and terminal X1/3 (GND).See page 29.4
NEXT PAGE
29.21
LENGTH READING PROBLEM
B. Boom Out Of Sequence In Automode Cont.
PREVIOUS PAGE
Correct?
Yes
NoSwitch power off. Remove wire 2 fromLG 321 (CM)terminal X1/2. Switch power on. Measure electrical current at terminal X1/2 (+ 20mA). Meter - in series
Correct?
Yes
No
Switch power off.Re-connect wire 2 toterminal X1/2. Faulty
length sensor unit. Replacelength sensor unit.
Switch power off. Re-connect wire 2to terminal X1/2.
Faulty wire between length transducer LG 321 (CM) and bus extension. Check wiring.
Remove lid from LWG 309 (OM) and measure supply voltage at terminalX1/1 (+24V) and X1/3 (GND). See page 29.2
Correct?
Yes
No
Faulty wire between length transducer LG 321 (CM) and bus extension. Check wiring.
NEXT PAGE
29.22
LENGTH READING PROBLEM
B. Boom Out Of Sequence In Automode Cont.
PREVIOUS PAGE
Turn the length poteniometer in the LWG 309 (OM)counter clockwise to a soft stop. Measure the voltageat terminal X1/2 (1V) and terminal X1/3 (GND).
Correct?
Yes
NoSwitch power off. Remove wire 2 fromLWG 309 (OM) terminal X1/2. Switch power on. Measure electrical current at terminal X1/2 (+ 4mA). Meter - in series.
Correct?
Yes
No
Switch power off.Re-connect wire 2 toterminal X1/2. Faulty
length sensor unit. Replacelength sensor unit.
Switch power off. Re-connect wire 2to terminal X1/2.
Faulty wire between length transducer LWG 309 (OM) and bus extension. Check wiring.
Turn the length poteniometer in the LWG 309 (OM)clockwise to a soft stop(10 turns). Measure the voltageat terminal X1/2 (5.6V) and terminal X1/3 (GND).
NEXT PAGE
29.23
LENGTH READING PROBLEM
B. Boom Out Of Sequence In Automode Cont.
PREVIOUS PAGE
Correct?
Yes
NoSwitch power off. Remove wire 2 fromLWG 309 (OM)terminal X1/2. Switch power on. Measure electrical current at terminal X1/2 (+ 20mA). Meter - in series.
Correct?
Yes
No
Switch power off.Re-connect wire 2 toterminal X1/2. Faulty
length sensor unit. Replacelength sensor unit.
Switch power off. Re-connect wire 2to terminal X1/2.
Faulty wire between length transducer LG 309 (OM) and bus extension. Check wiring.
NEXT PAGE
Reset all length transducer potentiometers.Select Boom service screen on console,compare the indicated IM length with the actual IM length.
29.24
LENGTH READING PROBLEM
B. Boom Out Of Sequence In Automode Cont.
PREVIOUS PAGE
Correct?Yes No
Fault is not located in the LMI circuit.Follow the crane service instructions tocontinue.
Faulty bus extension module.Contact Technical support forinstructions
END END
29.25
LENGTH READING PROBLEM
C. Outer Mid And Fly Section Are Not Retracted (E83)
START
Outer mid and fly sections are not fully retracted.
Switch to manual mode and retract the OM/Fly section fully.
E83 ?Switch to auto mode andcontiue normal crane operation
Switch to auto mode and retract the boom (CautionReduced load chart with E83)
Yes
No
E83 ?
Yes
No
Defect is not located in LMIcircuit. Refer to crane servicedocumentation to continue.
Check the position of the OM/Fly section
NEXT PAGE
29.26
Correct?
Yes
No
LENGTH READING PROBLEM
C. Outer Mid And Fly Section Are Not Retracted (E83) Cont.
PREVIOUS PAGE
Switch to auto mode and retractOM section fully.
Check the OM retract proximity switchand target adjustment.
Yes
No Correct?Defect is not located in LMIcircuit. Refer to crane servicedocumentation to continue.
Switch to auto mode andcontiue normal crane operation
Correct?
Yes
No
Adjust the switch and the target.
Measure the voltage at terminal 25(+24V) and terminal 27 (GND) inthe bus extension. See page 29.3
NEXT PAGE
29.27
LENGTH READING PROBLEM
C. Outer Mid And Fly Section Are Not Retracted (E83) Cont.
PREVIOUS PAGE
Correct?
Yes
No
Measure OM retract switch power supply at LG 321(CM) terminal X1/11 (+24V) and X1/7 (GND) See page 29.4
Defective bus extension. Checkconnectors, fuses and bus extensionpower supply.
Correct?
Yes
No
Measure OM retract switch signal at CM junctionbox terminal 10 (+24V) and 9 (GND) See page 29.5
Faulty wiring between bus extention and LG 321. Checkwiring.
Correct?
Yes
No
Measure signal at LG 321(CM) terminal X1/8 (+24V) and X1/7 (GND). See page 29.4
Faulty wiring between bus extention and LG 321. Checkwiring.
NEXT PAGE
29.28
LENGTH READING PROBLEM
C. Outer Mid And Fly Section Are Not Retracted (E83) Cont.
PREVIOUS PAGE
Correct?
Yes
No
Measure signal at bus extension terminal X1/35(+24V) and X1/27 (GND) See page 29.3
Defective wiring between CMjunction box and length transducerLG 321(CM). Check wiring.
Correct?
Yes
No
Digital input defective on bus extension. CheckLED’s on bus extension. Contact Technical Support for replacement procedure.
Faulty wiring between bus extention and LG 321(CM).Check wiring.
END
29.29
LENGTH READING PROBLEM
D. Error In Bus Extension (E61)
START
E61Error in the bus extension
Check crane power, batteryvoltage.
Correct?
Yes
No
Measure the power supply at the bus extensionterminal X1/26 (+24V) and 28 (GND). See page 29.3
Refer to the crane servicedocumentation to correctthe power failure.
Correct?
Yes
No
Check bus extention fuse FX Faulty crane electric wiring.Check wiring.
NEXT PAGE
29.30
LENGTH READING PROBLEM
D. Error In Bus Extension (E61) Cont.
PREVIOUS PAGE
Correct?
Yes
No
Check the bus extension cable wiring andconnections between bus extension and centralunit.
Switch power off. Replace the fuse.Switch power on and check again.
Correct?
Yes
No
Faulty bus extension. ContactTechnical Support for replaceprocedure.
If damage is visible replace the cable,otherwise rewire and tighten the connections. CAUTION: Twisted pairsmust remain twisted.
END
29.31
LENGTH READING PROBLEM
E. No Tele Function At All In Automode
START
Error:No tele-function at all in
automode.
Remove load from hook. Make sure no other error orwarning is preventing you from extending or retractingthe boom. Switch to manual mode and attempt extendingand retracting the boom in manual mode.
Correct?
Yes
No
Remove lid from bus extension. Measure crane powersupply at terminal X1/26 (+24V) and X1/28 (GND).See page 29.3
Malfunction is not related to LMI orboom control extension. Consult thecrane service documentation.
Correct?
Yes
No
Faulty crane eletric wiring.
Switch to auto mode. Start the engine. Operate theextend control. Measure the extend signal at busextension terminal X1/29 (+24V) and X1/28 (GND). See page 29.3
NEXT PAGE
29.32
LENGTH READING PROBLEM
E. No Tele Function At All In Automode Cont.
PREVIOUS PAGE
Correct?
Yes
No
Operate the retract control. Measure the retract signalat bus extension terminal X1/31 (+24V) and X1/28 (GND).
Faulty pilot pressure switch in the tele extend pilot pressure circuit orcrane electric harness faulty. Referto crane documentation.
Correct?
Yes
No
Faulty pilot pressure switch in the tele extend pilot pressure circuit orcrane electric harness faulty. Referto crane documentation.Select boom service screen on console.
Operate the extend control. The ramp valuefor the appropriate section should increasein steps from 0 to 255.
Correct?
Yes
No
Faulty digital input 1 on bus extension. Contact TechnicalSupport for replacement procedure.Select boom service screen on console.
Operate the retract control. The ramp valuefor the appropriate section should increasein steps from 0 to 255.
NEXT PAGE
29.33
LENGTH READING PROBLEM
E. No Tele Function At All In Automode Cont.
PREVIOUS PAGE
Correct?
Yes
No
Select manual mode. Retract all sections. Switch power off. Remove wire 2 from the analog output board terminal A 104 X1/2 (IM). Switch power on. Operate retract and extend control. Measure the electrical current (mA) between the wire 2 (removed from terminal) and the terminal X1/2. The signal should increase from 0 mA to approximately 800 mA.NOTE : In the ramping area the value may be < 800 mA.
Faulty digital input 2 on bus extension. Contact TechnicalSupport for replacement procedure.
Correct?
Yes
No Check the power supply to the analogoutput module A 104 (IM). Measure at terminal X1/1 (+24V) and X1/4 (GND).
Correct?
Yes
NoFaulty wiring in busextension. Check wiring.
Operate retract or extend control.Measure voltage at terminal A 104X1/2 (>0V) and X1/4
NEXT PAGE NEXT PAGE
29.34
LENGTH READING PROBLEM
E. No Tele Function At All In Automode Cont.
PREVIOUS PAGE PREVIOUS PAGE
Correct?
Yes
NoDefective analog output boardA 104 (IM). Contact TechnicalSupport for replacement procedures.
Refer to drawing of (K2, K6, K7logic table) to check the two way valveoperation.
Re-connect wire 2 to terminal A 104 X1/2.Operate the extend control. Measure at bus terminalX1/14 (>0V) and X1/28 (GND). Operate the retract control. Measure at bus terminal X1/15 (>0V) andX1/28 (GND).
Correct?
Yes
NoCheck fuse F5 in the busextension. If blown replacefuse. Check relay K5.
Faulty crane wiring or defective valve coil.Contact Technical support .
NEXT PAGE
29.35
LENGTH READING PROBLEM
E. No Tele Function At All In Automode Cont.
PREVIOUS PAGE
Correct?
Yes
No
Measure the two way valve signal (>/= +20V) at terminal 1 or 2 (IM junction box) and terminal 1 or 2 and 3 or 4 (CM junction box).
In the bus extension:Check fuse F2 for relay K2 (IM 2 way valve).Check fuse F6 for relay K6 (CM 2 way valve).Check fuse F7 for relay K7 (OM 2 way valve).Replace if blown.
Correct?
Yes
No
Faulty crane wiring or valve coil.Refer to Crane Service Documentation.
Faulty wiring between bus extension and 2way valve junction boxes on the IM and CMsection. Check wiring.
END
29.36
ANGLE READING PROBLEM
PROBLEMAngle Reading Incorrect
Crane is not in “Out of Load Chart” condition.
START
Check levelness of the angle sensor in cable reelwith main boom at horizontal remove cover from the cable reel.
Readjust the angle sensor to the correct position by loosening the mounting screws and moving the angle sensor.
Place the boom at 0 o. Check power supply to angle sensor on main board between X1-26 (+12/24V) and X1-28 (GND)
NEXT PAGE
Main board defective. replace main board andreset pressure channel. Note: Consult factory before replacing mainboard for further troubleshooting steps.
correct?NO
YES
correct?NO
YES
29.37
Replace angle sensor.correct?NO
YES
Measure supply to angle sensor in cablereel at terminal between X1-1 (+12/24V)and X1-3 (GND).
ANGLE READING PROBLEM
PREVIOUS PAGE
Measure signal in series from angle sensor in cable reel, one lead to wire #4 and the other lead X1-4. Boom Angle Signal :
0 Degrees 20 mA45 Degrees 12 mA90 Degrees 4 mA
NEXT PAGE
Faulty wiring between central unit andangle sensor. Check wiring.correct?
NO
YES
29.38
ANGLE READING PROBLEM
PREVIOUS PAGE
Faulty wiring between central unit andcable reel. Check wiring.correct?
NO
YES
Measure signal from angle sensor in centralunit. Measurement should be taken in seriesat X1-29 and wire #4.Boom Angle Signal :
0 Degrees 20 mA45 Degrees 12 mA90 Degrees 4 mA
Measure angle signal analog input module between test point MP0 and X1-4. The measure-ment should be between 0.5 - 4.5V.Boom Angle Signal :
0 Degrees 0.5 Volt45 Degrees 2.48 Volts90 Degrees 4.5 Volts
Faulty analog input module or CPU module incentral unit.correct?
NO
YES
END
29.39
LOAD READING PROBLEMPROBLEM
Load reading incorrect.
START
Check selected operating mode(codeon operating mode switch).
correct?NO
YES
Select operating mode switch to correct position(see operating mode in load chart).
Check boom length reading on display.
correct?NO
YES
Reset length potentiometer. With fully retractedboom, turn potentiometer axle counterclockwiseuntil it stops .
Measure radius and check with the displayed radius.
Check if mechanical adjustment of angle transduceris correct. Angle transducer box should in line withboom and adjusted to actual boom angle. correct?
NO
YES
Check power supply to pressure transducer (rodside). Unplug transducer cable from transducer.Measure voltage at the cable connection betweenA (+24V) and C (ground).
Check power supply at main board betweenX1-20 (+12/24V) and X1-22 (ground) for pistonand X1-23 (+12/24V) and X1-25 (ground) forrod side.
correct?NO
YES
NEXT PAGE
Fault in pressure transducer.
Replace the main in central unit.
correct?
NO
YES
29.40
LOAD READING PROBLEM
PREVIOUS PAGE
Measure in series piston side signal, in centralunit, remove wire #2 from X1-21. Connect onelead to wire #2 and the other to X1-21. The measurement should be between 4-20mA (4mA at 0 PSI to 20mA at 4410 PSI). Rod side, remove wire #2 from X1-24.
correct?NO
YES
correct?NO
YES
END
Measurement is not within 4-20mA.Fault in pressure transducer cable.
Measurement within 4-20mA, but 4mAdoes not equal 0 PSI. Adjust zero point on pressure transducers at console.
If transducer(s) are not adjustable,replace pressure transducer(s) andadjust zero point. Refer to page 30.5.
4-20mA
NO
YES
Measure pressure transducer signals on the analog input module between testpoints, (Piston side, MP0 (GND) and X1-1) (Rod side, MP0 (GND) and X1-2).The measurement should be between 0.5V - 4.5V at 0 PSI to 4.5V at 4410PSI.
Replace the analog input module board incentral unit.
29.41
BAD DATA TRANSFER BETWEEN CONSOLE & CENTRAL UNIT
PROBLEMError Code “E93 / E94”
No data transfer to and from console.
START
Make sure that EPROMS are correct and plugged intoEPROM MODULE is on main board.
correct?NO
YES
Place EPROM S in correct socket.
Measure process voltage on the main board in thecentral unit between MP24 (+5V) and MP0 (GND).
correct?NO
YES
Make sure external and internal power supply iscorrect.
NEXT PAGE
Check the H12 (TXD) LED on the main board ON/OFF.
On
Turn off system power. Check the continuityof the receive (RXD) and transfer (TXD) wires.
Check continuity between: X1-5 main board and X1-3 consoleX1-6 main board and X1-4 console
Off
correct?NO
YES
Check connections and replace cable from centralunit to console, if necessary.
29.42
PREVIOUS PAGE
BAD DATA TRANSFER BETWEEN CONSOLE & CENTRAL UNIT
Check if additional ground like between main board terminal X9 and central unit box mountingbracket is in place.
Install ground link - single cable minimum ofAWG14 (2.0mm2) between terminal X9/2 andcentral unit box mounting bracket. correct?
NO
YES
Ensure that cable shields are connected correctly.Refer to connections and wiring diagrams.
Make correct shield connection.Refer to connection and wiring diagrams,correct?
NO
YESFind out which component of the crane electricis spiking out (e.g. dump valve, outrigger relay).Install a diode or varistor across terminals of spiking component. Diode type such as 1N 4001can be used (watch + and - connection for diode).
END
29.43
INTERFERENCE PROBLEMPROBLEM
Interference from crane electric.Error Code “E93 / E94” intermittent.
Frozen console displays.
START
Check system out; - Bad DataTransfer Between Console & Central Unit.
correct?NO
YES
Replace or repair part which is defective.
Check if additional ground like between main board terminal X9 and central unit box mountingbracket is in place.
Install ground link - single cable minimum ofAWG14 (2.0mm2) between terminal X9/1 andcentral unit box mounting bracket. correct?
NO
YES
Ensure that cable shields are connected correctly.Refer to connections and wiring diagrams.
Make correct shield connection.Refer to connection and wiring diagramscorrect?
NO
YESFind out which component of the crane electricis spiking out (e.g. dump valve, outrigger relay).Install a diode or varistor across terminals of spiking component. Diode type such as 1N 4001can be used (watch + and - connection for diode).Refer to Drawing 8, “Suppressor Diode”
END
29.44
ERROR CODE DISPLAY
PROBLEM Error code displayed. Lever lockout activated.
Warning lights on. ERROR DISPLAY ERROR CAUSE ACTION E 01* Below radius or above angle Fallen below the minimum Lower boom back to a radius range. radius or above the angle given or angle given in the load in the load chart due to raising chart. the boom too far. E 02* Beyond radius or below The maximum radius or Raise boom back to a radius angle range. minimum angle given in the or angle given in the load load chart was exceeded due chart. to lowering the boom too far. E 03* Prohibited slewing range. Slewing range prohibited Slew back into admissible (no load area) with load. range. E 04* Operating mode not available. Operating mode switch in the Set operating mode switch console set incorrectly. correctly to the code assigned Operating mode is not per- to the operating mode of the missible with actual crane crane. configuration. E 05* Length range not permitted. Boom was telescoped too Telescope boom to correct far or not far enough. length given in the load chart. Length sensor adjustment See page 35.58 changed; i.e. length sensor cable slid off the cable drum. E 06* Fallen below angle range with Fallen below the minimum jib Luff in the jib to a radius or luffing jib operation. angle specified in the angle specified in the load respective load chart due to chart. luffing out the jib too far.
* This error can be corrected by the operator.
29.45
ERROR CODE DISPLAY ERROR DISPLAY ERROR CAUSE ACTION E 07 No acknowledgement signal Overload relay is stuck, from overload relay (K8). defective or not being selected. E 08 No acknowledgement signal Anti-Two-Block switch relay from Anti-Two-Block switch is defective or not being
relay (K9). selected.
E 11 Fallen below lower limiting Cable from central unit to length sensor Check cable. Replace if value for the measuring defective, not connected or water in the necessary. See page 35.58. channel "length". connectors Length potentiometer defective. Replace and reset length potentiometer. See page 35.58. Electronic component in the Replace main board and measuring channel defective on reset pressure channels. main board. E 12 Fallen below lower limiting Cable from central unit to Check cable as well as plug. value for the measuring the pressure transducer Replace if necessary. channel "pressure piston side". defective, loose or water in the plug. Pressure transducer on Replace pressure transducer piston side defective. and reset pressure channel. Electronic component in the Replace main board and measuring channel defective reset pressure channels. on main board. E 13 Fallen below lower limiting Cable from central unit to Check cable as well as plug. value for the measuring the pressure transducer Replace if necessary. channel "pressure rod side". defective, loose or water in in the plug. Pressure transducer on rod Replace pressure transducer side defective. and reset pressure channel. Electronic component in Replace main board and the measuring channel defective reset pressure channels. on main board. E 14 Fallen below upper limit value Cable from central unit to Check cable as well as plugs, in measuring channel "Force". force measuring point defective replace if need be. or water inside the plugs. Force transducer defective. Replace force transducer. Electronic component in the Replace main board and reset measuring channel defective. pressure channels.
29.46
ERROR CODE DISPLAY ERROR DISPLAY ERROR CAUSE ACTION E 15 Fallen below lower limiting Cable from central unit to the length/ Check cable. value for the measuring angle sensor defective or loose or Replace if necessary. channel "angle main boom". water inside plug. See page 35.58. Angle sensor defective. Replace angle sensor. and reset adjustment. Electronic component in the Replace main board and measuring channel defective. reset pressure channels. E 16 Fallen below lower limit Cable from central unit Check cable as well as plug, value for measuring channel to angle sensor defective replace if need be. "Luffing Jib Angle". or disconnected or water inside the plug. Angle sensor defective. Replace angle sensor. Electronic component in the Replace main board and reset measuring channel defective. pressure channels. . E 18 Front Stabilizer overloaded Exceeding capacities allowed for over Achieve a safe working area the front. Immediately. E 19 Error in the reference voltage. Electronic component on Replace main board and reset the main board defective. pressure channels. +5 volt supply E 1A Below limiting value for slewing Cable from central unit to the slewing Check wiring, replace if angle 1. angle sensor defective or loose. necessary. E 1B Below limiting value for slewing Slewing angle pot. defective. Replace and reset slewing angle angle 2. wiring, (external). potentiometer. Electronic component in the measuring Replace main board and reset channel defective on main board. pressure channels. E 21 Upper limiting value for the Cable from central unit to the Check cable. Replace if measuring channel "length" length/angle sensor defective necessary. See page 35.58. exceeded. or loose. Length potentiometer Replace and reset length defective. potentiometer. See page 35.58. Electronic component in the Replace main board and measuring channel defective reset pressure channels. on main board.
29.47
ERROR CODE DISPLAY ERROR DISPLAY ERROR CAUSE ACTION E 22 Upper limiting value for the Cable from central unit to the Check cable as well as plug. measuring channel "pressure pressure transducer defective, Replace if necessary. piston side” exceeded. loose or water in the plug. Pressure transducer on piston Replace pressure transducer side defective. and reset pressure channels. Electronic component in the Replace main board and measuring channel defective reset pressure channels. on main board. E 23 Upper limiting value for the Cable from central unit to the Check cable as well as plug. measuring channel "pressure pressure transducer defective, Replace if necessary. rod side" exceeded. loose or water in the plug. Pressure transducer on rod Replace pressure transducer side defective. and reset pressure channels. Electronic component in the Replace main board and measuring channel defective. reset pressure channels. on main board. E 24 Upper limit value in measuring Cable between central unit and Check cable as well as plug, channel "Force" exceeded. force measuring point defective replace if need be. or water inside the plug. Force sensor defective. Replace force sensor. Electronic component in the Replace main board and reset measuring channel defective. pressure channels. E 25 Upper limiting value for the Cable from central unit to the Check cable. measuring channel "angle length/angle sensor defective Replace if necessary. main boom" exceeded. or loose. Angle sensor defective. Replace angle sensor and reset mechanical adjustment. Electronic component in the Replace main board and reset measuring channel defective pressure channels. on main board. E 26 Upper limit value for See Error E 16. See Error E 16. measuring channel "Luffing Jib Angle" exceeded.
29.48
ERROR CODE DISPLAY ERROR DISPLAY ERROR CAUSE ACTION E 27 Upper limit value for the measur- Cable from central unit to the Check cable. channel 7 exceeded. Sensor of channel 7 defective Replace if necessary. or loose. Sensor of channel 7 defective. Replace angle sensor and reset mechanical adjustment. Electronic component in the Replace main board and reset measuring channel 7 defective. pressure channels. E 29 Error in the reference Supply and Reference voltages on Check supply voltages. voltage. MP10 is more than 3.3V. Electronic component on Replace main board and reset -5 volt supply the main board defective. pressure channels. A/D converter defective. E 2A Above limiting value for slewing Cable from central unit to the slewing Check wiring, replace if angle 1. angle sensor defective or loose. necessary. E 2B Above limiting value for slewing Slewing angle pot. defective. Replace and reset slewing angle angle 2. wiring, (external). potentiometer. Electronic component in the measuring Replace main board and reset channel defective on main board. pressure channels. E 31 Error in system program EPROM with system Replace EPROM with system program defective. program. Electronic component on Replace main board and reset the main board defective. pressure channels.
E 37 Error in program run EPROM with system program Replace system program defective. EPROM. Electronic component on the main Replace main board and reset board defective. pressure channels. E 38 Incorrect system program. CPU is equipped with an Equip main board with incorrect version of system correct version of system or program. Data EPROM. E 39 Incorrect system program. CPU is equipped with an Equip main board with incorrect version of system correct version of system or program. TLK EPROM. E 41 Error in the external RAM. RAM in the CPU on the Replace CPU Chip No. main board defective. 80C31. Replace main board and reset pressure channels. E 42 Error in the external write/ Internal defect in Exchange write/read memory read memory (RAM). digital part of CPU. (CMOS-RAM). Replace main board and reset pressure channels.
29.49
ERROR CODE DISPLAY ERROR DISPLAY ERROR CAUSE ACTION E 42 Error in the external Internal defect in digital part Exchange write/read memory write/read memory of CPU. (CMOS-RAM). Replace main (RAM) part 1. Board and reset pressure channels. E 43 Error in the external Internal defect in digital part Exchange write/read memory write/read memory of CPU. (CMOS-RAM). Replace main (RAM) part 2. Board and reset pressure channels. E 45 Error in internal Defective electronic Replace main board and communications. component. reset pressure channels. E 46 Error in A/D Defective electronic Replace main board and conversion component. reset pressure channels. E 47 Malfunction in the Internal defect in Replace main board and reset monitored write/read in digital part of CPU pressure channels. memory.
E 48 Malfunction in the monitored Inter defect in digital part of CPU Replace main board and reset pressure channels. E 51 Error in data memory. Data EPROM on the main Replace Data EPROM. board defective. Make sure BR3 on the main Eprom Module not bridge correctly. board is installed. E 52 Error in TLK memory. TLK EPROM on the main Replace main board and reset board defective. pressure channels. Eprom Module not bridge correctly. E 71 Incorrect acknowledgment of the A2B relay is stuck or defective. Replace K9 relay. A2B Relay on A101 Term. board. A2B relay is not being selected due to Check terminal board, main a break on the terminal board, main board and ribbon cables as well board or ribbon cable. as replace defective part, if necessary. E 72 – E 77 Analogous to E 71 for relays Analogous to E 71 for relays Analogous to E 71 for relays K2 – K7 K2 – K7 K2 – K7 E 89 Change of the operating code The operating mode switch in the Lower the load and set the during lifting a load. console was used during lifting operating mode switch correctly a load. to the code assigned to the actual operating mode of the crane.
29.50
ERROR CODE DISPLAY ERROR DISPLAY ERROR CAUSE ACTION E 91 No data transmission from 24V supply of console Check 24V at terminal Xl of console to central unit. interrupted. console electronics. (See page 35.42) Interruption or accidental Check the connection between ground in the line from console electronics and console electronics to central unit. If you find an central unit. accidental ground, the transmitter module in the console electronics can be damaged. You should, therefore, replace the console electronics. Transmitter / receiver module Replace console electronics defective. or main board respectively. E 92 Error in the data transmission Defective data line Check the connection between from console to central unit. from console electronics to console electronics and central (See page 35.42) central unit. unit. Transmitter / receiver Replace console electronics module defective. or main board respectively. E 93 Error in the data transmission Defective contact in the line Check the line to the console. from central unit to console. from central unit to console. (See page 35.42) Transmitter / receiver Replace console electronics module defective. or main board respectively. E 94 No data transmission from Interruption or accidental Check the line to the console central unit to console. ground in the data line from (in case of accidental ground (See page 35.42) central unit to console. also replace console electronics). 5V supply for the computer Check the connection to the in the central unit is missing. power supply. 5V supply voltage too low. Replace power supply module. Transmitter / receiver Replace console electronics module defective. or main board respectively. Data EPROM defective. Check data EPROM. Computer module defective. Replace main board. Electromagnetic interferences Eliminate interference source (e.g. when switching by inverse diodes or varistors. contactors or valves).
29.51
ERROR CODE DISPLAY ERROR DISPLAY ERROR CAUSE ACTION E 95 Error in the crane data EPROM Data EPROM defective. Replace data EPROM. Position of jumper for the selection Check the jumper position. of the type of EPROM is wrong. Electronic component on main board Replace main board and reset defective. pressure channels. E 96 Error in the internal RAM of the CPU or main board of the console Replace console main board. CPU of the console. defective. E 97 Error in the external RAM of the External RAM of the console Replace console main board. CPU of the console. defective. Electronic component on the main Replace console main board. board defective. E 98 Wrong jumper position in the The jumper position BR9/BR10 in the Check the jumper position. console. console does not correspond to the actual type of central unit. Electronic component on the main Replace console main board. board defective.
29.52
1 2
X1 : BROWN
X2 : RED
3 4
Drawing 1 : Slip Ring Unit
Drawing 2 : Boom Nose Junction Box
29.53
MP 25
+UBSMP1
KGND
KG
ND
F1
X1
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54
F2
J4J3J2J1 31
- +
KG
ND
H9
A2B
X1
KGND
J103 24 1 MP29
+5V/RS232
A2BK9
LMIK8
LOAD
LEVERLOCKOUT
K10
KG
ND
+UB
KGND
+UB
1 +UB
H12
TXD
H10
MAIN
ON
/OFF
H1 H
2 H3 H
4 H5 H
6
X13
DI 1-D
I 6 =>D
I 1D
I 6
X14
KGND
+UB
1
V10H
11V11 M
P41M
P40
PFAIL +UB
1pow
er o.k.
GND
+5V
+6V
+9V
KG
ND
AGN
D
X16
AGN
D
C
C
MP42PWM DC
- G1 +
MP24+BATT
MP23
VBAT
X15
KG
ND
GND
AGN
DK
GN
D
KG
ND
X12
X17
GND
MP21
SP5
X11J11
A B C D E F G H I J K L M
A B C D E F G H I J K L M
1
2
3
4
5
6
7
8
9
10
11
12
13
1
2
3
4
5
6
7
8
9
10
11
12
13
Drawing 3 : Main Board
77 76
MP 26
MP 4
MP 9
MP 8
LOCATIONS :
MP 1 - zone M13 = GND.MP 25 - zone M13 = +UBSMP 8 - zone M2 = +9VMP 9 - zone M2 = +6VMP 4 - zone M1 = +5V MP 26 - zone M1 = GND.MP 23 - zone A2 = VBATT MP 24 - zone D2 = +BATTMP 40 - zone M4 = +UB
MP 41 - zone M4 = POWER FAILMP 42 - zone G1 = +5VMP 21 - zone E5 = +5VMP 29 - zone D10 = +5VH1-H6 - zone I5 = DI 1-6
29.54
EJECT
MP2MP6
MP5
BR6
BR5
X3
J12
J8 J9 MP3 J6
SYSTEMD10
D1
MP4
X2X1
J13
MP7
P1
J1J2
J10
J11 J1
4
J15
J7
A102 CPU
BR
4 3 2 1
J6
J2J1
J5J3
DATAD1
TLKD3
A103 DATEN
X1
D3
D2
D14
D13
D6
D17
D21D7D15
D9
D20
D18
D19
D11
D12
Drawing 4 : CPU and Daten EPROM boards
29.55
X16
1216
X17
1240
+ ++ +
- +
MP12
J2
MP13
P7P6
P5P4
P3P2
P1
MP11
J1 MP9
MP10
MP17
- +MP0MP8
P8
MP7 -M
P1->7 6 5 4 3 2 1
VREFA
MP14
BR1
AG
ND AGND
AGNDAGND
MP16
1612
120
1240
BOARD P/N 9-333-103290X1:1-7 = ADC INPUT 0.5V/4mA…2.5V/20mA
offset adjust with P1-P7X1:8 = TEMP (0.5V + 10mV/oC)X1:9 = VREFA = 5.000V referenceX1:10 = AGND (reference GND)X1:11 = VREF+ = 5.0V power ADCX1:12-15 = CH01-04, DIN 1-4 / 10X1:16 = CH05, +UBS / 10X1:17 = CH06, HESIN(A2B) *4X1:18 = CH07, +9V *4X1:19 = CH08, VREFA / 2 = 2.500VX1:20 = UKLEMM, app. VREFA, limits ADC input to 5.0V
X1
Drawing 5 : Analog Input Module
29.56
Drawing 6 :Console Board
1 2 3 4 5 6 7 8 1 2 3 4
MP 2+7V
MP 5+5V
MP 0GND
MP 3-24V
MP 4-24V
MP 6
MP 7
MP 1+UB
J5
J4
J3
J1
J2
X1
X5
29.57
PATPAT
Drawing 7 : Length / AngleTransducer
ADJUST LENGTH POTENIOMETER WITH BOOM FULLY RETRACTED, TURN THE CENTER SCREW COUNTERCLOCKWISE TO A SOFT STOP.
X3123
135
XA2
X2 L
123
135
XB2
AX2
1 2 3 4 5 6 7 8
12345678S
X1
X27 (9)8 (10)
9333103309
X4
29.58
OUT IN
NORMALOPERATION
L/OOVERRIDE
+ _
COMPONENTCAUSING
INTERFERENCE
SUPPRESSOR DIODE
CAUTION: Make sure that + and - diode connections aremade as shown to ensure proper polarity.
Drawing 8 : Suppressor Diode
Drawing 9 : Central Unit Box
FUSE
( 4A
)
FUSE
( 10
A)
CAB
LE A
SSY.
TO
BO
OM
3 -P
AIR
CAB
LE B
US
EXTE
NSI
ON
CAB
LE A
SSY.
TO
CO
NSO
LE
CAB
LE T
O C
RAN
E IN
TER
FAC
E
CAB
LE A
SSY.
TO
PR
ESS.
TR
ANSD
UC
ER (
RO
D )
CAB
LE T
O A
REA
DEF
INIT
ION
CAB
LE A
SSY.
TO
PR
ESS.
TR
ANSD
UC
ER (
PIST
ON
)
29.59
MANUAL
SECTION 30
DS 350 Graphic Modular (BCS)Electrical Diagrams
P.A.T. – L.M.I
X1 1 2 11 12 13 18 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 53 54 59 60 61 62
1 2 3 4 5 6 GN
/YL
1 2 3 4 5
GN
/YL
71K
(+U
B)
51AJ
(GN
D)
73A
(LM
I UN
LOC
K SO
L.)
1
V VV V
VV
1 2 1 2 3 4 1 2 3 4
1 2 3 4
V
V
AA
V
V
BB
V
V
CC
12
pres. trans.(piston)
1 2 3 4
V
V
AA
V
V
BB
V
V
CC
12
pres. trans.(rod)
TO MAIN BOOM CONNECTOR
1 2 3 4 7 5 6
1 2 3 4 5 6 7
V V V V V V
A B C D E F
7 PI
N P
LUG
12
4 AMPFUSE
IN OU
T
10 AMPFUSE
IN OU
T
4 3
2 1
LMI BYPASSKEY SWITCH
12
1 2 3 4 5 6 7 8 X1
1 2 3 4 5 6 7 10 8 9
X812
X7 1 2 3 4
+UBEGND
+UB
GN
DTX
DR
XD A2B
A2B
LOAD D
1
+UB
ESI
G+
SIG
-G
ND
1 2 3 4
A B C D
1 2 3 4LIGHTBAR
V
V
V
V
V
V
V
V
CONSOLE (1318)
DS350GRAPHIC MODULAR B.C.S.
CENTRAL UNIT
+UB
GN
D
K10
LM
I UNL
OC
K S
.
51 52 3 4 5 6 7 8 9 10
8 9 1 2 3 4 5 6 7 10
+UB
GN
D+U
BG
ND
RXD TX
DA2
B B
YPAS
SA2
B B
YPAS
SLM
I BYP
ASS
+UB
K10
EXT
. HO
R. *
1
+UB
SG
ND
DI1
DI2
+24V
=O/F
-R
UB
.
DI4 +U
BPI
STO
NG
ND
+UB
RO
DG
ND
+UB
LEN
GTH
GN
DAN
GLE
FO
RC
EA2
B S
IGN
ALA2
B G
RO
UN
D
NO
T U
SED
NO
T U
SED
NO
T U
SED
NO
T U
SED
FUSE
(4 a
mp)
FUSE
(4 a
mp)
LMI B
YPAS
S+U
BS
FUSE
(10
amp)
FUSE
(10
amp)
1 OUTER SHIELD GROUNDED AT STRAINRELIEF CONNECTOR.
2 INNER SHIELD CUT AND INSULATED
3 INSULATE OUTER SHIELD AND CONNECT TO CHASIS GND.
*1) OPTIONAL FOR EXTERNAL HORN(EEC UNITS ONLY)
NOTES:
2
NO
NC
C
crane 12 o areadefinition switch
in ele. swivel
1 2 3 4
V
V
AA
V
V
BB
V
V
CC
V
V
DD
V
V
EE
CRANE SYSTEM AREADEF. SWITCH ELEC. SWIVEL
5 PINDEUTSCH
PLUG
K10
(CO
M) +
24V
DI 3
(+24
V H
OU
SEPI
N E
NG
AGED
)
74 (L
MI L
/O A
LAR
M
VV
744
HO
USE
LO
CK
PIN
SW
.
VV
A
(See Page 36.2)
30.1
+ 24
VSI
G.
GN
DLENGTH
TRANSDUCER
LWG
309 (TO N
OSE)B
RN
RED
1 2 3 4
V V
V V
A B A B
4.7K
1 2
321
3=RED2=BRN1=BLK
CORE
SHEI
LD
1 2 3
4.7K
7 PI
N P
LUG
1 2 3 4 5 6 7 8 X1
1 2 3 4 5 6 7
V V V V V V
A B C D E FA B C D E FV V V V V V
1 2 3 4 5 6 7
1 2 3 4 5 6 7
1 3 5X3
+ 24
VSI
G.
GN
D
ANGLETRANSDUCER
1 3 5X4
7 8X2
CORE
SHEILD
RT865BXL (BCS)DS350 Graphic Modular
Cable Reel to Fly Section
A
30.2
LMI -
CR
ANE
INTE
RFA
CE
23 -
PIN
PLU
GS/
S H
ARN
ESS
23 -
SOC
KET
REC
EPT
4 5 6 7 8 9
TELE
EXT
END
PR
ESSU
RE
SW.
TELE
RET
RA
CT
PRES
SUR
E SW
.
HIG
H =
AUT
O M
OD
E / N
ON
E =
MA
NU
AL M
OD
E
OM
/ FL
Y TE
LE
CM
TEL
E
IM T
ELE
A A
B B
C C
D D E E
F F
G G H H J J
K K L L
M M
N N
O O P P
Q Q R R S S
T T
U U V V
W W X X
71H
51AK
387A
388
239B
242B
243B
244B
323A
238A
1083
255A
257A
+ 24
VG
ND
TELE
OUT
OF
SEQ
UEN
CE
TELE
PRO
P. A
NA
LOG
GN
D.
TELE
RO
D D
RA
IN S
OLE
NO
ID
TELE
EXT
END
PR
OP.
SO
LEN
OID
TELE
RET
RA
CT
PRO
P. S
OLE
NO
ID
15 16 17 18131 2
K2
CO
M (
+24V
)K
2 N
O (
+24V
TO
IM 2
-WAY
SO
LS. )
K
3 C
OM
( +2
4V )
K3
NO
( +2
4V T
ELE
RO
D D
RAI
N S
OL.
)K
3 N
C
K4
CO
M
K4
NO
K4
NC
( TE
LE O
UT
OF
SEQ
UEN
CE
)
K5
CO
M
K5
NO
( PR
OP
EXT
)
K5
NC
( PR
OP
RET
)
K6
CO
M (
+ 24
V )
K6
NO
( +2
4V T
O C
M 2
-WAY
SO
LS. )
K6
NC
K7
CO
M (
+24V
)
K7
NO
( +2
4V T
O O
M 2
-WAY
SO
LS. )
K7
NC
ANAL
OG
INPU
T 1
(IM L
EN.)
ANAL
OG
INPU
T 2
(CM
LEN
.)
X1 26 28 29 31 33 30 32 34 36 38 40 42 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 25 64 63 27 41 39 37 35
+24V
GN
D
DI 1
( +2
4V =
TEL
E EX
T. P
RES
S. S
W. )
DI 2
( +2
4V =
TEL
E R
ET. P
RES
S. S
W. )
DI 3
( +2
4V =
AU
TO M
OD
E )
DI 1
GN
D
DI 2
GN
D
DI 3
GN
D
DI 4
GN
D
DI 5
GN
D
DI 6
GN
D
DI 7
GN
D
DI 7
( +2
4V =
IM %
RES
ET )
DI 6
( +2
4V =
IM R
ET )
DI 5
( +2
4V =
CM
RET
& %
RES
ET )
DI 4
( +2
4V =
OM
/ FL
Y R
ET )
+ 24
V
GN
D
3 5 9 10
3 5 8 9 117 10 12 14 1 4 2 13
8 11 13 14 4 1 2 6 7 12
1 2 4 5 6 10 11 12 14 3 9 16 13 17 18 8 7 15
4 3 2 1 A104X1
PV EXTENSION
= WIRES AREGROUPEDTOGETHER
1 2 3 4 5 6 7 8 9 10 11 12 13 14
V V V V V V V V V V V V V V
A B C D E F G H J K L M N P
14 - SOCKET PLUG
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
V V V V V V V V V V V V V V
19 - SOCKET PLUG
VV V V V
A101
RT865BXL (BCS)BUS EXTENSION WIRING DIAGRAM
1 OUTER SHIELD GROUNDED AT STRAINRELIEF CONNECTOR.
2 INNER SHIELD CUT AND INSULATED
NOTES:
1
2
1
2
1
2
1
21
B
C(See Page 36.4)
(See Page 36.4)
30.3
14
F
AG
ND
SIG
.-5
V
LENGTHTRANS.
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10 11 12 13 14
V V V V V V V V V V V V V V
A B C D E F G H J K L M N P
14 - SOCKET PLUG
B
A B C D E F G H J K L M N P
1 2 3 4 5 6 7 8 S 11 12 13 14 15 16 17 18 19
1 3 5
BR
NR
EDO
RG
YEL
GR
NB
LUV
IOG
RA
WH
T
BLK
WH
T/B
LK
1 2 3 4 5 6 7 8 9 10 11
1 2 3 4 5 6 7 8 9 10 11 12
BRN
RED
OR
GY
ELG
RN
BLU
VIO
GR
AW
HT
BLK
WH
T/B
LK
SHD W
HT
BR
NG
RN
CR
EB
LKR
ED PNK
YEL BLU
VIO GR
A
LENG
TH LG
321 (TO IM
)
D
7 8 11 12 13 14 15 16 17 18 19X2X3X1
1 2 3 6 7 12 4 9 10 5 8 11 134231
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10 11 12 13 14
V V V V V V V V V V V V V V
A B C D E F G H J K L M N P R S T U V
19 - SOCKET PLUG
C
A B C D E F G H J K L M N P R S T U V
14
AG
ND
SIG
.-5
V
LENGTHTRANS.
1 2 3 4 5 6 7 8 S 11 12 13 14 15 16 17 18 19
1 3 5
BR
NR
EDO
RG
YEL
GR
NB
LUV
IOG
RA
WH
T
BLK
WH
T/B
LK
1 2 3 4 5 6 7 8 9 10 11
1 2 3 4 5 6 7 8 9 10 11 12
BRN
RED
OR
GY
ELG
RN
BLU
VIO
GR
AW
HT
BLK
WH
T/B
LK
SHD W
HT
BR
NG
RN
CR
EB
LKR
ED PNK
YEL BLU
VIO GR
A
LENG
TH LG
321 (TO C
M)
E
7 8 11 12 13 14 15 16 17 18 19X2X3X1
1 2 3 6 7124 9 1058 11 13
RT865BXL (BCS)DS350 Graphic Modular
Cable Reels to IM & CM Section
30.4
WHT
WHT
BRN
BLK
BLUBLKBRN
WHT
RED 1
BLK 1
GRN 1
WHT 1
E
123456789
1011
VIOYELPNKREDBLKGRABLUCRESHD
WHTBRNGRN
BLUBLKBRN
WHT
TIE WRAPUSED TO IDENTIFY CABLE
RED
BLK
GRN
WHT
RED 1 = CM CYL (+)RED = CM PILOT (+)BLK 1 = OM CYL (+)BLK = OM PILOT (+)GRN 1 = CM CYL (-)GRN = CM PILOT (-)WHT 1= OM CYL (-)WHT = OM PILOT (-)
IS
1234
567
SHDWHTBRNGRN
REDYELBLUVIOGRABLKCREPNK
DBRNBLKWHTBLU
1423
IS
IS
(+)NONC(-)
OO
OO
REDBLKGRNWHT
RED = IM CYL (+)BLK = IM PILOT (+)GRN = IM CYL (-)WHT = IM PILOT (-)
JUNCTION BOX (IM)
PROXY SW 4(CM RETR)
BRNBLKWHTBLU
1423
IS
(+)NONC(-)
OO
OO
PROXY SW 1(OM/FLY RETR)
JUNCTION BOX (CM)
654321
3
42
1
BRNBLKWHTBLU
1423
IS
(+)NONC(-)
OO
OO
PROXY SW 3 (TOP)(IM % RESET)
F
BRNBLKWHTBLU
1423
IS
(+)NONC(-)
OO
OO
PROXY SW 2 (BOTTOM)(IM RETR. 2-POSITIONS)
BLU
BLK
BRN
BLU
JUNCTION BOXBOOM BASE
RT865BXL (BCS)DS350 Graphic Modular
Wiring to Proximity Switches
30.5
MANUAL
SECTION 31
DS 350 Graphic Modular (BCS)Service Bulletins &
Miscellaneous Information
P.A.T. – L.M.I
ERROR-E80-E85-E2D
E80 - Slewing pot out of range. E85 - This code has only been seen on the Modular Boom Control System. The error pertains to the internal calculation of radius ( not the displayed radius ). The displayed radius is calculated from the boom length and signals received from the upper cable reel to the C.U. in the cab. The other two length signals as well as all proximity switches inputs are received by the bus extension located on the left turntable upright behind the cab. The bus extension has it’s own processor which performs calculations and transmits data to the processor in the C.U. 1. Negative load display due to the velocity fuse in the piston side transducer port of the lift cylinder. A. The system sees a - 3,000 lb. load display and thinks that the boom must be deflecting backward. This confuses the processor when performing it’s internal calculation of radius. 2. Water in cannon connections located under the base boom. There are two fourteen conductor and one seven conductor cables running to the cable reels on the left side of the base boom section. A. Found water in these connectors which caused length and percentage problems. B. Found twisted wires, pinched wires and in general poor assembly from PAT. Some symptoms of water add poor assembly are that the bus extension may receive low voltage such as +2 volt input for a proximity switch .when the boom is extended. At this time you should see 0 volts and of course when any of the proximity switches see their target you should see 24 volt to the input. When the bus extension processor sees any voltage from these inputs when the sections are extended, the processor gets confused and shows E85. Also the lower two reels length signals may check okay at the reel, but through these connectors the signal changes until the signal reaches the bus extension.
3. On other cause that was found for the E85 is a bad eprom module. There is a small serial eprom ( located in the C.U. ) which contains some calibration factors which are used for calibration purposes. Sometimes this serial eprom loses it’s memory and causes the E85. In this case you must replace the eprom module. The Grove part number is 9-333-103289.
E2D - This is an error in the processor board located inside the bus extension box located behind the cab (top left board ) At this time there is no troubleshooting procedure for this board. The board must be replaced to correct this error. The Grove part number is 9-333-103718.
P.A.T. – L.M.IMANUAL
SECTION 32
iFLEX5 SERVICE INFORMATION
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 9333103876.
WARNINGS The LMI is an operational aid that warns a crane operator of approaching overload conditions and 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 the operator’s manual.
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.
Americas Training Grove 32-1iFLEX 5
DESCRIPTION OF THE SYSTEM The iFLEX5 system is a CAN bus system made up of a central microprocessor unit, operating console, length/angle sensor, pressure transducers, and anti-two block switches. All components and sensors are equipped with CAN bus controllers. The PAT 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 microprocessor. 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 chips in the central processor unit. This data is the reference information used to calculate the operating conditions. Boom length and boom angle are registered by the length/angle sensor, mounted inside the cable reel, which is mounted on the boom. The boom length is measured by the cable reel cable, which also serves as an electrical conductor for the anti two-block switches. The crane load is measured by pressure transducer block attached to the piston and rod side of the hoist cylinders. The interactive user guidance considerably simplifies the input of operating modes as well as the setting of geometry limit values.
Americas Training Grove 32-2iFLEX 5
DESCRIPTION OF THE SYSTEM COMPONENTS Pressure Transducer : The pressure transducer transforms hydraulic pressure into an electric signal. A pressure transducer block houses two transducers, CAN bus controller, and two bus connectors. One pressure transducer is connected to the piston side of the lift cylinder and the other to the rod side. The Length-Angle Transducer: The length-angle sensor (LWG), often referred to as the “cable reel”, is a combination of two transducers in one box, installed at the base section of the boom. It measures the length and the angle of the boom.
A reeling drum drives a potentiometer, which is the length transducer. Part of the length transducer circuit is the length cable on the drum, which is a two-conductor cable (screen and live). It is connected to the anti-two-block switch at the boom head and to a slip ring body in the LWG. The angle transducer is a potentiometer driven by a weighted pendulum that is oil damped. Both length and angle transducer are connected to a CAN bus controller board, which is connected to the bus. 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 hook 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 hook block strikes it. Console: The graphic console displays all geometrical information such as length and angle of main boom, working radius and head height of the boom. It also displays the actual load and the maximum load permitted by load chart. Furthermore, it has an alarm horn, a warning light for overload, and a pre-warning light. The graphic display allows for a simple interactive configuration setup, as well as sensor calibration (zero adjustment), and troubleshooting sensor output screen. The console has a warning light for anti-two-block conditions and an override switch for overload or anti-block condition. Central Unit: Inside the central unit there is a CPU and connection board. The board has a hard mounted connector for power, ground, bus controller, and slew indication. The board has a green LED, indicating relay energized and a communication LED that flashes through red, yellow, and green colors.
Americas Training Grove 32-3iFLEX 5
WHAT’S WRONG? 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 SLEWING DOES NOT MATCH THE ACTUAL SLEWING ANGLE Refer to section Slewing Sensing to check the slew sensor. 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 central unit, or the console itself. Refer to section No console display for further troubleshooting. I HAVE AN A2B PROBLEM Please go to sectionA2B 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!
Americas Training Grove 32-4iFLEX 5
ANGLE SENSING The System measures the angle of the main boom of the machine with an angle sensor. The angle sensor is contained within the cable reel, 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 cable reel. 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 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 cable reel and locate the angle sensor (right) and the CAN-Bus converter board (left):
Pressure Transducer
iFLEX5
CU
Angle
Sensor
CAN-Bus Converter
Cable Reel
Americas Training Grove 32-5iFLEX 5
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 GND 2 Signal 3 +5V Verify that the sensor is being supplied with 5V by measuring between pin 1 (GND) and Pin 3 (+) 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:
X14 (A2B)
X21 (angle)
X1 (CAN)
X20 (length)
LED
Americas Training Grove 32-6iFLEX 5
The angle sensor returns a voltage between 1.875V at 90 degrees and 3.125V at 0 degrees: Angle Sensor Signal on Pin 2 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 1 (GND) and Pin 2 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.
Americas Training Grove 32-7iFLEX 5
LENGTH SENSING 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 on the left side of the main boom. Block Diagram
The signal runs
from the length sensor to the CAN-Bus
converter board, both located in the cable reel. 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 5-8 turns of pre-loading on the reel. Opening the cable reel and locate the length sensor (right) and the CAN-Bus converter board (left):
Pressure Transducer
iFLEX5
CU
Cable Reel
Length Sensor
CAN-Bus Converter
Americas Training Grove 32-8iFLEX 5
Fully retract the boom and turn the screw of the length potentiometer with a small screwdriver counter clockwise to a soft stop. That should bring the sensor voltage to 0V (+/- 0.1Volt). Measure voltage between Pin 5 (-) and Pin 3 of Terminal X20 and compare.
Go back to your indication screen and compare length indicated and actual 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 also be in the software or in the converter board.
CAN-Bus electronics in cable reel.
X14 (A2B)
X21
X1 (CAN)
X20 (length)
LED
Potentiometer
Gear wheel with slip clutch
Americas Training Grove 32-9iFLEX 5
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: 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 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. For the boom control system, the length sensors are the same as described above with the exception of cable reel internals (location of hardware, wiring, and gear wheels). Refer to the LWG520 and LG152 spare part list for these differences.
Americas Training Grove 32-10iFLEX 5
PRESSURE SENSING The System measures the pressure of the boom lift cylinder for both rod- and piston-side. Both sensors are contained within one box that also contains the electronics needed for amplification and creation of the CAN-Bus signal. Block Diagram:
The signal runs from the pressure transducer as digital information on the CAN-Bus to the central unit.
So, what do you do when you are having a problem with your length read-out? Start by checking the pressure display. Refer to the section “Troubleshooting A Sensor Problem Using The Display” to call up the sensor signal on your console display. The easiest spot to check the signal at is when there is no pressure applied to the sensor at all. The only time this is for certain is when your pressure lines are drained and disconnected. In that case, the readout should show about 500mV (+/- 25mV) and 0 PSI. Small variations could be adjusted; see section Service Screen For Sensor Calibration. The CAN-Bus is digital and as such will either transmit the signal correctly or not at all. If your readings are off, chances are the pressure transducer is defective. Replace. Note: After exchanging the pressure transducer block, BOTH transducer channels need to be zeroed, see procedure Zero-Setting The Transducer Inputs.
iFLEX5
CU
Pressure Transducer
(2) Pressure- Measuring
Cells
CAN-Bus Converter
Americas Training Grove 32-11iFLEX 5
8 SLEWING SENSING The system measures the slewing (rotational position) of the crane’s upper with a slewing sensor. The slewing sensor is contained within the slip ring assembly. Block Diagram
The slew potentiometer has two potentiometers built in that are driven by the slip ring axle. As the slewing angle changes, so will the axle and with it the potentiometer’s outputs. Use the display screen by pressing ‘i’ (info) twice to show all sensor inputs. The table to the right show measured millivolt reading for the slew potentiotmeter.
0
500
1000
1500
2000
2500
3000
3500
4000
0 45 90 135 180 225 270 315 360
SLEW ANGLE
MIL
LIV
OLTS
Potentiometer 1
Potentiometer 2
0 45 90 135 180 -135 -90 -45 0
ANGLE (deg)
SL ANG 1 (mv)
SL ANG 2 (mv)
0 717 2161 30.3 1174 2645 60 1680 3150
89.9 2158 3595 120.1 2641 3141 150.1 3144 2639 180 3595 2161
-150.1 3144 1681 -120.1 2642 1180
-90 2160 718 -60.1 1681 1168 -30 1172 1680 0 718 2161
iFLEX5
CU
Slip Ring Assembly
Slew Potentiometer with (2)
outputs
Current
Converter
Modular Slew Pot - Voltage on Service Screen
Display screen for sensor inputs
Americas Training Grove 32-12iFLEX 5
The converter board is supplied with 12V from the central unit. The potentiometer and the board output two signals between 4 and 20mA that go to the central unit. You can measure them at the 12-pin crane interface connector. Start by making sure that the slew pot unit is supplied with crane voltage. Pin 7 must carry crane voltage and pin 2 is GND. The slew unit’s output can be found on pins 8 and 9. In order to measure the current, however, you have to disconnect a pin and measure in line with it (measuring meter in between the cable from the slew unit and the central unit). The two outputs will vary as shown in this chart:
Modular Slew Pot - Output Currents
0
4
8
12
16
20
24
0 90 180 270 360
Degrees
mA
mA 2
mA 3
(when the crane is over front, you should see about 4mA in one channel (wire #2) and 12mA in the other channel (wire #3)). Alternatively, you can also leave the wires connected and use your meter in Voltage-mode to measure the output signals. In that case, you will see the 4…20mA signal range as a 1.1 to 5.5Volt range. In that case, refer to the following chart: If the voltage or currents do not fall in line with the charts and tables shown here, and no system errors are present, the problem may be a mechanical. Open the slip ring unit and find out if the slew potentiometer is set correctly.
9 LOAD SENSING Please note that the load displayed by the LMI is not a direct measurement, but a calculated value that is based on a lot of factors. Outside of the measured values (sensors), those include:
• Operator settings such as: o Operating mode/configuration o Parts of Line/Reeving
• Rigging parts such as: • Hookblock weight • Sling weights, etc. • Tip height (length of load line used) • Boom weights • Boom attachments such as
Americas Training Grove 32-13iFLEX 5
NO CONSOLE DISPLAY If the console is not showing any lights, such as warning lights, backlighting, etc. it is most likely missing power. Start with the following: Next, check if power is being supplied by the central unit. Measure on the green connector. Pin 1 is +Ub (12V), Pin 2 is GND. If you have no power, check wiring harness and central unit. Otherwise, open console: Check fuses in console: one (F6) is located the connection board (mounted to the inside of the housing) which protects the override key switch function and the bargraph. The main fuse (F1) is located on the console processor board. If both fuses are fine, check for power on connector X6 on the connection board (Pin 1 = +Ub, Pin 2 = GND). If you have no power there (but you had power on the external connector), most likely the connection board is defective and needs to be replaced. If you have power on this connector, follow it to the console computer board, connector X1. Again, Pin 1 = +Ub and Pin 2 = GND. If you have no power there, the connecting cable must be defective or loose. If you still have power there, check fuse F1 again. Next, make sure all connectors are correctly in place: Connection board Computer board Pins X6 X1 4 X10 X22 6 X7 X2 10 Especially verify that the X10-X22 connection is right, since it could be plugged into X17 by mistake Check TxD LED is on. This LED is located in the center of the computer board and is normally blinking when the console is communicating. If you find voltage on all pins outlined and all connectors are in place, but you still do not get any light to come up (during power-up especially!), either the software is defective or the console electronic needs to be replaced.
Americas Training Grove 32-14iFLEX 5
A2B PROBLEM
First, perform the following operations: Are the control levers locked out and is the crane in an anti-two block condition?
YES, Lower the hook block and/or headache ball to correct two-block condition. If two (2) hoists are in use, both hooks must be lowered.
Is the anti-two block warning light on? Check Bypass plug installed, if not plug appropriate bypass plug into socket of junction box. Is the Bypass plug installed and the anti-two block warning light on? Turn power off, remove the bypass plug, and measure the resistance at the boom nose box between terminals 1 and 3 with an ohmmeter. This checks the function of the Anti-Two Block switch. Switch closed = 0Ohms (weight installed); Switch open => 1 Megaohm (weight removed) Ohmmeter reading are correct?
YES, Plug the bypass plug into the boom nose box and refer to system wiring to check wire connections in boom nose box. If wiring is correct, replace Anti-Two-Block switch.
Ensure the bypass plug is plugged into the boom nose box. Measure the A2B signal in the cable reel between X1:Brown and X2:Red wires on the slip ring with an ohmmeter. Switch closed =4700 ±500Ohms; Switch open => 1 Megaohm. Ohmmeter readings are correct?
NO, Check for damaged length cable and wiring. If broken length cable, refer to system wiring. Measure the A2B signal in the cable reel between terminal 7 and 8 with an ohmmeter. Switch closed =4700 ±500Ohms; Switch open => 1 Megaohm. Ohmmeter readings are correct?
NO, Replace slip ring Problem with wiring harness, cable reel length/angle board, and/or central unit.
Americas Training Grove 32-15iFLEX 5
CAN-BUS COMMUNICATION The System measures the length of the main boom, the angle of the main boom, the pressures of the lift cylinder, and the A2B state of the machine via a CAN-Bus connection. Since this is a digital bus connection, it is not possible to measure the signals on the bus with a multimeter. Instead, the LMI provides you with error codes that give you an indication of the bus state. The error codes are one of the following: E61 Error in the CAN bus data transfer for all CAN units E62 Error in the can bus data transfer of the pressure transducer sensor unit E63 Error in the can bus pressure transducer sensor unit E64 Error in the can bus data transfer of the length/angle sensor unit E65 Error in the can bus length/angle sensor unit Block Diagram The block diagram tries to clarify that: If the CU does not see any CAN-Bus component, it will report an E61. If it sees only the cable reel, it will report an E62 (pressure transducer missing). If it sees only the pressure transducer, it will report an E64 (cable reel missing). E63 means that the pressure transducer is available, but is reporting an internal error. E65 means that the cable reel unit is available, but is reporting an internal error. So, what do you do when you are having a problem with one of those codes? E61 In case of an E61, start by checking your cabling. You can verify that power is being supplied to the sensor by testing the CAN connectors per this layout: Connector M12, 5 contacts
Pin Layout (CiA DR-303-1 7.2)
Pin 1 Shield Pin 2 + Ub Pin 3 Ground Pin 4 CAN High Pin 5 CAN Low
Measure between pins 3 and 2 for crane voltage. If you see voltage, check all pins for continuity. Remember, the CU is reporting that neither cable reel nor pressure transducers are present.
Pressure Transducer
E63
iFLEX5
CU
Cable Reel
CAN-Bus Converter E65 E64 E61
E62
Americas Training Grove 32-16iFLEX 5
E62 In case of an E62 the CU is reporting no signal from the pressure transducer. Start by checking your cabling between CU and pressure transducer, even though it is not very likely that there is a problem with it since the same cable carries also the signals from the cable reel and those appear to be fine. You can verify that power is being supplied to the sensor by testing the CAN connectors per the above pin layout. If you are sure that the sensor is being supplied, you have to replace the pressure transducer. E63 In case of an E63, the pressure transducer is reporting an internal problem. You cannot troubleshoot any further, but need to replace the pressure transducer. E64 In case of an E64, the CU is reporting no signal from the cable reel unit. Start by checking your cabling between pressure transducer and cable reel. You can verify that power is being supplied to the sensor by testing the CAN connectors per the above pin layout or by opening up the cable reel (remove the lid) and making sure the red LED on the board is blinking.
CAN-Bus electronics in cable reel. If it is not, most likely power is missing. Verify by measurement on connector X1:
X14 (A2B)
X21
X1 (CAN)
X20
LE
Americas Training Grove 32-17iFLEX 5
X1 Pin CAN
1 CAN_SHLD1 2 CAN +UB 3 CAN GND 4 CAN_H 5 CAN_L
Measure between pins 3 (GND) and 2 (+). Next, check all pins of the CAN bus cable for continuity and cross-check for short circuits. E-64 means that the pressure transducer is working fine, but the cable reel is not – so we most likely have a defective connection between those two components. If this is tested to not be the case (missing connections, short circuits – measure with Ohm-meter), the board in the cable reel might be defective (see also chapter Angle Sensing). E65 In case of an E65, the cable reel is reporting an internal problem. In most cases, this will be an angle sensor, length potentiometer or A2B wiring. Go to those chapters (Angle Sensing, Length Sensing, A2B PROBLEM) to continue trouble shooting. BRIEF DESCRIPTION OF A CAN BUS SYSTEM CAN stands for “Controller Area Network”. Its intended use is as a serial bus system for a network of controllers. Each controller connected through a CAN chip is called a "node" and is mostly used to acquire data from a sensor. All nodes are connected to a common bus and all nodes are able to simultaneously read the data on that bus. Also, all nodes are able to transmit data on that bus however only one node at a given time has write access to the bus. If the message is relevant, it will be processed; otherwise it is ignored. The unique identifier also determines the priority of the message. The lower the numerical value of the identifier, the higher the priority. The cable bus is a twisted pair of shielded wire. Data can be transmitted in blocks from 0-8 bytes at a maximum transfer rate of 1 Mbit/s for networks up to 40 mtrs. For longer network distances the maximum transfer rate must be reduced to 50 Kbit/s for a 1 km network distance. CAN will operate in extremely harsh environments and the extensive error checking mechanisms ensure that any transmission errors are detected.
Americas Training Grove 32-18iFLEX 5
P.A.T. – L.M.IMANUAL
SECTION 33
TROUBLESHOOTING a SENSOR PROBLEM USING
the DISPLAY
Troubleshooting A Sensor Problem Using The Display
TROUBLESHOOTING A SENSOR PROBLEM USING THE DISPLAY To determine whether there is a problem with a sensor, the iFLEX5 system has “sensor output screen” built in to make trouble-shooting easier. This is the right place to start if you are suspecting a problem with a sensor (and you don’t have an error code displayed). To access the sensor output screen, press the “INFO” button twice 10
.
10
to review software version information, press the “INFO” button once
.
10
To EXIT the sensor output screen, press the “INFO” button once from the software version screen to return to the operating screen
.
10
The screen will show all sensor inputs as in the example below. For each sensor, an equivalent voltage is shown in millivolts, along with the physical sensor value that that voltage refers to. Pressure sensors are shown with physical values of [bar], angle sensors and slew sensors in degrees and length sensors in feet (or meter for metric charts). At the bottom of the screen, the console software version is shown.
10
The values shown in the screen here are just examples of actual values. Refer to the table listed below for actual value ranges. If you suspect a sensor error or problem with a sensor, compare the indicated physical value of the sensor on the display screen with the real value, i.e. length, angle, etc.
Press “INFO” To review software version information
Americas Training Grove 33-1iFLEX 5
The voltages given are internal calculation values only; you will not be able to actually measure them anywhere on the electronics! Typical values to be expected are:
• Pressure transducers (piston and rod), 500mV @ 0 PSI; 4500mV @ maximum PSI • Length sensor, 500mV @ retracted boom length; voltage extended depends on the various
boom lengths. • Angle sensor, 4500mV at 0°; 2500mV at 45°; or 500mV at 90°
Please refer to table below for more values. Voltage Values displayed [mV] +/- 10mV
Value displayed Value
Pressure Transducers 300 bar, type 314 PSI Bar
500 0 0 1500 1088 75 2500 2176 150 3500 3263 225 4500 4351 300
Angle Sensor degrees
500 90 boom vertical 1500 67.5 2500 45 3500 22.5 4500 0 boom horizontal
Length Sensor feet
500 0 fully retracted 1500 2500 3500 4500
If the displayed value does differ from the actual value, please refer to the following sections to find the cause of the problem: If the displayed angle is incorrect, please go to section Angle Sensing. If the displayed length is incorrect, please go to section Length Sensing If the displayed pressures are incorrect, please go to section Pressure Sensing
Americas Training Grove 33-2iFLEX 5
Troubleshooting A Sensor Problem Using The Display
SLEW POT SIGNALS:
Reference Angle Sig 1 (mA) ±0.03mA
Sig 2 (mA) ±0.03mA
0° 4.00 12.00 45° 8.00 16.00 90° 12.00 20.00 135° 16.00 16.00 180° 20.00 12.00 -135° 16.00 8.00 -90° 12.00 4.00 -45° 8.00 8.00 If the displayed angle is incorrect, please go to section Slewing Sensing
Americas Training Grove 33-3iFLEX 5
DRAWINGS COMPONENTS OF THE LMI SYSTEM PAT IFLEX5
1 Central-Micro-Processor Unit2 Operating Console3 Pressure Transducers4 Length/Angle Sensor5 Anti Two-Block Switch(es)
POWERLOCKOUT
OTHER
PAT
Americas Training Grove 33-4iFLEX 5
BLOCK DIAGRAM
CAN-BUS
RS 485 Serial
Interface
Current 4..20mA
CAN-connector
iflex5 Central Unit
Dual Pressure
Graphic Console
Length/Angle Sensor A2B
Slew Sensor
70 pin Connector
Crane Power
CAN-connector
CAN-connector
Lockout
Americas Training Grove 33-5iFLEX 5
ELECTRICAL SYSTEM DIAGRAM STANDARD SYSTEM Central Unit to Crane and Console Wiring Diagram
Americas Training Grove 33-6iFLEX 5
Cable Reel (length/angle sensor) Wiring Diagram
Americas Training Grove 33-7iFLEX 5
Boom Extension Anti-two Block Wiring Diagram
MAIN CENTRAL UNIT CONNECTOR This is a 70 pass connector.
Americas Training Grove 33-8iFLEX 5
ELECTRICAL SYSTEM DIAGRAM BOOM CONTROL SYSTEM Central Unit to Crane Interface Wiring Diagram
Am
eric
as T
rain
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1
Americas Training Grove 33-9iFLEX 5
Console and Sensor Wiring Diagram
BOOM BASE CONNECTIONTO LG152/0056REFER TO CABLE REEL (LG152/0056) WIRING DIAGRAM
TO LWG520/0002REFER TO CABLE REEL (LWG520/0002) WIRING DIAGRAM
Americas Training Grove 33-10iFLEX 5
Cable Reel (LG152/0056) Wiring Diagram TO BOOM BASE CONNECTORREFER TO CONSOLE AND SENSOR WIRING DIAGRAM
TO LWG520/0002REFER TO CABLE REEL LWG520/0002 WIRING DIAGRAM
Americas Training Grove 33-11iFLEX 5
Cable Reel (LWG520/0002) Wiring Diagram
LUFF
ING
JIB
CO
NN
ECTI
ON
REF
ER T
O L
UFF
ING
EXT
ENSI
ON
W
IRIN
G D
IAG
RAM
TO LG152/0056REFER TO CABLE REEL (LG152/0056) WIRING DIAGRAM
TO PRESSURE TRANSDUCER BLOCKREFER TO CONSOLE AND SENSOR WIRING DIAGRAM
Americas Training Grove 33-12iFLEX 5
Luffer Extension Wiring Diagram
BOOM TIP CONNECTIONTO LWG520/0002REFER TO CABLE REEL (LWG520/0002) WIRING DIAGRAM
Americas Training Grove 33-13iFLEX 5
SPARE PART LISTINGS CENTRAL UNIT, IFLEX5 PART NO. 9333103866 NO. PART NO. QTY DESCRIPTION 1 9333103890 1 CENTRAL UNIT ACCY, GROUNDING KIT 2 9333103891 1 BATTERY, LITHIUM 3V 3 9333102541 1 KEY SWITCH 4* 9333103908 1 CENTRAL UNIT COVER iFLEX 5* 9333101978 1 SCREW SET 6* 9333103058 1 SPARE KEY 7 9333101591 42” GASKET * ITEM NOT SHOWN
1 2
3
7
Americas Training Grove 33-14iFLEX 5
Spare Part Listings
GRAPHIC CONSOLE ASSY, VERTICAL PART NO. 9333103868 NO. PART NO. QTY DESCRIPTION 1 9333101691 1 SPARE KEY, GRAPHIC CONSOLE 2 9333103895 1 KEYSWITCH, WITH CABLE 3 9333103892 1 FRONTFACE WITH DISPLAY, COMPUTER BOARDS, AND
LED BOARDS 4 9333103893 1 CONNECTION BOARD WITH BUZZER 5 9333103894 1 FUSE, 2 AMP AUTO 6 9333103899 1 CABLE, 4 POL COMPUTER BRD X1 TO CONN BRD X6,X11 7 9333103900 1 CABLE, 10 POL COMPUTER BRD X2 TO CONN BRD X7 8 9333103901 1 CABLE, 6 POL COMPUTER BRD X10 TO CONN BRD X23 9 9333103902 1 5 LED BOARD, LMI/A2B ALARM LITE 10 9333103903 1 8 LED BOARD, LED’S BY SELECTION BUTTONS
1,2
3
5
4
2
3
6
7
8
9
10
Americas Training Grove 33-15iFLEX 5
CABLE REEL, LWG508 PART NO. 9333103873 NO. PART NO. QTY DESCRIPTION 1 NSS 1 CABLE REEL ACCY, LWG508 DRUM BODY W/LENGTH CABLE 2 9333102986 139’ LENGTH SENSOR CABLE 3 9333103896 1 BOARD, LENGTH AND ANGLE OUTPUT 4 9333103897 1 LENGTH POTENTIOMETER LWG508 5 9333103898 1 ANGLE SENSOR, WG143/09 6 9333103904 1 SLIP RING ASSEMBLY 2 CONDUCTOR 7* 9333103905 1 25T GEAR WHEEL 8 9333101625 1 75T GEAR WHEEL 9* 9333103906 1 CONNECTOR, 5 POLE W/WIRES 10* 9333103907 1 LID, BLACK 11* 9333101565 1 CABLE REEL ACCY, GASKET FOR COVER 12* 9333101566 10 CABLE REEL ACCY, SCREW/CAPTIVE * ITEM NOT SHOWN
Also see detail on next page.
4
7
3 2
5 8
6
1
9
Americas Training Grove 33-16iFLEX 5
Spare Part Listings
3
4
5 6
8
Americas Training Grove 33-17iFLEX 5
CABLE REEL, LWG520 PART NO. 9333103962 NO. PART NO. QTY DESCRIPTION 1 NSS 1 CABLE REEL ACCY, LWG520 DRUM BODY W/LENGTH CABLE 2* 9333103773 176’ LENGTH SENSOR CABLE 11 CORE 3* 9333103966 1 BOARD, 2 LENGTH AND ANGLE OUTPUT 4 9333103967 1 BOARD, FILTER 5 9333103897 1 LENGTH POTENTIOMETER LWG 6 9333103898 1 ANGLE SENSOR, WG143/09 7 9333102737 1 SLIP RING ASSEMBLY 11 CONDUCTOR 8* 9333103905 1 25T GEAR WHEEL 9 9333101780 1 90T GEAR WHEEL 10* 9333103906 1 CONNECTOR, 5 POLE W/WIRES 11* 9333103907 1 LID, BLACK 12* 9333101565 1 CABLE REEL ACCY, GASKET FOR COVER 13* 9333101566 10 CABLE REEL ACCY, SCREW/CAPTIVE * ITEM NOT SHOWN
4
2
6
7
1
5
10
9
3
Americas Training Grove 33-18iFLEX 5
Spare Part Listings
CABLE REEL, LWG152 PART NO. 9333103963 NO. PART NO. QTY DESCRIPTION 1 NSS 1 CABLE REEL ACCY, LG152 DRUM BODY W/LENGTH CABLE 2* 9333103775 87’ LENGTH SENSOR CABLE 3 CORE 3 9333101557 1 TERMINAL STRIP 4* 9333103967 1 BOARD, FILTER 5 9333103897 1 LENGTH POTENTIOMETER LWG 6 9333103756 1 SLIP RING ASSEMBLY 4 CONDUCTOR 7 9333103758 1 55T GEAR WHEEL ON POTENTIOMETER 8 9333103757 1 45T GEAR WHEEL ON CENTER SHAFT 9 9333102902 4 HARDWARE, STANDOFF 6MM X 117MM MM 10* 9333101965 1 HARDWARE, GASKET 11* 9333103762 1 SENSOR ACCY, COVER KT152 12* 9333101964 1 SENSOR ACCY, NUTS (4) & WASHER (4) FOR KT152 COVER 13 9333103968 1 CABLE ASSEMBLY, 2.5m * ITEM NOT SHOWN
7 13
3
2
1
5
9 6
8
Americas Training Grove 33-19iFLEX 5
PRESSURE TRANSDUCER BLOCK, DAV314/0014 PART NO. 9333103870
CABLE ASSEMBLY 11M, PART NO. 9333103872
WIRING HARNESS STANDARD, PART NO. 9333103869
Americas Training Grove 33-20iFLEX 5
Spare Part Listings
WIRING HARNESS BOOM CONTROL, PART NO. 9333103911 6 Cables for:
1. Console 2. Crane interface 7 conductors 3. Crane interface 24 conductors 4. LG152 cable reel 5. CAN bus cable 6. Optional radio wind speed receiver
CABLE ASSEMBLY, 14M PART NO. 9333103916
Americas Training Grove 33-21iFLEX 5
P.A.T. – L.M.IMANUAL
SECTION 34
SERVICE SCREEN for SENSOR CALIBRATION
SERVICE SCREEN FOR SENSOR CALIBRATION ACTIVATING THE SERVICE SCREEN FOR SENSOR CALIBRATION To activate the service screen and sensor calibration function, press the INFO key on the console to activate the INFO Function. Now press the CTRL key.
10
.
11
At this point, a five digit Authorization Number must be entered. Only authorized personnel may adjust the zero-point settings. Use the “>” key to switch between digits; use the “+” and “-“ keys to increase and decrease each digit. Use the enter key to confirm entry.
Americas Training Grove 34-1iFLEX 5
Service Screen For Sensor Calibration
Now, having successfully entered a valid password, the piston-side zero-point setting function is activated. The ESC key will allow you to leave the sensor calibration function. The return key toggles between the piston-side, the rod-side zero setting, and length, and angle calibration.
This is the rod pressure adjustment screen. The ESC key will allow you to leave the sensor calibration function. The return key toggles between the piston-side, the rod-side zero setting, and length, and angle calibration.
The return key toggles between the piston-side, the rod-side zero setting, and length, and angle calibration. When the sensor calibration is finished, pressing the ESC or INFO key returns the console display to normal.
Americas Training Grove 34-2iFLEX 5
ZERO-SETTING THE TRANSDUCER INPUTS NOTE: The only thing adjustable for the pressure transducers is the zero point, which is the voltage the transducer outputs when there is no (zero) pressure sensed. CAUTION: Ensure there is no pressure in the hydraulic line when disconnecting the hoses from pressure transducers. The display shows which transducer (piston-side, rod-side or force) is being zeroed and a horizontal dial marks the present pressure (or force) difference in %. By pressing the + key, the input pressure (or force) is adjusted upwards, and by pressing the minus (-)key, the input value is adjusted downwards. When the plus (+) and minus (-) keys are pressed simultaneously, the zero setting occurs automatically. Manual adjustments may be preformed using + or -.
Americas Training Grove 34-3iFLEX 5
Service Screen For Sensor Calibration
LENGTH SENSOR CALIBRATION PROCEDURE NOTE: The length sensor can be calibrated for its zero point and its full range. This means, for the correct voltage for retracted boom and for the extended boom. With retracted boom, the potentiometer of the length sensor has to be at its 0 position, which is all the way counter-clockwise. For extended boom, the adjustment is done by software as described in 6 section Length Sensor Adjustment Procedure. The length should be calibrated to be about 0.1 feet (or 0.05m for metric) accurate for retracted and extended lengths. Perform the following steps: Fully retract the main boom and check if indicated length is within 0.1’ of actual retracted boom length. If it is not, adjust length potentiometer as described in 6.3.1. Afterwards always adjust retracted length by software as described in section Length Sensor Adjustment Procedure. Cable Reel LWG508 Adjustment Procedure
Now perform Length Sensor Adjustment Procedure as detailed in section Length Sensor Adjustment Procedure.
Americas Training Grove 34-4iFLEX 5
Length Sensor Adjustment Procedure See section Activating the Service Screen for Sensor Calibration on how to access the length sensor calibration screen. Select the length calibration by pressing “OK” at the “Calibrate Length” screen.
The screen will change now and show the picture to the right. Fully retract the main boom and verify the indicated boom length matches the retracted boom length of your crane. If incorrect, make sure you have adjusted the length pot in cable reel (see section Cable Reel LWG508 Adjustment Procedure.) Now, press the ‘OK’ button to calibrate retracted length. The indication will change to show your correct retracted boom length.
Now extend main boom all the way out. Make sure you are within the allowed operating range (especially maximum radius).
Americas Training Grove 34-5iFLEX 5
Service Screen For Sensor Calibration
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. Cut old cable at cable drum. 2. Disconnect damaged length cable from junction box at the boom nose. 3. Open cable reel cover and disconnect bus connector. 4. Remove cable reel from mounting brackets. 5. Remove damaged length cable, which is mounted to the slip rings in the cable reel, from slip ring
terminal. 6. On the backside of the cable reel, open the strain relief attached to the axle in the center of the
drum. Pull existing length cable out of the cable reel. 7. Pull new length cable through the hole, pipe and strain relief and push it through the axle of the
reeling drum. Tighten new strain relief to ensure sealing. 8. Reconnect the length cable to the slip ring. 9. Remount cable reel to the boom. 10. Turn reeling drum clockwise to spool the new cable neatly onto the drum. 11. Set pre-load on cable reel by turning the drum counter-clockwise 5 to 8 turns. 12. Run the new 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 into the boom tip junction box.
13. Connect the length cable into the boom tip junction box. 14. Reset length potentiometer in length angle transducer (screw is located in center of white gear);
with boom fully retracted, turn potentiometer carefully counter-clockwise until it stops. Recheck length and angle display. Refer to section Cable Reel LWG508 Adjustment Procedure.
15. Connect bus connector 16. Follow Length Sensor Adjustment Procedure.
Americas Training Grove 34-6iFLEX 5
ANGLE SENSOR CALIBRATION PROCEDURE Material required – calibrated inclinometer. See section Activating the Service Screen for Sensor Calibration on how to access the angle sensor calibration screen. Select the angle calibration by pressing “OK” at the calibrate angle screen.
With fully retracted main boom, boom down to a flat angle close to zero degrees, making sure you stay within the allowed operating range. Using the calibrated inclinometer placed flat on the main boom, verify that the indicated boom angle matches the measured boom angle within +/- 0.2 degrees. If not, mechanically adjust the angle sensor. The angle should be set to be +/-0.1 of the measured angle. Press “OK” when the sensor is mechanically set.
Americas Training Grove 34-7iFLEX 5
Service Screen For Sensor Calibration
Boom up to the next correction angle, 45 degrees (range is 40°- 50°). When the boom angle is within the calibration range, the screen will add the ‘CHANGE’, ‘SET” and ‘OK’ text as shown on the left. Measure the boom angle with the inclinometer and when the boom is positioned in the calibration range, compare the measured angle to the displayed angle. If the indicated angle is within +/- 0.1 degrees of the measured angle, confirm with “OK”. Otherwise, select “SET” to adjust the angle.
Once you push ‘SET’ , the screen is going to change to the angle adjustment screen. Use the ‘+’ and ‘-”buttons to adjust the indicated angle to match the measured angle. When the display shows the correct angle, press ‘OK’.
Repeat the above procedure to verify/set the angle at 60° (range 55°- 65°). and 70° (range 65°- 75°). boom angles. Press ESC to leave service screen.
Americas Training Grove 34-8iFLEX 5
ZERO-SETTING THE SLEW POTENTIOMETER NOTE: The only thing adjustable for the slew potentiometer is the zero point, which is complete when the boom is at the 0° position over the front of the crane. Defining the crane zero position: The zero setting consists of defining zero-point offset. To define the zero-point or the slew potentiometer the super structure must be positioned so the boom is in the zero degree position over the front and the house lock pin engaged. Using graphic console for zero-setting of slew pot potentiometer: Press return until the slew adjustment screen is displayed. The display shows a scale from –10 to +10 degree, a horizontal mark shows the current position of the slew pot wiper. By pressing the “+” and “-“ keys simultaneously, the zero setting occurs automatically. Note: The indicator line will move to zero on the bar graph. When the operator is finished, pressing the ESC key returns the console display to normal.
Americas Training Grove 34-9iFLEX 5
P.A.T. – L.M.IMANUAL
SECTION 35
Boom Control
IFLEX5 BOOM CONTROL SYSTEM (BCS) RT9000E / RT800E BAS ICS
Terminology: BCS = boom control system IM = innermid boom section CM = center-mid boom section OM/Fly = outer-mid and fly boom section DI = digital input, refer to table 3 for definitions DO = digital output, refer to table 4 for definitions PWM = pulse width modulation 0 = off with regard to digital inputs and outputs 1 = on with regard to digital inputs and outputs The BCS controls the boom telescoping sequence by controlling the current supplied to the proportional solenoids on the 4-way directional control valves. These valves provide oil to the telescoping cylinders. Here are the basic components, inputs, outputs, and logical functions to make this happen.
Components: • iFLEX5 control system (central unit), located in the cab. • BCS relay junction box assy, located on rear exterior of cab. • Cable reel to measure overall length, located on boom base section. • Cable reel to measure inner-mid length, located on boom base section. • Proximity switch to sense inner-mid fully retracted, located on boom base section. • Proximity switch to sense center-mid fully retracted, located on boom inner-mid section. • Auto/Manual switch, located on the right hand arm rest in the cab. • Section selector switch, located on the right hand arm rest in the cab. • Boom out of sequence light, located on the front console in the cab. • Extend pressure switch, located on superstructure. • Retract pressure switch, located on superstructure. • Inner-mid pilot operated 4-way directional control valve with extend and retract proportional
solenoids, located on the superstructure. • Center-mid pilot operated 4-way directional control valve with extend and retract proportional
solenoids, located on the superstructure. • Tele two stage relief valve, located on the superstructure.
Manual / Auto Mode: There are two modes of operation, manual or automatic mode. This is selectable by a switch in the right hand arm rest in the cab, and is seen by the BCS as digital input 17. DI1 17=0 is manual mode. And DI 17=1 is auto mode. 1 Refer to table 1 for digital input definitions
Americas Training Grove 35-1iFLEX 5
Americas Training Grove 35-2iFLEX 5
Manual Mode Operation: Primarily used for boom maintenance and function the boom in an unlikely event of a BCS failure. In manual mode the boom is controlled by the section selector switch in the right hand arm rest in the cab. When IM selected, crane electric provides full power to the extend and retract proportional solenoids on the IM pilot operated 4-way directional control valve. This means the telescoping action is controlled directly by moving the joystick or foot operated treadle valve. The BCS does not control movement. Likewise when CM is selected, crane electric provides full power to the extend and retract proportional solenoids on the CM pilot operated 4-way directional control valve. Note: In the event of an LMI error, overload, or A2B condition the proportional valves will be not be energized unless the LMI bypass is activated, either from the central unit or console.
Auto Mode Operation: An extend or retract action is initiated by moving the joystick or foot operated treadle valve causing hydraulic pilot pressure to activate an extend or retract pressure switch. The pressure switch signals are seen as digital inputs to the BCS. As an example of extend from fully retracted, the BCS realizes DI 19=1 (extend pressure switch on) and simultaneously activates DO2 8 (IM extend) and DO 3 (PWM 2, IM proportional solenoid). DO 8 energizes a relay in the BCS relay junction box assy to direct DO 3 to the IM pilot operated 4-way directional control extend proportional solenoid. Figure 1 illustrates how DO 3 is directed to the solenoid valve. DO 3 is a PWM output and ramps the output according to variables in the data software. Ramp-up output is time based. When the IM section approaches a change over point (change in sequence), DO 3 is ramped down according to variables in the data software. Ramp-down output is percentage based. See table 1 and table 2 for sequencing information. At the specified change over point, the BCS turns off DO 8 (IM extend) and simultaneously turns on DO 6 (CM extend) and DO 1 (PWM 1, CM proportional solenoid). DO 6 energizes a relay in the BCS relay junction box assy to direct DO 1 to the CM pilot operated 4-way directional control extend proportional solenoid. DO 1 is a PWM output and ramps the output according to variables in the data software. When the CM section approaches a change over point DO 1 ouput is ramped down according to variables in the data software. And so on. When retracting, the BCS realizes DO 18=1 (retract pressure switch) and does not activate DO 6 or DO 8. DO 1 or DO 3 are activated based on the current boom position. figure 1 2 Refer to table 2 for digital output definitions
TELE SEQUENCE: RT9000E: Mode “A” - not available RT800E: Mode “A” Mode “B” table1
Jib Mode (not selectable, realized by operating mode selection)
table 2 Note: Retract sequence is opposite of extend sequence. IFLEX5 BCS DIGITAL INPUTS: table 1
Digital Input
Description *C.U. X2 Terminal
**MP
6 CM (Center-Mid) Retracted (boom proximity switch) 54 R89 7 IM (Inner-Mid) Retracted (boom proximity switch) 55 R90 8 Luffing Extension Raise (cab switch) 56 R91 9 Luffing Extension Lower (cab switch) 57 R92 10 Luffing Extension Raise (remote switch on ext.) 58 R93 11 Luffing Extension Lower (remote switch on ext.) 59 R94 16 “A” Mode (cab switch) 64 R100 17 Auto Mode (cab switch) 65 R101 18 Boom Retract (pressure switch) 66 R102 19 Boom Extend (pressure switch) 67 R103
Mode "B" Extend Sequence in Percentage Tele 1 (IM) Tele 2 (CM) Tele 3 (OM/Fly)
0 0 0 75 0 0 75 75 0 100 75 0 100 100 0 100 100 100
Jib Mode Extend Sequence in Percentage Tele 1 (IM) Tele 2 (CM) Tele 3 (OM/Fly)
100 0 0 100 100 0 100 100 100
Americas Training Grove 35-3iFLEX 5
RT9000E / RT800E IFLEX5 BCS DIGITAL OUTPUTS: table 2 Digital Output Description C.U. X2 Terminal
1 PWM 1 CM Proportional Solenoid 2 2 +UB CAN bus 3 3 PWM 2 IM Proportional Solenoid 4 4 +UB to Slew Potentiometer Electronics 5 5 PWM 3 Luffing Extension Proportional Solenoid 6 6 CM Extend Relay K1 Coil in Junction Box 7 7 PWM 4 Luffing Extension Proportional Solenoid 8 8 IM Extend Relay K2 Coil in Junction Box 9 9 Luffing Extension Raise Solenoid 14 10 External LMI Alarm, Option on Boom 15 11 Luffing Extension Lower Solenoid 16 12 Rear Axle Oscillate Signal 17 13 Tele Rod Drain Solenoid 18 14 Boom Out of Sequence Lamp 19 15 Tele Two Stage Relief Solenoid 20
*C.U. = Central Unit **MP = Measuring Point; i.e. R89 designates resistor number; see sketches below for specific location; Notes: must measure on bottom leg of the resistor. DO 1 = PWM 1 DO 3 = PWM 2 DO 5 = PWM 3 DO 7 = PWM 4
Americas Training Grove 35-4iFLEX 5
A convenient method to monitor digital inputs (DI) and digital outputs (DO) is utilizing the iTOOL5 or iFLASH terminal function. At the flashing command prompt press and hold “Ctrl” and “A” to enter the RTOS (an asterisk will display). Type “digshow” and press “Enter”. The result should be the screen shown below. The inputs and outputs are counted from right to left and top to bottom as illustrated below. *digshow (RTOS command to display digital inputs and outputs) T E S T D E R D I G I T A L - E I N - U N D A U S G A E N G E ======================================================================= Baugr. | Port | Modus | IN-Wert | IN-Wert | OUT-Wert | OUT-Wert | Status | :Taste | | (Hex) | (Bin) | (Hex) | (Bin) | =NoLoad -------|--------|--------|---------|----------|----------|----------|-------- Basis | 0 : 1 | NORMAL | 00 | 00000000 | 05 | 00000101 | 0000-1 Basis | 1 : 2 | NORMAL | 00 | 00000000 | 82 | 10000010 | 0011-0 Basis | 2 : 3 | NORMAL | 98 | 10011000 | 00 | | Erw. | 0 : 4 | NORMAL | 00 | 00000000 | 00 | 00000000 | 1111-1 Erw. | 1 : 5 | NORMAL | 00 | 00000000 | 00 | 00000000 | 1111-1 Erw. | 2 : 6 | NORMAL | 00 | 00000000 | 00 | 00000000 | 1111-1 -------|--------|--------|---------|----------|----------|----------|-------- Baugruppencodierung Basis : 0F = 00001111
Baugruppencodierung Erweiterung: FF = 11111111 Hubendschalter UNTB/OFFEN/OK/KURZ: 0000 X:Exit Blank:Redraw S:Slow F:Fast
Other methods to determine digital input and output states is by probing the junction box mounted on the rear of the cab, the C.U. 70-pass connector pins (X2), or specific resistors on the main board, or terminal strip in the. See table above and sketches below. Be cautious not to short the probe across connector pins. Junction Box Assy – located on rear exterior of cab
DO 16 DI 9
DI 1
DI 8
DO 1
Americas Training Grove 35-5iFLEX 5
Americas Training Grove 35-6iFLEX 5
Resistor bank to measure digital input (DI) state. Note: must measure on bottom leg of the resistor.
C.U. 70-pass connector pins (X2)
IFLEX5 BCS ANALOG IN PUTS AND PWM OUTPUTS:
Another useful tool to monitor analog inputs and PWM outputs is utilizing the iTOOL5 or iFLASH terminal function. At the flashing command prompt press and hold “Ctrl” and “A” to enter the RTOS (an asterisk will display). Type “adctest” and press “Enter”. The result should be the screen shown below. *adctest T E S T D E R A N A L O G E I N G A E N G E =============================================== Ch | MUX | Error | Kanal+ | Value | Value | UADC | Special | | | Valid | (Hex) | (Dec) | [mV] | ---+-----+-------+--------+-------+-------+------+----------------- 0 | | ok | 0008 | 0310 | 784 | 784 | I_Kanal 1 = 4.356 mA 1 | | ok | 0009 | 0816 | 2070 | 2070 | I_Kanal 2 = 11.500 mA 2 | | ok | 000A | 0000 | 0 | 0 | I_Kanal 3 = 0.000 mA 3 | | ok | 000B | 0000 | 0 | 0 | I_Kanal 4 = 0.000 mA 4 | | ok | 000C | 0307 | 775 | 775 | Temperature = +27°C 5 | 0 | ok | 000D | 0B90 | 2960 | 2960 | I_Kanal 5 = 16.444 mA 5 | 1 | ok | 000D | 0000 | 0 | 0 | I_Kanal 6 = 0.000 mA 5 | 2 | ok | 000D | 0000 | 0 | 0 | I_Kanal 7 = 0.000 mA 5 | 3 | ok | 000D | 0000 | 0 | 0 | I_Kanal 8 = 0.000 mA 5 | 4 | ok | 000D | 0098 | 152 | 152 | I_PWM 1 = 0 mA 5 | 5 | ok | 000D | 0014 | 20 | 20 | I_PWM 2 = 10 mA 5 | 6 | ok | 000D | 0000 | 0 | 0 | I_PWM 3 = 0 mA 5 | 7 | ok | 000D | 0000 | 0 | 0 | I_PWM 4 = 0 mA OPERATINGMODE X: Exit Blank: Redraw S: Slow F: Fast P: PWM-Settings T: Testmode O: Operatingmode C: ADC-Clockset E: Extensionmodule T E S T D E R A N A L O G E I N G A E N G E
Kanal Description 1 Slew Angle 1 2 Slew Angle 2 3 Wind Speed 5 Luffing Extension Offset Angle
PWM Description
1 Center-Mid Tele Output 2 Inner-Mid Tele Output 3 Luffing Extension Raise Output 4 Luffing Extension Raise Output
Note: DO 1 = PWM 1 DO 3 = PWM 2 DO 5 = PWM 3
DO 7 = PWM 4
Americas Training Grove 35-7iFLEX 5
Boom Status / Luffer Status
IM Tele Output (0-255)
CM Tele Output (0-255)
Luffing Ext Raise Output (0-255)
Luffing Offset Angle(degrees)
Length 2 (IM) (feet)
IFLEX5 BCS TEST DISPLAY: To view additional information on the console display, push buttons “F1” and “F4” simultaneously. To return to the normal screen push button “F1” or “F4”.
Status No. Description 1 - 11 Mode B extend 29 Error Mode B extend 31 - 41 Mode B retract 59 Error Mode B retract 61 - 67 Mode A extend 79 Error Mode A extend 81 - 85 Mode A retract 99 Error Mode A retract 100 Manual Mode A neutral or extend 101 Manual Mode B neutral or extend 102 - 108 Manual Mode retract at overload, A2B, error condition 110 Mode A, Out of Sequence 112 Mode B, Out of Sequence 127 Mode A or B, neutral position 200 - 202 Luffing jib raise 210 - 212 Luffing jib lower
Americas Training Grove 35-8iFLEX 5
BOOM OUT OF SEQUENCE: Digital Output 14 boom out of sequence is lamp, located on the front crane console, is activated when the sections become greater than 3.5% out of sequence. Refer to sequence charts above. Another indication for out of sequence are the flashing section percentages located at the bottom of the console display
TELE ROD DRAIN VALVE: The tele rod drain valve is a normally closed valve that when energized opens to allow oil in the rod side of the tele cylinders a path to tank. The valve is de-energized to prevent flow to tank. The Boom Control System energizes this valve at all times unless the boom is fully retracted, or the retract pressure switch is activated. See the logic chart below. Digital Output 13 is on unless: Tele Rod Drain Solenoid IM retract sw. CM retract sw. Retract pressure sw. (DO13) (DI 7) (DI 6) (DI 18) 0 1 1 0 1
TELE TWO STAGE RELIEF VALVE: The two stage tele relief valve is a normally closed valve that when energized increases the tele extend relief pressure from 2500 psi to 3000 psi. The Boom Control System energizes this valve when the retract pressure switch is activated, or when the OM/Fly section is greater than 4% while extending. See the logic chart below. Tele Two Stage Relief Solenoid (DO15)
Retract pressure sw. (DI 18)
Extend pressure sw. (DI 19)
OM/Fly Percentage
IM rertract sw. (DI 7)
CM retract sw. (DI 6)
1 1
1 1 >4%
0 1 1
boom section percentage display
Americas Training Grove 35-9iFLEX 5
P.A.T. – L.M.IMANUAL
SECTION 36
Luffing Boom Extension
HYDRAULIC LUFFING BOOM EXTENSION: Hydraulic control of the extension consists of a four-way, three position directional control valve, a hose reel, a proportional control valve and a double acting cylinder. The four-way, three position directional control valve is mounted on the turntable. There are two solenoids for directing the flow for extension or retraction of the cylinder. The hose reel is mounted on the boom and conveys the hydraulic fluid to the cylinder on the boom extension. The proportional control valve is mounted to the cylinder on the boom extension. The offset angle is measured directly by a potentiometer located on the base adapter. The opposite end of a lever arm mounted on the potentiometer shaft rests on and follows the structure which offsets. PAT does not supply the potentiometer. There are two ways to offset the luffing extension. The first is two switches located in the left hand armrest. One switch is a luffing system ON/OFF switch. The other is a RAISE/LOWER switch. This switch has momentary positions on either side, and a return to center position. It raises or lowers the extension by controlling the raise and lower solenoids on the four–way three position directional valve. This switch also sends an actuation signals to the LMI. DI 8=1 (raise) DI 9=1 (lower). The proportional solenoid on the luffing cylinder is energized by DO 5 & 7 (PWM 3 & 4) if DI 8=1. The proportional valve on the luffing cylinder is not be energized for luffer lower. Hydraulically the proportional valve is bypassed for luffer lower. Raise and lower can also be activated form remote switches located on the extension. Remote raise is DI 10 and remote lower is DI 11. The raise and lower solenoids on the turntable are energized by DO 9 & 11 respectively. If DI 10=1, then DO 5, 7, & 9=1. If DI 11=1, then DO 11=1. The proportional valve on the luffing cylinder is not be energized for luffer lower. Hydraulically the proportional valve is bypassed for luffer lower. See sketch below.
Americas Training Grove 36-1iFLEX 5
P.A.T. – L.M.IMANUAL
SECTION 37
ERROR CODE LISTING
ERROR CODES The following Error Code Table gives a brief description of Error Codes elimination. Refer to the noted sections for detailed Troubleshooting information. Error Code Error Possible Cause Elimination E01 Fallen below radius
range or angle range exceeded
• Fallen below the minimum radius or gone past the maximum angle specified in the respective load chart due to luffing up the boom too far
• Luff down the boom to a radius or angle specified in the load chart.
E02 Radius range exceeded or fallen below angle range
• Gone past the maximum radius or fallen below the minimum angle specified in the respective load chart due to luffing down the boom too far
• Luff up the boom to a radius or angle specified in the load chart.
E03 Non-permitted slewing zone (no load area)
• The slewing zone with load is not permitted
• Slew to permitted area
E04
Operating mode not acknowledged or non permitted slewing zone
• An incorrect operating mode has been selected
• Set the correct operating mode for the operating configuration in question. Refer to Operator’s Handbook.
• The boom is in a non-
permitted slewing zone • Slew the boom to a
permitted area. Refer to Section 8.
E05
Prohibited length range
• Boom has been extended either too far or not far enough, e.g. if it is prohibited to go beyond a certain maximum boom length or with load curves for jibs where the main boom has to be extended to a certain length
• Extend/retract boom to the correct length
• Length sensor adjustment has changed, e.g. the cable slid off the length sensor reel.
• Retract boom. Check the prestress of the cable reel (cable must be taut). Open the length sensor and carefully turn the length sensor pot counterclockwise until the detent by means of a screw driver
• Clutch between length sensor pot and drive is defective
• Replace the complete clutch including drive wheel and adjust length sensor pot as described above
Americas Training Grove 37-1iFLEX 5
Error Code Error Possible Cause Elimination E11 Fallen below lower
limit value for measuring channel "length main boom"
• Length potentiometer is defective
• Replace length potentiometer, see section Length Sensing
E12
Fallen below the lower limit value in the measuring channel "pressure piston side"
• Pressure transducer is defective.
• Replace pressure transducer, see section Pressure Sensing
E13
Fallen below lower limit value in the measuring channel "pressure rod side"
• refer to E12 • refer to E12
E14 Fallen below lower limit value in measuring channel "force"
• Force transducer defective
• Electronic component in the measuring channel is defective.
• Replace force transducer
• Replace sensor unit
E15 Fallen below lower limit value in measuring channel "angle main boom"
• Angle potentiometer defective
• Replace angle sensor, see section Angle Sensing
• Electronic component in the measuring channel defective.
• Replace electronic board, see section Angle Sensing
E16 Fallen below lower limit value in measuring channel "angle 2"
• Angle potentiometer defective
• Refer to E-15
• Electronic component in the measuring channel defective.
• Refer to E-15
E17 Fallen below lower limit value "length telescope I (+II)"
• Length potentiometer defective
• Replace length sensor, see section Length Sensing
• Electronic component in the measuring channel defective
• Replace electronic board, see section Length Sensing
E18 Front outrigger overloaded
• Front outrigger overloaded
•
E1A Fallen below lower limit value in measuring channel "slewing angle 1".
• Cable between the central unit and the slewing angle sensor defective or loose.
• Check cable as well as plugs, replace, if need be.
Americas Training Grove 37-2iFLEX 5
Error Code Error Possible Cause Elimination • Slewing angle
potentiometer is defective • Replace slewing angle
sensor • Electronic component in
the measuring channel defective
• Replace sensor unit
E1B Fallen below lower limit value in measuring channel "slewing angle 2"
• refer to E1A
• refer to E1A
E21
Upper limit value in measuring channel “main boom length” has been exceeded.
• refer to E11
• refer to E11
E22
Upper limit value in measuring channel “pressure piston side” has been exceeded
• refer to E12
• refer to E12
E23
Upper limit value in measuring channel “pressure rod side” has been exceeded.
• refer to E12
• refer to E12
E24 Upper limit value in measuring channel “force” has been exceeded.
• refer to E14
• refer to E14
E25
Upper limit value in measuring channel “main boom angle” has been exceeded.
• refer to E15 • refer to E15
E26 Upper limit value in measuring channel “angle 2” has been exceeded.
• refer to E16 • refer to E16
E27 Upper limit value in measuring channel “length telescope I (+II) has been exceeded.
• refer to E17 • refer to E17
E2A Upper limit value in measuring channel “slewing angle 1” has been exceeded
• refer to E1A
• refer to E1A
E2B Upper limit value in measuring channel “slewing angle 2” has been exceeded
• refer to E1A
• refer to E1A
E31
Error in the system program
• The system program file is defective.
• Flash-EPROM defective
• Upload valid system software
Replace central unit
Americas Training Grove 37-3iFLEX 5
Error Code Error Possible Cause Elimination E37 Error in the logical
program flow • System program file is
defective • Flash-EPROM defective
• Upload valid system software
• Replace central unit
E38
System program and crane data file do not match.
• The system program in the LMI does not match to the programming in the crane data file
• Upload valid system program file or the valid crane data file
E39
System program and load chart file do not match
• The system program in the LMI and the programming in the load chart file do not match.
• Upload valid system program file or the valid load chart file
E43
Error in the write/read memory, (RAM)
• Write/read memory (RAM) or central unit defective.
• Replace central unit
E47 Error in the monitored write/ read memory. The CRC verification of the monitored write/read memory provides an incoherent result
• The CRC sign of the monitored write/read memory is wrong
• The buffer battery is
decharged (< 2V at 1kOhm).
• Central unit defective.
• Restart the LMI • Replace buffer battery
on the central unit. • Replace central unit
E51
Error in the crane data file
• No valid data in the crane data file.
• Flash-EPROM defective
• Upload valid crane data file
• Replace central unit
E52
Error in load chart file.
• No valid data in the load chart file
• Flash-EPROM defective
• Upload valid load chart file
• Replace central unit
E56
Error in crane data file.
• No valid data in the crane data file during calibration.
• Flash-EPROM defective
• Restore or upload valid crane data file
• Replace central unit
E57
Error in serial crane data file.
• Calibration data file does not contain valid data.
• Flash-EPROM defective
• Upload calibration data file
• Replace central unit
E60 The number of the selected File base and the programmed value are not identical
• No valid data in the load chart file
• Upload valid load chart file
• Base number not programmed
• Program the correct base number (1 for base 1, 2 for base 2)
Americas Training Grove 37-4iFLEX 5
Error Code Error Possible Cause Elimination • Load chart file wrongly
programmed • Check base
programming in the load chart file.
E61
Error in the CAN bus data transfer for all CAN units
• CAN Bus cable between the central unit and the sensor units defective or not connected.
• Check the connection between the central unit and the sensor units (wiring harness). See section CAN-Bus Communication
• Short circuit in a CAN Bus cable
• Replace Can Bus cable
• Can bus port in the central unit defective
• Replace the central unit
E62
Error in the can bus data transfer of the pressure transducer sensor unit
• Cable between the central unit and the sensor unit defective or not connected.
• Check the cable to the sensor unit (wiring harness). See section CAN-Bus Communication
• Sensor unit is defective • Replace the sensor unit E63
Error in the can bus pressure transducer sensor unit
• The analog values of the sensor unit are invalid
• Replace the sensor unit See section CAN-Bus Communication.
E64
Error in the can bus data transfer of the length/angle sensor unit
• Cable between the pressure transducer and cable reel defective or not connected.
• Check the cable to the sensor unit. See section CAN-Bus Communication
• Sensor unit is defective • Replace the electronic board in the cable reel, see section CAN-Bus Communication
E65
Error in the can bus length/angle sensor unit
• Angle sensor defective • Replace the angle sensor, see section CAN-Bus Communication
• Length sensor defective • Replace the length sensor, see section CAN-Bus Communication
• Sensor unit is defective • Replace the electronic board in the cable reel, see section CAN-Bus Communication
E66
Error in the can bus data transfer of the 2nd length/angle sensor unit
• See E62 • See E62
E67
Error in the can bus of the 2nd length /angle sensor unit
• See E63 • See E63
Americas Training Grove 37-5iFLEX 5
Error Code Error Possible Cause Elimination E68
Error in the can bus data transfer of the force sensor unit
• See E62 • See E62
E69
Error in the can bus force sensor unit
• See E63 • See E63
E80 Error in the slewing angle measurement
• The difference between the average of the slewing angle and one of the wipers of the slewing potentiometer is out of the tolerance
• See section Slewing Sensing
E84
Wrong rigging condition.
• The selected rigging condition is not contained in the crane data file.
• Select another rigging condition
• Check the programming
in the crane data file. E85
Error in the radius determination
• The computed radius is too small (negative deflection)
• Check the programming in the crane data file.
E89
Operating mode switchover with load.
• The operating mode on the console has been switched over with the boom loaded.
• Select operating mode without load on the boom
E91 No data trans-mission form the console to the central unit
• Power supply of the console is interrupted
• Check power at terminal X1 of the console electronics
• Interruption or accidental ground in the line between console electronics and central unit
• Check the connection console electronics - central unit. In case of an accidental ground, the transmitter module of the console electronics might be damaged.
• Transmitter/receiver module of console is defective
• Exchange console electronics or CU resp.
E92 Error in the data transmission from console to central unit
• Loose connection in the line between console electronics and central unit
• Transmitter/receiver module is defective
• Check the connection between console electronics and central unit
• Exchange console electronics or CU resp.
E93 Error in the data transmission from the central unit to the console
• refer to E92 • refer to E92
Americas Training Grove 37-6iFLEX 5
Error Code Error Possible Cause Elimination E94
No data trans-mission from the central unit to the console
• Interruption or accidental ground in the line central unit – console
• Check line to the console (in case of accidental ground, replace console electronics, too).
• Transmitter/receiver module is defective
• Exchange console electronics or CU resp.
• Computer module is defective
• Exchange CU.
• Electro-magnetic interferences (e.g. when switching contactors or valves)
• Eliminate the source of interferences by inverse diodes or varistors.
E95
Error in the console File
• The console File is defective.
• Replace the console software
E96
Error in the internal RAM of the console.
• The CPU of the console is defective.
• The console main board
is defective.
• Replace console electronics.
E97
Error in the external RAM of the console
• The external RAM of the console is defective.
• The console main board
is defective.
• Replace the external RAM of the console.
• Replace the console
electronics. EAB Short circuit in the
A2B switch circuit • Short circuit in the A2B
switch • Short circuit in the cable
to the A2B switch
• Replace A2B switch • Replace cable to the
A2B switch EAC A2B switch circuit
disconnected • Disconnected cable in the
A2B switch • Disconnected cable to the
A2B switch
• Connect or replace cable in the A2B switch
• Connect or replace
cable to the A2B switch EAD No valid A2B switch
status • Sensor wrong function • CAN bus delay
• Replace A2B switch • Replace cable to the
A2B switch EC0 Prohibited area • Boom is about to collide
with the engine hood, switch off
• Move boom to permitted area
EC1 Approaching prohibited area
• Boom is about to collide with the engine hood, prewarning
• Move boom to permitted area
Note: If an error message is displayed which is not contained in above list, please contact the PAT service department.
Americas Training Grove 37-7iFLEX 5
P.A.T. – L.M.IMANUAL
SECTION 38
TROUBLESHOOTING MOISTURE
TROUBLESHOOTING MOISTURE The PAT iFLEX5 LMI contains electronic components in various locations, such as central unit, sensors, junction boxes etc. These internal components cannot be designed to withstand exposure to moisture over a longer period of time. For this reason, the housings of the components are water protected according to IP 65. If you find water or moisture inside any of the housings, the source for the water ingress has to be detected and corrected to ensure proper operation. There are two major possibilities for the occurrence of excessive moisture inside an enclosure: 1) Water ingress 2) Condensation This outline gives instructions for detecting the cause for excessive moisture by using simple troubleshooting methods and how to prevent the moisture ingress from happening again. WATER INGRESS There are 6 possibilities for water to enter an enclosure: 1) Spray Cleaning 2) Missing / Loose Screws 3) Bent Lid 4) Defective Gasket 5) Loose Strain Relieves 6) Water Entry Through External Cabling It is possible to find out the source of water ingress by going through the following steps and ruling out one possibility after the other until the cause is identified: 1) Spray Cleaning
The enclosures used for the PAT LMI system are water protected to IP 65. This means protection against the environment, such as rain. However, through the use of spray cleaner at short distances, it is possible to force water through the gasket or strain relieves. For this reason, avoid spraying any components from short distances with spray cleaners. Convey this fact to any member of a maintenance crew.
2) Missing / Loose Screws
All screws have to be present and to be equally tight to ensure water protection of the enclosure. If there are screws missing, replace them. If no screw is missing, check the tightness. If any were loose, then open all screws and then re-tighten them equally.
3) Bent Lid
An enclosure will only seal correctly if the lid is not bent. To check this, loosen all screws of the lid, take the lid off the box and visually inspect it for deflection. If the lid is bent or damaged, it needs to be replaced. Try to determine what has caused the lid to be bent and eliminate the reason for that. Order a new lid through your PAT representative.
Americas Training Grove 38-1iFLEX 5
Troubleshooting Moisture
4) Defective Gasket
The gasket underneath the lid seals the unit. The gasket needs to be in good condition in order to seal correctly. If the gasket is torn, brittle or severely bent, it needs to be replaced. Order a new gasket through your PAT representative.
5) Loose Strain Relieves
The strain relieves allow cabling to enter the box without allowing water to enter it. The strain relieves have to be correctly tightened in order to do this. Check the tightness by taking the external cable into one hand and carefully trying to turn it. If the internal wires turn with the outer cable, the strain relief is loose. Get a new grommet (insert) through your PAT representative and replace the existing one with the new one. Tighten the strain relief correctly. Note: Whenever a strain relief is opened, i.e. to replace a cable, a new grommet needs to be used. Never re-use any grommet or the strain relief will not seal properly!
6) Water Entry Through External Cabling
Even with a tight strain relief, water may still enter the box through the inside of the cable. In this case, you have to find out why and where water enters the cable. Look for damages to the cable itself and inspect the opposite side of the cable. In example, if the cable comes from a connector that is full of water, the water will run through the inside of the cable and fill up the central unit, too.
CONDENSATION In a climate with high humidity and rapidly changing temperatures, condensation can happen inside any enclosure, usually the larger the volume of the box, the more likely. In this case, water drops build up on the inner components when humid air is trapped inside the box. With condensation, water tightness is not a problem – the box is sealed just fine, which is what prevents the trapped air from exiting the box. There are two ways to deal with condensation:
1. If the volume is very small, a desiccant bag might be able to soak up the air’s humidity. 2. If the effect is more severe, the only way to get rid of this effect is then to give the box the
ability to breath without sacrificing its water tightness. Contact your PAT representative for breathing elements to than can be added to the box and will help to reduce the effects of humid climates.
Americas Training Grove 38-2iFLEX 5
P.A.T. – L.M.IMANUAL
SECTION 39
SOFTWARE TRANSFER INFORMATIONS INFORMATION
SOFTWARE TRANSFER INSTRUCTIONS FOR THE CONSOLE USING THE FLASH MODULE
• Remove the console from the dash by removing 8 mounting screws. • Remove four screws from the rear of the console housing, exposing the internal boards. • Attach the Console Flash Module to X6 and X7 simultaneously. • Power on the system. • At power-on if the software in the console does not match that in the Flash Module, an
option to update will be presented. This option will disappear after 10 seconds until power is cycled.
• Immediately after seeing the update option, press and hold the Horn button until it’s light stops blinking.
• Software is finished updating when the Grove logo appears. • Cycle power – if the software is updated correctly the update option will not appear at
power-on. • Verify software update/version by pressing the Info button three during system operation.
REMOVE FLASH MODULE WHEN FINISHED – IT IS NOT TO REMAIN IN THE CONSOLE! • Attach the housing and the four inner screws from the rear of the Console, exposing the
internal boards. • Insert the console into the dash and mount in place with the 8 screws.
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SOFTWARE TRANSFER INSTRUCTIONS FOR THE IFLASH PALM AND CENTRAL UNIT INTRODUCTION iFLASH allows for transfer data files between the palm and the PC and Palm and iflex system. Data files can not be transferred with the Palm software program „HotSync. IFLASH Desktop iFLASH desktop is the program, which takes care of the data transfer, is provided for communication or the transfer of files between PC and the iFLASH Palm iFLASH Palm iFLASH Palm is the program which runs on the Palm. This program must be transferred to the Palm using Hotsync. Please contact PAT on information on how you can obtain this software. INSTALLING IFLASH DESKTOP The iFLASH Desktop needs no installation. Just copy to your Desktop or any convenient folder.
INSTALLING IFLASH The iFLASH program must be installed onto the Palm. To install iflash on the Palm, use the hotsync program of the Palm. The file name is iFLASH*.prc. Follow the normal Hotsync procedure for transferring the program from the PC to the Palm. Instructions for Hotsync will be in your Palm documentation or on Palm's web site.
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DATA TRANSFER FROM THE PC TO THE PALM
Palm - Put Palm into the HotSync Cradle and turn it on. PC - Deactivate HotSync manager. If Hotsync manager is not deactivated, the program will
respond with an error, "unable to open specified port…" PC - Double click on iFLASH Desktop PC - Select the necessary serial interface (COM1, COM2,...)
PC - Click on „Add File to Store...“
PC - Select the file which you want to transfer and click "Open"
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Software Transfer Instructions for the iFLASH Palm and Central Unit
Palm - Start iflash Palm - Select File Store. Palm - Select Receive. Palm - palm will show "waiting for connection" PC - click on OK. PC - When the transfer is complete the following message will appear.
Palm - "Transfer complete" will show on the palm. The file should now be stored in the Palm.
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DATA TRANSFER FROM THE PALM TO THE PC
Palm - Put Palm into the HotSync Cradle and turn it on. PC - Deactivate HotSync manager. If Hotsync manager is not deactivated, the program will
respond with an error, "unable to open specified port…" PC - Double click on iFLASH Desktop PC - Select the necessary serial interface (COM1, COM2,...)
PC - Click on „Refresh File List“ Palm - Start iflash Palm - Select File Store. Palm - Select Send. Palm - palm will show "sending Filelist" PC - When the transfer is complete the window will be updated with the files from
the Palm file store.
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Software Transfer Instructions for the iFLASH Palm and Central Unit
Palm - "Sending complete" will show on the palm. PC - Select the file you need and click „Retrieve marked File(s)“
After that you will get the following message:
Palm - select „Receive“. PC Click „OK“.
Wait until „Transfer completed“ is displayed in the status bar of the Palm. Acknowledge the message on the PC:
The file has been successfully filed in the folder created by the iFLASH Palm Desktop.
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TRANSFERRING SYSTEM, DATA OR TLK FILES FROM THE PALM TO THE
IFLEX5
Connect the Palm with the iFLEX5 via its serial cable. Power the iFLEX system Select iFLASH program Select Settings. Note - The values are saved after the first time. This can be skipped later. Set Speed to: 9600 Set Data Bits to: 8 Set Parity to: N Set Stop Bits to: 1 Select Save. Select Palm to iFLEX Select the file to be transferred from the file selection box. Select Start Transfer
Wait until all bytes have been transferred in the line „Progress“. The data have been successfully transferred to the iFLEX5.
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Software Transfer Instructions for the iFLASH Palm and Central Unit
TRANSFERRING SYSTEM, DATA OR TLK FILES FROM THE IFLEX5 TO THE
PALM “
Connect the Palm with the iFLEX5 via its serial cable. Power the iFLEX system Select iFLASH program Select Settings. Select Settings. Note - The values are saved after the first time. This can be skipped later. Set Data Bits to: 8 Set Parity to: N Set Stop Bits to: 1 Select Save. Select iFLEX to Palm Select the corresponding parameter data file in the displayed selection box. See parameter file
section. Select the file to be transferred from the file selection box. Using your Stylus, check off either “save brn file” or “save bin file” in the selection „Save file as“ –
depending on how you want the file to be stored. Select Start Transfer Wait until the message „complete“ appears in the line „Progress“
The iFLEX has to be restarted manually.
The data has been successfully transferred and can be found in the „FileStore.“ Quit the dialog with „Done“ and switch to the „FileStore“. The file name of the stored file gets the name of the parameter data file – except for the extension. Example: Parameter file : 12k.ADR 12k.BIN and 12k.BRN If this file name exists already in the „Filestore“, it will be counted upward by one. Example: Parameter file :12k.ADR 12k_01.BIN and 12k_01.BRN 12k_02.BIN and 12k_02.BRN, etc. PARAMETER FILES There are several files required for transferring from iflex to palm. These files are called parameter files. You should have a parameter file for each of the file types that you wish to transfer from the iflex to the Palm. These files will have a "adr" extension on the filename. Examples are tlkprom.adr, datprom.adr. These files must be transferred from the PC to the Palm using the file store program. Please contact PAT for information on acquiring these files.
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