pat 2 manual

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)


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


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 permissible 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


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


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


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



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


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


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


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


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


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


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)


ANGLE SIGNAL0 DEG. = -3.125V45 DEG. = -2.50V90 DEG. = -1.875V


14

3

3.2


Connections

13

17

16

15

14

18

19

12

11

20

13

3

2

1


1 2 A 1

2 10 H 8

3 5 C 3

13 6 D 4


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


CM / IM RET. SW.

LENGTHRESET SW.

1

3

3.3


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)



13

17

16

15

14

18

19

12

11

20

3

2

1



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:


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:


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


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


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

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


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


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


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

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


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


SECTION 5

DS 350 GRAPHIC BCSBOOM ANGLE


.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


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


ANGLE SIGNAL0 DEG. = -3.125V45 DEG. = -2.50V90 DEG. = -1.875V


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


SECTION 6

DS 350 GRAPHIC BCSANTI - TWO - BLOCK


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


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


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


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


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




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


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


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


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.


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.


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.


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


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 .


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


Previous Page


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.


(-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


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


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


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


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.


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


No

Yes


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.


Yes

No

Next Page

11.21

Previous Page

Have you foundany wiring faults?

No

Yes


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


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


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


Previous Page


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.


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.


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



Previous Page

No




Yes


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.


*

Isthe voltage

decreasing from-500mV to

-4.5V?



Main board component defective.See section 10 for

replacement procedure.

Yes

No

Next Page

11.25


Previous Page


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.


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


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


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


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


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


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.


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


Previous Page

Measure switch signal at LWG 221 terminal 10(24V) and 9 (GND)


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.


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


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


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


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.


11.43

ERROR CODE DISPLAY


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.


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


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


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


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


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



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


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.


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.


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


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


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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

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12.1

To page 12.2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 IS


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=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)


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


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

)


TMS/TTS 870INTERFACE

12.2

B

CO

NT

INU

ED

FR

OM

PA

GE

12.1


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


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


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



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


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)


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


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

)


RT865BXLINTERFACE

12.6

B

CO

NT

INU

ED

FR

OM

PA

GE

12.5


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


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


19 20 21 22 23 24 25 26 27 28 29 30 31



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


WHTBRNGRN

341

2


RED

BLK

GRN

WHT


IS

1234

567

SHDWHTBRNGRN


D 341

2

1423

1423

IS

IS

(+)NONC(-)

OO

OO

REDBLKGRNWHT


JUNCTION BOX (IM)

PROXY SW 4(CM RETR)

1423

1423

IS

(+)NONC(-)

OO

OO


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


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


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


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



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


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


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


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


SECTION 17

DS 350 Graphic ModularPISTON, ROD


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



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


+ 500MV (.500V) = MIN. SIGNAL (ZERO PRESSURE)+ 4.50V = MAX. SIGNAL (300 BAR PRESSURE)


* 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




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




* THESE MEASUREMENTS ARE MADE IN PARALLEL17.3


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.


SECTION 18

DS 350 Graphic ModularBOOM ANGLE


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



- +

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


E15

E25

WORKINGRANGE

.0V

.500v MIN.

4.50v MAX.

5.0V

ERRORCODE

ERRORCODE

X2

6 Pin Connector

6 Pin Plug


+ 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.


TERMINAL


(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


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


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) 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

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ALL

VOTA

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AR

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RED

WIT

HR

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GN

D (M

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* TH

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MEA

SUR

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TS A

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MAD

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PAR

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L

- +

1

2

5

3R

W

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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

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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


SECTION 19

DS 350 Graphic ModularANTI - TWO - BLOCK


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


6 PIN DUMMY PLUG

4.7KRESISTOR

ΩΩΩΩ


NOTES: OUTER SHIELD GROUNDED AT STRAIN RELIEF CONNECTOR



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


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


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


A2B CABLE

(BLACK)

(BROWN)

(RED)

1

2

3

1

2

3

A

B

1

2

19.6


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?







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




START


fixed?

Does the console indicateAnti-Two-Block warning?


If console displays isblank, fault is located

in power supply, wiring or fuses.


If Load Moment LimitLight is lit, the faultis located in LMI,

cables, wiring, fuses orconsole.


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


STEP ACTION


2 Open cable reel cover and disconnect wiring from terminal block. Pull 7- conductor cable out of strain relief.


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.




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.


10 Set preload on cable reel by turning the drum counter-clockwise 5 to 8 turns.


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



START


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.


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


START



Turn power off or disconnectwire from X1-31 in central unit.



NO

YES

NO

YES


NEXT PAGE

NO

YES


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


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


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.



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


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.




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.


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


NO

YES

20.14


PREVIOUS PAGE


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



START


correct?NO

YES



correct?NO

YES

Reset length potentiometer. With fully retractedboom, turn potentiometer axle counterclockwiseuntil it stops .See drawing 7 on page 20.33.


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


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.




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


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.


NO

YES


Make correct shield connection.Refer to connection and wiring diagrams,correct?

NO


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


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.


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.


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



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


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


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


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


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


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


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


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





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”


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



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



-+

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


+ 500MV (.500V) = MIN. SIGNAL (RETRACTED BOOM)+ 4.50V = MAX. SIGNAL (10 TURNS ON POT)



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


W # 71K =

W # 51AJ =

A

B

C

1

2

3

4D

5E

LMI L/O ALARM (EEC)


+

+

F1 +UBS+24V

+UB

+0V

+UBS0VRXDTXD

STOP

+

K10A

K9

K8A2B-OA2B-I

10LOAD-I

+ +UBS

K10B


+ +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


DE 5

DE 6

+ +UBS

1

0V

0V

0V

0V

0V

0V

0V

0V

23456789

1112131415161718192021222324252627282930313233343536515253545758596061626465666768697677

12

3

4A

10A

4

5

13

14


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


= CONNECTED

CH #1CH #5

3-PairTwistedCable

MAIN

BO

ARD

23.6



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


TERMINAL


(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



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


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



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


W # 71K =

W # 51AJ =

A

B

C

1

2

3

4D

5E

LMI L/O ALARM (EEC)


+

+

F1 +UBS+24V

+UB

+0V

+UBS0VRXDTXD

STOP

+

K10A

K9

K8A2B-OA2B-I

10LOAD-I

+ +UBS

K10B


+ +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


DE 5

DE 6

+ +UBS

1

0V

0V

0V

0V

0V

0V

0V

0V

23456789

1112131415161718192021222324252627282930313233343536515253545758596061626465666768697677

12

3

4A

10A

4

5

13

14


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


= CONNECTED

123123

PISTON TRANSDUCER

ROD TRANSDUCER

DS350 Graphic Modular BCSPiston & Rod Transducers

to C.P.U. Connections


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




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






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




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






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


insert

BOOM LENGTH SIGNALRETRACTED = 4mAMAX RANGE = 20 mA

BOOM ANGLE SIGNAL90o = 4mA0o = 20 mA

W # 73A

24 VOLTS

GND


W # 71K =

W # 51AJ =

A

B

C

1

2

3

4D

5E

LMI L/O ALARM (EEC)


+

+

F1 +UBS+24V

+UB

+0V

+UBS0VRXDTXD

STOP

+

K10A

K9

K8A2B-OA2B-I

10LOAD-I

+ +UBS

K10B


+ +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


DE 5

DE 6

+ +UBS

1

0V

0V

0V

0V

0V

0V

0V

0V

23456789

1112131415161718192021222324252627282930313233343536515253545758596061626465666768697677

12

3

4A

10A

4

5

13

14


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


= 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



-+

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


E15

E25

WORKING RANGE

.0V

.500v MIN.

4.50v MAX.

5.0V

ERRORCODE

ERRORCODE

X2

6 Pin Connector

6 Pin Plug


+ 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.


TERMINAL


(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



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


6 PIN DUMMY PLUG

4.7KRESISTOR

ΩΩΩΩ


NOTES:OUTER SHIELD GROUNDED ATSTRAIN RELIEF CONNECTOR



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


+ +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


DE 5

DE 6

+ +UBS

1

0V

0V

0V

0V

0V

0V

0V

0V

23456789

1112131415161718192021222324252627282930313233343536515253545758596061626465666768697677

W # 73A

24 VOLTS

GND


W # 71K =

W # 51AJ =

A

B

C

1

2

3

12

3

4A

10A

4D

5E

LMI L/O ALARM (EEC)


4

5

13

14


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


= CONNECTED

3-PairTwistedCable

MAIN

BO

ARD

26.2

3

2 1

Auxiliary Boom Nose


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


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


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


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


A2B CABLE

(BLACK)

(BROWN)

(RED)

1

2

3

1

2

3

A

B

1

2

26.6


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


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



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


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


+ +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


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


W # 71K =

W # 51AJ =

A

B

C

1

2

3

4D

5E

LMI L/O ALARM (EEC)


4

5

13

14


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


= 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


15161718

13

12

9

15

16

13

1718

8

7

1

24

5

6


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?







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




START


fixed?

Does the console indicateAnti-Two-Block warning?


If console displays isblank, fault is located

in power supply,wiring or fuses.


If Load Moment LimitLight is lit, the faultis located in LMI,

cables, wiring, fuses orconsole.


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


STEP ACTION


2 Open cable reel cover and disconnect wiring from terminal block. Pull conductor cable out of strain relief.


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.




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.


10 Set preload on cable reel by turning the drum counter-clockwise.


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



START


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.


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


START



Turn power off or disconnectwire from X1-31 in central unit.



NO

YES

NO

YES


NEXT PAGE

NO

YES


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


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


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.



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


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


PREVIOUS PAGE

29.12


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.


NEXT PAGE



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


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



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


Correct?

Yes

No

NEXT PAGE

29.14



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


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



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


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


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



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



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




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



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





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



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





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


NEXT PAGE

29.22



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




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



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




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



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


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


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



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



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


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


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


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


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



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



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



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




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).


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


NO

YES

29.38


PREVIOUS PAGE


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



START


correct?NO

YES



correct?NO

YES

Reset length potentiometer. With fully retractedboom, turn potentiometer axle counterclockwiseuntil it stops .


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


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




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




NO

YES


Make correct shield connection.Refer to connection and wiring diagrams,correct?

NO


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




NO

YES


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.


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



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 = +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


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


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


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


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) 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.

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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


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


14 - SOCKET PLUG

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19


19 - SOCKET PLUG

VV V V V

A101

RT865BXL (BCS)BUS EXTENSION WIRING DIAGRAM



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



14 - SOCKET PLUG

B


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



19 - SOCKET PLUG

C


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


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


WHTBRNGRN

BLUBLKBRN

WHT


RED

BLK

GRN

WHT


IS

1234

567

SHDWHTBRNGRN


DBRNBLKWHTBLU

1423

IS

IS

(+)NONC(-)

OO

OO

REDBLKGRNWHT


JUNCTION BOX (IM)

PROXY SW 4(CM RETR)

BRNBLKWHTBLU

1423

IS

(+)NONC(-)

OO

OO


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


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.


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.


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.


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!


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


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


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.


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


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


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.


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


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


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


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.


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.


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


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


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.



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


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


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


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


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


ELECTRICAL SYSTEM DIAGRAM STANDARD SYSTEM Central Unit to Crane and Console Wiring Diagram


Cable Reel (length/angle sensor) Wiring Diagram


Boom Extension Anti-two Block Wiring Diagram

MAIN CENTRAL UNIT CONNECTOR This is a 70 pass connector.


ELECTRICAL SYSTEM DIAGRAM BOOM CONTROL SYSTEM Central Unit to Crane Interface Wiring Diagram

Am

eric

as T

rain

ing

Gro

ve1-

1


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


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


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


Luffer Extension Wiring Diagram

BOOM TIP CONNECTIONTO LWG520/0002REFER TO CABLE REEL (LWG520/0002) WIRING DIAGRAM


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


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


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


Spare Part Listings

3

4

5 6

8


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


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


PRESSURE TRANSDUCER BLOCK, DAV314/0014 PART NO. 9333103870

CABLE ASSEMBLY 11M, PART NO. 9333103872

WIRING HARNESS STANDARD, PART NO. 9333103869


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



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.


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.


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 -.



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.


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).



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.


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.



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.


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.



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



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


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


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



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


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


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



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.



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


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.


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.


E26 Upper limit value in measuring channel “angle 2” has been exceeded.


E27 Upper limit value in measuring channel “length telescope I (+II) has been exceeded.


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


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.


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.


• Upload valid crane data file


E52

Error in load chart file.

• No valid data in the load chart file


• Upload valid load chart file


E56

Error in crane data file.

• No valid data in the crane data file during calibration.


• Restore or upload valid crane data file


E57

Error in serial crane data file.

• Calibration data file does not contain valid data.


• Upload calibration data file


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)


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



Error Code Error Possible Cause Elimination E68

Error in the can bus data transfer of the force sensor unit


E69

Error in the can bus force sensor unit


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


E93 Error in the data transmission from the central unit to the console



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


• 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.



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.


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.



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.


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.


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"


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.


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.



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.


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.



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.


pat 2 manual

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