Pat 2 Manual

LEVEL II VE RO G T PA

DS350 GRAPHIC (BOOM CONTROL SYSTEM)

DS350 GRAPHIC MODULAR DS350 GRAPHIC MODULAR iFLEX5 SYSTEM

P.A.T. - L.M.I. SYSTEM MANUAL

P.A.T. - L.M.I. LEVEL II MANUAL INDEX DS350 Graphic (BCS) Section 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Description DS350 Graphic Console Descriptions Connections & Wiring Diagram, DS350 Graphic (BCS) Hydraulic, Electrical Theory & Component Location DS350 Graphic (BCS) Boom Length Connections & Wiring Diagrams DS350 Graphic (BCS) Piston, Rod Connections & Wiring Diagrams DS350 Graphic (BCS) Boom Angle Connections & Wiring Diagrams DS350 Graphic (BCS) Anti - Two - Block Connections & Wiring Diagrams DS350 Graphic (BCS) Digital Inputs DS350 Graphic (BCS) Central Unit P.C. Board Layout DS350 Graphic (BCS) Basic Adjustments and Checks. DS350 Graphic (BCS) Main Board and Transducer Replacement Procedure DS350 Graphic (BCS) Troubleshooting Guide Appendix: Boom Length Troubleshooting DS350 Graphic (BCS) Electrical Diagrams DS350 Graphic (BCS) Service Bulletins & Miscellaneous Information

P.A.T. - L.M.I. LEVEL II MANUAL INDEX DS350 Graphic Modular Section

Description

14.

DS350 Graphic Modular Console Connections, Wiring Diagram

15.

DS350 Graphic Modular Central Unit P.C. Board Layout

16.

DS350 Graphic Modular Boom Length Connections & 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

P.A.T. - L.M.I. LEVEL II MANUAL INDEX DS350 Graphic Modular (BCS) Section 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.

Description DS350 Graphic Modular (BCS) Console Connections, Wiring Diagrams DS350 Graphic Modular (BCS) Component Location DS350 Graphic Modular (BCS) Boom Length Connections & Wiring Diagrams DS350 Graphic Modular (BCS) Piston, Rod Connections & Wiring Diagrams DS350 Graphic Modular (BCS) Boom Angle Connections & Wiring Diagrams DS350 Graphic Modular (BCS) Anti - Two - Block Connections & Wiring Diagrams DS350 Graphic Modular (BCS) Digital Inputs DS350 Graphic Modular (BCS) Central Unit P.C. Modular Board Layout DS350 Graphic Modular (BCS) Troubleshooting Guide DS350 Graphic Modular (BCS) Electrical Diagrams DS350 Graphic Modular (BCS) Service Bulletins & Miscellaneous Information

P.A.T. - L.M.I. LEVEL II MANUAL INDEX iFLEX5 System 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

38.

Troubleshooting Moisture

39.

Software Transfer Instructions Information 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

P.A.T. – L.M.I MANUAL SECTION 1

DS 350 GRAPHIC CONSOLE DESCRIPTION, CONNECTIONS & WIRING DIAGRAM

PAT LOAD MOMENT INDICATOR PAT

DS 350

!

STOP

STOP

156ft

0335

TARE

!

90.0ft ?

79.4

LIM

o

SEL

50.8ft STOP

MAX

i

(lbs)

02 73.5oo ACT

(lbs)

34.900 100%

100%

CTRL

100%

STOP

F1

F2

F3

F4

DS 350 / 1319 GRAPHIC OPERATOR’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 handbook for 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 provides the 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 aggravate the crane’s condition. 1)LOAD MOMENT: Generally the product of a force and its moment arm: specifically, the product of 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 and also 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 understand the 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.

WARNING The 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

WARNING This system is equipped with an override key on the central microprocessor unit. This key switch bypasses control lever lockout function of load moment indicator device. The switch may only be used by authorized personnel during emergency situations. 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/angle sensor, 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 processor memory 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 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 transducers attached to the piston and rod side of the lift cylinders.

1.4

VE GRO

1

NOTE: If PAT System is to be used in conjunction with a jib having an existing Grove/Krueger Anti-TwoBlock system, a special connector cable is required. Consult Grove customer services for requirement.

2

5

3

3 4 5 CONSOLE

4 2

1 ANTI-TWO-BLOCK SWITCHES 2 PRESSURE TRANSDUCERS 3 LENGTH/ANGLE SENSOR-ANTITWO-BLOCK CABLE REEL 4 OPERATING CONSOLE 5 CENTRAL MICRO PROCESSOR UNIT 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. After ignition of the engine the system starts with an automatic test of all lamps, the audible alarm and the complete LMI system.

Start Self check of LMI System

Error?

Error code

yes

no yes

In case of system malfunction an error code number will be displayed on the console.

Within 2 hours?

After restarting the engine within 2 hours, the system will by-pass “Pre-Setup”.

no

Basic system information for crane operator will be displayed.

Interactive INPUT operating mode

Experienced operators who are familiar with the LMI system can by-pass the info run.

Interactive INPUT reevings

Inputs OK?

The system will display information and directions which the operator will follow by using the respective function of the key. no

The system is in the programming procedure. The operator has to set the LMI to the configuration of the crane.

yes Ready for Operation

The system is ready for operation.

4 SYSTEM’S OPERATION During the startup phase the crane operator will receive information about the function and meaning of the various elements of the 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-Setup The 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.

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 OPERATOR MANUALS READ AND UNDERSTAND * PUSH “ INFO”

Prior to operating, the operator shall carefully and thoroughly read and understand the 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 limitations of the crane and the LMI.

THE LMI SYSTEM IS AN OPERATIONAL AID WHICH CAN FAIL * PUSH “ INFO”

The load moment indicator (LMI) is a system which supports an operator in his action 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 OPERATE ACCORDING TO IN CAB LOAD CAPACITY CHARTS * PUSH “ INFO”

For the loading capacity of the crane only the load capacity charts are relevant. The operator 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.

The operator is entirely responsible for safe crane operation. YOU ARE ALWAYS RESPONSIBLE FOR YOUR LIFT OPERATIONS * PUSH “ INFO”

IF IN DOUBT CONSULT THE OPERATOR MANUALS BEFORE OPERATING THE CRANE * PUSH “ INFO”

He has to make sure that the crane is in good condition and that he works on a firm and level supporting surface. The operator shall fully acquaint himself with the most recent government regulations and industry standards relevant to safe craning operations.

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

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 values Display 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 better identification of displays and operating elements, they are continuously back lit during operation.

4.3 Control Identification This unit contains a display and different controls which are described as follows: Fig.2: Operating Console

PATDS 350 12

!

STOP

Legend to Fig. 2 : 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. F1 F2 F3 F4

LC Display Area Load Moment Limit Light Load Moment Prewarning Light Alarm Light “Anti - Two - Block” Override Key Warning Light Button “Alarm Stop” Button and Control Light “TARE” Button and Control Light “LIMITS” Button and Control Light “SELECT OPERATION MODE” Button and Control Light “INFO” Button and Control Light “CONTROL” Audible Alarm By-Pass Key Switch Button and Control Light “By-Pass ANTI - TWO - BLOCK” Button and Control Light “By-Pass LMI SHUT-OFF FUNCTION” Button “Function 1” Button “Function 2” Button “Function 3” Button “Function 4”

2

6

STOP

7 3

TARE

! 8 LIM

4

5

1

9 SEL

STOP

14

STOP

15

F1 13

1.8

F2

F3

F4

10

i

11

CTRL

!

1.

2.

3.

STOP

!

The LC display visualizes graphical symbols, text and numerical values. Depending on the selected operating mode the corresponding information is indicated on the display. The red Load Moment Limit Light warns the operator that a rated load condition has 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. 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 EPROM used in the central unit. The red Anti-Two-Block Warning Light will light up when the Anti-Two-Block limit 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.

4.

5.

STOP

STOP

6.

The red Override Key Warning Light flashes when the bypass key switch is turned and the button is pushed. This switch deactivates the cut-off function of the LMI. WARNING Should the red override key warning light continue to flash (with the by-pass key 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 lockout function 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.

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.

7.

TARE

After pushing the Tare Button before lifting, the display of actual load will be set 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 a load 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

8.

9.

LIM

This button will be used for future functions: - Slewing Angle Limitation - Tip Height Limitation - Radius Limitation Boom AngleLimitation is used.

SEL

If, during the crane operation, you wish to change the crane configuration, this button can be pushed for quick setting without having to go through the whole LMI programming procedure again. (ie. Hoist Reeving, Hoist, Extension)

i

10.

CTRL

11.

PAT

12.

13. B

A

With the system being ready for operation, this function serves to display the system configuration. The display shows the crane symbol representing the adjusted configuration (marked in black), the extended operating code number 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 at every system start.

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).

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 switch It can be operated only by using the matching key WARNING Since 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 use of 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

14.

15.

STOP

This button can be operated only if key switch is turned to position 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. This button can be operated only if key switch is turned to position 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 & Observations Prior to operating the crane, the following electrical connections must be checked to ensure that the system is properly connected for the crane configuration.

Machines with only a Main Hoist If the crane works only with the boom and without boom extension or jib, no additional connections are necessary. However, be sure the weight of the anti-two-block switch is properly installed on the main hoist load 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 junction box on the boom extension or jib and the boom junction box. The weight attached to the main hoist anti-twoblock 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 Hoists If 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, to prevent 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 fixed with 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

3 1 5 2 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

B A

5

3 1 4 2 Fig. 3 : Removal of the Anti-TwoBlock Retainer

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 for the 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.

WARNING The following test shall be performed with care to prevent damage to the machine or injury to personnel. Proper functioning of 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.

Operation After being properly programmed, the LMI is operational. Therefore, the operator shall be thoroughly familiar 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. Their combined weights shall be subtracted from the listed load capacities as stated on the load capacity chart 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 mechanical parts 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 system malfunction. 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 action which 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 E01 E02 E03 E04 E05 E06

Error Fallen below the radius or above angle range Radius range exceeded or fallen below angle range Boom position is out of the permissible working area Operating mode not existing Prohibited length range 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 shall call the Local Distributor.

Operating Errors Malfunctions in the system which are caused by range exceedings or operating errors by the crane operator himself 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: ABOVE ANGLE RANGE ANGLE = 80.0 o

E01: FALLEN BELOW RADIUS RANGE RADIUS = 27.4 ft

Cause: Fallen below the minimum radius or above the angle given in the load capacity chart due to raising the boom too far.

Elimination: Lower boom back to a radius or angle given in the load capacity chart.

ERROR 02 E02: BELOW ANGLE RANGE ANGLE = 25.0 o

E02: RADIUS RANGE EXCEEDED RADIUS = 75.6 ft

Cause: The maximum radius or minimum angle given in the load capacity chart was exceeded due to lowering the boom too far.

Elimination: Raise boom back to a radius or angle given in the load capacity chart.

ERROR 03 E03: NO - LOAD AREA

Cause: Boom position is out of the permissible working area (over front)

Elimination: Move boom back to permissible working area. See lifting diagram in the load capacity charts.

1.18

ERROR 04 E04: OPERATING MODE NOT AVAILABLE SEE LOAD CAPACITY CHART * PUSH “INFO”

Cause: 1 Operating mode switch in the console set incorrectly.

Elimination: Set operating mode switch correctly to the code assigned to the operating mode of the crane. Cause: 2 Elimination: Operating mode is not permissible Be sure crane is set up according with the actual crane configuration, to proper operating configurboom position or area definition. ations.

ERROR 05 E05: LENGTH RANGE NOT PERMITTED LENGTH = 75.3 ft

Cause: 1 Elimination: Boom was telescoped too far or not Telescope boom to correct far enough, i.e. load curves for “on length, given in the load capacity rubber”, you may only operate up to chart. a certain maximum or minimum boom length or with load curves for jibs where you have to telescope the main boom to a certain length. Cause: 2 Length sensor adjustment changed i.e. length sensor cable slid off the length sensor drum.

Elimination: For elimination refer to service manual.

1.19

ERROR 06 E06: RADIUS RANGE EXCEEDED RADIUS = 96.6 ft

E06: BELOW JIB ANGLE RANGE JIB ANGLE = 15.0o

Cause: The minimum angle or maximum radius of the luffing fly jib given in the load capacity chart was exceeded due 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.

!

DIM STOP

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 DIMswitch 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).

H8 V2

X3

H7

A2B K9

LMI K8

SHUT OFF

SHUT OFF

H4

H1 V8

OUT OF SEQUENCE

OUTER MID

V11

R15

V1

K7

R16

R9

V5

K4

K1

+24.0 R10

R3

R4

R17 R18 H10

H5

H3

R13

K6

R14

R11

R12

R7

V3

R8

K10 LEVER LOCKOUT

K2

R5

R2

R6

F4

IM

X1

77 76 75

K3

67 66 65 64 63 62 61 60

X1 80 79 78

V6

D RO

F5

Q

F6

X1

R1

49 48 47 SE

F7

K5

4W

70 69 68

CM

OM

F8

V7

ROD DRAIN

X4

V9

4 - WAY

CENTER MID

V10

X1

H2

INNER MID

H6

8 10 12 14 16 18 20 22 24 26 28 71 72 73 74

H9

X1

7 9 11 13 15 17 19 21 23 25 27 29

F1

X1

2 4 6

1 2 3 4

1 3 5

X4

F3

F2

59 58 57 56 55 54 53

X1 52 51 50

X1 43 42 41

40 39 38

X1

37 36 35 34 33 32 31 30

46 45 44 X1

1.21

80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

DS350 Graphic Console to C.P.U. Connections

6 5

LMI BY - PASS KEY

14

o o

7

o o

13

LMI BUTTON BY - PASS A2B BUTTON BY - PASS CONSOLE BY-PASS KEY

8

DI (8)

7

LMI (7)

6

A2B (6)

5

COMM. (5)

DATA FROM C.U.

4

RXD (4)

DATA TO C.U.

3

TXD (3)

2 1

2 3 4 1

GND (2) +24V (1)

1.22

48 47 46 45 44 43 42 41 40 39 38 37 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

DE 6

LENGTH RESET SW.

DE 5

CM / IM RET. SW.

DE 4

OM / FLY RET. / % SW.

-5V

-SIG

GND

86

K7 = OM / FLY - 2 WAY

o 30 o o

87A 87

85

F8

86

o o30 o

K6 = CM 2 - WAY

87A 87

85

F7

86

o 30 o o

K5 = 4 - WAY DIREC. VALVE

87A 87

85

F6

86

o 30 o o

K4 = TELE OUT OF SEQ.

87A 87

85

F5

86

o 30 o o

K3 = ROD DRAIN SOL.

87A 87

85

F4

86

o o30 o

K2 = IM 2 - WAY

87A 87

85

F3

86

K1= NOT USED

o 30 o o

87A 87

85

F2

87A 87

. .

o 30 o oK10

o o o K9

o o o K8

SIG 0-SIG

86

.

K10

o

UB

UB DE 3

AUTO MODE SW. ON

DE 2

PRESS. SW. BOOM RET.

DE 1

PRESS. SW. BOOM EXT.

0 (UB) 0 (UB) RXD TXD UB

-SIG +SIG

-SIG

0 (UB)

85

A2B COMPARATOR

-9V +9V -5V

GND

-SIG

-5V +5V GND

-SIG

-5V +5V GND LEN.(OA) -5V ANGLE GND X4 0(UB) +UB

4 3 2 1

) ) ) )

0 (UB) / GND +24 V

FIVE SECTION BOOM SERVICE SCREEN (TMS/TTS 870 & RT865BXL)

PAT

DS 350

!

STOP

STOP

156ft

0335

TARE

!

90.0ft ?

Ramp Seq.

1

CM Hex Value

0

IM Hex Value

79.4

255

SEL

OM/Fly Hex Value

0

STOP

LIM

o

1

255

0

0

50.8ft MAX

02

38.2 38.2

38.2 38.2

100%

(lbs)

73.5oo ACT

(lbs)

34.900 100%

i CTRL

100%

STOP

F1

Length of IM

F2

F3

F4

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 the ramping up and ramping down of the output signal to the solenoids. 1.23

P.A.T. – L.M.I MANUAL SECTION 2

DS 350 GRAPHIC BCS HYDRAULIC, ELECTRICAL THEORY & COMPONENT LOCATION

DS350 GRAPHIC with BOOM CONTROL SYSTEM The DS 350 load moment indicator (LMI) with boom control extension is designed to aid the crane operator through the crane operations. The DS 350 with boom control extension is not, and shall not, be a substitute for good operator judgment, experience and use of accepted safe crane operating procedure.

2. Warnings The DS 350 load moment indicator (LMI) with boom control extension is an operational aid that warns the crane operator when he approaches an overload condition, a two block condition and an out of boom sequence condition. The boom control extension controls the sequence of the boom during operation. It still remains the operator’s responsibility to select 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 is prohibited. Should an out of sequence condition occur, the crane operator is responsible to select manual 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 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 provided by the crane and load moment indicator manufacturer. Proper functioning depends upon proper daily inspection and observance of the operating instructions provided with the crane and load moment indicator.

2.1

Boom control information flow

Operator moves control to extend or retract position.

Directional pressure switch transmits signal to B.C.S.

B.C.S. checks input for Automode.

off

Operation in manual mode - no control output.

correct

Console displays length and % of each section.

on

B.C.S. checks input for A mode or B mode and prepares the control logic for that mode.

B.C.S. checks the retract and % reset switches on the boom and obtains the length signals.

incorrect

B.C.S. defaults into a rigging mode, console displays error code or dashboard warning light indicates "out of sequence".

continue on next page

2.2

TMS,TTS 870 & RT 865 BXL

B.C.S. activates relays to power up valves. This enables the oil to flow into the cylinder.

B.C.S. switches relay to correct position for the rod side dump valve

B.C.S. ramps up the analog output current for the pressure reducing valves (proportional valves)

The pressure reducing valves open linear an the pilot pressure increases until maximum pressure is obtained.

continue on next page

2.3

TM9150, TM9100

continuation

B.C.S. senses the boom length and calculates the percentage of each section while extending or retracting.

incorrect

correct

B.C.S. starts the ramp down process when approaching a change over point.The analog output current decreases and slows down the section.

Out of sequence warning and lock out.

TMS/TTS 870 & RT 865 BXL

At the change over point the B.C.S. changes relay combination to close the flow to the actual cylinder and enable flow to the next cylinder.

The B.C.S. ramps up the analog signal by a linear current increase of the pressure reducing valves. The section speeds up to its maximum speed.

2.4

TM9150 & TM9100

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 the crane. Mode A: Increased stability. The heavy IM (inner mid section) remains retracted until the CM (center mid section) and OM/Fly (outer mid and fly section) becomes fully extended. This enables a better load chart for the boom between fully retracted and extended. Mode B: Increased structural capacity. The stronger sections IM & CM extends in a programmed sequence keeping the weaker section OM & Fly fully or partially retracted.

Model TM 9150 TM 9100 TMS 870 TTS 870 RT 865 BXL

2.5

Mode B A, B A, B A, B B

WHERE ARE THE CONTROLS? PILOT CONTROL Standard joystick or foot operated treadle valve.

The following switches are located inside, and on the upper right hand side of the cab directly above the window.

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 and maintenance purposes. Loads cannot be lifted while on manual mode as the capacity is reduced greatly by 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 will prevent 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 can only 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 been selected 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 boom sections are at least 3% out of synchronization. At this point the load would have to be set down, and the manual controls operated to reset the boom.

2.6

2.7

CENTER MID ON

INNER MID

CENTER MID

BOOM MODE

INNER MID ON

OUTER MID FLY

BOOM TELE SECTION SELECT

OUTER MID FLY ON

M A N U A L

A U T O

BOOM NOT SYNC

B BOOM TELE MODE

A

BOOM TELESCOPE SYSTEM

WHERE ARE THE COMPONENTS LOCATED ? VALVES S / S Pressure reducing valve ( 800 P.S.I. ) and rod side dump lie within the turntable uprights. This is also where 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 of the superstructure. The Sequence valve lies just below the 4 - way valve , also on the right side of the superstructure. SWITCHES S / S On the 4 - way valve are the 3 pressure switches which control the opening of the dump valves and the direction of movement inputs to the PAT system. PAT BOX S / S Inside 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 the boom. These numbers indicate the fuse number that corresponds to the valve the relay controls. When troubleshooting any problems, it's always a good idea to check these fuses first. VALVES IN BOOM The 2 way valves for the inner mid are mounted in the rear of the inner mid as shown. Piston flow is to the 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 upper right. 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 BOOM Four Proximity switches are mounted on the left side of the boom. Each of the switches are adjusted to indicate to the PAT system that all the boom sections have been fully retracted. CABLE REELS ON BOOM Three cable reels are mounted on the left side of the boom. The top reel is the basic L.M.I. reel with the small thin cable for A2B. The other two reels have a large cable installed and are primarily used to provide power to the 2 way valves inside the boom. They also pickup inputs from two of the proximity switches to send back to the PAT system.

2.8

2.9

SEQUENCE VALVE 1000 PSI

TELE EXTEND

TMS / TTS 870 & RT865BXL with Boom Control Turntable Components

P.A.T. DS350 GRAPHIC C.P.U. BOARD LOCATION TMS870/TTS870 (5 section boom)

THIRD WRAP K11

K12

MH

AH

VALVE CONTROL BOARD A111

DIGITAL INPUT EXTENSION BOARD A112

DECODER BOARD A110

DIODE BOARD A113

X1 TERMINAL BOARD A104

2.10

MAIN BOARD A101

2.11 (BOTTOM VIEW OF C.P.U.)

CABLE ASSY TO BOOM

PRES. TRAN. CABLE ASSY (ROD)

DATA LOGGER DOWNLOAD RECEPT. (DATA LOGGER OPTIONAL)

KEY BYPASS SWITCH

FUSE (2A)

CRANE INTERFACE CABLE

FUSE (10A)

CABLE ASSY TO BOOM

CABLE ASSY TO CONSOLE

PRES. TRAN. CABLE ASSY (PISTON)

TMS / TTS870 Central Processing Unit 5 - Section Boom

2.12 (BOTTOM VIEW OF C.P.U.)

CABLE ASSY TO BOOM

PRES. TRAN. CABLE ASSY (ROD)

AREA DEF CABLE

DATA LOGGER DOWNLOAD RECEPT. (DATA LOGGER OPTIONAL)

KEY BYPASS SWITCH

FUSE (2A)

CRANE INTERFACE CABLE

FUSE (10A)

CABLE ASSY TO BOOM

CABLE ASSY TO CONSOLE

PRES. TRAN. CABLE ASSY (PISTON)

RT865BXL Central Processing Unit

INNER MID PILOT INNER MID RED GREEN CYL CABLE INNER MID BLACK

WHITE PILOT

INNER MID CYLINDER

OUTER MID PILOT

OUTER MID CYLINDER

CENTER MID CYLINDER

CENTER MID PILOT

OUTER MID BLACK

WHITE CYL

B CENTER MID RED GREEN CYL OUTER MID BLACK

WHITE PILOT

C CENTER MID RED GREEN PILOT

2.13

2.14

See detail “A” See detail “C”

IM % reset switch

PAT

See detail “C”

CM retract and % reset switch

IM retract switch

PAT

OM retract and % reset switch

See detail “C”

IM length sensor LG221

DS350 Graphic - BCS

Boom Control components TMS/TTS 870 and RT 865BXL

PAT

Boom length sensor LG208

CM length and angle sensor LWG221

2.15

PRE - TENSION (LENGTH SENSOR) SPRING BY ROTATING DRUM (35) REVOLUTIONS COUNTER CLOCKWISE. THEN UNSPOOL THE LENGTH CABLE AND SECURE TO BUSHING ON THE INNER - MID PER DETAIL “A”.

PRE - TENSION (LENGTH SENSOR) SPRING BY ROTATING DRUM (30) REVOLUTIONS COUNTER CLOCKWISE. THEN UNSPOOL THE LENGTH CABLE AND SECURE TO BUSHING ON THE CENTER - MID PER DETAIL “B”

3

3

2

2

PAT

PAT

PRE - TENSION (LENGTH SENSOR) SPRING BY ROTATING DRUM (16) REVOLUTIONS COUNTER CLOCKWISE. THEN UNSPOOL THE LENGTH CABLE AND SECURE TO BUSHING ON THE BOOM NOSE PER DETAIL “A”.

5

PAT

8

1

REMOVE 1/4 - 20 NUTS ON BOTTOM OF CABLE GUIDE. INSERT CABLE GUIDE SCREWS THRU EXISTING ANGLE BRKT AND SECURE IN PLACE WITH 1/4 - 20 NUTS REMOVED PREVIOUSLY. CENTER LINE OF CABLE GUIDE MUST BE ALIGNED W/ CENTER LINE OF CABLE REEL DRUM. AFTER MACHINE IS CALIBRATED, REMOVE PROTECTIVE PAPER CORROSION INHIBTOR AND ADHERE TO INSIDE HOUSING COVER SURFACE OF CABLE REEL.

5

7

8

DS350 Graphic - BCS

1

7

7

5

Boom Control components TMS/TTS 870 and RT 865BXL

2.16

0.13

18

See detail “A”

See detail “B”

0.44

3.94

16

6

1.34

PAT

DETAIL “C”

CENTER LINE OF TARGETS & PROXIMITY SW.

0.44

0.44

18

16

6

4

4

1.0

To wi be a t of h c e ligne n ca bl e t e r l d ree ine ld rum

DETAIL “B”

4

DETAIL “A”

INSTALL PROXIMITY SWITCH 0.13” FROM TARGET WHEN BOOM SECTIONS ARE FULLY RETRACTED.

THIS TARGET IS ONLY INSTALLED IF THE BOOM IS EQUIPPED WITH A BOOM EXTENSION STOP BLOCK.

INSTALL PROXIMITY SWITCH 0.44” FROM TARGET WHEN BOOM SECTIONS ARE FULLY RETRACTED.

PLACE (3) TIE WRAPS, 120 DEGREES APART AROUND BUSHING. WRAP CABLE (8-10) REVOLUTIONS OVER THE TIE WRAPS STARTING FROM THE OUTSIDE AND WORKING INWARD. ALLOW AMPLE CABLE TO REACH JUNCTION BOX. SECURE CABLE WITH (2) ADDITIONAL TIE WRAPS.

2.17

CABLE GUIDES ON THE BASE & INNER MID SECTIONS ASSOCIATED WITH TOP AND MIDDLE CABLE REEL MUST BE ALIGNED WITH CENTER OF CABLE REEL DRUM

CENTER LINE OF CABLE GUIDES

19

19

CENTER LINE OF CABLE REEL DRUM

INSTALL SHIMS AS REQUIRED TO ASSURE CENTER LINE OF CABLE REEL DRUMS ARE PARRALLEL TO BOOM BASE SECTION AND PLUMB WHEN CRANE IS ON A LEVEL \ SURFACE.

PARTIAL TOP VIEW

DS350 Graphic - BCS

Boom Control components TMS/TTS 870 and RT 865BXL

HOW DOES THE SYSTEM WORK? HYDRAULIC 1. Pilot operated 4 way valve provides oil flow to extend and retract the 3 telescoping cylinders. On this valve are 2 pressure reducing valves electrically operated by the PAT system. Their function is to reduce the pilot pressure when nearing the point a section must stop in order to slow it down smoothly, then they will increase the pilot pressure back 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 and one for retract. These pressure switches tell the PAT which direction has been selected by the operator, so it will know which 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 joystick pressure 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 be released through a .078 orifice. 2. Two - way valves control the oil to each telescope cylinder. One for the pilot pressure to the holding valve and one for the piston side oil to flow. These are operated in pairs only. When a pair of two-way valves are de-energized, that particular telescope cylinder will then operate. The other two pair of two way - valves must be energized to prevent movement of the other two telescope cylinders. These valves are also switched on and off by the PAT system when in Automatic mode. They are controlled by an individual 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 be released back to tank by the way of a .078 orifice. This valve is controlled by the normally closed contacts of the third pressure 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. This valve is electrically operated by the PAT system and is switched on to dump rod side pressure when the controller is in neutral.

2.18

Sequence valve The sequence valve maintains pressure on the rod side to prevent the cylinders from extending when the 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 first begin 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 the 800 P.S.I. pressure reducing valve when trying to retract.

2.19

ELECTRIC Automatic Mode Proportional voltage is sent by the PAT system to the coils on the 4 - way valve, either to the extend or the retract side as determined by the pressure switches in the joystick lines an the K-5 relay in the PAT system. The current is applied gradually and removed gradually by the PAT system to assure smooth starts and transitions between boom section change over. Extending the inner mid The proportional output building up while extending the inner mid followed by full current and a fully open 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 have dumped momentarily, the current will be reapplied proportionally to allow a smooth start of the center mid. K-5 relay remains energized during the entire process. This is because the operator never left off on the controller and the extend pressure switch always remained in the on position. Retracting the inner mid While retracting the inner mid, followed by full current and a fully open 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 the piston side dump valve stayed energized before, during , and after 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 our normally closed pressure switch kept the piston side dump valve energized and K - 5 relay which directs the proportional voltage never energized. This is a default mode so that if there is an electrical problem current could always be applied to the retract side to bring in the boom in for repairs. Manual Mode Extending the inner and center mid Any time manual mode is selected voltage to the proportional solenoids is at maximum voltage. This means the 4 way valve will respond directly to the input from the controller, without the ramp up and ramp down feature as provided when under control by the PAT system. The 2 way valves for the appropriate sections are controlled by the manual switch. Although it is not required to release the controller to neutral when changing boom sections, it is preferred. When releasing the controller to neutral the rod side and piston side will drain, which will allow for a smooth transition between boom sections when on manual mode. Note that K-5 relay never energizes, now that we are in manual mode both coils on the 4 - way valve will remain energized with full voltage. Retracting the inner and center mid Anytime 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 valve energizes briefly as we stop controller input to change sections, and the piston side dump valve is not energized during retraction.

2.20

OM 2 - WAYS CM 2 - WAYS ANALOG SIG. - RET. VALVE ANALOG SIG. - EXT. VALVE SIG. ANALOG OUTPUT BOR. TELE OUT OF SEQ.

ROD SIDE DUMP IM 2-WAYS

F2

o

o

GND +24 V

10 A

)

3

3 2 1

DE 5

CM / IM RET. SW.

DE 4

OM / FLY RET. / % SW.

-5V

-SIG

GND

86

o 30 o o

K7 = OM / FLY - 2 WAY

87A 87

DS350 Graphic X1 Terminal Board

85

F8

86

o o30 o

K6 = CM 2 - WAY

87A 87

85

F7

86

o 30 o o

K5 = 4 - WAY DIREC. VALVE

87A 87

85

F6

86

o 30 o o

K4 = TELE OUT OF SEQ.

87A 87

85

F5

86

o 30 o o

K3 = ROD DRAIN SOL.

87A 87

85

F4

86

K2 = IM 2 - WAY

o o30 o

87A 87

85

F3

86

K1= NOT USED

o 30 o o

87A 87

85

F2

87A 87

. .

o 30 o oK10

o o o K9

o o o K8

SIG 0-SIG

86

.

K10

o

UB

UB DE 3

AUTO MODE SW. ON

DE 2

PRESS. SW. BOOM RET.

DE 1

PRESS. SW. BOOM EXT.

0 (UB) 0 (UB) RXD TXD UB

-SIG +SIG

-SIG

0 (UB)

85

A2B COMPARATOR

-9V +9V -5V 1 2 3 4

GND

-SIG

-5V +5V GND

X5

-SIG

-5V 40 COND.

+5V GND LEN.(OA) -5V

X6

ANGLE 26 COND.

GND X4 0(UB) +UB

2.21

4 3 2 1

) ) ) )

X4 MEMORY EXTENSION

1

22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

LENGTH RESET SW.

MEASURE PINS

2

48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23

DE 6

2X SERIAL INTERFACE

F1

2A

80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

X1

( ( (

3 2 1

X7 0 (UB) / GND +24 V

X9

BR14

w

w w w

w

PILOT

w

w TEST PORT

w

w

800 PSI

w

ROD DRAIN

TO DUAL RETURN MANIFOLD

PISTON DRAIN

.078 w

)

P1

)

w PRESSURE SWITCH EXTEND

P2 TO CASE DRAIN MANIFOLD

W

W

RET

EXT

~

PRESSURE SWITCH EXTEND

EXT

B A P1 D

RET

B A

49.9 GPM

P1

GP

w

w

220300

w

w

w

w

3650 w

)

w

w

w

w 3800

)

SEQUENCE VALVE WITH CHECK 1000 PSI

1500

3000 w

LS TELE

P2

D

LIFT

W

~

OPEN

PRESSURE SWITCH RETRACT

OUT TO DRAIN MANIFOLD

2.22

PILOT

w

w

w

800 PSI

K3

w

ROD DRAIN

w

)

)

w PRESSURE SWITCH EXTEND

P2

NO

TO CASE DRAIN MANIFOLD

DI 1

RET

A

NC

W

W

EXT

B

~

PRESSURE SWITCH EXTEND

EXT

P1 D

RET

B

A

49.9 GPM

P1

GP

K5

w

220300

w

w

w

w

w

3650 w

)

w

w

w

w

3800

K5

3000

)

SEQUENCE VALVE WITH CHECK 1000 PSI

PISTON DRAIN

.078

TO DUAL RETURN MANIFOLD

P1

1500

w LS TELE

P2

DI 2

~

D

LIFT

W

NO

OUT

PRESSURE SWITCH RETRACT

TO DRAIN MANIFOLD

2.23

w

CYLINDER FULLY RETRACTED

w

w 2.24

PILOT

w

DS350 GRAPHIC BOOM CONTROL SYSTEM “B” MODE Ramping value 1

8

255

2

CENTER MID

INNER MID

6

50 40

0

7

t

3 Proportional solenoid valve 1

Proportional solenoid valve 2

5

4 sec. 0

40

47

50

2 sec.

RT 865BXL TTS/TMS 870 1 2

Maximum Ramping value -valve fully open-

6

Minimum ramping value CM

7

Time based ramping up i.e. 12 cycles = 6 seconds

8

Maximum Ramping value -valve fully open-

Ramping down

3

Minimum ramping value IM

5

Change over point -Ramping value 0-valve closed-

2.25

Length [%]

DS350 GRAPHIC BOOM CONTROL SYSTEM AUTOMATIC MODE EXTEND INNER MID

EXTEND CENTER MID

PROPORTIONAL OUTPUT

PROPORTIONAL VALVE

START

OM 2 WAYS

CM 2 WAYS

CHANGE OVER

CLOSED OPEN

CLOSED OPEN

CLOSED

IM 2 WAYS

OPEN

OPEN

OPEN ROD DRAIN

OPEN CLOSED

K5 RELAY

OPEN CLOSED

OPEN PISTON DRAIN

STOP

OPEN CLOSED

OPEN CLOSED

EXTEND

2.26

DS350 GRAPHIC BOOM CONTROL SYSTEM AUTOMATIC MODE RETRACT INNER MID

RETRACT CENTER MID

PROPORTIONAL OUTPUT

PROPORTIONAL VALVE

START

CHANGE OVER

STOP

CLOSED

OM 2 WAYS

OPEN

CLOSED

CM 2 WAYS

OPEN

CLOSED

IM 2 WAYS

OPEN

OPEN

OPEN ROD DRAIN

OPEN CLOSED

OPEN CLOSED

PISTON DRAIN

K5 RELAY

2.27

DS350 GRAPHIC BOOM CONTROL SYSTEM MANUAL MODE

EXTEND INNER MID

EXTEND CENTER MID PROPORTIONAL VALVE

START

CHANGE OVER

STOP

CLOSED

OM 2 WAYS

OPEN

CLOSED

CM 2 WAYS

OPEN

CLOSED

IM 2 WAYS

OPEN

OPEN

OPEN ROD DRAIN

OPEN CLOSED

CLOSED

OPEN PISTON DRAIN

OPEN

OPEN CLOSED

OPEN CLOSED

K5 RELAY

2.28

DS350 GRAPHIC BOOM CONTROL SYSTEM MANUAL MODE

RETRACT INNER MID

RETRACT CENTER MID PROPORTIONAL VALVE

START

CHANGE OVER

STOP

OM 2 WAYS

CLOSED

CM 2 WAYS

OPEN

CLOSED

IM 2 WAYS

OPEN

OPEN

OPEN ROD DRAIN

OPEN CLOSED

OPEN CLOSED

PISTON DRAIN

K5 RELAY

2.29

DS350 GRAPHIC (BCS) Automode control of two way valves K2 0 1 1 0 0

K6 1 0 1 0 0

K7 1 1 0 0 0

DESCRIPTION IM EXTENDING OR RETRACTING CM EXTENDING OR RETRACTING OM/FLY EXTENDING OR RETRACTING OUT OF SEQUENCE NEUTRAL POSITION

Rod side dump valve logic TMS/TTS 870 and RT 865 BXL Note: K3 is energized in neutral controller position or during the change over transition while both section do not move. DI 1 EXTEND SELECT 0 0 0 0 0 0 0 0 1 1 1 1

DI 2 RETRACT SELECT 0 0 0 0 1 1 1 1 0 0 0 0

DI 4 OM/FLY RETRACTED 0 0 1 1 0 0 1 1 0 0 1 1

DI 5 IM & CM RETRACTED 0 1 0 1 0 1 0 1 0 1 0 1

Analog Outputs ANALOG 1 1

CU DESCRIPTION TERMINAL A111 X1/5 Analog GND for proportional extend or retract solenoid valves. A111 X1/6 Analog signal for proportional extend or retract solenoid valves.

2.30

K3 ROD DRAIN SOLENOID 1 1 1 1 0 0 0 0 0 0 0 0

DS350 GRAPHIC (BCS) Input Output Logic TMS/TTS 870 AND RT 865 BXL Mode

Ext. auto IM Ret. auto IM Ext. auto CM Ret. auto CM Ext. auto OM Ret. auto OM

Ext. DI 1 1 0 1 0 1 0

Ext. manual IM Ret. manual IM Ext. manual CM Ret. manual CM Ext. manual OM Ret.manual OM neutral

Retr. DI 2 0 1 0 1 0 1

1 0 1 0 1 0 0

Relay K2 0 0 1 1 1 1

0 1 0 1 0 1 0

Relay K6 1 1 0 0 1 1

0 0 0 0 0 0 0

Relay K7 1 1 1 1 0 0

0 0 0 0 0 0 0

Relay K5 1 0 1 0 1 0

0 0 0 0 0 0 0

2 way IM 0 0 1 1 1 1

0 0 0 0 0 0 0

2.31

2 way CM 1 1 0 0 1 1

0 0 1 1 1 1 0

2 way OM 1 1 1 1 0 0

1 1 0 0 1 1 0

analog output board 1 1 1 1 1 1

1 1 1 1 0 0 0

Prop.Valve ext. 1 0 1 0 1 0

0 0 0 0 0 0 0

Prop Valve retr. 0 1 0 1 0 1

1 0 1 0 1 0 0

0 1 0 1 0 1 0

DS350 GRAPHIC (BCS) Boom sequence TMS/TTS 870, RT 865 BXL Main Boom Mode AUTO B AUTO B AUTO B AUTO B AUTO B AUTO B AUTO B AUTO B

IM % 0 50 50 75 75 100 100 100

CM % 0 0 50 50 75 75 100 100

OM % 0 0 0 0 0 0 0 100

FLY % 0 0 0 0 0 0 0 100

AUTO A AUTO A AUTO A AUTO A

0 0 0 100

0 100 100 100

0 0 100 100

0 0 100 100

Boom sequence TMS/TTS 870, RT 865 BXL, TM 9100 AND TM9150 boom extensions Mode AUTO AUTO AUTO

IM % 100 100 100

CM % 0 100 100

OM % 0 0 100

2.32

FLY % 0 0 100

PAT DS350 Graphic (BCS) NOTES 1. 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 also an analog signal to the PAT as well. 7.

E-07 error code is generated from voltage noise created across the extend and retract pressures switches. 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 fully retracted, at which time the PAT will automatically reset the retracted boom length percentage as shown: OM / Fly Mid IM IM

0% 0% 1% 0 % ( with boom stop pulled down )

10. Pilot pressure switch signal / Analog output signal Two 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 series wire #20 & A 104 X1-63. Retracting the boom: Pressure switch signal changes from 0V to +24V, electrical flows to retract. Min. current =0mA, max. current=800mA(measure coil current while retracting, meter in series 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 is likely 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 against boom stop. Center mid retract & percentage reset switch: Reset proximity switch provides +24V signal to A 114 or A 112 X1-9. Outer mid / fly retract & percentage reset switch: Reset proximity switch provides +24V signal to A 104 X1-76. Retract proximity switch provides a +24V signal to A 104 X1-78 when boom stop is disengage.

2.34

P.A.T. – L.M.I MANUAL SECTION 3

DS 350 GRAPHIC BCS BOOM LENGTH CONNECTIONS & WIRING DIAGRAMS

80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

DS350 Graphic Boom Length to C.P.U. Connections LG 208 CABLE REEL (TO NOSE)

17

18

R.F. FILTERS

10 9 6

8

5

7 6

A B

5

CORE

1 2

4

1 2 3 3

4 2

3

3

LG

4.7K

SHIELD

2

2

1

1

1 PIN 1 & 5 = GND PIN 3 & 6 = -5V PIN 2 = LENGTH SIGNAL

5 6

3

1 2

BOOM LENGTH SIGNAL RETRACTED = -0.500V MAX RANGE = -4.5V * NOTE - MAX LENGTH SIGNAL VARIES WITH BOOM MAX VOLTAGE - 4.5V IS FOR 10 TURNS ON POT.

Boom Base Junction Box 1

1

A 1

2

3

B 2

3

4

C 3

5

7

E

5

6

8

F

6

3 2 1

TERMINALS : 1-2 & 4-5 ARE JUMP TOGETHER

3.1

48 47 46 45 44 43 42 41 40 39 38 37 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

DE 6

LENGTH RESET SW.

DE 5

CM / IM RET. SW.

DE 4

OM / FLY RET. / % SW.

-5V

-SIG

GND

86

o 30 o o

K7 = OM / FLY - 2 WAY

87A 87

85

F8

86

K6 = CM 2 - WAY

o o30 o

87A 87

85

F7

86

o 30 o o

K5 = 4 - WAY DIREC. VALVE

87A 87

85

F6

86

K4 = TELE OUT OF SEQ.

o 30 o o

87A 87

85

F5

86

o 30 o o

K3 = ROD DRAIN SOL.

87A 87

85

F4

86

K2 = IM 2 - WAY

o o30 o

87A 87

85

F3

86

K1= NOT USED

o 30 o o

87A 87

85

F2

87A 87

. .

o 30 o oK10

o o o K9

o o o K8

SIG 0-SIG

86

.

K10

o

UB

UB DE 3

AUTO MODE SW. ON

DE 2

PRESS. SW. BOOM RET.

DE 1

PRESS. SW. BOOM EXT.

0 (UB) 0 (UB) RXD TXD UB

-SIG +SIG

-SIG

0 (UB)

85

A2B COMPARATOR

-9V +9V -5V

GND

-SIG

-5V +5V GND

-SIG

-5V +5V GND LEN.(OA) -5V ANGLE GND X4 0(UB) +UB

4 3 2 1

) ) ) )

0 (UB) / GND +24 V

8

DS350 Graphic Boom Length to C.P.U. Connections LWG 221 CABLE REEL (TO CM) 20 19 18 17 16 TERMINALS FOR PROX. SWITCHES SEE PG. 12.1-12.4

15 14 13

48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23

Boom Base Junction Box

12 11

1

10

2

A 1

2 10 H 8

9

3

8 7

5

C 3

13 6

D 4

LG

WG

6 5 4

13

3

3

2

2

1

1

80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

TERMINALS : 1-2 & 4-5 ARE JUMP TOGETHER

PIN 1 & 5 = GND PIN 3 & 6 = -5V PIN 2 = LENGTH SIGNAL PIN 4 = ANGLE SIGNAL

BOOM LENGTH SIGNAL RETRACTED = -0.500V MAX RANGE = -4.5V ANGLE SIGNAL 0 DEG. = -3.125V 45 DEG. = -2.50V 90 DEG. = -1.875V * NOTE - MAX LENGTH SIGNAL VARIES WITH BOOM MAX VOLTAGE - 4.5V IS FOR 10 TURNS ON POT.

3 4 1

3.2

22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

DE 6

LENGTH RESET SW.

DE 5

CM / IM RET. SW.

DE 4

OM / FLY RET. / % SW.

-5V

-SIG

GND

86

K7 = OM / FLY - 2 WAY

o 30 o o

87A 87

85

F8

86

o o30 o

K6 = CM 2 - WAY

87A 87

85

F7

86

o 30 o o

K5 = 4 - WAY DIREC. VALVE

87A 87

85

F6

86

o 30 o o

K4 = TELE OUT OF SEQ.

87A 87

85

F5

86

o 30 o o

K3 = ROD DRAIN SOL.

87A 87

85

F4

86

o o30 o

K2 = IM 2 - WAY

87A 87

85

F3

86

K1= NOT USED

o 30 o o

87A 87

85

F2

87A 87

. .

o 30 o oK10

o o o K9

o o o K8

SIG 0-SIG

86

.

K10

o

UB

UB DE 3

AUTO MODE SW. ON

DE 2

PRESS. SW. BOOM RET.

DE 1

PRESS. SW. BOOM EXT.

0 (UB) 0 (UB) RXD TXD UB

-SIG +SIG

-SIG

0 (UB)

85

A2B COMPARATOR

-9V +9V -5V

GND

-SIG

-5V +5V GND

-SIG

-5V +5V GND LEN.(OA) -5V ANGLE GND X4 0(UB) +UB

4 3 2 1

) ) ) )

0 (UB) / GND +24 V

80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

DS350 Graphic Boom Length to C.P.U. Connections LG 221 CABLE REEL (TO IM) 20 19 18 17 16 15 14 TERMINALS FOR PROX. SWITCHES SEE PG. 12.1-12.4

13

Boom Base Junction Box

12 11 10 9 8

1

2

A 1

2

9

G 7

3

5

C 3

7 6 5

LG

4 3

3

2

2

1

1

TERMINALS : 1-2 & 4-5 ARE JUMP TOGETHER

PIN 1 & 5 = GND PIN 3 & 6 = -5V PIN 2 = LENGTH SIGNAL

7 BOOM LENGTH SIGNAL RETRACTED = -0.500V MAX RANGE = -4.5V * NOTE - MAX LENGTH SIGNAL VARIES WITH BOOM MAX VOLTAGE - 4.5V IS FOR 10 TURNS ON POT.

3 1

3.3

48 47 46 45 44 43 42 41 40 39 38 37 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

DE 6

LENGTH RESET SW.

DE 5

CM / IM RET. SW.

DE 4

OM / FLY RET. / % SW.

-5V

-SIG

GND

86

K7 = OM / FLY - 2 WAY

o 30 o o

87A 87

85

F8

86

o o30 o

K6 = CM 2 - WAY

87A 87

85

F7

86

o 30 o o

K5 = 4 - WAY DIREC. VALVE

87A 87

85

F6

86

o 30 o o

K4 = TELE OUT OF SEQ.

87A 87

85

F5

86

o 30 o o

K3 = ROD DRAIN SOL.

87A 87

85

F4

86

o o30 o

K2 = IM 2 - WAY

87A 87

85

F3

86

K1= NOT USED

o 30 o o

87A 87

85

F2

87A 87

. .

o 30 o oK10

o o o K9

o o o K8

SIG 0-SIG

86

.

K10

o

UB

UB DE 3

AUTO MODE SW. ON

DE 2

PRESS. SW. BOOM RET.

DE 1

PRESS. SW. BOOM EXT.

0 (UB) 0 (UB) RXD TXD UB

-SIG +SIG

-SIG

0 (UB)

85

A2B COMPARATOR

-9V +9V -5V

GND

-SIG

-5V +5V GND

-SIG

-5V +5V GND LEN.(OA) -5V ANGLE GND X4 0(UB) +UB

4 3 2 1

) ) ) )

0 (UB) / GND +24 V

3.4

(3 TURNS OF CABLE REEL = 1 TURN OF LENGTH POT. = 0.4V) CHART SHOWS TYPICAL VOLTAGE SIGNALS. THESE VOLTAGES ARE TO BE USED AS A REFERENCE ONLY, THE ACTUAL SIGNAL MAY VARY SLIGHTLY. FOR SPECIFIC BOOM LENGTH VOLTAGES, CHECK VOLTAGES AT MP 6 OR X1-10 AND COMPARE WITH TEST DATA IN CENTRAL UNIT.

CHANNEL # 1

NO. OF TURNS NO. OF TURNS "INPUT" SIGNAL AT "OUTPUT" SIGNAL AT ON CABLE REEL ON LENGTH POT. TERM. X1-10 IN C.U. MP 6 TEST POINT ON MAIN BOARD IN C.U. 0 0 -0.5V 0.5V 3 1 -0.9V 0.9V 6 2 -1.30V 1.30V 9 3 -1.70V 1.70V 12 4 -2.10V 2.10V 15 5 -2.50V 2.50V 18 6 -2.90V 2.90V 21 7 -3.30V 3.30V 24 8 -3.70V 3.70V 27 9 -4.10V 4.10V 30 10 -4.50V 4.50V

PAT DS350Graphic(BCS) MAIN BOOM LENGTH SIGNAL VOLTAGE

X1

CABLE REEL ASS’Y

1

1

0.0V (GND)

8

{

ERROR CODE

FIXED RESISTOR

3 : 1 RATIO

ZERO ADJUSTMENT RETRACTED BOOM

3.5

PRELOAD SPRING 30 REVOLUTIONS COUNTERCLOCKWISE (CENTER REEL)

CH. #1 OPERATING WINDOW

0 1 2 3 4 5 6 7 8 9 10

LENGTH SENSOR 10 K Ω /10 TURNS

.0V

E 11 .500V MIN. WORKING RANGE

{

ERROR CODE

- 500MV (-.500V) “MINIMUM SIGNAL” (RETRACTED BOOM)

2

2

4.50V MAX. E 21 5.0V

10

AMP

TO A/D CONVERTER MP 6 TEST POINT

- 4.50V “MAXIMUM SIGNAL” (10 TURNS ON POT)

MP 6 VOLTAGES + 500MV (.500V) = MIN. SIGNAL (RETRACTED BOOM) +4.50V = MAX. SIGNAL (10 TURNS ON POT) ALL VOLTAGES ARE MEASURED WITH REFERENCE TO GND (TERMINAL X1-8 ON “A104”OR MP 15 ON MAIN BOARD).

CABLE REEL TERMINAL

X1

#

CENTRAL UNIT TERMINAL BOARD WIRE NUMBER TEST POINT ON MAIN BOARD

FIXED RESISTOR

3

3

11

-5V

X1

P.A.T. DS350 Graphic (BCS) BOOM LENGTH MEASURING CHANNEL CHANNEL # 1

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).

-0.50

-5.00

1 2 3 4 5 6 7 8 9 10111213 1415 16

3.6

PAT PAT

ADJUST TOP OF ANGLE SENSOR PARALLEL WITH BOOM.

1 2 3 4 5 6 7 8 9 101112 131415 16

ADJUST LENGTH POTENIOMETER WITH BOOM FULLY RETRACTED, TURN THE CENTER SCREW COUNTERCLOCKWISE TO A SOFT STOP.

3.7

LENGTH MEASUREMENT: CONNECTION BOARD W/VOLTMETER ON X1:8 & X1:11 VOLTMETER SHOULD MEASURE -5.0 VOLTS BETWEEN CONNECTIONS X1 - 8 (NEGATIVE) AND X1 - 11 (POSITIVE).

H8 V2

X3

H7

A2B K9

LMI K8

SHUT OFF

SHUT OFF

H4

H1 V8

R15

V5

OUT OF SEQUENCE

OUTER MID

V11

K7

K4

R9

R10

R16

V1

K1

R3

R4

R17 R18 H10

H5

H6

H3

R14

R8

R5

V3

K10 LEVER LOCKOUT

K2

R2

R6

F4

67 66 65 64 63 62 61 60

IM

X1

77 76 75

D RO

F5

X1 80 79 78

X1

R1

49 48 47 Q

F6

R7

SE

F7

R12

4W

70 69 68

CM

OM

F8

R11

K3

INNER MID

R13

K5

V6

ROD DRAIN

K6

X1

H2 V7

4 - WAY

X4

V9

CENTER MID

V10

8 10 12 14 16 18 20 22 24 26 28 71 72 73 74

H9

X1

7 9 11 13 15 17 19 21 23 25 27 29

F1 -5.00

X1

2 4 6

1 2 3 4

1 3 5

X4

F3

F2

59 58 57 56 55 54 53

X1 52 51 50

X1 43 42 41

40 39 38

X1

37 36 35 34 33 32 31 30

46 45 44 X1

3.8

LENGTH MEASUREMENT: CONNECTION BOARD W/VOLTMETER ON X1:8 & X1:10 WITH BOOM FULLY RETRACTED THEVOLTMETER SHOULD MEASURE -0.50 VOLTS BETWEEN CONNECTIONS X1 - 8 (NEGATIVE) AND X1 - 10 (POSITIVE).

H8 V2

X3

H7

A2B K9

LMI K8

SHUT OFF

SHUT OFF

H4

H1 V8

K7

V5

OUT OF SEQUENCE

OUTER MID

V11

R15

V1

K4

R9

R10

R16

K1

R3

R4

R17 R18 H10

H5

H3

R13

K6

R14

R11

R12

R7

V3

R8

K10 LEVER LOCKOUT

K2

R5

R2

R6

F4

IM

X1

77 76 75

K3

67 66 65 64 63 62 61 60

X1 80 79 78

V6

D RO

F5

Q

F6

X1

R1

49 48 47 SE

F7

K5

4W

70 69 68

CM

OM

F8

V7

ROD DRAIN

X4

V9

4 - WAY

CENTER MID

V10

X1

H2

INNER MID

H6

8 10 12 14 16 18 20 22 24 26 28 71 72 73 74

H9

X1

7 9 11 13 15 17 19 21 23 25 27 29

F1 -0.50

X1

2 4 6

1 2 3 4

1 3 5

X4

F3

F2

59 58 57 56 55 54 53

X1 52 51 50

X1 43 42 41

40 39 38

X1

37 36 35 34 33 32 31 30

46 45 44 X1

3.9

P.A.T. – L.M.I MANUAL SECTION 4

DS 350 GRAPHIC BCS PISTON, ROD CONNECTIONS & WIRING DIAGRAMS

80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

DS350 Graphic Piston Pressure Transducer to C.P.U. Connections

48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23

14

o o o o

13

PRESSURE TRANSDUCER PISTON SIDE

DAVS

D

4

C

3

B

2

A

1

4 3 2 1

4.1

22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

DE 6

LENGTH RESET SW.

DE 5

CM / IM RET. SW.

DE 4

OM / FLY RET. / % SW.

-5V

-SIG

GND

86

K7 = OM / FLY - 2 WAY

o 30 o o

87A 87

85

F8

86

o o30 o

K6 = CM 2 - WAY

87A 87

85

F7

86

o 30 o o

K5 = 4 - WAY DIREC. VALVE

87A 87

85

F6

86

o 30 o o

K4 = TELE OUT OF SEQ.

87A 87

85

F5

86

o 30 o o

K3 = ROD DRAIN SOL.

87A 87

85

F4

86

o o30 o

K2 = IM 2 - WAY

87A 87

85

F3

86

K1= NOT USED

o 30 o o

87A 87

85

F2

87A 87

. .

o 30 o oK10

o o o K9

o o o K8

SIG 0-SIG

86

.

K10

o

UB

UB DE 3

AUTO MODE SW. ON

DE 2

PRESS. SW. BOOM RET.

DE 1

PRESS. SW. BOOM EXT.

0 (UB) 0 (UB) RXD TXD UB

-SIG +SIG

-SIG

0 (UB)

85

A2B COMPARATOR

-9V +9V -5V

GND

-SIG

-5V +5V GND

-SIG

-5V +5V GND LEN.(OA) -5V ANGLE GND X4 0(UB) +UB

4 3 2 1

) ) ) )

0 (UB) / GND +24 V

4.2

CHART SHOWS TYPICAL VOLTAGE SIGNALS. THESE VOLTAGES ARE TO BE USED AS A REFERENCE ONLY, THE ACTUAL SIGNAL MAY VARY SLIGHTLY.

PAT DS350Graphic (BCS) PISTON PRESSURE TRANSDUCER VOLTAGE SIGNALS 0 145 290 435 580 725 870 1015 1160 1305 1450 1595 1740 1885 2030 2175 2320 2465 2610 2755 2900 3045 3190 3335 3480 3625 3770 3915 4060 4205 4350

PRESSURE (P.S.I.)

"INPUT" SIGNAL AT TERM. X1-21 IN CENTRAL UNIT 0 MV. -33.3 MV. -66.6 MV. -99.9 MV. -133.3 MV. -166.6 MV. -199.9 MV. -233.2 MV. -266.6 MV. -299.9 MV. -333.2 MV. -366.5 MV. -399.9 MV. -433.2 MV. -466.5 MV. -499.8 MV. -533.1 MV. -566.5 MV. -599.8 MV. -633.1 MV. -666.4 MV. -699.7 MV. -733.1 MV. -766.4 MV. -799.7 MV. -833.1 MV. -866.3 MV. -899.7 MV. -932.9 MV. -966.3 MV. -999.9 MV. CHANNEL # 2

"OUTPUT" SIGNAL AT MP 4 TEST POINT ON MAIN BOARD IN C.U. 0.5 V. 0.63 V. 0.77 V. 0.89 V. 1.03 V. 1.17 V. 1.29 V. 1.43 V. 1.53 V. 1.69 V. 1.83 V. 1.97 V. 2.09 V. 2.23 V. 2.36 V. 2.49 V. 2.63 V. 2.76 V. 2.89 V. 3.03 V. 3.16 V. 3.29 V. 3.43 V. 3.56 V. 3.69 V. 3.83 V. 3.96 V. 4.09 V. 4.23 V. 4.36 V. 4.50 V.

4.3

~

300 BAR MAX. (4410 PSI)

DAVS 301

PRESSURE TRANSDUCER (PISTON SIDE)

TEST POINT ON MAIN BOARD

WIRE NUMBER

CENTRAL UNIT TERMINAL BOARD

PRESSURE FROM PISTON SIDE OF LIFT CYLINDERS

#

X1

D C B

A

18

X1

19

20

21 AMP

P4

0.0V (GND)

- 5.0V

TO A/D CONVERTER

5.0V

MP 4 VOLTAGES

MP 4 TEST POINT

E 22

4.50V MAX.

.500V MIN.

+4.50V = MAX. SIGNAL (300 BAR PRESSURE) ALL VOLTAGES ARE MEASURED WITH REFERENCE TO GND (TERMINAL X1-19 “A104” OR MP 15 ON MAIN BOARD.)

+ 500MV (.500V) = MIN. SIGNAL (ZERO PRESSURE)

{

ERROR CODE

WORKING RANGE

E 12

.0V

P.A.T. DS350 Graphic (BCS) PISTON PRESSURE MEASURING CHANNEL CHANNEL # 2

2

3

4

{

ERROR CODE

P4 ZERO POINT ADJUSTMENT

+ 5.0V

OUTPUT SIGNAL : ZERO PRESSURE = 0.000V MAX. PRESSURE = -1.0V (+ / - 25 MV)

1

X1

CH. #2 OPERATING WINDOW

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 CONNECTIONS X1:18 (+5.0V) & X1: 19 (GROUND) VOLTMETER SHOULD MEASURE -5.0 VOLTS BETWEEN CONNECTIONS X1:20 (-5.0V) & X1: 19 (GROUND)

H8 V2

H4

V1

A2B K9

LMI K8

SHUT OFF

SHUT OFF

H1 V5

OUT OF SEQUENCE

V8

R17 R18 H10

8 10 12 14 16 18 20 22 24 26 28 71 72 73 74

H9

X1

7 9 11 13 15 17 19 21 23 25 27 29

F1

X1

2 4 6

1 3 5

+5.00

V3

K10 LEVER LOCKOUT

4.4

X1

-5.00

X1

P.A.T. DS350 Graphic

E12 ERROR CODE The following step - by - step procedures, with illustrations, are designed to assist in eliminating error code E12. Since various problems can cause an E12, these procedures will check out the complete piston pressure transducer system.

4.5

TERMINAL BOARD ERROR CODE 12, DRAWING #1

1.

LOWER BOOM ALL THE WAY DOWN, SHUT OFF ENGINE. DISCONNECT HYDRAULIC HOSE FROM LIFT CYLINDER TO THE PISTON SIDE PRESSURE TRANSDUCER SO THAT NO HYDRAULIC PRESSURE IS APPLIED TO TRANSDUCER.

2.

CONNECT A DIGITAL VOLTMETER NEGATIVE (-) LEAD TO X1 - 19 AND POSITIVE (+) LEAD TO X1 - 21 ON TERMINAL BOARD IN THE P.A.T. CENTRAL UNIT VOLTAGE SHOULD BE .000 VOLT +/- .025 VOLT. THIS IS THE OUTPUT SIGNAL FOR THE PISTON PRESSURE TRANSDUCER. RECORD THIS VOLTAGE VDC.

H8 V2

A2B

V1

K9

SHUT OFF H4

7 9 11 13 15 17 19 21 23 25 27 29

H9

LMI K8 SHUT OFF

H1 V8

V5

OUT OF SEQUENCE

X1

PISTON PRESSURE TRANSDUCER OUTPUT SIGNAL = .000 VOLT +/- .025V AT ZERO HYDRAULIC PRESSURE.

R17 R18 H10 H3 V7

ROD DRAIN

4 - WAY

V9

X1

X1

V3

H2 V6

K10 LEVER LOCKOUT

INNER MID

H5

X1

8 10 12 14 16 18 20 22 24 26 28 71 72 73 74

F1

2 4 6

1 3 5

.000

X1

R2

4.6

R1

4.7

TERMINAL BOARD ERROR CODE 12, DRAWING #3

5.

IF UNABLE TO ADJUST VOLTAGE AT “MP4” TO .500V (500MV) WITH POT “P4”, DISCONNECT THE SIGNAL WIRE FROM TERMINAL X1 - 21 ON TERMINAL BOARD AND CONNECT A JUMPER WIRE BETWEEN TERMINAL X1 - 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 BOARD IS DEFECTIVE. REPLACE MAIN BOARD. IF VOLTAGE CAN BE ADJUSTED WITH JUMPER WIRE IN PLACE, PRESSURE TRANSDUCER OR CABLE IS DEFECTIVE.

H8 V2

A2B

V1

K9

SHUT OFF H4

7 9 11 13 15 17 19 21 23 25 27 29

H9

LMI K8 SHUT OFF

H1 V8

V5

OUT OF SEQUENCE

X1

DISCONNECT FROM X1 - 21

R17 R18 H10 H3 V7

ROD DRAIN

4 - WAY

V9

X1

JUMPER WIRE

X1

V3

H2 V6

K10 LEVER LOCKOUT

INNER MID

H5

X1

8 10 12 14 16 18 20 22 24 26 28 71 72 73 74

F1

2 4 6

1 3 5

X1

R2

4.8

R1

PRESSURE TRANSDUCER PLUG ERROR 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.

.

.

C B A D

4.9

80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

DS350 Graphic Rod Pressure Transducer to C.P.U. Connections

48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23

14

o o o o

13

PRESSURE TRANSDUCER ROD SIDE

DAVS

D

4

C

3

B

2

A

1

4 3 2 1

4.10

22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

DE 6

LENGTH RESET SW.

DE 5

CM / IM RET. SW.

DE 4

OM / FLY RET. / % SW.

-5V

-SIG

GND

86

K7 = OM / FLY - 2 WAY

o 30 o o

87A 87

85

F8

86

o o30 o

K6 = CM 2 - WAY

87A 87

85

F7

86

o 30 o o

K5 = 4 - WAY DIREC. VALVE

87A 87

85

F6

86

o 30 o o

K4 = TELE OUT OF SEQ.

87A 87

85

F5

86

o 30 o o

K3 = ROD DRAIN SOL.

87A 87

85

F4

86

o o30 o

K2 = IM 2 - WAY

87A 87

85

F3

86

K1= NOT USED

o 30 o o

87A 87

85

F2

87A 87

. .

o 30 o oK10

o o o K9

o o o K8

SIG 0-SIG

86

.

K10

o

UB

UB DE 3

AUTO MODE SW. ON

DE 2

PRESS. SW. BOOM RET.

DE 1

PRESS. SW. BOOM EXT.

0 (UB) 0 (UB) RXD TXD UB

-SIG +SIG

-SIG

0 (UB)

85

A2B COMPARATOR

-9V +9V -5V

GND

-SIG

-5V +5V GND

-SIG

-5V +5V GND LEN.(OA) -5V ANGLE GND X4 0(UB) +UB

4 3 2 1

) ) ) )

0 (UB) / GND +24 V

4.11

0 145 290 435 580 725 870 1015 1160 1305 1450 1595 1740 1885 2030 2175 2320 2465 2610 2755 2900 3045 3190 3335 3480 3625 3770 3915 4060 4205 4350

PRESSURE (P.S.I.)

"INPUT" SIGNAL AT TERM. X1-16 IN CENTRAL UNIT 0 MV. -33.3 MV. -66.6 MV. -99.9 MV. -133.3 MV. -166.6 MV. -199.9 MV. -233.2 MV. -266.6 MV. -299.9 MV. -333.2 MV. -366.5 MV. -399.9 MV. -433.2 MV. -466.5 MV. -499.8 MV. -533.1 MV. -566.5 MV. -599.8 MV. -633.1 MV. -666.4 MV. -699.7 MV. -733.1 MV. -766.4 MV. -799.7 MV. -833.1 MV. -866.3 MV. -899.7 MV. -932.9 MV. -966.3 MV. -999.9 MV. CHANNEL # 3

"OUTPUT" SIGNAL AT MP 5 TEST POINT ON MAIN BOARD IN C.U. 0.5 V. 0.63 V. 0.77 V. 0.89 V. 1.03 V. 1.17 V. 1.29 V. 1.43 V. 1.53 V. 1.69 V. 1.83 V. 1.97 V. 2.09 V. 2.23 V. 2.36 V. 2.49 V. 2.63 V. 2.76 V. 2.89 V. 3.03 V. 3.16 V. 3.29 V. 3.43 V. 3.56 V. 3.69 V. 3.83 V. 3.96 V. 4.09 V. 4.23 V. 4.36 V. 4.50 V.

CHART SHOWS TYPICAL VOLTAGE SIGNALS. THESE VOLTAGES ARE TO BE USED AS A REFERENCE ONLY, THE ACTUAL SIGNAL MAY VARY SLIGHTLY.

PAT DS350Graphic (BCS) ROD PRESSURE TRANSDUCER VOLTAGE SIGNALS

4.12

~

300 BAR MAX. (4410 PSI)

DAVS 301

PRESSURE TRANSDUCER (ROD SIDE)

TEST POINT ON MAIN BOARD

WIRE NUMBER

CENTRAL UNIT TERMINAL BOARD

PRESSURE FROM ROD SIDE OF LIFT CYLINDERS

#

X1

D C B

A

13

X1

14

15

16 AMP

P5

0.0V (GND)

- 5.0V

TO A/D CONVERTER

5.0V

MP 5 VOLTAGES

MP 5 TEST POINT

E 23

4.50V MAX.

.500V MIN.

+4.50V = MAX. SIGNAL (300 BAR PRESSURE) ALL VOLTAGES ARE MEASURED WITH REFERENCE TO GND (TERMINAL X1-14 “A104” OR MP 15) ON MAIN BOARD.

+ 500MV (.500V) = MIN. SIGNAL (ZERO PRESSURE)

{

ERROR CODE

WORKING RANGE

E 13

.0V

P.A.T. DS350 Graphic (BCS) ROD PRESSURE MEASURING CHANNEL CHANNEL #3

2

3

4

{

ERROR CODE

P5 ZERO POINT ADJUSTMENT

+ 5.0V

OUTPUT SIGNAL : ZERO PRESSURE = 0.000V MAX. PRESSURE = -1.0V (+ / - 25 MV)

1

X1

CH. #3 OPERATING WINDOW

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 CONNECTIOS X1:13 (+5.0V) & X1: 14 (GROUND) VOLTMETER SHOULD MEASURE -5.0 VOLTS BETWEEN CONNECTIOS X1:15 (-5.0V) & X1: 14 (GROUND)

-5.00

H8 V2

H4

V1

A2B K9

LMI K8

SHUT OFF

SHUT OFF

H1 V5

OUT OF SEQUENCE

V8

R17 R18 H10

8 10 12 14 16 18 20 22 24 26 28 71 72 73 74

H9

X1

7 9 11 13 15 17 19 21 23 25 27 29

F1

X1

2 4 6

1 3 5

+5.00

V3

K10 LEVER LOCKOUT

4.13

X1

X1

P.A.T. DS350 Graphic

E13 ERROR CODE The following step - by - step procedures, with illustrations, are designed to assist in eliminating error code E13. Since various problems can cause an E13, these procedures will check out the complete rod pressure transducer system.

4.14

TERMINAL BOARD ERROR CODE 13, DRAWING #1

1.

LOWER BOOM ALL THE WAY DOWN, SHUT OFF ENGINE. DISCONNECT HYDRAULIC HOSE FROM LIFT CYLINDER TO THE ROD SIDE PRESSURE TRANSDUCER SO THAT NO HYDRAULIC PRESSURE IS APPLIED TO TRANSDUCER.

2.

CONNECT A DIGITAL VOLTMETER NEGATIVE (-) LEAD TO X1 - 19 AND POSITIVE (+) LEAD TO X1 - 16 ON TERMINAL BOARD IN THE P.A.T. CENTRAL UNIT VOLTAGE SHOULD BE .000 VOLT +/- .025 VOLT. THIS IS THE OUTPUT SIGNAL FOR THE ROD PRESSURE TRANSDUCER. RECORD THIS VOLTAGE VDC.

2 4 6

1 3 5

X1

H8 V2

A2B

V1

K9

SHUT OFF H4

LMI K8 SHUT OFF

H1 V8

OUT OF SEQUENCE

V5

R17 R18 H10 H3

.000

X1

V3

H2 V6

K10 LEVER LOCKOUT

INNER MID

V7

ROD DRAIN

4 - WAY

V9

8 10 12 14 16 18 20 22 24 26 28 71 72 73 74

H9

7 9 11 13 15 17 19 21 23 25 27 29

ROD PRESSURE TRANSDUCER OUTPUT SIGNAL = .000 VOLT X1 +/- .025V AT ZERO X1 HYDRAULIC PRESSURE.

F1

H5

X1

R2

4.15

R1

4.16

TERMINAL BOARD ERROR CODE 13, DRAWING #3

5.

IF UNABLE TO ADJUST VOLTAGE AT “MP5” TO .500V (500MV) WITH POT “P5”, DISCONNECT THE SIGNAL WIRE FROM TERMINAL X1 - 16 ON TERMINAL BOARD AND CONNECT A JUMPER WIRE BETWEEN TERMINAL X1 - 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 BOARD IS DEFECTIVE. REPLACE MAIN BOARD. IF VOLTAGE CAN BE ADJUSTED WITH JUMPER WIRE IN PLACE, PRESSURE TRANSDUCER OR CABLE IS DEFECTIVE.

A2B

V1

K9

SHUT OFF H4

LMI K8 SHUT OFF

H1 V8

OUT OF SEQUENCE

V5

H10 H3

V3

H2 V6

K10 LEVER LOCKOUT

INNER MID

V7

ROD DRAIN

4 - WAY

V9

X1

JUMPER WIRE X1

R17 R18

H5

X1

8 10 12 14 16 18 20 22 24 26 28 71 72 73 74

H8 V2

7 9 11 13 15 17 19 21 23 25 27 29

H9

DISCONNECT X1 FROM X1 - 16

2 4 6

1 3 5

F1

X1

R2

4.17

R1

PRESSURE TRANSDUCER PLUG ERROR 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.

.

.

C B A D

4.18

P.A.T. – L.M.I MANUAL SECTION 5

DS 350 GRAPHIC BCS BOOM ANGLE CONNECTIONS & WIRING DIAGRAMS

80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49

DS350 Graphic Boom Angle to C.P.U. Connections

48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23

14

o o o o

13

CABLE REEL

17

R.F. FILTERS

18

10 9 8 7

A B

1 2

5 4

1 2 3 3

4 2

3

LG

4.7K

CORE

WG

6 SHIELD

1

2 1

3

1

PIN 1 & 5 = GND PIN 3 & 6 = -5V PIN 2 = LENGTH SIGNAL PIN 4 = ANGLE SIGNAL

3 2 4 1

2

BOOM LENGTH SIGNAL RETRACTED = -0.500V MAX RANGE = -4.5V ANGLE SIGNAL 0 DEG. = -3.125V 45 DEG. = -2.50V 90 DEG. = -1.875V * NOTE - MAX LENGTH SIGNAL VARIES WITH BOOM MAX VOLTAGE - 4.5V IS FOR 10 TURNS ON POT.

5.1

22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

DE 6

LENGTH RESET SW.

DE 5

CM / IM RET. SW.

DE 4

OM / FLY RET. / % SW.

-5V

-SIG

GND

86

K7 = OM / FLY - 2 WAY

o 30 o o

87A 87

85

F8

86

o o30 o

K6 = CM 2 - WAY

87A 87

85

F7

86

o 30 o o

K5 = 4 - WAY DIREC. VALVE

87A 87

85

F6

86

o 30 o o

K4 = TELE OUT OF SEQ.

87A 87

85

F5

86

o 30 o o

K3 = ROD DRAIN SOL.

87A 87

85

F4

86

o o30 o

K2 = IM 2 - WAY

87A 87

85

F3

86

K1= NOT USED

o 30 o o

87A 87

85

F2

87A 87

. .

o 30 o oK10

o o o K9

o o o K8

SIG 0-SIG

86

.

K10

o

UB

UB DE 3

AUTO MODE SW. ON

DE 2

PRESS. SW. BOOM RET.

DE 1

PRESS. SW. BOOM EXT.

0 (UB) 0 (UB) RXD TXD UB

-SIG +SIG

-SIG

0 (UB)

85

A2B COMPARATOR

-9V +9V -5V

GND

-SIG

-5V +5V GND

-SIG

-5V +5V GND LEN.(OA) -5V ANGLE GND X4 0(UB) +UB

4 3 2 1

) ) ) )

0 (UB) / GND +24 V

5.2

"INPUT" SIGNAL AT TERM. B IN CANNON PLUG AND TERM. X1-9 IN C.U. -1.87 -1.93 -2.00 -2.07 -2.14 -2.21 -2.28 -2.35 -2.42 -2.49 -2.56 -2.63 -2.70 -2.77 -2.84 -2.91 -2.98 -3.05 -3.12 CHANNEL # 5

"OUTPUT" SIGNAL AT MP 8 TEST POINT ON MAIN BOARD IN C.U. +.48 +.70 +.92 +1.15 +1.37 +1.60 +1.80 +2.04 +2.26 +2.48 +2.70 +2.92 +3.15 +3.38 +3.60 +3.82 +4.04 +4.27 +4.49

CHART SHOWS TYPICAL VOLTAGE SIGNALS. THESE VOLTAGES ARE TO BE USED AS A REFERENCE ONLY, THE ACTUAL SIGNAL MAY VARY SLIGHTLY.

90 DEGS. 85 DEGS. 80 DEGS. 75 DEGS. 70 DEGS. 65 DEGS. 60 DEGS. 55 DEGS. 50 DEGS. 45 DEGS. 40 DEGS. 35 DEGS. 30 DEGS. 25 DEGS. 20 DEGS. 15 DEGS. 10 DEGS. 5 DEGS. 0 DEGS.

ACTUAL BOOM ANGLE

PAT DS350Graphic (BCS) BOOM ANGLE SIGNAL VOLTAGE

#

X1

TERMINAL STRIP IN JUNCTION BOX

14 SOCKET PLUG JUNCTION BOX BOOM BASE

TEST POINT ON MAIN BOARD

WIRE NUMBER

CENTRAL UNIT TERMINAL BOARD

CABLE REEL TERMINAL

ANGLE SENSOR

0o

90o

BOOM ANGLE SENSOR PENDULUM

5.3

1

13

6

(PART OF THE ANGLE POTENTIOMETER)

FIXED RESISTOR

3

5

6

2

3

4

1

C

D

X1

3 11

4 9

A 1 8

AMP

5.0V

4.50V MAX.

.500V MIN.

TO A/D CONVERTER MP 8 TEST POINT

E 25

WORKING RANGE

E 15

MP 8 VOLTAGES

{

ERROR CODE

{

ERROR CODE

.0V

-5V

+ 500MV (.500V) = 90o ANGLE MIN. SIGNAL + 2.50V = 45o ANGLE +4.50V = 0o ANGLE MAX. SIGNAL ALL VOLTAGES ARE MEASURED WITH REFERENCE TO GND (TERMINAL X1-8 “A104” OR MP 15 ON MAIN BOARD.)

0.0V (GND)

P.A.T. DS350 Graphic (BCS) BOOM ANGLE MEASURING CHANNEL CHANNEL # 5

“MAXIMUM SIGNAL” -3.125V = 0o ANGLE

4

“MINIMUM SIGNAL” -1.875V = 90o ANGLE

(PART OF THE ANGLE POTENTIOMETER)

FIXED RESISTOR

5

X1

CH. #5 OPERATING WINDOW

P.A.T. – L.M.I MANUAL SECTION 6

DS 350 GRAPHIC BCS ANTI - TWO - BLOCK CONNECTIONS & WIRING DIAGRAMS

6.1

4.7K

A B 1 2

1

1 2

1 2 3 3

SHIELD

LENGTH CABLE

4 2

3

CORE

SHIELD

A2B

L.M.I.

CONSOLE BYPASS KEY BLUE

WEIGHT ASS’Y

A2B SWITCH ASS’Y

18

17

1

1

7 6

8

1

5

6

7

+SIG

*

OUTPUT

CENTRAL UNIT TERMINAL BOARD

1 X1

2

UB +24V

SOME MODELS USE MULTIPLE SOLENOID VALVES.

86

87

K9

87A

V3 85 K8 LMI OVERLOAD

A2B ELECTRONICS V2

7

6

6 K9 7

34 0- SIG

35

30

45

44

46

47

48

- # - WIRE NUMBER

X1

FROM CRANE SUPPLY +24V

3

X1 49

PAT DS350 Graphic LMI ANTI TWO BLOCK & SHUTOFF CKT.

14 SOCKET PLUG

6

8

10

1

5

14

13

F2-10A

7

LMI BYPASS KEY (CU)

5

6

73

9

R.F. FILTERS

CABLE REEL

SLIP RINGS

3 GREY

2 2 4 VIOLET

4

1 3 RED

LEVER LOCKOUT SOLENOID VALVE *

UB +24V

K10

30

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 OHMS A2B SWITCH OPEN = GREATER THAN 1 MEGOHM

1 2

4.70

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) OHMS A2B SWITCH OPEN = GREATER THAN 1 MEGAOHM

X2 RED SHEILD X1 BROWN CORE

4.70

X2 : RED

X1 : BROWN

6.3

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) OHMS A2B SWITCH OPEN = GREATER THAN 1 MEGOHM

4.70

1 2 3 4 5 6 7 8 9 101112131415 16

6.4

DRAWING 4: BOOM BASE JUNCTION BOX W/VOLTMETER ON 5 & 6 TURN POWER OFF OR DISCONNECT X1:35 ON CONNECTION BOARD IN CENTRAL UNIT. MEASURE THE RESISTANCE BETWEEN TERMINALS 5 & 6. A2B SWITCH CLOSED = 4700 (+/- 500) OHMS A2B SWITCH OPEN = GREATER THAN 1 MEGAOHM

3 4 5 6 7

1

6.5

2

4.70

DRAWING 5: CONNECTION BOARD W/VOLTMETER ON X1:34 & X1:35 TURN POWER OFF TO CENTRAL UNIT. MEASURE THE RESISTANCE BETWEEN X1:34 & X1:35. A2B SWITCH CLOSED = 4700 (+/- 500) OHMS A2B SWITCH OPEN = GREATER THAN 1 MEGOHM

LMI K8 SHUT OFF

H1 V8

OUT OF SEQUENCE

OUTER MID

V11

K7

R16

R9

V5

K4

K1

R10

R3

R4

R17 R18 H10

H3

R13

R11

R12

R7

V6

K3

R8

R5

F4

D

X1

77 76 75

K10 LEVER LOCKOUT

K2

R2

R6

67 66 65 64 63 62 61 60

IM

RO

F5

Q

F6

X1 80 79 78

V3

R1

49 48 47

SE

70 69 68

F7

K5

4W

4.70

R14

CM

OM

F8

K6

V7

ROD DRAIN

X4

V9

4 - WAY

CENTER MID

V10

X1

H2

INNER MID

H5

H6

X1

71 72 73 74

A2B K9 SHUT OFF H4

R15

V1

X1

X1

8 10 12 14 16 18 20 22 24 26 28

H8 V2

H7

7 9 11 13 15 17 19 21 23 25 27 29

F1 H9

X3

X1

2 4 6

1 2 3 4

1 3 5

X4

F3

F2

59 58 57 56 55 54 53

X1 52 51 50

X1 43 42 41

40 39 38

X1

37 36

35 34 33 32 31 30

46 45 44

X1

6.6

DRAWING 6: CONNECTION BOARD W/TEMPORARY 4.7k RESISTOR INSTALLED TURN POWER OFF TO CENTRAL UNIT. INSTALL THE RESISTANCE BETWEEN X1:34 & X1:35. TURN POWER ON TO CENTRAL UNIT AND THE A2B ALARM SHOULD BE INACTIVE.

X3

R15

K4

R16

R9

R10

K1

R3

71 72 73 74

K7

8 10 12 14 16 18 20 22 24 26 28

LMI K8 SHUT OFF

7 9 11 13 15 17 19 21 23 25 27 29

A2B K9 SHUT OFF

2 4 6

1 3 5

1 2 3 4

F1

R4

K10 K6

K5

K3

LEVER LOCKOUT

K2

X4 R13

R14

R11

R12

R7

R8

R5

R2

R6

R1

49 48 47 F8 70 69 68

80 79 78

77 76 75

F7

F6

F5

F4

67 66 65 64 63 62 61 60

43 42 41

40 39 38

37 36

F3

F2 59 58 57 56 55 54 53

35 34 33 32 31 30

4.70kΩ

6.7

52 51 50

46 45 44

P.A.T. – L.M.I MANUAL SECTION 7

DS 350 GRAPHIC BCS DIGITAL INPUTS

DS350 GRAPHIC (BCS) Digital Inputs INPUT 1

CU DESCRIPTION TERMINAL A104 TELE EXTEND (+24V) X1/38

NOTES GROVE PRESSURE SWITCH SIGNAL

2

A104 X1/40

TELE RETRACT (+24V)

GROVE PRESSURE SWITCH SIGNAL

3

A104 X1/42

AUTO MODE SELECTED (+24V)

GROVE SELECTOR SWITCH SIGNAL

4

A104 X1/76

PROX. SWITCH OM/FLY RETRACTED PAT SWITCH ON CM - SIGNAL VIA CM & OM/FLY % RESET (+24V) CABLE REEL

5

A104 X1/78

PROX. SWITCH CM/IM RETRACTED (+24V)

PAT SWITCH ON BOOM BASE

6

A104 X1/80

PROX. SWITCH IM % RESET (+24V)

PAT SWITCH ON BOOM BASE

E1

A112/A114 HOUSE LOCK PIN SWITCH SIGNAL X1/1

GROVE LIMIT SWITCH (RT865BXL ONLY)

E2

A112/A114 AUTO MODE A = ON X1/3 AUTO MODE B = OFF

GROVE SELECTOR SWITCH SIGNAL (NOT FOR RT865BXL)

E3

A112/A114 FRONT O/R OVERLOAD X1/6 (GROUND SIGNAL)

GROVE FRONT O/R SWITCH SIGNAL (NOT FOR RT865BXL)

E4

A112/A114 AREA DEFINATION SWITCH X1/7 ON RUBBER

SWIVEL LIMIT SWITCH (RT865BXL ONLY)

E5

A112/A114 PROX. SWITCH CM RETRACTED & X1/9 CM % RESET (+24V)

PAT SWITCH ON IM - SIGNAL VIA IM CABLE REEL

7.1

P.A.T. – L.M.I MANUAL SECTION 8

DS 350 GRAPHIC BCS CENTRAL UNIT, P.C. BOARD LAYOUT & CONNECTIONS

P.A.T. DS350 Graphic (BCS) 5 - Section Boom - Main Board

Power Supply Test Points: MP 1 = +5V MP 2 = -5V MP 11 = Ground H-4 MP 12 = +5V MP 13 = Digital Ground MP 15 = Analog Ground MP 19 = -5V

Analog Measuring Channels / Test Points: Ch. 1 Boom Length - MP 6 / P6(Do Not Adjust) Ch. 2 Piston Pressure - MP 4 / P4 Ch. 3 Rod Pressure - MP 5 / P5 Ch. 5 Bom Angle - MP 8 / P8(Do Not Adjust)

E-1 E-4 B-7 B-7 E-1 E-1

8.1

G-3 G-4 G-3 G-2

DS350 GRAPHIC BCS X1 Terminals A104 Board X1 TERM.

DESCRIPTION

X1 TERM.

DESCRIPTION

1,2 3,4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24 25 26 27 28 29 30 31 32 33,36 34 35 37 38 39 40 41 42

24V Battery - Input GND () Battery - Input F1 (2 amp) GND F1 (2 amp) Load Side ub GND (Inner Shield Connection) GND Boom Angle Signal Boom Length Signal -5Volt Supply/Length/Angle Transducer GND (Inner Shield Connection) +5Volt Supply/Piston Pressure Transducer GND -5Volt/Rod Pressure Transducer Rod Pressure Signal GND (Inner Shield Connection) +5Volt Supply/Piston Pressure Transducer GND -5Volt Supply/Piston Pressure Transducer Piston Pressure Signal GND (Inner Shield Connection) Length (I/M) Signal -5Volt Supply / Length Sensor +9 Volt Supply/Force Transducer -9 Volt Supply/Force Transducer + Force Signal - Force Signal 24V (ub) TXD Data Transmit to Console RXD Data Received from Console GND (oub) 0 Signal A2B A2B Signal Digital Input 1 (-) Digital Input 1 (+) Tele Ext. Press. SW. Digital Input 2 (-) Digital Input 2 (+) Tele Retr. Press. SW. Digital Input 3 (-) 8.2 Digital Input 3 (+) Auto Mode

43 44

+C/M Prox. Switch LMI Shut-off Signal (LMI By Pass Key) +24V (ub) from F1 (2amp) (LMI By Pass Key) A2B Shut off Signal (A2B By Pass Key) +24V Battery from F2 (10 amp) Output to Lever Lockout K10 LMI Lockout Alarm Not Used K2 +24V K2 (NO) I/M 2 way valve Not Used K3 +24V K3 (NO) Tele Rod Drain Sol. Not Used K4 +24V Not Used K4 (NO) Tele out of Seq. Sol. K5 +24V K5 (NO) Extend K5 (NC) Retract K6 +24V K6 (NO) C/M 2 way valve Not Used K7 +24V K7 (NO) O/M - Fly 2 way valve Not Used Length Signal C/M -5V Digital Input 4 GND Digital Input 4 Prox. Switch O/M Fly Retract Digital Input 5 GND Digital Input 5 Prox. Switch CM/IM Retract Digital Input 6 GND Digital Input 6 Prox. Switch Length Reset

45 46 47 48 49 50,51,52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70,71,72 73 74 75 76 77 78 79 80

P.A.T. DS350 Graphic (BCS) 5 - Section Boom - X1 Terminal Board (A104)

V1

K9

A2B

LMI K8

SHUT OFF

X3

H7

H4

H1 V8

OUT OF SEQUENCE

OUTER MID

V11

R15

SHUT OFF

K7

R16

R9

V5

K4

K1

R10

R3

R4

R17 R18 H10

H6

H3

R13

R11

R12

R7

V6

K3

R8

R5

X1

77 76 75

K10 LEVER LOCKOUT

K2

R2

R6

F4

64 63 62 61 60

IM

67 66 65

F5

D RO

F6

X1 80 79 78

V3

R1

49 48 47

Q SE

F7

K5

4W

70 69 68

R14

CM

OM

F8

K6

V7

ROD DRAIN

X4

V9

4 - WAY

CENTER MID

V10

X1

H2

INNER MID

H5

X1

71 72 73 74

H8 V2

X1

X1

8 10 12 14 16 18 20 22 24 26 28

H9

7 9 11 13 15 17 19 21 23 25 27 29

F1

X1

2 4 6

1 2 3 4

1 3 5

X4

F3

F2

59 58 57 56

X1 55 54 53

52 51 50

X1 43 42 41

40 39 38

37 36 35

34 33 32 31 30

46 45 44 X1

X1

8.3

DS350 GRAPHIC (BCS) Relay Outputs INPUT K1

DESCRIPTION CU TERMINAL NOT USED A104 X1/52

NOTES NONE

K2

A104 X1/54

2 - WAY IM SOLENOID VALVES (2) PILOT PRESSURE PISTON SIDE PRESSURE

OFF = IM EXTENDS OR RETRACTS ON = IM IS NOT ALLOWED TO MOVE REFER TO TRUTH TABLE 1

K3

A104 X1/57

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

A104 X1/61

TELE OUT OF SEQUENCE

PROVIDES SIGNAL TO GRV WARNING LIGHT

K5

A104 X1/62

ANALOG OUTPUT SIGNAL FROM ANALOG BOARD

ANALOG OUTPUT TO PROPORTIONAL SOLENOID VALVES, EXTEND & RETRACT, RELAY K5 SELECTS EXTEND OR RETRACT

K5

A104 X1/63

ANALOG OUTPUT SIGNAL TO PROPORTIONAL EXTEND SOLENOID VALVE

MAXIMUM 800mA TO EXTEND VALVE ONE VALVE FOR ALL SECTIONS

K5

A104 X1/64

MAXIMUM 800mA TO RETRACT VALVE ONE ANALOG OUTPUT SIGNAL TO PROPORTIONAL RETRACT SOLENOID VALVE FOR ALL SECTIONS VALVE

K6

A104 X1/66

2 - WAY CM SOLENOID VALVES (2) PILOT PRESSURE PISTON SIDE PRESSURE

K7

A104 X1/69

2 - WAY OM/FLY SOLENOID VALVES OFF = OM/FLY EXTENDS OR RETRACTS ON = (2) PILOT PRESSURE PISTON SIDE OM/FLY IS NOT ALLOWED TO MOVE PRESSURE

K8

A104 X1/44

LMI CUT OFF INTERNAL RELAY

CONNECT LMI BYPASS VIA DIODE ASSEMBLY FROM GRAPHIC CONSOLE AND CU KEY SWITCH

K9

A104 X1/46

A2B CUT OFF INTERNAL RELAY

CONNECT A2B BYPASS FROM GRAPHIC CONSOLE

K10

A104 X1/48

LMI UNLOCK RELAY OUTPUT

POWERS THE LMI UNLOCK SOLENOID WHEN NO OVERLOAD, A2B OR ERROR CONDITION

K10

A104 X1/49

EXTERNAL ALARM OUTPUT

USED FOR EEC UNITS ONLY

8.4

OFF = CM EXTENDS OR RETRACTS ON = CM IS NOT ALLOWED TO MOVE

P.A.T. DS350 Graphic (BCS) 5 - Section Boom - Diode Board(A113) 24 000 35 0003 PAT BS Z:E

XD1

12 11 10

9

XC1 8

7

6

X1

XB1 5

XA1

4

3

2 1

X1

P.A.T. DS350 Graphic (BCS) 5 - Section Boom - Valve Control Board (A111) MP11

MP4 MP5

MP6 MP7

..

J3

1

3

..

1

X3 MP10

J1

X2

..

J2 3

MP3MP2 MP8

MP1

X1

F1

8.5

P.A.T. DS350 Graphic (BCS) 5 - Section Boom - Digital Input Extention Board (A112) X2/IN X3/OUT

MP5 MP1

+5V

MP4

MP2

MP3

MP6 GND C11 C12

MP0

H12

H11

H10

H9

H8

H7

H6

H5

H4

H3

7 8

H13

H2

6

H14

4 5

H15

H1

1 2 3

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

H16

1 30

25

15

20

8.6

10

5

3

2

DS350 GRAPHIC (BCS) PAT - GROVE Interface Grove wire number

Interface connector

Description

71 51 73 387 388 239 242 243 244 [507] [505] [338] 323 [74] [744] 240 147 238 1083 255 257

A

POWER SUPPLY +24V

B

CRANE GND

C

LMI UNLOCK SOLENOID (RELAY OUTPUT)

D

TELE EXTEND PRESSURE SWITCH (INPUT)

E

TELE RETRACT PRESSURE SWITCH (INPUT)

F

HIGH = AUTO MODE, LOW = MANUAL MODE (INPUT)

G

SELECT OM / FLY IN MANUAL MODE (INPUT)

H

SELECT CM IN MANUAL MODE (INPUT)

J

SELECT IM IN MANUAL MODE (INPUT)

K

3RD WRAP CUT OFF MAIN HOIST RT ONLY

L

3RD WRAP CUT OFF AUX. HOIST RT ONLY

M

3RD WRAP WARNING LIGHT (GND) RT ONLY

N

TELE OUT OF SEQUENCE SIGNAL (RELAY OUTPUT)

O

ADDITIONAL EXTERNAL ALARM (RT ONLY EEC)

P

HOUSE LOCK PIN SWITCH - PICK & CARRY

Q

AUTO MODE A = HIGH, AUTO MODE B = LOW (INPUT)

R

FRONT OUTRIGGER OVERLOAD (INPUT)

S

PROPORTIONAL TELE - SOLENOID GND.

T

TELE ROD DRAIN SOLENOID VALVE SIGNAL

U

PROPORTIONAL TELE - SOLENOID (EXTEND)

V

PROPORTIONAL TELE - SOLENOID (RETRACT)

W X

8.7

IS

TELE RETRACT PROP SOL

TELE EXT PROP SOL

A111 1 X1

2 3

13 14 15 20 21

23 - SOCKET RECEPT S/S HARNESS (REF)

TMS/TTS 870 INTERFACE TELE PROP ANALOG GND

56 57 1 2 3 4 48 38 40 42 36 37 39 41 75 77 79 59 61 49 62 63 64

TELE ROD DRAIN SOL

7 19 10 11 12

240 147 238 1083 255 257

8

FRONT O/R OVERLOAD

6 9

HIGH SIGNAL = AUTO MODE A NO SIGNAL = AUTO MODE B

5

323

To Boom Base Junction Box 4

TELE OUT OF SEQ.

B 3

CM TELE

2

IM TELE

8 10 2 3 5 7 11 12 13 14 1

OM/FLY TELE

9

TELE RETRACT PRESS. SW.

6

HIGH=AUTO / NONE=MANUAL

4

7 8

TELE EXT. PRESS. SW.

8.8 1

5 6

LMI UNLOCK SOLS

K7 (COM) +24V

68 69

GND

A113 4 X1

71 51 73 387 388 239 242 243 244

K6 (COM) +24V K6 (NO) +24V TO CM 2-WAY SOLS

65 66

+24V

K2 (COM) +24V K2 (NO) +24V TO IM 2-WAY SOLS

53 54

4 5 6

18

LMI - CRANE INTERFACE 23 - PIN PLUG

1 2 3 4 5 6 7 8 9 101112 13 14 15 16 17 1819 20 2122 23 24 25 A B C D E F G H J KLM N O P Q R S T UV W X A B C D E F G H J KLM N O P Q R S T UV W X

16

5 6 9 10

DI E5 GND

DI E5 (+24V=CM RET)

DI E3 (GND=FRONT O/R OL)

A114 3 4 X1

DI E3 (+24V)

[ +24=MODE A 0V=MODE B DI E2 GND DI E2

A1 (PROP)

AGND

GND

GND

+24V

+24V

K5 (NC) OUTPUT TO RET PROP

K5 (COM) K5 (NO) OUTPUT TO EXT PROP

K10 (NC) +24V TO LMI L/O ALARM

K4 (COM) +24V K4 (NC) +24V TO TELE OUT OF SEQ

DI 6 GND

DI 4 GND DI 5 GND

DI 2 GND DI 3 GND

DI 1 GND

DI GND

DI 2 (+24V=TELE RET PRES SW) DI 3 (+24V=AUTO MODE

DI 1 (+24V=TELE EXT PRES SW)

K3 (NO) +24V TO TELE ROD DRAIN +24V +24V GND GND K10 (NO) +24V TO LMI UNLOCK SOLS

K3 (COM) +24V

K7 (NO) +24V TO OM/FLY 2-WAY SOLS

+24V

IS

CONTINUED FROM PAGE 12.1 22 47

DI EXTENSION BOARD 24 350 300 301

9 10 11 12 7 12

9 8

17 22 23 24 25

P.A.T. – L.M.I MANUAL SECTION 9

DS 350 GRAPHIC BCS BASIC 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= - 9V @ MP 16= + 5V @ MP 17= - 5V @ MP 19= +5V @ MP 1= -5V @ MP 2=

VDC MP 15 Ground - Force Transducer VDC MP 15 Ground - Force Transducer VDC MP 15 Ground - Internal to Board VDC MP 15 Ground - Internal to Board VDC MP 15 Ground - Internal to Board VDC MP 15 Ground - Jib Angle, Length / Angle Rod, Piston VDC MP15 Ground - Piston & Rod Pressure VDC MP 13 Ground - Internal to Board VDC MP 15 Ground - Internal to Board VDC MP 15 Ground - Internal to Board

+5V @ MP 18= +5V @ MP 12 = +12V @ MP 21= + 6V @ MP 20 = 4.

5.

6.

Boom Length: (MP 15 Ground for Meter) Fully Retracted Ft. Fully Extended Ft. - 5 Volt Reference Voltage

VDC @ X1-10 VDC @ X1-10 VDC @ X1-11

Boom Angle: (MP 15 Ground for Meter) Minimum Angle Degs. Maximum Angle Degs. - 5 Volt Reference Voltage

VDC @ X1-9 VDC @ X1-9 VDC @ X1 -11

Pressure Transducers: (MP 15 Ground for Meter) Piston Zero Point VDC @ X1-21 VDC @ MP 4 Rod Zero Point VDC @ X1-16 VDC @ MP 5 +5 Volt Reference Voltage @ X1-13 & 18 - 5 Volt Reference Voltage @ X1-15 & 20

9.1

VDC @ MP 6 VDC @ MP 6

VDC @ MP 8 VDC @ MP 8

P.A.T. DS350 Graphic (BCS) 5 - Section Boom - Main Board (A101)

Power Supply Test Points: MP 1 = +5V MP 2 = -5V MP 11 = Ground H-4 MP 12 = +5V MP 13 = Digital Ground MP 15 = Analog Ground MP 19 = -5V

Analog Measuring Channels / Test Points: Ch. 1 Boom Length - MP 6 / P6(Do Not Adjust) Ch. 2 Piston Pressure - MP 4 / P4 Ch. 3 Rod Pressure - MP 5 / P5 Ch. 5 Bom Angle - MP 8 / P8(Do Not Adjust)

E-1 E-4 B-7 B-7 E-1 E-1

9.2

G-3 G-4 G-3 G-2

P.A.T. – L.M.I MANUAL SECTION 10

DS 350 GRAPHIC BCS MAIN BOARD & TRANSDUCER REPLACEMENT PROCEDURE

P.AT DS350 Graphic TMS/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 right of 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 be checked and readjusted with no hydraulic pressure applied to the pressure transducers

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 terminal X1/21 for piston signal. Signal voltage should be .000 volt +/- .025 volts. B. Refer to instructions on pages 10.3 and 10.4 for adjustment of pressure channel zero points. If the main board is replaced, the data and system EPROM must be removed from the old board and installed on the new board. Refer to page 10.5 for EPROM location.

10.1

TERMINAL BOARD

V2

V1

K9

SHUT OFF

LMI K8 SHUT OFF

H1

OUT OF SEQUENCE

V5

PISTON PRESSURE TRANSDUCER OUTPUT SIGNAL = .000 VOLT +/- .025V AT ZERO HYDRAULIC PRESSURE.

R17 R18 H10 H3 V7

ROD DRAIN

4 - WAY

V9

.000

X1

V3

H2 V6

K10 LEVER LOCKOUT

INNER MID

H5

8 10 12 14 16 18 20 22 24 26 28 71 72 73 74

7 9 11 13 15 17 19 21 23 25 27 29

H8

V8

2 4 6

1 3 5

H9

H4

X1

ROD PRESSURE TRANSDUCER OUTPUT SIGNAL = .000 VOLT X1 X1 HYDRAULIC +/- .025V AT ZERO PRESSURE.

.000

F1

A2B

X1

R2

10.2

R1

10.3

10.4

10.5

P.A.T. – L.M.I MANUAL SECTION 11

DS 350 GRAPHIC BCS TROUBLESHOOTING GUIDE

GENERAL FLOWCHART

This section explains how to handle a problem that may arise with the P.A.T. Load Moment Indicator 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 you to one of the more detailed flowcharts shown on pages 11.2-11.40.

START

What’s Wrong?

Lever Lockout Activated

Length Cable Problem

Go to Page 11.2

Go to Page 11.3

Wrong Length Displayed

Go to Page 11.10

Wrong Angle Displayed

Go to Page 11.32

No Display

Go to Page 11.4

No Function Anti-Two-Block

Go to Page 11.7

Wrong Load Displayed

Bad Data Transfer Console/CPU

Interface Problem

Go to Page 11.35

Go to Pages 11. 38

Go to Page 11.40

Error Code Displayed

Go to Page 11.41 11.1

LEVER LOCKOUT ACTIVATED PROBLEM The lever lockout system of the crane is activated. Crane movements “hoist up”, telescope out”, and “boom down” are stopped. Crane is not in overload or two-block condition.

START

Set the override key switch in central unit into upper position to override LMI.

fixed?

YES

NO Does light in console indicate Anti-Two-Block warning?

NO

Fault in crane electric or hydraulic system.

Check lever lockout system in crane

YES

If console display is blank, fault is located in power supply, wiring or fuses.

Fault in Anti-Two Block system.

If Load Moment Limit Light (7) displays fault is located in LMI, cables, wiring, fuses or console.

Go to Page 11.4

Go to Page 11.7

Read error code displayed on console display (1) and go to Page11.41.

11.2

BROKEN LENGTH CABLE PROBLEM Damaged 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 PROBLEM Blank console display. No warninglight shown. Crane movements stopped.

START

Check fuses on CPU box.

correct?

NO

Replace fuses.

YES Measure crane voltage on terminal board (terminal 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 18V system will switch off.

correct?

NO

Check crane power supply for faulty crane electric or if power supply is too low.

YES

Measure crane voltage on terminal board (terminal block X4) between Pin 2 (+24V) and Pin 3 (ground). Refer to Drawing 3, “Terminal Board”, on page 11.50.

correct?

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.

NO

YES

NEXT PAGE

11.4

NO DISPLAY continued 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 connectors between terminal board and main board. Check wiring and connections.

NO

YES

Measure voltages out of power supply between: MP 15 = ground (analog) and MP 1 = +5V MP 15 = ground (analog) and MP 2 = -5V MP 13 = ground (digital) and MP 12 = +5V MP 15 = ground (analog) and MP 18 = +5V MP 15 = ground (analog) and MP 19 = -5V MP= Measuring Points on Main Board. Refer to Drawing 4, “Main Board”, on page 11.51.

correct?

Short circuit in external wiring. Check external wiring of system for defects.

NO

YES

NEXT PAGE

11.5

NO DISPLAY continued PREVIOUS PAGE

Disconnect ribbon cables from X2 and X3 of main board. Measure voltages out of power supply between: MP 15 = ground (analog) and MP 1 = +5V MP 15 = ground (analog) and MP 2 = -5V MP 13 = ground (digital) and MP 12 = +5V MP 15 = ground (analog) and MP 18 = +5V MP 15 = ground (analog) and MP 19 = -5V MP= Measuring Points on Main Board. Refer to Drawing 4, “Main Board”, on page 11.51.

correct?

Defective power supply on main board. Replace main board and reset pressure channels - see Section 10.

NO

YES

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.

correct?

Fault in wiring between terminal block X1 and console board. Check wiring. Refer to Drawing 5, “Console Board”, on page 11.52.

NO

YES

Replace console board.

END

11.6

ANTI-TWO-BLOCK PROBLEM PROBLEM Function of Anti-Two-Block System is faulty.

START Check to see whether or not crane is in two-block condition.

NO Lower hook down in safe position.

correct?

YES

Check if jumper / dummy plug is plugged into receptacle at boom nose.

NO correct?

Plug appropriate plug into socket of junction box.

YES Remove jumper / dummy plug and check function of anti-two-block switch with ohmmeter between terminals 1 and 2 in the receptacle.Switch closed=4700 + 500 Ohms (weight installed) Switch open => 1 Megaohm (weight removed) Safe Condition = 0 ohm Block-To-Block = > 1 megaohm NO correct?

YES NEXT PAGE

11.7

Replace Anti-Two-Block switch.

ANTI-TWO-BLOCK PROBLEM PREVIOUS PAGE

Disconnect wire from terminal block X1, Pin 35 in central unit. Measure between Pin 1 and Pin 2 of receptacle at boom nose with ohmmeter. Switch closed = 0 Ohm Switch open = >1 Megohm

NO correct?

Fault in wiring cable from Anti-Two-Block switch to junction box at boom nose or short circuit in length cable. Check wiring.

YES

For next measurement reconnect jumper / dummy plug, then disconnect length cable from slip rings 7 / 8 in cable reel. With ohmmeter, measure between center and shield of length cable. Anti-Two-Block switch open = > 1 megohm Anti-Two-Block switch closed = 4700 Ohms + 500 Ohms. Reconnect length cable to slip ring.

Faulty wiring between receptacle at boom nose and cable reel or damaged length cable. Check out wiring. In case of damaged length cable, replace length cable

NO correct?

YES

NEXT PAGE

11.8

ANTI-TWO-BLOCK PROBLEM PREVIOUS PAGE

Check Anti-Two-Block signal in central unit. With ohmmeter measure between wire disconnected from terminal block X1, Pin 35 and Pin 34. Anti-Two-Block switch closed = 4700 Ohms + 500 Ohms Anti-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 diagram for wires # 5 (+) and # 6 (-). If fault is found check cable.

NO correct?

YES

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.

NO

If problem still exist, replace main board and reset pressure channel.

correct?

YES

END

11.9

BOOM LENGTH PERCENTAGE PROBLEM A.

Boom Length Percentage Error Boom length percentage error

Keep the boom stop block latched. Switch to Manual Mode and retract the boom completely.

Is the percentage reading (1%, 0%, 0%)? Yes

No Continue to Page 11.15

The LMI does not recognize the one or more reset switch signals. Check proximity switch target adjustment , If damage is visible install new switch.

Measure voltage supply to IM switch at terminal 1 or 2 (+24V) and 5 or 6 (GND) in the junction box at the front of the boom base.

Is the Voltage Correct?

No

Yes Keep the inner mid section retracted. Measure the inner mid reset switch signal at terminal 3 (24V) and 5 (GND) in the junction box at the front of the boom base section.

Next Page

Faulty voltage supply wiring to switch. Replace defective cables.

11.10

BOOM LENGTH PERCENTAGE PROBLEM Previous Page

Is the voltage correct ?

No

Yes

Measure the IM reset switch signal at terminal 5 (24V) and 9 (GND) in the length sensor LG221.

Is the Voltage Correct ?

Defective IM reset switch. Replace proximity switch.

No

Yes Measure the IM reset switch signal at terminal 15 (24V) and 14 (GND) in the boom base junction box.

Is the voltage correct?

Faulty wiring in cable connecting the junction box with the length sensor.

No

Yes

Measure the IM reset switch signal at central unit terminal A104 80 (24V) and A 101 36 (GND).

Is the voltage correct?

Faulty wiring in cable connecting the length sensor LG221 and the boom base junction box.

No

Yes Measure the CM reset switch signal at terminal 10 (24V) and 9 (GND) in the length sensor LG221.

Defective CM reset switch Replace proximity switch.

Next Page

11.11

BOOM LENGTH PERCENTAGE PROBLEM Previous Page

Is the voltage correct ?

No

Yes Measure the CM reset switch signal at terminal 30 (24V) and 14 (GND) in the boom base junction box.

Is the voltage correct ?

Faulty wiring in cable connecting the junction box with the length sensor.

No

Yes Measure the CM reset switch signal at central unit terminal Al14-9 (24V) and A l04-36 (GND).

Is the voltage correct ?

Faulty wiring in cable connecting the boom base junction box with the LG221.

No

Yes Measure voltage supply to OM switch at terminal 11 (+24V) and 9 (GND) in the center mid junction box.

Is the voltage correct ?

Faulty wiring in cable connecting the central unit and the boom base junction box.

No

Yes Measure voltage supply to CM switch at terminal 7 (+24V) and 5 (GND) in the inner mid junction box.

Next Page

Faulty wiring in cable connecting the central unit and the boom base junction box.

11.12

BOOM LENGTH PERCENTAGE PROBLEM Previous Page

Is the voltage correct ?

No

Yes Keep the outer mid (OM) section retracted. Measure the OM reset switch signal at terminal 10 (24V) and 9 (GND) in the center mid junction box .

Is the voltage correct ?

Faulty voltage supply wiring to switch. Replace defective cables.

No

Yes Measure the CM reset switch signal at terminal 10 (24V) and 9 (GND) in the length- angle sensor LWG221.

Is the voltage correct ?

Faulty wiring in cable connecting the center mid junction box and the LWG 221.

No

Yes

Measure the OM reset switch signal at terminal 17 (24V) and 14 (GND) in the boom base junction box.

Faulty wiring in cable connecting the junction box with the length sensor.

Next Page

11.13

BOOM LENGTH PERCENTAGE PROBLEM Previous Page

Is the voltage correct ?

No

Yes Measure the OM reset switch signal at central unit terminal Al04-78 (24V) and Al04-36 (GND).

Faulty wiring in cable connecting the boom base junction box with the LWG 221.

Is the voltage correct ?

Defective digital input 4, 5 on main board or digital input 5 on extension board. Contact service dealer to obtain replacement instructions.

Faulty wiring in cable connecting the central unit and the boom base junction box.

11.14

BOOM LENGTH PERCENTAGE PROBLEM B.

Main Boom Length Error Main boom length error

In manual mode retract all boom sections. Pull the boom stop and retract the inner mid section completely.

Is the main boom length indicated correctly? Yes

No CAUTION: High tension on cable reel drum! CAUTION: To avoid length potentiometer damage. do not turn the length potentiometer past the stop.

Is the length cable spooled properly on the LG 208 drum ?

Continue with * on page 11.17

No

Yes With all sections completely retracted, un-spool the length cable carefully. Let the drum rewind slowly and spool the cable manually back on the drum. Check the roller guides for correct adjustment.

Reset the length potentiometer.

Has the adjustment corrected the boom length indication.

Yes Continue with * on page 11.17.

No 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 voltage correct (-5V) ?

No

Yes

Possible short or wiring fault between central unit and cable reel. Measure with the DVM at the length transducer (LG 208) terminal 1(GND) and 3 (-5V)

Is the voltage correct (-5V) ?

Main board component defective Contact authorized service dealer for the board replacement procedure.

No

Yes

Verify the length sensor signal. Measure the voltage at the length transducer (LG 208) terminal 1 (GND) and 2 (-500mV) with fully retracted boom.

Is the voltage correct ? (-500mV)

Faulty wiring between central unit and length transducer. Check wiring, junction boxes and connectors for faulty wiring.

No

Yes Check the length signal in the central unit. Measure the signal at central unit terminal A104 Xl/10(-5OOmV) and Al 04 Xl/8(GND) with fully retracted boom.

Next Page

11.16

Defective length potentiometer. Replace length potentiometer assembly. For instruction how to change the length potentiometer assembly refer to Section 3.

BOOM LENGTH PERCENTAGE PROBLEM

Previous Page

Is the voltage correct ? (-500mV)

Yes

No Check the wiring that connects the LG 208 with the central unit. Inspect the cable and connectors.

Have you found any wiring faults ?

Main board component defective. Contact authorized service dealer for the board replacement procedure.

Yes

No Connect the voltmeter central unit terminal A104 X1/10 (signal) and A104 Xl/8 (GND). Use a small screwdriver to turn the length potentiometer carefully clockwise. The voltage should decrease from -500mV to -4.5V.

Is the voltage decreasing from -500mV to -4.5V ?

Correct the wiring problem.

*

Yes

No Check the wiring that connects the LG 208 with the central unit. Inspect the cable and connectors.

Main board component defective. Contact authorized service dealer for the board replacement procedure.

Next Page

11.17

BOOM LENGTH PERCENTAGE PROBLEM

Previous Page

Have you found any wiring faults ?

Yes

No Connect the voltmeter central unit 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)

Correct the wiring problem.

Yes

No

Defective length potentiometer assembly. Replace and adjust length potentiometer.

Reset length transducer. Continue with section 14.

11.18

BOOM LENGTH PERCENTAGE PROBLEM C. Inner Mid Length Error In manual mode retract all boom sections. Pull the boom stop and retract the inner mid section completely.

Is the inner mid boom length Yes indicated correctly?

Continue with * CAUTION : High tension on cable reel drum ! on page 11.21 CAUTION : To avoid length potentiometer damage, do not turn the length potentiometer past the stop. No

Is the length cable spooled properly on the 221 drum?

No

Yes Reset the length potentiometer.

With all sections completely retracted, un - spool the length cable carefully. Let the drum rewind slowly and spool the cable manually back on the drum. Check the roolerguides for correct adjustment.

Has the adjustment corrected the inner mid length indication? Continue with * on page 11.21 Check the power supply to the length sensor. Measure the power supply voltage at central unit terminal A104 X1/11 (-5V) and A104 X1/8 (GND)

Next Page

11.19

BOOM LENGTH PERCENTAGE PROBLEM Previous Page

Is the voltage correct (-5V)?

No

Yes Possible short or wiring fault between central unit and cable reel. Measure with the DVM at the length transducers (LG 221) terminal 1 (GND) and 3 (-5V)

Is the voltage correct (-5V)?

Main board component defective. Contact authorized service dealer for the board replacement procedure.

No

Yes Faulty wiring between central unit and length transducer. Check wiring, junction boxes and connectors for faulty wiring.

Verify the length sensor signal. Measure the voltage at the length transducer (LG 221) terminal 1 (GND) and 2 (-500mV) with fully retracted boom.

Is the voltage correct (-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

BOOM LENGTH PERCENTAGE PROBLEM Previous Page

Is the voltage correct (-500mV)?

Yes

No Check the wiring that connects the LG 221 with the central unit. Inspect the cable and the connections.

Have you found any wiring faults?

Main board component defective. See section 10 for replacement procedure.

Yes

No Connect the voltmeter to central unit terminal 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 voltage decreasing from -500mV to - 4.5V?

Yes

No Check the wiring between length transducer LG 221 and central unit Inspect cable connectors and junction boxes.

Main board component defective. See section 10 for replacement procedure.

Next Page

11.21

BOOM LENGTH PERCENTAGE PROBLEM Previous Page

Have you found any wiring faults?

Yes

No 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 = -500mV 10 turns = - 4.5V

Correct the wiring problem.

Yes

No

Defective length potentiometer assembly. Replace and adjust length potentiometer.

Reset length transducer. Possible main board defect.

11.22

BOOM LENGTH PERCENTAGE PROBLEM D. Center Mid Length Error In manual mode retract all boom sections. Pull the boom stop and retract the inner mid section completely.

Is the center mid length indicated correctly?

Yes Continue with * on page 11.25

No

CAUTION: High tension on cable reel drum. CAUTION: To avoid length potentiometer damage, do not Is the turn the length potentiometer past the stop. length cable No spooled properly on the LWG 221 drum?

Yes

Reset the length potentiometer.

Has the adjustment corrected the center mid length indication?

With all sections completely retracted, un-spooled the length cable carefully. Let the drum rewind slowly and spool the cable manually back on the drum. Check the roller guides for correct adjustment.

Yes Continue with * on page 11.25

No

Check the power supply to the length sensor. Measure the power supply voltage at central unit terminal A 104 X1-11 (-5V) and A104 X1-8 (GND).

Next Page

11.23

BOOM LENGTH PERCENTAGE PROBLEM Previous Page

Is the voltage correct (-5V)?

No

Yes Possible short or wiring fault between central unit and cable reel. Measure at the length transducer, terminal 1 (GND) and 3 (-5V).

Is the voltage correct (-5V)?

Main board component defective. Follow board replacement procedure.

No

Yes Verify the length sensor signal. Measure the voltage at the length transducer, terminal 1 (GND) and 2 (-500mV) with fully retracted boom.

Is the voltage correct (-500mV)?

Faulty wiring between central unit and length transducer. Check wiring, junction boxes and connectors for faulty wiring.

No

Yes Measure the signal at central unit terminal A 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

BOOM LENGTH PERCENTAGE PROBLEM Previous Page

Is the voltage correct (-500mV)?

Yes

No Check the wiring that connects the LG 221 with the central unit. Inspect the cable and the connections.

Have you found any wiring faults?

Main board component defective. See section 10 for replacement procedure.

Yes

No

Connect the voltmeter central unit terminal A 104 X1-73 (signal) and A 104 X1-8 (GND). Turn length potentiometer clockwise. 0 turns = -500mV, 10 turns = -4.5V.

Correct the wiring problem.

* Is the voltage decreasing from -500mV to -4.5V?

Yes

No Check the wiring that connects the LG 221 with the central unit. Inspect the cable and the connections.

Main board component defective. See section 10 for replacement procedure.

Next Page

11.25

BOOM LENGTH PERCENTAGE PROBLEM Previous Page

Have you found any wiring faults?

Yes

No

Connect the voltmeter to terminal 2 (signal) and terminal 1 (GND) in the cable reel. Turn the length potentiometer clockwise. 0 turns = -500mV, 10 turns = -4.5V.

Is the voltage correct? 0 turns = -500mV 10 turns = - 4.5V

Correct the wiring problem.

Yes

No

Defective length potentiometer assembly. Replace and adjust length potentiometer.

Possible main board defect. Follow main board replacement procedure.

11.26

BOOM LENGTH PERCENTAGE PROBLEM E. No Extend or Retract Function in Automode

Switch to manual mode and extend or retract the boom manually.

Does the boom extend or retract?

No

Yes Switch to automode. Start the engine and operate the extend control. Measure the voltage at central unit terminal A 104 X1-38 (24V) and A 104 X1-37 (GND) while operating the extend control.

Is the voltage correct?

Defect in crane electric or hydraulic circuit. Reset crane fuse breaker. Check LMI fuses in the central unit enclosure.

No

Yes Switch to automode. Start the engine and operate the retract control. Measure the voltage at central unit terminal A 104 X1-40 (24V) and A 104 X1-39 (GND) while operating the extend control.

Is the voltage correct?

Faulty wiring to extend pressure switch or defective pressure switch. Correct the wiring and replace the switch if defective.

No

Yes Select the service screen on the console by pressing the two outer keys (F1 & F4) simultaneously. The ramping value for the selected section shall increase from 0 to 255. The ramping value remains 0 in the neutral position.

Faulty wiring to retract pressure switch or defective pressure switch. Correct the wiring and replace the switch if defective.

Next Page

11.27

BOOM LENGTH PERCENTAGE PROBLEM Previous Page

Is the ramping value increasing?

No

Yes Continue to troubleshoot the wiring to the 2 way value and the hydraulic circuit.

Check ribbon cable connection in central unit and wiring in the central unit.

11.28

BOOM LENGTH PERCENTAGE PROBLEM F. Out of Sequence Warning Boom sections are out of sequence (Automode)

Follow instructions in section A.

Is the problem corrected?

Yes

End

No Follow instructions in section B.

Is the problem corrected?

Yes

End

No Follow instructions in section C.

Is the problem corrected?

Yes

End

No Follow instructions in section D.

Is the problem corrected? No

Yes

End

Next Page

11.29

BOOM LENGTH PERCENTAGE PROBLEM Previous Page

With outer mid section completely retracted check the adjustment for the OM retract switch target.

Is the switch and target adjusted correctly?

No

Yes Measure the switch signal at central unit. A 104 X1-76 (24V) and A 104 X1-36 (GND)

Is the voltage correct?

Adjust OM retract switch and target.

Yes

No

Faulty wiring. Check the voltage at terminal 17 (24V) and 13 (GND) in the boom base junction box.

Have you found a fault in the wiring? No Next Page

Main board component defective. See main board replacement procedure.

Yes

Correct the wiring between boom base junction box and central unit.

11.30

BOOM LENGTH PERCENTAGE PROBLEM Previous Page

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

Is the voltage correct?

Yes

No Check the signal at terminal 10 (24V) and 9 (GND) in CM junction box. Refer to section 9.1 and 11.

Is the voltage correct?

Correct the wiring between LWG 221 and boom base junction box. Refer to section 9 and 11.

No

Yes Retract all boom section in manual 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 PROBLEM Angle 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.

NO correct? YES

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 angle sensor on Terminal Board, Terminal X1, Pin 8 (ground) and Pin 11 (-5V) +/- 50mv. Refer to Drawing 3 “Terminal Board” on page 11.50.

NO correct? YES

Main board defective. replace main board and reset pressure channel. Refer to Section 10 of this Manual. Note: Consult factory before replacing main board for further troubleshooting steps.

NEXT PAGE

11.32

ANGLE READING PROBLEM

PREVIOUS PAGE

Measure supply to angle sensor in cable reel at terminal between Pin 5 (ground) and Pin 6 (-5V) +/- 50mv. Refer to Drawing 6, Length / Angle Transducer on page 11.53.

NO correct?

Faulty wiring between central unit and angle sensor. Check wiring.

YES

Measure signal from angle sensor in cable reel at terminal between Pin 4 (signal) and Pin 5 (ground). Boom Angle Signal Voltages: 0 Degrees -3.12 Volts 45 Degrees -2.49 Volts 75 Degrees -2.07 Volts For more detailed signal voltages refer to : Boom Angle Signal Voltage Chart in Section 5.

NO correct? YES

Remove wire # 4 from Terminal, in thecable reel, 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 adjust according to instructions on page 11.53

NEXT PAGE

11.33

ANGLE READING PROBLEM PREVIOUS PAGE

Measure signal from angle sensor in cable reel at terminal between Pin # 9 (signal) and Pin # 8 (ground). Boom Angle Signal Voltages: 0 Degrees -3.12 Volts 45 Degrees -2.49 Volts 75 Degrees -2.07 Volts For more detailed signal voltages refer to : Boom Angle Signal Voltage Chart in Section 5.

NO correct?

Faulty wiring between central unit and cable reel. Check wiring.

YES

Measure angle signal of amplified output on main board between test point MP 15(ground) and MP 8 (angle signal). Note: Negative signal at terminal X1 Pin 9 will 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 Volts For more detailed signal voltages refer to : Boom Angle Signal Voltage Chart in Section 5. Main board defective. replace main board and reset pressure channel. Refer to Section 10 of the System Manual. Note: Consult factory before replacing main board for further troubleshooting steps.

NO correct?

YES

END

11.34

LOAD READING PROBLEM PROBLEM Load reading incorrect. START Check selected operating mode(code on operating mode switch).

NO correct?

Select operating mode switch to correct position (see operating mode in load chart).

YES Check boom length reading on display.

NO correct?

Reset length potentiometer. With fully retracted boom, turn potentiometer axle counterclockwise until it stops

YES Measure radius and check with the displayed radius.

NO correct?

Check if mechanical adjustment of angle transducer is correct. Angle transducer box should in line with boom and adjusted to actual boom angle.

YES Check power supply to pressure transducer (rod side). 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 Pin 13 (+5V). Power supply on main board defected. Check power supply out and measure between test point MP15 = ground and MP18 = +5V and between test point MP15 = ground and MP2 = -5V. If incorrect, replace main board and reset pressure channel.

NO correct? YES NEXT PAGE

11.35

LOAD READING PROBLEM PREVIOUS PAGE

Check power supply to pressure transducer (piston side). Unplug transducer cable from transducer. Measure on terminal board at terminal block X1. Measure between Pin 19 (ground) and Pin 20 (-5V). Measure between Pin 19 (ground) and Pin 18 (+5V).

NO correct? YES

Power supply on main board defective. Check power supply and measure between test point MP 15 = ground and MP 18 = +5V and between test point MP 15 = ground and MP 2 = -5V. If incorrect, replace main board and reset pressure channels.

Check power supply at transducer plugs. Measure between B = ground and A = +5V. Measure between B = ground and C = -5V.

NO

Faulty wiring. Check wiring (pressure transducer cable).

correct? YES

Plug transducer cable back into transducer. Check out signal from transducer. Measure between B = ground and D = signal in transducer plug. Signal = 0 to -1V (+/- 20mV). NO correct?

Transducer defective - replace transducer.

YES NEXT PAGE

11.36

LOAD READING PROBLEM PREVIOUS PAGE Plug transducer cables back into transducer. Check transducer signals in central unit. Disconnect 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) between Pin 19 (ground) and wire # 4 (piston and rod side transducer cable).

NO correct?

Faulty wiring. Check wiring (pressure transducer cable). Transducer defective-replace transducer and reset pressure channel as described below.

YES Reconnect wire # 4 from transducer cables back to terminal X1, Pin 16 (rod side) and terminal X1, Pin 21 (piston side). Without pressure in hoses, check 0 point adjustment on main board by disconnecting hydraulic 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).

NO correct? 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 PROBLEM Error Code “E93 / E94” No data transfer to and from console.

START

Make sure that Data EPROM is plugged into main board socket D5 and System EPROM is plugged into main board socket D4. Check that EPROMS are inserted with notch on EPROM to matching notch on socket.

NO Place EPROM in correct socket.

correct? YES

Check supply crane voltage for console in central unit at terminal board (block X1) between Pin 33 (ground) and Pin 30 (+24V). Make sure external and internal power supply is correct.

NO correct? YES

Defective internal power supply. Replace main board and reset pressure channel. or Defect in terminal board. Replace terminal board.

NEXT PAGE

11.38

BAD DATA TRANSFER BETWEEN CONSOLE & CENTRAL UNIT

PREVIOUS PAGE

Check power supply to console between console terminal # 2 = ground (KM) and terminal # 1 = +24V.

NO

Faulty wiring in cable from central unit to console. Replace cable.

correct? YES Ensure that wires are properly connected between terminal block X1 Pin 31 and console terminal Pin 4 and between terminal block X1 Pin 32 and console terminal Pin 3.

NO correct?

Defective electronic components on main board and / or console board. Replace console board and / or replace main board.

YES

END

11.39

INTERFERENCE PROBLEM PROBLEM Interference from crane electric. Error Code “E93 / E94” intermittent. Frozen console displays.

START Check system out; Pg. 11.38&39 - Bad Data Transfer Between Console & Central Unit. NO Replace or repair part which is defective.

correct? YES Check if additional ground like between main board terminal X9 and central unit box mounting bracket is in place.

NO correct?

Install ground link - single cable minimum of AWG14 (2.0mm2) between terminal X9/1 and central unit box mounting bracket.

YES Ensure that cable shields are connected correctly. Refer to connections and wiring diagrams.

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

NO correct? YES Find out which component of the crane electric is spiking out (e.g. dump valve, outrigger relay). Install a diode or varistor across terminals of spiking component. Diode type such as 1N 4001 can be used (watch + and - connection for diode).

END

11.40

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 range.

Fallen below the minimum radius or above the angle given in the load chart due to raising the boom too far.

Lower boom back to a radius or angle given in the load chart.

E 02*

Beyond radius or below angle range.

The maximum radius or minimum angle given in the load chart was exceeded due to lowering the boom too far.

Raise boom back to a radius or angle given in the load chart.

E 03*

Prohibited slewing range. (no load area)

Slewing range prohibited with load.

Slew back into admissible range.

E 04*

Operating mode not available.

Operating mode switch in the console set incorrectly. Operating mode is not permissible with actual crane configuration.

Set operating mode switch correctly to the code assigned to the operating mode of the crane.

E 05*

Length range not permitted.

Boom was telescoped too far or not far enough.

Telescope boom to correct length given in the load chart.

Length sensor adjustment changed; i.e. length sensor cable slid off the cable drum.

See Section No. 3

Fallen below the minimum jib angle specified in the respective load chart due to luffing out the jib too far.

Luff in the jib to a radius or angle specified in the load chart.

E 06*

Fallen below angle range with luffing jib operation.

* This error can be corrected by the operator.

11.41

ERROR CODE DISPLAY ERROR DISPLAY

ERROR

CAUSE

ACTION

E 07

No acknowledgment signal from overload relay (K8).

Overload relay is stuck, defective or not being selected.

Replace relay.

E 08

No acknowledgment signal from Anti-Two-Block switch relay (K9).

Anti-Two-Block switch relay is defective or not being selected.

Replace relay.

E 11

Fallen below lower limiting value for the measuring channel "length".

E 12

E 13

E 14

Fallen below lower limiting value for the measuring channel "pressure piston side".

Fallen below lower limiting value for the measuring channel "pressure rod side".

Fallen below upper limit value in measuring channel "Force".

Cable from central unit to length sensor Check cable. Replace if defective, not connected or water in the necessary. See Section 3. connectors Length potentiometer defective.

Replace and reset length potentiometer. See Section 3.

Electronic component in the measuring channel defective on main board.

Replace main board and reset pressure channels. See Section 10.

Cable from central unit to the pressure transducer defective, loose or water in the plug.

Check cable as well as plug. Replace if necessary. See Section 10.

Pressure transducer on piston side defective.

Replace pressure transducer and reset pressure channel. See Section 10.

Electronic component in the measuring channel defective on main board.

Replace main board and reset pressure channels. See Section 10.

Cable from central unit to the pressure transducer defective, loose or water in in the plug.

Check cable as well as plug. Replace if necessary. See Section 10.

Pressure transducer on rod side defective.

Replace pressure transducer and reset pressure channel. See Section 10.

Electronic component in the measuring channel defective on main board.

Replace main board and reset pressure channels. See Section 10.

Cable from central unit to force measuring point defective or water inside the plugs. Force transducer defective. Electronic component in the measuring channel defective.

11.42

Check cable as well as plugs, replace if need be. Replace force transducer. Replace main board and reset pressure channels. Section 10

ERROR CODE DISPLAY

ERROR DISPLAY E 15

E 16

ERROR Fallen below lower limiting value for the measuring channel "angle main boom".

Fallen below lower limit value for measuring channel "Luffing Jib Angle".

CAUSE

ACTION

Cable from central unit to the length/ angle sensor defective or loose or water inside plug.

Check cable. Replace if necessary. See Section 5.

Angle sensor defective.

Replace angle sensor. and reset adjustment.

Electronic component in the measuring channel defective.

Replace main board and reset pressure channels. See Section 10.

Cable from central unit to angle sensor defective or disconnected or water inside the plug.

Check cable as well as plug, replace if need be.

Angle sensor defective.

Replace angle sensor.

Electronic component in the measuring channel defective.

Replace main board and reset pressure channels. See Section 10.

E 18

Front Stabilizer overloaded

Exceeding capacities allowed for over the front.

Achieve a safe working area Immediately.

E 19

Error in the reference voltage.

Electronic component on the main board defective.

Replace main board and reset pressure channels. See Section 10.

Bad power supply on main board.

Check wiring, replace if need be.

Bad force transducer wiring, (external).

Check force transducer cable, replace if need be.

Cable from central unit to the length/angle sensor defective or loose. Length potentiometer defective.

Check cable. Replace if necessary. See Section 3. Replace and reset length potentiometer.

Electronic component in the measuring channel defective on main board.

Replace main board and reset pressure channels. See Section 10.

+5 volt supply E 20

Error in the reference voltage. -9 volt supply

E 21

Upper limiting value for the measuring channel "length" exceeded.

11.43

ERROR CODE DISPLAY

ERROR DISPLAY E 22

E 23

E 24

E 25

E 26

ERROR Upper limiting value for the measuring channel "pressure piston side” exceeded.

Upper limiting value for the measuring channel "pressure rod side" exceeded.

Upper limit value in measuring channel "Force" exceeded.

Upper limiting value for the measuring channel "angle main boom" exceeded.

Upper limit value for measuring channel "Luffing Jib Angle" exceeded.

CAUSE

ACTION

Cable from central unit to the pressure transducer defective, loose or water in the plug.

Check cable as well as plug. Replace if necessary. See Section 10.

Pressure transducer on piston side defective.

Replace pressure transducer and reset pressure channels. See Section 10.

Electronic component in the measuring channel defective on main board.

Replace main board and reset pressure channels. See Section 10.

Cable from central unit to the pressure transducer defective, loose or water in the plug.

Check cable as well as plug. Replace if necessary. See Section 10.

Pressure transducer on rod side defective. See Section 10.

Replace pressure transducer and reset pressure channels.

Electronic component in the measuring channel defective. on main board.

Replace main board and reset pressure channels. See Section 10.

Cable between central unit and force measuring point defective or water inside the plug.

Check cable as well as plug, replace if need be.

Force sensor defective.

Replace force sensor.

Electronic component in the measuring channel defective. See Section 7. Cable from central unit to the length/angle sensor defective or loose. Angle sensor defective. mechanical adjustment. Electronic component in the measuring channel defective on main board. See Error E 16.

Replace main board and reset pressure channels.

11.44

Check cable. Replace if necessary. See Section 5. Replace angle sensor and reset Replace main board and reset pressure channels. See Section 10. See Error E 16.

ERROR CODE DISPLAY ERROR DISPLAY E 29

ERROR Error in the reference voltage. -5 volt supply

E 31

E 37

Error in system program

Error in program run

CAUSE Supply and Reference voltages on MP10 is more than 3.3V Electronic component on the main board defective.

EPROM with system program defective. Electronic component on the main board defective. EPROM with system program defective. Electronic component on the main board defective.

ACTION Check supply voltages. Replace main board and reset pressure channels. See section 10. Replace EPROM with system program. Replace main board and reset pressure channels. See section 10. Replace system program EPROM. Replace main board and reset pressure channels. See section10.

E 38

Incorrect system program.

CPU is equipped with an incorrect version of system program.

Equip main board with correct version of system EPROM.

E 41

Error in the external RAM.

RAM in the CPU on the main board defective.

Replace CPU Chip No. 80C31. Replace main board and reset pressure channels. See Section 10.

E 42

Error in the external write/ read memory (RAM).

Internal defect in digital part of CPU.

Exchange write/read memory (CMOS-RAM). Replace main board and reset pressure channels. See Section 10.

E 45

Error in internal communications.

Defective electronic component.

E 47

Malfunction in the monitored write/read memory.

Internal defect in in digital part of CPU

Replace main board and reset pressure channels. See Section 10. Replace main board and reset pressure channels. See Section 10.

E 48

Malfunction in the monitored

Inter defect in digital part of CPU

Replace main board and reset pressure channels. See section 10

E 51

Error in data memory.

Data EPROM on the main board defective.

Replace Data EPROM. Make sure BR3 on the main board is installed. See Drawing 4 on page 11.51.

11.45

ERROR CODE DISPLAY

ERROR DISPLAY

ERROR

CAUSE

ACTION

E 60

Error in EPROM

DATA-EPROM is not plugged into the correct socket or location is not programmed correctly in the EPROM.

Properly install DATA-EPROM See page 11.51

E 70

Error in return signal

No or wrong return signal from digital input extension module to processor.

E 71

Incorrect acknowledgment of the A2B Relay on A101 Term. board.

A2B relay is stuck or defective.

Ribbon cable defective or bad Connection. Replace cable. Digital input circuit defective. Replace module. Decoder circuit defective. Replace decoder module. Replace K9 relay. See page 11.50

A2B relay is not being selected due to a break on the terminal board, main board or ribbon cable.

E 72 – E 77

Analogous to E 71 for relays K2 – K7

Analogous to E 71 for relays K2 – K7

Check terminal board, main board and ribbon cables as well as replace defective part, if necessary. Analogous to E 71 for relays K2 – K7

E 80

Error in return signal

No or wrong return signal from analog output extension module to processor. (for inner mid)

Ribbon cable defective or bad Connection. Replace cable. 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 fully retracted while the center mid section or the inner mid section retracts or extends.

Select manual mode, manually retract the outer mid and fly section until fully retracted. Return to auto mode. Check fly section cable adjustment. The fly section shall not be extended when center mid section is fully retracted.

11.46

ERROR CODE DISPLAY ERROR DISPLAY

ERROR

CAUSE

ACTION

E 89

Change of the operating code during lifting a load.

The operating mode switch in the console was used during lifting a load.

Lower the load and set the operating mode switch correctly to the code assigned to the actual operating mode of the crane.

E 91

No data transmission from console to central unit. (See page 11.38 - 11.40)

24V supply of console interrupted.

Check 24V at terminal Xl of console electronics.

Interruption or accidental ground in the line from console electronics to central unit.

Check the connection between console electronics and central unit. If you find an accidental ground, the transmitter module in the console electronics can be damaged. You should, therefore, replace the console electronics. Replace console electronics or main board respectively. Check the connection between console electronics and central unit. Replace console electronics or main board respectively.

E 92

E 93

E 94

Error in the data transmission from console to central unit. (See page 11.38 - 11.40)

Transmitter / receiver module defective. Defective data line from console electronics to central unit. Transmitter / receiver module defective.

Error in the data transmission from central unit to console. (See page 11.38 - 11.40)

Defective contact in the line from central unit to console. Transmitter / receiver module defective.

No data transmission from central unit to console. (See page 11.38 - 11.40)

Interruption or accidental ground in the data line from central unit to console.

Check the line to the console. Replace console electronics or main board respectively.

5V supply for the computer in the central unit is missing. 5V supply voltage too low. Transmitter / receiver module defective.

Check the line to the console (in case of accidental ground also replace console electronics). Check the connection to the power supply. Replace power supply module. Replace console electronics or main board respectively.

Data EPROM defective.

Check data EPROM.

Computer module defective.

Replace main board.

Electromagnetic interference’s (e.g. when switching contactors or valves).

Eliminate interference source by inverse diodes or varistors.

11.47

ERROR CODE DISPLAY

ERROR DISPLAY E 95

ERROR Error in the crane data EPROM

CAUSE

ACTION

Data EPROM defective. Position of jumper for the selection of the type of EPROM is wrong. Electronic component on main board defective.

Replace data EPROM. Check the jumper position. Replace main board and reset pressure channels.

E 96

Error in the internal RAM of the CPU of the console.

CPU or main board of the console defective.

Replace console main board.

E 97

Error in the external RAM of the CPU of the console.

External RAM of the console defective. Electronic component on the main board defective.

Replace console main board.

E 98

Wrong jumper position in the console.

Replace console main board.

The jumper position BR9/BR10 in the Check the jumper position. console does not correspond to the actual type of central unit. Electronic component on the main Replace console main board. board defective.

11.48

Drawing 1 : Slip Ring Unit

X2 : RED

X1 : BROWN

4

3

1

2

Drawing 2 : Boom Nose Junction Box

11.49

Drawing 3 : Terminal Board

X3

H7

A2B K9

LMI K8

SHUT OFF

SHUT OFF

H4

H1 V8

OUT OF SEQUENCE

OUTER MID

V11

R15

V1

K7

R16

R9

V5

K4

K1

R10

R3

R4

R17 R18 H10

H3

R13

R14

R11

R12

K3

R8

R5

K10 LEVER LOCKOUT

K2

R2

R6

F4

67 66 65 64 63 62 61 60

IM

X1

77 76 75

V6

D RO

F5

X1 80 79 78

V3

R1

49 48 47 Q

F6

R7

SE

F7

K5

4W

70 69 68

CM

OM

F8

V7

ROD DRAIN

K6

4 - WAY

X4

V9

CENTER MID

V10

X1

H2

INNER MID

H5

H6

X1

71 72 73 74

H8 V2

X1

X1

8 10 12 14 16 18 20 22 24 26 28

H9

7 9 11 13 15 17 19 21 23 25 27 29

F1

X1

2 4 6

1 2 3 4

1 3 5

X4

F3

F2

59 58 57 56 55 54 53

X1 52 51 50

X1 43 42 41

40 39 38

X1

37 36 35 34 33 32 31 30

46 45 44 X1

11.50

Drawing 4 : Main Board

Power Supply Test Points: MP 1 = +5V MP 2 = -5V MP 11 = Ground H-4 MP 12 = +5V MP 13 = Digital Ground MP 15 = Analog Ground MP 19 = -5V

Analog Measuring Channels / Test Points: Ch. 1 Boom Length - MP 6 / P6(Do Not Adjust) Ch. 2 Piston Pressure - MP 4 / P4 Ch. 3 Rod Pressure - MP 5 / P5 Ch. 5 Bom Angle - MP 8 / P8(Do Not Adjust)

E-1 E-4 B-7 B-7 E-1 E-1

11.51

G-3 G-4 G-3 G-2

Drawing 5 :Console Board

MP 2 +7V

MP 5 +5V MP 0 GND

MP 3 -24V MP 4 -24V

MP 6

MP 7

MP 1 +UB

J2

J5

J1

J4 J3

X1 X5 1 2 3 4

1 2 3 4 5 6 7 8

11. 52

Drawing 6 : Length / Angle Transducer

PAT PAT

1 2 3 4 5 6 7 8 9 101112 131415 16

ADJUST LENGTH POTENIOMETER WITH BOOM FULLY RETRACTED, TURN THE CENTER SCREW COUNTERCLOCKWISE TO A SOFT STOP.

11.53

Drawing 7 : Suppressor Diode

COMPONENT CAUSING INTERFERENCE

_

+ SUPPRESSOR DIODE

CAUTION: Make sure that + and - diode connections are made as shown to ensure proper polarity.

Drawing 8 : Central Unit Box

FUSE (10A) FUSE (2A)

OVERRIDE KEY SWITCH

(BOTTOM VIEW OF C.P.U.)

11.54

NORMAL OPERATION

OUT

L/O OVERRIDE

IN

P.A.T. – L.M.I MANUAL SECTION 11 APPENDIX

DS 350 GRAPHIC BCS BOOM LENGTH TROUBLESHOOTING PROCEDURE

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 fully extended. 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 switches Proximity switches are all four being made when boom is fully retracted to reset zero point with swingaway stop pulled down. Proxy switch Terminal to check in reference to Ground( X1/ 36) OM/Fly Retracted A 104 X 1/76 CM Retracted A 114 X 1/9 IM+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 correct Reset the length potentiometers by turning them counterclockwise until they stop with the boom fully retracted. If still not correct Press the outer two keys simultaneously ( F1& F4 on the PAT console) to obtain the length indication for the inner mid and center mid. With the boom stop disengaged the total length retracted should be 35.4 and extended 137.8 With the inner mid extended it should read 61.0 With the inner mid and the center mid extended it should read 86.6 If still not correct Check the voltage on terminal #6, #7 and #9 on the main board for .495 to .500 volts with the boom fully retracted. If off, reset per the calibration papers inside the box. Ch. #3 - Force transducer not used Ch. #4 - Rod transducer - Do not touch Ch. #5 - Piston transducer-Do not touch Ch. #6 - Total Overall Length - (top reel) Ch. #7 - Center mid / Inner mid - (middle reel) Ch. #8 - Angle transducer - Do not touch Ch. #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 are mechanically 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 following procedure. 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 length indication 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 the boom length on the graphic console. With the boom stop disengaged calibrate the IM length to retracted 35.4 and extended 61.0. Read the boom 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. Read the 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 and IM % reset switch. If not adjust the targets to the correct position. If still not check the power supply to each switch using the wiring diagram. If all LEDs are switched on check the signal voltage returning to the central unit terminal. The voltage shall not be lower than 20 Volts with reference to crane GND ( Xl - 36 ) for

OM / Fly retract CM retract IM + CM retract IM % reset

A104 X 1 / 76 A l 14 X 1 / 9 A 104 X 1 / 78 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 to indicate 1 % extension for the IM section. To read 0 % you must pull the boom stop down and pass the target.

The IM reset target must be adjusted with the boom stop engaged and the boom fully retracted onto the boom stop. The IM + CM retract switch has two targets providing the boom is equipped with boom stop retracted against boom stop and another target for retracted against base section. Do not attempt to adjust targets 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 reference crane GND ). Appendix 3

If not use the electrical diagram to identify the cause. Measure signal of pressure switch located on the right, inside the valve bank compartment. Disconnect wire 387 from the switch and measure 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 the control 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 terminal of 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 cathode terminal of the diode matrix board. - Should measure crane voltage ( 24 Volt on cathode of diode connected 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 terminal of 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 voltage sequence is incorrect on the cathode of the diodes refer to the Grove electrical documentation and check wiring. 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, K7 on 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 in Auto 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 in Auto 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 the operator) the boom in Auto mode the ramping value should climb up to a 800 mA with fully open solenoid valve. Should the measurement fail check for complete solenoid circuit - Check solenoid coil resistance for continuity. Check for good analog ground from A111 board to solenoid. Connect Ohm meter to the removed wire ends of terminal A111 Xl / 5 and 6 and test closed circuit. Note that you will not measure any 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 particular telescope 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 and extend ). Signal extend from NO contact of K5. Signal retract from NC contact of K5. The current to open 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 fully retracted 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 are controlled 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 for the 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 a. A104 b. A111 c. A114

Part Number ( PAT ) 024 - 350 - 300 - 092 024 - 350 - 300 - 135 ( B ) 024 - 350 - 300 - 301

Description Extension Board Analog Control Board Digital Extension Board

E. System description ( basic ): The PAT DS350 Boom Control System ( designated as System Under Test or SUT ) it is a microprocessor controlled system that optimizes the boom configuration during lift operations. To understand the basic theory of the system, one must think in terms of action - reaction, i.e. for every action there 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 this discussion is true for retract operations. The sequence of events that must occur for the boom to start moving is as follows: 1. The SUT detects whether the operator has selected Automatic mode or Manual mode, and in Auto mode, whether Mode A or Mode B is selected. The Auto / Manual switch toggles a digital input on A104 - X1 - P42. If Auto is selected, this signal will be high ( from here on out, all signal levels will be specified as either high or low. A high signal being crane voltage, 24 V, and low being near ground level ), if Manual is selected, the signal is low. Mode A or B operations are controlled with a switch located in the cab. This switch controls the A114 - X1 - P3 input. A high signal indicates Mode A, a low indicates Mode B. If the Auto mode is selected, the status of Mode A / B switch can be readily seen on the A114 board by looking at the H2 LED. If the LED is illuminated, Mode A is selected, if it is not then Mode 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 boom retract operations. The output of these switches are piped into the SUT as digital inputs. These switches are normally open and switch crane voltage ( 24V ) on or off. Assuming that an extend operation is being performed, 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 onto X1 - P63. This analog control is generated from the A114 board, A114 - X1 - P6, and is a variable voltage output that is determined by a digital code supplied by the microprocessor. This code is determined by the position 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 the boom will be selected. The logic of these signals are such that to select a section the signal level to that sections control valves must go low. Each section has two ( 2 ) control valves, for a total of six ( 6 ) that must be de - energized in tandem. One valve is pilot pressure and the other is the main flow valve. The SUT supplies control from the following terminals: Inner Mid ( IM ) Center Mid ( CM ) Outer Mid / Fly ( OM/F

A104 - X1 - P54 to boom base junction box P - 19 and P - 24 A104 - X1 - P66 to boom base junction box P - 20 and P - 26 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 / retract operation is selected, these signals become active and control the flow of hydraulic oil. The logic table for these valves is as follows:

A104 - X1 - P54 A104 - X1 - P66 A104 - X1 - P69

IM

CM

OM /F

0 1 1

1 0 1

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 initializes both the IM 2 - way valves for hydraulic flow. b. The analog board, A111 - X1 - P6, generates the control voltage for voltage for the proportional valves. This signal is directed to either the extend or retract sections of the proportional 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 the pressure of fluid to the cylinder depending on the current output from the A111 board, 800mA yields 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 of the 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 attached sheet. The IM will extend at full speed until the cross over point is reached, 50% in mode B. At this point the speed of the section will ramp down and then stop, then the CM will start to extend under the same conditions as the IM. Appendix 8

TMS /TTS870 Boom Sequence, Auto Mode A and B Mode ( A / B ) A A A A B B B B B B B B

IM % 0 0 0 100 0 50 50 75 75 100 100 100

CM % 0 100 100 100 0 0 50 50 75 75 100 100

OM / Fly % 0 0 100 100 0 0 0 0 0 0 0 100

7. During the retract sequence, the operation is the same with the exception of the presence of the proximity 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 the CM 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 fully counter 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 the CM.

Appendix 9

OK_______ 6. Place the boom select switch into the OM / Fly position, verify that the OM / Fly lamp illuminates. OK_______ 7. Extend the OM / Fly about 2 ft. to verify that the OM / Fly does extend, then completely retract 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 the chassie as ground. Verify that the signal level in Manual mode is low and high in Auto mode. 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 goes high 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, around 25 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 to measure current, 10 amp setting. Connect the black lead to A104 - X1 - P63 and the red lead to wire 20. Extend the boom to verify that the current is between 750 mA and 850 mA. 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 the signal goes to a higher voltage level, around 25 volts. Record Voltage ____________ OK_______ 16. Disconnect wire 21 from A104 - X1 - P64 on the extension board. Set the meter to measure current, 10 amp setting. Connect the black lead to A104 - X1 - P64 and the red lead to wire 21. Extend the boom about 10 ft., then retract the boom to verify that the current measurement is between 750 mA and 850 mA. Record Voltage ____________ Appendix 10

OK_______17. Select Manual mode, and ensure the boom is fully retracted with the stop block disengaged. 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 on A104 - X1 - P76 and verify a high signal. OK_______ 19. Using the meter, monitor the signal from proximity switch 2, CM / IM retract signal on A104 - X1 - P78 and verify a high signal. OK_______ 20. Using the meter, monitor the signal from proximity switch 3, length reset signal on A104 - X1 - P80 and verify a low signal. OK_______ 21. Using the meter, monitor the signal from proximity switch 4, CM retract signal on A114 - 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 on A104 - X1 - P76. While retracting the OM / Fly verify the signal changes from low to high, until the sections bottoms out. OK_______ 24. Using the meter, monitor the CM proximity retract switch input signal on A114 - 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 on A104 - X1 - P78. While retracting the CM - IM verify the signal changes from low to high, until section bottoms out. OK_______ 26. Using the meter, monitor the length reset proximity switch signal on A104 - X1 - P80 to verify the signal is high. OK_______ 27. Fully retract all boom sections and switch to Auto mode. Using the meter, monitor the telescope 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 and telescope the CM out about 5 ft. Switch to Auto mode and verify the signal level on A104 - 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. During normal 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 input signal, A111 - X1 - P6. Verify that the console displays E - 18 error code. Remove the jumper 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 the telescope 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 stays low. OK______ 32. While monitoring the telescope rod drain signal on A104 - X1 - P57, stop extending the boom at about 5 ft., when the extend operation stops and boom comes to a rest, verify that the signal goes high. NOTE: Ensure that all safety precautions are performed before performing the following steps. Ensure that the outriggers 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 A and raise the boom to approximately 60 degrees. OK_______ 34. Fully extend the boom and verify that each section sequence as listed on the attached sheet. 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 B and raise the boom to approximately 60 degrees. OK_______ 37. Retract the boom and verify the sequence is the inverse of extend. G. Final If 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 Product Support Service Department.

Crane Model Number: ___________________

S /N:_______________

PAT CPU Part Number:__________________

S / N_______________

Signature:____________________

Date:_______________

Appendix 12

TMS870,TTS870 & RT865B 5 Section Boom Drift Test PURPOSE: To determine the cause of the telescope cylinder drift. TEST DESCRIPTION: The boom shall be loaded with each section extended approximately 1- 1/2’ to 2’ to determine the cause of suspected leakage in the telescope cylinder or hold valve. The boom is only partially extended to reduce the effects of thermal contraction of the oil in the cylinders. TEST PREPARATION: 1

Reeve the machine with a minimum of two parts line.

2

Fully retract boom and extend each section (in manual mode) from 18” to 24” and mark off 1” increments for 6” on the Inner, center and outer mid sections.

3

Select a load (including hook block) between 20,000 to 25,000 pounds and position it at a 25’ to 30’ radius. TEST PROCEDURE:

1

Switch boom control system to automatic mode. (Note: Boom will be out of sequence.)

2

Hoist load approximately 2’ off of the ground with the boom nose positioned over the load. Keep the engine running or the ignition switch on during the test.

3

Observe the marks on the boom sections for 30 minutes to determine which section(s) are retracting. A slight compression of the oil is normal when the load is picked. Approximately 1” per section would be expected. The sections should extend back to the original position when the load is lowered to the ground.

4

Hoist the load to the ground, observe and record the movement of the marks on the boom sections.

5

Determine which section(s) are retracting and reposition the boom sections to there original positions.

6

Switch boom control system to manual mode and select a section that is not retracting. This Will help to determine if the hold valve is leaking or if the cylinder has an internal leak. Appendix 13

TMS870,TMS870 & RT865B Hold Valve Drift Test – continued

7

Repeat steps 2 through 5. If the section(s) do not retract in the manual mode, the hold valve is most likely leaking. If the section retracts, the cylinder may have an internal leak or both the hold valve and the two way valve on the piston side are leaking.

NOTE: The piston side two way valves located inside the boom are N.O. valves connected in-line with the hold valves. When in the Automatic Mode with the telescope controller in the neutral position and the power on, the piston side two way valves are not powered shut. This permits any leakage past the hold valve to drain through the piston side drain valve and the .078 in line orifice. When in the Manual Mode under the same conditions, the two way valves are powered shut on the sections not selected. This should block any leakage from the hold valve and prevent the cylinder from retracting. Prior to assuming that the cylinder has a leak, the two way valve should be checked to ensure that 24 volts are present at the valve with the system in manual mode with an other section selected. Thermal contraction will cause a cylinder to retract as the fluid in the cylinder cools. The change in length of the cylinder is proportional to the extended length of the cylinder and the change of the temperature of the oil in the cylinder. The coefficient of expansion for API Group 1 oil is approximately 0.00043/ 0F. A cylinder that is extended 25’ which has had the oil cool 100 F would retract about 13 “as the oil cools. A cylinder that is extended 2’ which has had the oil cool 100 Degrees F will retract about 1” due to the thermal contraction. Testing the boom almost fully refracted greatly reduces the effect of thermal contraction and ensures a proper diagnosis of the system.

Appendix 14

P.A.T. – L.M.I MANUAL SECTION 12

DS 350 GRAPHIC BCS ELECTRICAL DIAGRAMS

DI 4 (PROXY 1 OM/FLY RETRACT)

DI 5 (PROXY 2 CM/IM RETRACT)

DI 6 (PROXY 3 LENGTH RESET)

A2B SIGNAL

PROXY (+) GND

7 8 10 11 9 35 34 24 73 43 36 80 78 76

A2B GND LENGTH (IM) LENGTH (CM)

IS AGND LENGTH (O.A. BOOM)

30 31 32 33 44 46

-5V ANGLE

+24V TXD RXD GND LMI BYPASS A2B BYPASS

PRESS. PISTON SIG.

AGND -5V

+5V

PRESS. ROD SIG.

IS

AGND -5V

+5V

IS

A 104 12 13 14 15 16 17 18 19 20 21 28 29 X1

1 4 3

1 2 3 4 IS 1 2 3 4

2 56 7 8 9

13

11

+24V

IS

GN/YL

To page 12.2 IS 1 2 3 4 5 6

7 8

9 10 11 12 13 14

14

12

12.1

A 14 SOCKET PLUG

A BCD A BCD

PRES. TRANS. (ROD)

1 2 3 4

A BCD A BCD

PRES. TRANS. (PISTON)

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

A BC DE FG H I

J

K

L M N

A BC DE FG H I

J

K

L M N

1 2 3 4

To Boom Base Junction Box

5 6 7 8 9 10 11 12 13 14

14 PIN PLUG

1 2 3 4 5 6 7

8 9 10 11 12 13 14

X1 1 2 3 4 5 6 7 8 +24V GND TXD RXD COM. A2B LMI DI

1 2 3 4

X7 1 2 3 4

+24V GND

X8 1 2

CONSOLE

TMS/TTS 870 WIRING CONNECTIONS

IS

TELE RETRACT PROP SOL

A111 1 X1

2 3

13 14 15 20 21

23 - SOCKET RECEPT S/S HARNESS (REF)

TMS/TTS 870 INTERFACE TELE EXT PROP SOL

10 11 12

TELE PROP ANALOG GND

56 57 1 2 3 4 48 38 40 42 36 37 39 41 75 77 79 59 61 49 62 63 64

TELE ROD DRAIN SOL

8 719

240 147 238 1083 255 257

6 9

FRONT O/R OVERLOAD

5

HIGH SIGNAL = AUTO MODE A NO SIGNAL = AUTO MODE B

To Boom Base Junction Box 4

323

B 3

TELE OUT OF SEQ.

2

CM TELE

2 3 5 7 11 12 13 14 1

IM TELE

8 10

OM/FLY TELE

9

TELE RETRACT PRESS. SW.

6

HIGH=AUTO / NONE=MANUAL

4

LMI UNLOCK SOLS

12.2 1

7 8

TELE EXT. PRESS. SW.

4 5 6 68 69

GND

A113 X1

71 51 73 387 388 239 242 243 244

K6 (COM) +24V K6 (NO) +24V TO CM 2-WAY SOLS

65 66

+24V

K2 (COM) +24V K2 (NO) +24V TO IM 2-WAY SOLS

53 54

4 5 6

18

LMI - CRANE INTERFACE 23 - PIN PLUG

1 2 3 4 5 6 7 8 9 101112 13 14 15 1617 1819 20 2122 23 24 25 A B C D E F G H J KLM N O P Q R S T UV W X A B C D E F G H J KLM N O P Q R S T UV W X

16

5 6 9 10

DI E5 GND

DI E5 (+24V=CM RET)

DI E3 (GND=FRONT O/R OL)

A114 3 4 X1

DI E3 (+24V)

[ +24=MODE A 0V=MODE B DI E2 GND DI E2

A1 (PROP)

AGND

GND

GND

+24V

+24V

K5 (NC) OUTPUT TO RET PROP

K5 (COM) K5 (NO) OUTPUT TO EXT PROP

K10 (NC) +24V TO LMI L/O ALARM

K4 (COM) +24V K4 (NC) +24V TO TELE OUT OF SEQ

DI 6 GND

DI 4 GND DI 5 GND

DI 2 GND DI 3 GND

DI 1 GND

DI GND

DI 2 (+24V=TELE RET PRES SW) DI 3 (+24V=AUTO MODE

DI 1 (+24V=TELE EXT PRES SW)

K3 (NO) +24V TO TELE ROD DRAIN +24V +24V GND GND K10 (NO) +24V TO LMI UNLOCK SOLS

K3 (COM) +24V

K7 (NO) +24V TO OM/FLY 2-WAY SOLS

K7 (COM) +24V

+24V

IS

CONTINUED FROM PAGE 12.1 22 47

DI EXTENSION BOARD 24 350 300 301

9 10 11 12 7 12

9 8

17 22 23 24 25

A

B

14 SOCKET PLUG 1 14

2

3

4

5

6

7

8 9

10

IS

11 12 13

1

2

3 4

5 6

7

8

9

10

11 12 13 14

IS

A

B

C

D

E

F

G

H J

K

L M N

P

A

B

C

D E F G H

J

K

L M N P R S T U V

A

B

C

D

E

F

G

H J

K

L M N

P

A

B

C

D E F G H

J

K

L M N P R S T U V

1

2

3

4

7

8 9

10

11 12 13 14

1

2

3 4 5 6 7 8

9

10

11 12

14

3

1

4

5

6

7 8

9

3

2 13

1 7

2

3

4

3

19 20 21 22 23 24 25 26 27 28

10 11 12 13 14 15 16 17 18 4 12

5 9 6 7 4

13

8

6

10 11 7 5 8

29

30

14 9 10 11 12

31

12 14

TMS/TTS870 WIRING CONNECTIONS

5 6

12.3 123 6 7

10 11

12 4 9 10

3 2 1

3

AGND SIG. -5V

10 11

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

GRA

0 0

VIO

2

RED PNK YEL BLU

1

WHT BRN GRN CRE BLK

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

4.7K

SHD

VV 4.7K

WHT/ BLK

BRN RED ORG YEL GRN BLU VIO GRA WHT BLK

VV

A B A B

1 2 3 4 5 6 7 8 9

BRN RED ORG YEL GRN BLU VIO GRA WHT

BRN RED ORG YEL GRN BLU VIO GRA WHT

1234 12

LENGTH TRANS.

BRN RED ORG YEL GRN BLU VIO GRA WHT BLK

BRN

RED

3=RED 2=BRN 1=BLK

BLK WHT/BLK

SHEILD

LG208 (TO NOSE)

CORE

10 11

SHD

AGND SIG. -5V

1 2 3 4 5 6 7 8 9

LENGTH/ANGLE LG221 (TO IM)

ANGLE TRANS.

LENGTH/ANGLELWG221 (TOCM)

LENGTH TRANS.

LENGTH TRANSDUCER

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

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

E

1

C

VIO

7

AGND SIG. -5V SIG. AGND -5V

56

1 3 4 2

11

3

2 4

1234

5 8

RED PNK YEL BLU

9 14 12 7 5

CRE BLK

8 6 4

WHT BRN GRN

1 2 3 13

BLK WHT/BLK

3

WHT/ BLK

2

GRA

1 1

5 6

D

VIO YEL PNK RED BLK GRA BLU CRE SHD

C

WHT BRN GRN

JUNCTION BOX (CM) RED 1 1 RED 2 3 BLK 1 BLK 4 5 GRN 1

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 (-)

TIE WRAP USED TO IDENTIFY CABLE

GRN 6 WHT 1 7 WHT 8 9 3 10 4 11 1

PROXY SW 3 (TOP) (LENGTH RESET) 1 1 (+) 4 4 NO 2 2 NC 3 3 (-)

PROXY SW 1 (OM/FLY RETR) 1

1

4 2

2

3

IS

(+)

4 NO

O

O

2 NC

O

O

3

12.4

RED YEL BLU VIO GRA BLK CRE PNK

D

1 2 3 4

(-)

3

SHD WHT BRN GRN

5 6 7

E

RED BLK GRN WHT

RED = IM CYL (+) BLK = IM PILOT (+) GRN = IM CYL (-) WHT = IM PILOT (-) PROXY SW 4 (CM RETR)

3 4 1

1 4 2

2

3

IS IS

1

(+)

4 NO

O

O

2 NC

O

O

3

(-)

O

O

O

IS

IS JUNCTION BOX (IM)

O

4 2 1

6 5 4 3 2 1

3

2 3

4 4 1 1 2

JUNCTION BOX BOOM BASE

PROXY SW 2 (BOTTOM) (CM/IM RETR. 2-POSITIONS) 1 1 (+) 4 O O 4 NO 2 2 NC O O 3 3 (-) IS

TMS/TTS 870 WIRING CONNECTIONS

30 31 32 33 44 46

DI 4 (PROXY 1 OM/FLY RETRACT)

DI 5 (PROXY 2 CM/IM RETRACT)

DI 6 (PROXY 3 LENGTH RESET)

PROXY (+) GND

A2B SIGNAL

A2B GND LENGTH (IM) LENGTH (CM)

-5V ANGLE

IS AGND LENGTH (O.A. BOOM)

+24V TXD RXD GND LMI BYPASS A2B BYPASS

PRESS. PISTON SIG.

AGND -5V

+5V

PRESS. ROD SIG.

IS

AGND -5V

+5V

IS

A 104 12 13 14 15 16 17 18 19 20 21 28 29 X1

7 8 10 11 9 35 34 24 73 43 36 80 78 76

1 2 3 4

IS 1 2 3 4

1 4 3

2 56 7 8 9

13

11

+24V

IS

GN/YL

To page 12.6 IS 1 2 3 4 5 6

7 8 9 10 11 12 13 14

14

12

12.5

A 14 SOCKET PLUG

A BCD A BCD

PRES. TRANS. (ROD)

1 2 3 4

A BCD A BCD

PRES. TRANS. (PISTON)

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

A BC DE FG H I

J

K

L M N

A BC DE FG H I

J

K

L M N

To Boom Base Junction Box

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

RT865BXL WIRING CONNECTIONS

14 PIN PLUG

1 2 3 4 5 6 7

8 9 10 11 12 13 14

X1 1 2 3 4 5 6 7 8 +24V GND TXD RXD COM. A2B LMI DI

1 2 3 4

X7 1 2 3 4

+24V GND

X8 1 2

CONSOLE

2 3

13 14 16 20 21 17 22 23 24 25

A B C D E F G H J KLM N O P Q R S T UV W X A B C D E F G H J KLM N O P Q R S T UV W X

4 5 6

18

7 8 9 10

12o

1 2 3 4 5 6 7 8 9 101112 13 14 15 1617 18 19 20 2122 23 24 25

1 2 3 4 A B C D E A B C D E

NO

COM

CRANE 12o AREA DEFINITION SWITCH IN ELECTRICAL SWIVEL

348o NC

DI E5 GND

DI E5 (+24V=CM RET)

DI E4 (GND=FRONT O/R OL)

DI E1 GND

DI E1 (+24V HOUSE PIN ENGAGED)

A1 (PROP)

AGND

GND

GND

+24V

+24V

K5 (NC) OUTPUT TO RET PROP

K5 (COM) K5 (NO) OUTPUT TO EXT PROP

K10 (NC) +24V TO LMI L/O ALARM

K4 (COM) +24V K4 (NC) +24V TO TELE OUT OF SEQ

DI 6 GND

DI 4 GND DI 5 GND

DI 2 GND DI 3 GND

DI 1 GND

DI GND

DI 2 (+24V=TELE RET PRES SW) DI 3 (+24V=AUTO MODE

DI 1 (+24V=TELE EXT PRES SW)

K3 (NO) +24V TO TELE ROD DRAIN +24V +24V GND GND K10 (NO) +24V TO LMI UNLOCK SOLS

K3 (COM) +24V

DI E4 (+24V AREA DEF.)

A114 1 2 X1

AREA DEF. INTERFACE 5 SOCKET PLUG

A111 1 X1

SWIVEL HARNESS 5 PIN RECEPTACLE

IS

TELE RETRACT PROP SOL

TELE EXT PROP SOL

TELE ROD DRAIN SOL

238 1083 255 257

56 57 1 2 3 4 48 38 40 42 36 37 39 41 75 77 79 59 61 49 62 63 64

23 - SOCKET RECEPT S/S HARNESS (REF)

RT865BXL INTERFACE 8 7 19 10 11 12

TELE PROP ANALOG GND

6 9

HOUSE LOCK PIN SWITCH

5

323 74 744

To Boom Base Junction Box 4

LMI L/O ALARM

B 3

TELE OUT OF SEQ.

2

CM TELE

8 10 2 3 5 7 11 12 13 14 1

IM TELE

9

OM/FLY TELE

6

TELE RETRACT PRESS. SW.

4

7 8

HIGH=AUTO MODE/NONE=MANUAL MODE

12.6 1

5 6

TELE EXT. PRESS. SW.

K7 (COM) +24V

68 69

LMI UNLOCK SOLS

A113 4 X1

71 51 73 387 388 239 242 243 244

K6 (COM) +24V K6 (NO) +24V TO CM 2-WAY SOLS

65 66

GND

K2 (COM) +24V K2 (NO) +24V TO IM 2-WAY SOLS

53 54

+24V

+24V

47

K7 (NO) +24V TO OM/FLY 2-WAY SOLS

IS

CONTINUED FROM PAGE 12.5 22

DI EXTENSION BOARD 24 350 300 301

9 10 11 12 7 12

9 8

15

LMI - CRANE INTERFACE 23 - PIN PLUG

1 2 3 4

A

B

14 SOCKET PLUG 1 14

2

3

4

5

6

7

8 9

10

11 12 13

IS

1

2

3

4

5 6

7

8

9

10

11 12 13 14

IS

A

B

C

D

E

F

G

H J

K

L M N

P

A

B

C

D E F G H

J

K

L M N P R S T U V

A

B

C

D

E

F

G

H J

K

L M N

P

A

B

C

D E F G H

J

K

L M N P R S T U V

2

3

4

5 6

7

8 9

10

10

11 12

1

1

2

3 4 5 6 7 8

9

14

3 4

1

5

6

7 8

9

3

2 13

1 7

2 3

4

3

19 20 21 22 23 24 25 26 27 28

10 11 12 13 14 15 16 17 18 4 12

5 9 6 7 4

13 8 6

10 11 7 5

8

29

30

14 9 10 11 12

31

12 14

RT865BXL WIRING CONNECTIONS

5 6

12.7 123 6 7

10 11

12

3 2 1

3

AGND SIG. -5V

10 11

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

GRA

0 0

VIO

2

RED PNK YEL BLU

1

WHT BRN GRN CRE BLK

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

4.7K

SHD

VV 4.7K

WHT/ BLK

BRN RED ORG YEL GRN BLU VIO GRA WHT BLK

VV

A B A B

1 2 3 4 5 6 7 8 9

BRN RED ORG YEL GRN BLU VIO GRA WHT

BRN RED ORG YEL GRN BLU VIO GRA WHT

1234 12

LENGTH TRANS.

BRN RED ORG YEL GRN BLU VIO GRA WHT BLK

BRN

RED

3=RED 2=BRN 1=BLK

BLK WHT/BLK

SHEILD

LG208 (TO NOSE)

CORE

10 11

SHD

AGND SIG. -5V

1 2 3 4 5 6 7 8 9

LENGTH/ANGLE LG221 (TO IM)

LENGTH TRANSDUCER

ANGLE TRANS.

LENGTH/ANGLELWG221 (TOCM)

LENGTH TRANS.

E

1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

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

1 3 4 2

11

C

VIO

7

AGND SIG. -5V SIG. AGND -5V

56

5 8

3

2 4

123 4

4 9 10

RED PNK YEL BLU

9 14 12 7 5

CRE BLK

8 6 4

WHT BRN GRN

1 2 3 13

BLK WHT/BLK

3

WHT/ BLK

2

GRA

1 1

11 12 13 14

D

VIO YEL PNK RED BLK GRA BLU CRE SHD

C

WHT BRN GRN

JUNCTION BOX (CM) RED 1 1 RED 2 3 BLK 1 BLK 4 5 GRN 1

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 (-)

TIE WRAP USED TO IDENTIFY CABLE

GRN 6 WHT 1 7 WHT 8 9 3 10 4 11 1

PROXY SW 3 (TOP) (LENGTH RESET) 1 1 (+) 4 4 NO 2 2 NC 3 3 (-)

PROXY SW 1 (OM/FLY RETR) 1

1

4 2

2

3

IS

(+)

4 NO

O

O

2 NC

O

O

3

12.8

RED YEL BLU VIO GRA BLK CRE PNK

D

1 2 3 4

(-)

3

SHD WHT BRN GRN

5 6 7

E

RED BLK GRN WHT

RED = IM CYL (+) BLK = IM PILOT (+) GRN = IM CYL (-) WHT = IM PILOT (-) PROXY SW 4 (CM RETR)

3 4 1

1 4 2

2

3

IS IS

1

(+)

4 NO

O

O

2 NC

O

O

3

(-)

O

O

O

IS

IS JUNCTION BOX (IM)

O

4 2 1

6 5 4 3 2 1

3

2 3

4 4 1 1 2

JUNCTION BOX BOOM BASE

PROXY SW 2 (BOTTOM) (CM/IM RETR. 2-POSITIONS) 1 1 (+) 4 O O 4 NO 2 2 NC O O 3 3 (-) IS

RT865BXL WIRING CONNECTIONS

P.A.T. – L.M.I MANUAL SECTION 13

DS 350 GRAPHIC BCS SERVICE BULLETINS & MISCELLANEOUS INFORMATION

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.

X1

L1

J2 1

J1

Central Unit with DS350 modular or DS150 mainboard or compatible interface like 24 350 30 0128 ( J1 = closed / J2 = 1 -2)

L1

J1

Central Unit with DS350G mainboard or compatible interface like 24 350 30 0127 ( J1 = open / J2 = 2-3)

J2 1

X1

13.1

P.A.T. – L.M.I MANUAL SECTION 14

DS 350 Graphic Modular CONSOLE CONNECTIONS & WIRING DIAGRAM

14.1

VIEW OF BACKSIDE OF GRAPHIC CONSOLE

J1

J2

1 2 3 4 5 6 7 8

X1

MP 1 +UB

MP 0 GND

MP 7

MP 6

MP 2 +7V

MP 5 +5V

J4

J5

X5 1 2 3 4

J3

MP 4 -24V

MP 3 -24V

+UB GND RXD TXD A2B BYPASS A2B BYPASS LMI BYPASS +UB

ELECTRICAL WIRING FROM CENTRAL UNIT TO CONSOLE

+UB

GND

CENTRAL UNIT MAIN BOARD

51 52 3 4 5 6 7 8 9 10 8

9

1

2 3

5 6 7

6 7

10

10

11 12 13 14

CONSOLE (1318)

A B C D

1 2 3 4

LOAD

DI

A2B

8 X1

GND

7

A2B

3

X7 1 2 3 4

LIGHTBAR

4 5 6 RXD

4 5

TXD

2

3

SIG -

+UB

1

2

GND

1

+UB SIG +

14.2

4

X8 +UB 1 GND 2

8

9 11 12 13 14

P.A.T. – L.M.I MANUAL SECTION 15

DS 350 Graphic Modular CENTRAL UNIT, P.C. BOARD LAYOUT & CONNECTIONS

PAT DS350 Graphic Modular CENTRAL UNIT TERMINAL BOARD CONNECTIONS X1 TERM.

DESCRIPTION

X1 TERM.

DESCRIPTION

1,3

+12V Battery - Input

27

Length Signal

2,4

GND ( ) Battery-Input

28

GND

29

Angle Signal

30

Force Signal

31

A2B Signal

32

A2B Ground

5

Data Received from Console

6

Data Transmit to Console

7

A2B Bypass

8

A2B Bypass

33,34,35,36 9

LMI Bypass

10

+ 12V (ub)

11

+UBR

12

LMI Lockout Solenoid

13

Ext. Hor. # 1

14

Not Used

51

+UB

52

GND

53

Fuse (4 AMP)

54

Fuse (4 AMP)

57

Not Used

58

Not Used

60

+UBS

+UBS

15

GND

16

Digital Input # 1

61

Fuse (10AMP)

17

Digital Input # 2

62

Fuse (10 AMP)

18

Digital Input # 3

64

UB

65

GND

19

Digital Input # 4

20

+UB Piston Pressure Transducer

21

Piston Pressure Signal

22

GND (Inner Shield Connection)

23

+UB Rod Pressure Transducer

24

Rod Pressure Signal

25

GND (Inner Shield Connection)

26

+UB Length Transducer

66,67,68,69

15.1

Not Used

76

+UB

77

GND

+UBS

+ CONSOLE 4

K8 DIN DIN

F2- 10A

REL

DAV 1

DAV 2

LWG 1 LG 2 HES DHG

S1

SI-UB

24 352 31 0001

ADDITIONAL TERMS

LOAD KEY SWITCH SI-REL

DE 5,6

+UBS

76 77

+ +UBS 0V

15.2

A107 MEMORY EXTENTION

12V

A101 MAIN BOARD DS350 MODULAR/CURRENT IN

S2

A106 ANALOGG INPUT

DE 1-4

K10B X3

+UBS

11 REL -M 12 REL -A 13 REL -R 14 + +UBS 15 DE 1 16 17 DE 2 18 DE 3 19 DE 4 20 + +UBS I 21 DAV1 U 0V 22 23 + +UBS I 24 DAV2 U 0V 25 26 + +UBS I 27 LG 1 U 0V 28 I 29 WG 1 U I 30 LG 1 U 31 0V 32 33 + +UBS I 34 S1 DHG 1 U 0V 35 I 36 S2 DHG 2 U 51 + +UB 0V 52 F1 - 4A 53 SI - OUT 54 SI - IN 57 A2B-0 58 A2B-I LOAD-I 59 60 + +UBS F2-10A 61 SI-REL 62 SI-REL 64 + +UBS 65 0V 66 DE 5 67 68 DE 6 69

X12

+ +UBS

A105 SERIAL EXTENSION

A2B-O A2B-I LOAD-I

K9

A102 X11 CPUMODULE

0V RXD TXD

+

10

K10A

+ +UBS

STOP

LOAD SWITCH

5 6 7 8 9

+ +12V 0V

X3

2 3

A103 DATENMODULE

12V

A104 DIGITAL OUTPUT

+UB

F1

1

3

1

1 3

2

1

1

1

2 3

4 1

2 3

4

1

2

3

4

7

5

6

2

2

2

2

3

1

1

1

V V V

6 PIN PLUG

+UBE SIG+ SIGGND

+UB GND TXD RXD A2B A2B LOAD D1

GN/YL

73 (LMI UNLOCK SOL.)

A A

B C B C

V

V V V V

71 (+UB) 51 (GND)

1 2 3 4 5 6 7

V V

LIGHTBAR

V V V

1 2 3 4

A B C A B C

V

A BC D V V V V

1 2 3 4

V V

NO C

1 2 3 4

V V V V

1 2 3 4

V V VV V V

X7 1 2 3 4

X8 +UBE 1 GND 2

A BCD E A BCD E

V V V V V

1 2 3 4 5 6 7 8 X1

1 2 3 4 5 6 TO MAIN BOOM CONNECTOR

NC over front on rubber

3

2

1

DS350 GRAPHIC MODULAR CENTRAL UNIT

1

OUTER SHIELD GROUNDED AT STRAIN RELIEF CONNECTOR.

2

INNER SHIELD CUT AND INSULATED

C

CRANE SYSTEM AREA DEF. SWITCH ELEC. SWIVEL

10 AMP FUSE

NOTES:

NO

NC on outriggers

FUSE (10 amp)

FUSE (10 amp)

+UBS

LMI BYPASS

FUSE (4 amp)

FUSE (4 amp) 4

LMI BYPASS KEY SWITCH

5 PIN DEUTSCH 1 2 3 4 PLUG V V V V V

15.3

V V

61 62

4 AMP FUSE

10 8 9 11 12 13 14

1 2 3 4 5 6 7

59 60

26 27 28 29 30 31 32 33 34 35 36 53 54

CONSOLE (1318) 1 2 3

NOT USED

NOT USED

NOT USED

NOT USED

A2B GROUND

A2B SIGNAL

ANGLE

FORCE

GND

LENGTH

+UB

GND

ROD

+UB

GND

PISTON

+UB

DI4

DI3

DI1

DI2

GND

EXT. HOR. *1

2

4

23 24 25

IN

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

20 21 22

OUT

9

13 14 15 16 17 18 19

OUT

8

+UBS

GND +UB GND RXD TXD A2B BYPASS A2B BYPASS LMI BYPASS +UB

51 52 3 4 5 6 7 8 9 10

IN

GN/YL

1 2 3

+UB

+UBR

LMI UNLOCK S.

+UB GND

X1 1 2 12 11

pres. trans. (piston)

pres. trans. (rod)

3

INSULATE OUTER SHIELD AND CONNECT TO CHASIS GND. *1) OPTIONAL FOR EXTERNAL HORN (EEC UNITS ONLY)

P.A.T. DS350 Graphic Modular MAIN BOARD A

B

C

D

E

F

G

H

I

J

K

L

M

-

1

G1

MP42

+

KGND

MP 26

KGND

MP 4 +5V MP 9

C

+6V X15

GND

1

GND

AGND

KGND

+BATT

C

MP24

MP23

VBAT

2

+UB1

PWM DC

MP 8

2

+9V

GND

3

4

5 +UB1 +UB

DI 6

KGND

X12

6

MP41 MP40 V10 H11 V11

H1 H2 H3 H4 H5 H6

DI 1

MP21

5

PFAIL+UB1

DI 1- DI 6 =>

X17

4

power o.k.

X14

3

6

J11

X11

7

7

SP5

X13

H12

TXD

AGND

H10

K8

MP29

10 LEVER LOCKOUT K10

A2B

+UB

2 1

MAIN ON/OFF

KGND

J10 3 4

9

LMI KGND

10

LOAD

+5V/RS232

AGND

9

F1

69 68 67 66 65 64

62 61

60 59 58 57

55 54

52 51

12

KGND

3 1

77 76

F2

H9 A2B

KGND

+

J4 J3 J2 J1

KGND

X1

12

-

11

KGND

K9

11

X1

13

8

X16

8

KGND MP 1 +UB

36

A

35 34 33

32

B

31

30 29 28 27 26

C

D

25 24 23

E

22 21 20

F

19 18 17 16 15

G

14

13 12 11

H

I

10 9

8

J

7

6

5

K

4

3

2

L

1

MP25

M

LOCATIONS :

LED’S

MP 1 - zone M13 = KGND. MP 25 - zone M13 = +UBS CONSOLE, SENSORS, DI’s MP 8 - zone M2 = +9V MP 41 - zone M4 = POWER FAIL MP 9 - zone M2 = +6V MP 4 - zone M1 = +5V MP 42 - zone G1 = +5V MP 26 - zone M1 = GND. MP 21 - zone E5 = +5V MP 23 - zone A2 = VBATT MP 29 - zone D10 = +5V MP 24 - zone D2 = +BATT H1-H6 - zone I5 = DI 1-6 MP 40 - zone M4 = +UB

H 8 - zone M3 - LOAD H 9 - zone E11 - A2B H 10 - zone G9 - MAIN IN/OUT H 11 - zone M3 - POWER H 12 - zone I11 - TXD

15.4

13

P.A.T. DS350 Graphic Modular EXTENSION BOARDS

MP7 J1 J13

J12

J2

D3

D1 MP4

D2

X1

D14

X2 D13

P1

SYSTEM D10 J8

D6 J9 MP3 J6 D17

J10

D15

D7

D21

D9 D12

J15

J11

J14

D18

J7

D11 D19

D20

X3

BR6

MP6MP5

EJECT BR5

MP2

A102 CPU

J1

J2

DATA D1 J5 J3

TLK D3 J6

BR 4 3 2 1

X1

A103 DATEN

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.

15.5

DS350 Graphic Module Analog Input Module

+

P7

MP12

1 2

40

AGND

AGND -

P6

MP13

J2

20

P5

16 P4 P3

MP9

J1

MP11

X16

P2

MP10

P1

1 1 2

X1

MP17

BR1

-

MP0

+

MP8

+

+

VREFA

P8

+

7 6 5

MP16 16

MP7 - MP1->

X17

1 2

+

4

MP14

3 2 1

40 1 2 AGND

AGND

BOARD P/N 9-333-103290 X1:1-7 X1:8 X1:9 X1:10 X1:11 X1:12-15 X1:16 X1:17 X1:18 X1:19 X1:20

ADC INPUT 0.5 V … 4.5 V, Note: If channel adjustments are made through the software and graphic console, DO NOT adjust offset with P1 - P7 = TEMP (0.5V + 10mV/oC) MP 1 = AGND = VREFA = 5.000V reference MP 8 = + 5V = AGND (reference GND) MP 1 - 7 = Input channels 1 - 7 - 0.5V/ 4mA = VREF+ = 5.0V power ADC 2.5V/20mA = CH01-04, DIN 1-4 / 10 MP 14 = + 13V REF 02 = CH05, +UBS / 10 MP 16 = HESIN input voltage = CH06, HESIN(A2B) *4 MP 17 = app 5.4V clamp for inputs = CH07, +9V *4 = CH08, VREFA / 2 = 2.500V = UKLEMM, app. VREFA, limits ADC input to 5.0V

15.6

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= + 9V @ MP 8= +5V @ MP 4= +6V @ MP 9= +5V @ MP 42= +5V @ MP 29= +12/+24V @ MP 40= 3.

4.

5.

6.

VDC MP 1 Ground VDC MP 1 Ground VDC MP 1 Ground VDC MP 1 Ground VDC MP 1 Ground VDC MP 1 Ground VDC MP 1 Ground

Boom Length: Fully Retracted Ft. Fully Extended Ft. Fully Retracted Ft. Fully Extended Ft. +12/+24V Volt Reference Voltage

mA @ X1-27 mA @ X1-27 VDC @ MP X1-3(A106), MP 0 (GND) VDC @ MP X1-3(A106), MP 0 (GND) VDC @ X1-26 (X1-28 GND)

Boom Angle: Minimum Angle Degs. Maximum Angle Degs. Minimum Angle Degs. Maximum Angle Degs. +12/+24V Volt Reference Voltage

mA @ X1-29 mA @ X1-29 VDC @ MP X1-4(A106), MP 0 (GND) VDC @ MP X1-4(A106), MP 0 (GND) VDC @ X1-26 (X1-28 GND)

Pressure Transducers: Piston Zero Point mA @ X1-21 / Rod Zero Point mA @ X1-24 / Piston +12/+24 Volt Reference Voltage Rod +12/+24 Volt Reference Voltage Analog Input Module (A106): +5V @ MP8 = +5V @ MP17= +5V @ MP16=

VDC MP 0 Ground VDC MP 0 Ground VDC MP 0 Ground

15.7

VDC @ X1-1(A106), MP0 (GND) VDC @ X1-2(A106), MP0 (GND) VDC @ X1-20 (X1-22 GND) VDC @ X1-23 (X1-25 GND)

P.A.T. – L.M.I MANUAL SECTION 16

DS 350 Graphic Modular BOOM LENGTH CONNECTIONS & WIRING DIAGRAMS

P1

AGND

MP14

.0V ERROR CODE

J1

E11 .500v MIN.

MP7 - MP1->

1 2

MP16

16

1 2

-

AGND

1

BR1

20 40

X1

AGND

X1 26 27 28

WORKING RANGE

- +

MP11

MP10

J2

VOLTAGES X1 3 ANALOG INPUT MODULE + 500MV (.500V) = MIN. SIGNAL (RETRACTED BOOM) + 4.50V = MAX. SIGNAL (10 TURNS ON POT) ALL VOTAGES ARE MEASURED WITH REFERENCE TO GND (TERMINAL X1 - 28) ON MAIN BOARD. * THESE MEASUREMENTS ARE MADE IN PARALLEL

4.50v MAX. ERROR CODE

(GND)

P2

LENGTH

P3 MP9

VREFA

P4

+UB

MP12

P5

Channel # 1 OPERATING WINDOW

MP17

P6 MP13

MP0 MP8

- +

AGND

P7

P8

A

+

E21 5.0V

16.1

Current Based Amplifier All sensing devices used for Analog Inputs now have a current output. (min. signal 4mA, max. signal 20mA) This circuit is measured in series.

1

2 3

E11 / E21 1

6 Pin

2

GND

Measure Voltage - Length transducer at X1 2(+) & 3 (-) Range 1V to 5.6V

7 8 X2

Measure Amps - Length transducer at X1 2(+) & (-) WIRE 2. Range 4 mA to 20 mA

DS350 GRAPHIC MODULAR BOOM LENGTH MEASURING CHANNEL CHANNEL # 1

5 3 1 GND

5 3 1

5 3 1 X4

+UB

Measure Voltage - Length transducer at X1 1(+) & 3 (-) Range 10V to 30V

1 OUT

CORE

+UB

SHIELD

1 OUT

(measurements in cable reel)

5 3 1 X3

Plug

1 2 3 4 5 6 7

1 2 3 4 5 6 1 2 3 4 5 6 7

S 8 7 6 5 4 3 2 1 X1 6 Pin

6 5 7

4 3 2 1

Connector

DS350 Graphic Modular Boom Length Signal

16.2

NO. OF TURNS ON CABLE REEL

NO. OF TURNS ON LENGTH POT

SIGNAL AT X1 TERM. PIN #27 ON C.P.U. TERMINAL

SIGNAL ON ANALOG MODULE AT X1-3 (X1-28 GND.)

0

0

4 mA

.5 V

3

1

5.5 mA

.9 V

6

2

7.2 mA

1.3 V

9

3

8.7 mA

1.7 V

12

4

10.4 mA

2.1 V

15

5

12.0 mA

2.5 V

18

6

13.6 mA

2.9 V

21

7

15.2 mA

3.3 V

24

8

16.8 mA

3.7 V

27

9

18.4 mA

4.1 V

30

10

20 mA

4.5 V CHANNEL # 1

( 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.

MEASURE VOLTAGE IN LENGTH TRANSDUCER AT X1 - 1 (+) & X1 - 3 (-)… RANGE = 10V - 30V.

24.0

XA2

1 2 3 4 5 6 7 8

16.3

1 2 3 4 5 6 7 8 S

X2

1 X3 1 2 3 3 5 L

XB2

X2

1 X4 1 2 3 3 5 A

X2 X1

9333103309

7 (9) 8 (10)

MEASURE VOLTAGE IN LENGTH TRANSDUCER AT X1 - 2 (+) & X1 - 3 (-)… RANGE = 1V - 5.6V.

1.0

XA2

1 2 3 4 5 6 7 8

16.4

1 2 3 4 5 6 7 8 S

X2

1 X3 1 2 3 3 5 L

XB2

X2

1 X4 1 2 3 3 5 A

X2 X1

9333103309

7 (9) 8 (10)

MEASURE AMPERAGE IN LENGTH TRANSDUCER AT X1 - 2 (+) & WIRE #2 (-)… RANGE = 4mA - 20mA.

4.00

XA2

1 2 3 4 5 6 7 8

16.5

1 2 3 4 5 6 7 8 S

X2

1 X3 1 2 3 3 5 L

XB2

X2

1 X4 1 2 3 3 5 A

X2 X1

9333103309

7 (9) 8 (10)

P.A.T. – L.M.I MANUAL SECTION 17

DS 350 Graphic Modular PISTON, ROD CONNECTIONS & WIRING DIAGRAMS

GRAPHIC CONSOLE SPECIAL FUNCTION 0 - SETTING OF TRANSDUCER INPUT 0 - SETTING OF PRESSURE AND FORCE INPUTS The 0 - setting consists of calculating an appropriate 0 - point offset, which, when added to the transducer measurement, allows the real physical pressure of force to be calculated. To achieve this, 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 press the CTRL key. 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

0 - SETTING THE TRANSDUCER INPUTS Now, having successfully entered a valid password, the piston - side 0 - point setting function is activated. 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 - key, the input value is adjusted downwards. When the + and - keys are pressed simultaneously, the 0 - setting occurs automatically. Manual adjustments 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 normal display.

17.1

AGND

MP14

.0V ERROR CODE

J1

E12 .500v MIN.

MP7 - MP1->

1 2

MP16

16

1 2

17.2

VOLTAGES X1 1 ANALOG INPUT MODULE + 500MV (.500V) = MIN. SIGNAL (ZERO PRESSURE) + 4.50V = MAX. SIGNAL (300 BAR PRESSURE) ALL VOTAGES ARE MEASURED WITH REFERENCE TO GND (TERMINAL X1 - 22) ON MAIN BOARD. * THESE MEASUREMENTS ARE MADE IN PARALLEL

AGND

1

BR1

20 40

X1

AGND

X1 20 21 22 -

WORKING RANGE

- +

MP11

MP10

J2

A

+

4.50v MAX. ERROR CODE

(GND)

P1

(PISTON)

P2

OUTPUT SIGNAL

P3 MP9

VREFA

P4

+UB

MP12

P5

Channel # 2 OPERATING WINDOW

MP17

P6 MP13

MP0 MP8

- +

AGND

P7

P8

E22 5.0V

1

2 3

Current Based Amplifier All sensing devices used for Analog Inputs now have a current output. (min. signal 4mA, max. signal 20mA) This circuit is measured in series.

E12 / E22 (measurements at transducer)

1 2 3

4

Measure Voltage - (Elec) Piston transducer at A (+) & C (-) Range 10V to 30V Measure Voltage - (Elec) Piston transducer at B (+) & C (-) Range 0V

A B C A B C

Measure resistance - (Hyd) Piston transducer at B (+) & C (-) Range 200 - 300 Ohm PRESS. TRANS. (PISTON)

DS350 GRAPHIC MODULAR PISTON PRESSURE MEASURING CHANNEL CHANNEL # 2

4

AGND

MP14

.0V ERROR CODE

J1

E13 .500v MIN.

MP7 - MP1->

1 2

MP16

16

1 2

17.3

VOLTAGES X1 2 ANALOG INPUT MODULE + 500MV (.500V) = MIN. SIGNAL (ZERO PRESSURE) + 4.50V = MAX. SIGNAL (300 BAR PRESSURE) ALL VOTAGES ARE MEASURED WITH REFERENCE TO GND (TERMINAL X1 - 25) ON MAIN BOARD. * THESE MEASUREMENTS ARE MADE IN PARALLEL

E13 / E23

AGND

1

BR1

20 40

X1

AGND

X1 23 24 25 -

WORKING RANGE

- +

MP11

MP10

J2

A

+

4.50v MAX. ERROR CODE

(GND)

P1

(ROD)

P2

OUTPUT SIGNAL

P3 MP9

+UB

P4

MP17

MP12

P5

Channel # 3 OPERATING WINDOW

VREFA

P6 MP13

MP0 MP8

- +

AGND

P7

P8

E23 5.0V

1

2 3

Current Based Amplifier All sensing devices used for Analog Inputs now have a current output. (min. signal 4mA, max. signal 20mA) This circuit is measured in series.

(measurements at transducer)

1 2 3

4

Measure Voltage - (Elec) Rod transducer at A (+) & C (-) Range 10V to 30V Measure Voltage - (Elec) Rod transducer at B (+) & C (-) Range 0V

A B C A B C

Measure resistance - (Hyd) Rod transducer at B (+) & C (-) Range 200 - 300 Ohm PRESS. TRANS. (ROD)

DS350 GRAPHIC MODULAR ROD PRESSURE MEASURING CHANNEL CHANNEL # 3

4

DS350 Graphic Modular PRESSURE 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. MEASURING RESISTANCE BETWEEN B (+) AND C (-) RANGE 200 - 300 Ohm.

+24.0

+0.

C

A B

17.4

P.A.T. – L.M.I MANUAL SECTION 18

DS 350 Graphic Modular BOOM ANGLE CONNECTIONS & WIRING DIAGRAMS

P5

P4

P3

P2

MP9

AGND

MP14

Channel # 5 OPERATING WINDOW

VREFA

P6 MP13

MP0 MP8

- +

AGND

P7

P1

P8

.500v MIN.

1 2

MP16

16

1 2

18.1

VOLTAGES X1 4 ANALOG INPUT MODULE + 500MV (.500V) = 90o ANGLE MIN. SIGNAL + 2.50V = 45o ANGLE + 4.5 V = 0o ANGLE MAX. SIGNAL ALL VOTAGES ARE MEASURED WITH REFERENCE TO GND (TERMINAL X1 - 28) ON MAIN BOARD. * THESE MEASUREMENTS ARE MADE IN PARALLEL

E15 / E25

X1 26 28 29

WORKING RANGE

AGND

1

BR1

20 40

X1

AGND

4.50v MAX.

ERROR CODE

(90o TO 0o)

MP10

MP7 - MP1->

- +

MP11

E15

(GND)

J1 J2

+UB

MP17

ERROR CODE

ANGLE

.0V MP12

+

A

E25 5.0V

Current Based Amplifier All sensing devices used for Analog Inputs now have a current output. (min. signal 4mA, max. signal 20mA) This circuit is measured in series.

SHIELD CORE

1

1

3 4

6 Pin

2

Plug

(measurements in cable reel)

7 8 X2

Measure Amps - Angle transducer at X1 4(+) & (-) WIRE 4. Range 4 mA to 20 mA

5 3 1 X4

+UB

GND

5 3 1 1 OUT

+UB

GND

Measure Voltage - Angle transducer at X1 2(+) & 3 (-) Range 1V to 5.6V

1 OUT

5 3 1

Measure Voltage - Angle transducer at X1 1(+) & 3 (-) Range 10V to 30V

5 3 1 X3

1 2 3 4 5 6 7

1 2 3 4 5 6 1 2 3 4 5 6 7

S 8 7 6 5 4 3 2 1 X1 6 Pin

DS350 GRAPHIC MODULAR BOOM ANGLE MEASURING CHANNEL CHANNEL # 5

6 5 7

4 3 2 1

Connector

DS350 Graphic Modular Boom Angle Signal

18.2

ACTUAL BOOM ANGLE IN DEGS. 90o

SIGNAL AT X1 TERM. PIN #29 ON C.P.U. TERMINAL 4.0 mA

SIGNAL ON ANALOG MODULE AT X1-4 (X1-28 GND.) 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

o

25

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 CHANNEL #5

CHART SHOWS TYPICAL MILLI-AMP AND VOLTAGE SIGNALS. THESE VALUES ARE TO BE USED AS A REFERENCE ONLY, THE ACTUAL SIGNAL MAY VARY SLIGHTLY.

24.0

1 2 3 4 5 6 7 8 S

18.3 9333103309

X1

X2

X2

XB2

X2

XA2

7 (9) 8 (10)

A

1 X4 1 2 3 3 5

L

1 X3 1 2 3 3 5

MEASURE VOLTAGE IN ANGLE TRANSDUCER AT X1 - 1 (+) & X1 - 3 (-)… RANGE = 10V - 30V.

1 2 3 4 5 6 7 8

1.0

1 2 3 4 5 6 7 8 S

18.4 9333103309

X1

X2

X2

XB2

X2

XA2

7 (9) 8 (10)

A

1 X4 1 2 3 3 5

L

1 X3 1 2 3 3 5

MEASURE VOLTAGE IN ANGLE TRANSDUCER AT X1 - 2 (+) & X1 - 3 (-)… RANGE = 1V - 5.6V.

1 2 3 4 5 6 7 8

20.0

1 2 3 4 5 6 7 8 S

18.5 9333103309

X1

X2

X2

XB2

X2

XA2

7 (9) 8 (10)

A

1 X4 1 2 3 3 5

L

1 X3 1 2 3 3 5

MEASURE AMPERAGE IN ANGLE TRANSDUCER AT X1 - 4 (+) & WIRE #4 (-)… RANGE = 4mA - 20mA.

1 2 3 4 5 6 7 8

D S350 Graphic Modular Slewing Angle

18-6

8

3

1

1 2 3

4 1 2 3

4

1 2 3

4

5

6 2

1

2

2

1

1

1

1

1

+UBE SIG+ SIGGND

1 2 3 4

X7 1 2 3 4 1 2 3 4

1 2 3 4

1 2 3 4 5 6 7

A B C A B C

A B C A B C

1 2 34 5 6 TO MAIN BOOM CONNECTOR

pres. trans. (piston)

pres. trans. (rod)

GN/YL

FUSE (10 amp)

FUSE (10 amp)

+UBS

LMI BYPASS

FUSE (4 amp) 4

3

2

1

10 AMP FUSE LMI BYPASS KEY SWITCH

6 PIN PLUG

+UB GND TXD RXD A2B A2B LOAD D1

Rear Axle Oscil. Relay

X8 +UBE 1 GND 2

V V V

LMI Lockout Alarm

1 2 3 4 5 6 7 8 X1

V V V

V V V V

V V (LMI UNLOCK SOL.)

10 8 9 11 12 13 14

1 2 3 4 5 6 7

FUSE (4 amp)

4 AMP FUSE

V V V

V V

71 (+UB) 51 (GND) 73

GND

2

V V V

6

4

2

V V VV V V

5

V V

18-7

V V

4

3

2

CONSOLE (1318) 1 2 3

SLEW 2

+ 12 V

A2B GROUND

SLEW 1

A2B SIGNAL

ANGLE

GND

+UB

LENGTH

ROD GND

+UB

GND

+UB

PISTON

DI4

DI2

DI3

DI1

+UBS

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

IN

6

61 62

OUT

5

59 60

26 27 28 29 31 32 30 33 34 35 53 54

OUT

4

23 24 25

IN

1 2 3

51 52 3 4 5 6 7 8 9 10 14 15 16 17 18 19 20 21 22

GN/YL

1 2 12 11 13

DI GND

+UB

X2/1 1 2 3

GND +UB GND RXD TXD A2B BYPASS A2B BYPASS LMI BYPASS +UB

GND

K10 NC

EXT. HOR. *1

LMI UNLOCK S.

+UBR K10 COM

+UB GND X1

D.O.Module

2

1

2

3

4

1

2

5

3

V V V V

NOTES: 1

OUTER SHIELD GROUNDED AT STRAIN RELIEF CONNECTOR.

2

INNER SHIELD CUT AND INSULATED

3

INSULATE OUTER SHIELD AND CONNECT TO CHASIS GND.

A BC D V V V V

1 2 3 4 LIGHTBAR

*1) OPTIONAL FOR EXTERNAL HORN (EEC UNITS ONLY)

DS350 GRAPHIC MODULAR with SLEWING POTINTIOMETER

P2

1

P1

1 2

MP7 - MP1->

MP16 16

MP14

VOLTAGES X1 5 ANALOG INPUT MODULE + 500MV (.500V) = MIN. SIGNAL BOOM OVER FRONT + 4.50V = MAX. SIGNAL BOOM OVER REAR ALL VOTAGES ARE MEASURED WITH REFERENCE TO GND (MP 0) ON ANALOG BOARD. * THESE MEASUREMENTS ARE MADE IN PARALLEL

MP11

P3

MP9

J1

P4

DS350 GRAPHIC MODULAR SLEW ANGLE #1

J2

P5

- + MP0 MP8 BR1

P8 VREFA

AGND

AGND

20 40

P6

MP13

MP10

P7 MP17 X1

MP12

- +

4 mA .500V (A106)

18-8

AGND 1 2

E2A

WORKING RANGE

E1A

5.0V

4.50v MAX.

.500v MIN.

AGND

12 mA 2.5V (A106)

12 mA 2.5V (A106)

OPEN 4.5V (A106)

Current Based Amplifier All sensing devices used for Analog Inputs now have a current output. (min. signal 4mA, max. signal 20mA) This circuit is measured in series.

ERROR CODE

ERROR CODE

OPERATING WINDOW .0V (GND)

SLEW ANGLE 1

+UB 2 2 W

1 R

1

1

A

5 Y

3

3 B

4

2 4 3

+

-

X1 33 30 35

SLEW ANGLE 2

P2

1

P1

1 2

MP7 - MP1->

MP16 16

MP14

VOLTAGES X1 6 ANALOG INPUT MODULE + 500MV (.500V) = MIN. SIGNAL BOOM OVER FRONT + 4.50V = MAX. SIGNAL BOOM OVER REAR ALL VOTAGES ARE MEASURED WITH REFERENCE TO GND (MP 0) ON ANALOG BOARD. * THESE MEASUREMENTS ARE MADE IN PARALLEL

MP11

P3

MP9

J1

P4

DS350 GRAPHIC MODULAR SLEW ANGLE #2

J2

P5

- + MP0 MP8 BR1

P8 VREFA

AGND

AGND

20 40

P6

MP13

MP10

P7 MP17 X1

MP12

- +

12 mA 2.5V (A106)

18-9

AGND 1 2

E2B

WORKING RANGE

E1B

5.0V

4.50v MAX.

.500v MIN.

AGND

4 mA .500V (A106)

OPEN 4.5V (A106)

12mA 2.5V (A106)

Current Based Amplifier All sensing devices used for Analog Inputs now have a current output. (min. signal 4mA, max. signal 20mA) This circuit is measured in series.

ERROR CODE

ERROR CODE

OPERATING WINDOW .0V (GND)

SLEW ANGLE 2

+UB 2 2 W

1 R

1

1

A

5 Y

3

3 B

4

3 4 2

+

-

X1 33 34 35

SLEW ANGLE 1

DS350 Graphic Modular Slewing Potentiometer Components

Electrical Slip ring Assembly Slewing Potentiometer

Printed Circuit Slewing Board

18-10

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.

Collar set fastened to shaft by two (2) set screws. Printed Circuit Slewing Board (showing X1 Terminal Board)

Potentiometer

18-11

Collar

Slotted Clutch Plate

Plug to the Slip ring Circuit Board

Slotted Clutch Plate Potentiometer

Collar

18-12

Note: These four (4) washers must be installed before proceeding to the next step.

Plastic Shield installed on top of four washers .

18-13

Clutch plate installed on top of slip ring assembly.

18-14

Position the collar so there is between 1/32” to 1/16” clearance to the bottom of the potentiometer.

Tighten set screws.

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 mounted slew 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 Handbook for detailed instructions.

18-17

3. Remove the Slip Ring cover.

4. Loosen the three screws that secure the potentiometer.

DO NOT ATTEMPT TO ROTATE THIS SLOTTED SHAFT.

18-18

5. Disengage the house lock pin and swing approximately 10 deg. to the right (clockwise). Slowly swing back to the left and engage the house lock pin*. Rotate the body of the slew potentiometer until the slew angle indicates 0.6 deg. (+/- 0.1 deg.). NOTE: This value may not be obtainable due to limited wire length on the slew potentiometer, or the electrical terminals interferance with one of the mounting screws, if this occurs,reposition the collar set screwed to the potentiometer shaft and repeat step 5.

6. Disengage the house lock pin and swing approximately 10 deg. to the left (counterclockwise). Slowly swing back to the right and engage the house lock pin*. If the angle indicated on the console does not exceed +/- 1.0 deg., proceed to step 7. If the indicated angle exceeds +/- 1.0 deg. Return to step 5.

7. Tighten the three screws that secure the slew potentiometer to the mounting plate. Install the slip ring cover.

8. Disengage the house lock pin and swing approximately 10 deg. to the right (clockwise). Slowly swing back to the left and engage the house lock pin*. If the angle indicated on the console does not exceed +/- 1.0 deg., proceed to step 9. If it does exceed +/- 1.0 return to step 4.

9. Disengage the house lock pin and swing approximately 10 deg. to the left (counterclockwise). Slowly swing back to the right and engage the house lock pin*. Verify the angle indicated on the console does not exceed +/- 1.0 deg. If the angle exceeds +/- 1.0 deg., Return to step 4. * IF THE SUPERSTRUCTURE SWINGS PAST THE HOUSE LOCK PIN ENGAGED POSITION, THE PROCEDURE MUST BE REPEATED.

18-19

P.A.T. – L.M.I MANUAL SECTION 19

DS 350 Graphic Modular ANTI - TWO - BLOCK CONNECTIONS & WIRING DIAGRAMS

ANTI - TWO - BLOCK WIRING DIAGRAM

1

6 Pin

2

GND

19.1

2 1

7 8 X2

5 3 1 X4

1 2 3 4 5 6

5 3 1 X3

1 2 3 4 5 6 7 2

S 8 7 6 5 4 3 2 1 X1 6 Pin

6 5 1

1 2

4 3 2 1

1

3

ANTI - TWO BLOCK SWITCH

NOTES: OUTER SHIELD GROUNDED AT 1 STRAIN RELIEF CONNECTOR 2

CUT AND INSULATE INNER SHIELD

1

SWITCH PREWIRED AND POTTED

!

IMPORTANT CHANGE

7

Plug

1 2 3 4 5 6 7

5 3 1 +UB

5 3 1

GND

1

1 OUT

CORE

+UB

SHIELD

6 PIN

SHIELD

To Central Unit

1 OUT

3

1 2 3 4 5 6

CORE

6 PIN DUMMY PLUG

!

CONNECTOR

4.7K Ω RESISTOR

2

Connector

1

ANTI - TWO - BLOCK WIRING DIAGRAM 4.7K Ω RESISTOR

To Central Unit 1 2

SHIELD

2

3 4 2

5 3 1

3

1

4

19.2

1 2

7 8 5 3 1 X2 X4

1

A B

1 2 3 4 5 6

5 3 1 X3

1 2 3 4 5 6 7 2

S 8 7 6 5 4 3 2 1 X1 1 2

1 2

3

6 5

1

3

1 2

Plug

1 2 3 4 5 6 7

5 3 1 +UB

1 2 3

B

6 Pin

2

GND

A

1

GND

CORE

CORE

1 OUT

SHIELD

6 PIN DUMMY PLUG

+UB

A B

1 OUT

!

1

6

6 Pin

1

4 3 21

Connector

1

5

3

ANTI - TWO BLOCK SWITCH

7

2

1

NO. 1

1 2

3

AUX. BOOM NOSE ANTI - TWO BLOCK SWITCH

PART NO.

QTY

1 2 3 4 5

9-333-102764 9-333-102717 9-333-102666 9-333-102663 9-333-102230

1 1 1 4 1

6

9-333-102765

1

DESCRIP. COMP. ASSEM. 2-POLE JUMPER BAR TAGS, TERMINAL STRIP BLOCK, TERMINAL STRIP SWITCH A2B, WITH RETAINER CRIMP COMP. ASSEM., DUMMY PLUG

NOTES: OUTER SHIELD GROUNDED AT 1 STRAIN RELIEF CONNECTOR 2

CUT AND INSULATE INNER SHIELD

1

SWITCH PREWIRED AND POTTED

!

IMPORTANT CHANGE

Auxiliary Boom Nose

3 4

2

1

NO.

PART NO.

QTY

1 2

9-333-102238 9-333-102235

1 1

3+ 4

9-333-102767 9-333-102687

1 2

19.3

DESCRIPTION SWITCH, A2B W/O CRIMP CONDUIT 10 FEET (MUST CUT TO LENGTH) JUNCTION BOX ASSEM. SCREW

Auxiliary Boom Nose JUNCTION BOX ASSEMBLY

1(BLACK)

1 2(BROWN)

A2B CABLE

3(RED)

1

A

2

B

2 3

Complete Assembly # 9-333-102767 NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

PART NO.

QTY

9-333-102758 9-333-102793 9-333-101984 9-333-102759 9-333-102663 9-333-102664 9-333-102665 9-333-102666 9-333-102760 9-333-102482 9-333-102612 9-333-102669 9-333-102266 9-333-102480

1 1 1 1 3 1 2 1 1 1 1 4 4 4

DESCRIPTION Junction Box Strain Relief (90o) Locknut Mounting rail, terminal strip Block, terminal strip End plate, terminal strip End bracket, terminal strip Tags, terminal strip Connector, cannon 2-pin male recp. Gasket Cover, dust Screw #4 Lockwasher #4 Nut #4 19.4

19.5 PART NO. 9-333-102238 7-110-151205 9-333-102235 9-333-102690 9-333-102687

NO. 1 2 3 4+ 5

1 2

QTY 1 2 1

DESCRIPTION Switch, A2B W/O Crimp Capscrew Conduit 10 feet (must cut to length) Junction box assembly Screw

Fixed Swingaway Extension

Fixed Swingaway JUNCTION BOX ASSEMBLY

1(BLACK)

1 A2B CABLE

2(BROWN)

2

3(RED)

3

1

A

2

B

Complete Assembly # 9-333-102690 NO. 1 2 3 4 5 6 7 8 9 10 11 12 13

PART NO. 9-333-102758 9-333-102674 9-333-102759 9-333-102663 9-333-102664 9-333-102665 9-333-102666 9-333-102760 9-333-102482 9-333-102612 9-333-102669 9-333-102266 9-333-102480

QTY

DESCRIPTION 1 1 1 3 1 2 1 1 1 1 4 4 4

Junction Box Strain Relief Mounting rail, terminal strip Block, terminal strip End plate, terminal strip End bracket, terminal strip Tags, terminal strip Connector, cannon 2-pin male recp. Gasket Cover, dust Screw #4 Lockwasher #4 19.6 Nut #4

P.A.T. – L.M.I MANUAL SECTION 20

DS 350 Graphic Modular TROUBLESHOOTING GUIDE

PAT DS350 Graphic Modular LOAD MOMENT INDICATOR TROUBLESHOOTING

General Flowchart Lever Lockout Activated Broken Length Cable No Display Anti - Two - Block Length Reading Problem Angle Reading Problem Load Reading Problem Bad Data Transfer Between Console & Central Unit Error Code Displayed

20.1

20.2 20.3 20.4 20.5 20.7 20.10 20.13 20.16 20.18 20.20

GENERAL FLOWCHART

This section explains how to handle a problem that may arise with the P.A.T. Load Moment Indicator System - P.A.T. DS350 Graphic Modular. The procedures are easy to follow and are given in flowcharts on the following pages. Start with general flowchart below which will guide you to one of the more detailed flowcharts shown on pages 20.3 through 20.19.

START

What’s Wrong?

Lever Lockout Activated

Length Cable Problem

Go to Page 20.3

Go to Page 20.4

Wrong Length Displayed

Go to Page 20.10

Wrong Angle Displayed

Go to Page 20.13

No Display

No Function Anti-Two-Block

Go to Page 20.5

Go to Page 20.7

Wrong Load Displayed

Go to Page 20.16

20.2

Bad Data Transfer

Error Code Displayed

Go to Page 20.18

Go to Page 20.20

LEVER LOCKOUT ACTIVATED PROBLEM The lever lockout system of the crane is activated. Crane movements “hoist up”, telescope out”, and “boom down” are stopped. Crane is not in overload or two-block condition.

START

Set the override key switch in central unit into upper position to override LMI.

fixed?

YES

NO Does the console indicate Anti-Two-Block warning?

NO

YES

Fault in crane electric or hydraulic system.

If console displays is blank, fault is located in power supply, wiring or fuses.

Fault in Anti-Two Block system.

If Load Moment Limit Light is lit, the fault is located in LMI, cables, wiring, fuses or console.

Check lever lockout system in crane

Go to page 20.5

Go to page 20.7

Read error code displayed on console and go to page20.20.

20.3

BROKEN LENGTH CABLE PROBLEM Damaged or broken length cable.

STEP

ACTION

1

Cut old cable at cable drum.

2

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

3

Remove cable reel from mounting brackets.

4

Remove damaged length cable, which is mounted to the slip rings in the cable reel, from Terminal X1 and X2 See drawing 1 on page 20.28.

5

Turn the cable reel and open the stain relief attached to the axle in the center of the drum. Pull existing length cable out of the cable reel.

6

Disconnect damaged length cable from Anti-Two-Block switch receptacle at the boom nose.

7

Pull new length cable through the hole, pipe and strain relief and push it through the axle of the reeling drum. Tighten strain relief to ensure sealing.

8

Dismantle length cable near slip ring and reconnect shield to terminal No. X1 and center to No. X2 See drawing 1 on page 20.28.

9

Remount cable reel to the boom. Turn reeling drum clockwise to get rest of new cable onto the drum.

10

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

11

Reconnect new cable to Terminal No. 1 (center) and ground terminal (shield) of receptacle at the boom nose.

12

Reset length potentiometer in length angle transducer (screw is located in center of white gear): with boom fully retracted, turn potentiometer carefully counter-clockwise until it stops. Check function of Anti-Two-Block switch. Recheck length and angle display.

20.4

NO DISPLAY PROBLEM Blank console display. No warninglight shown. Crane movements stopped.

START

Check fuses on CPU box.

correct?

NO

Replace fuses.

YES 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?

NO

Check crane power supply for faulty crane electric or if power supply is too low.

YES

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.

correct?

Defect on main board. Replace main board, see replacement procedure.

NO

YES

NEXT PAGE

20.5

NO DISPLAY continued

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 the cable between console and central unit. Replace cable if necessary.

NO

YES

Display is defective. Replace the console.

END

20.6

ANTI-TWO-BLOCK PROBLEM PROBLEM Function of Anti-Two-Block System is faulty.

START Check to see whether or not crane is in two-block condition.

NO Lower hook down in safe position.

correct?

YES

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

NO

Plug appropriate plug into socket of junction box.

correct?

YES Measure the resistance at the boom nose box 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 Ohms Switch Open = > 1 Megaohm

NO correct?

YES NEXT PAGE

20.7

Replace Anti-Two-Block switch.

ANTI-TWO-BLOCK PROBLEM PREVIOUS PAGE

Measure the A2B signal in the cable reel between X1:Brown and X2:Red wires on the slip ring with an ohmmeter. See drawing 1 on page 20.28. Switch closed = 4700 +/- 500 Ohms Switch open = >1 Megohm Reconnect slip ring wires.

NO correct?

Fault in wiring cable from junction box at boom nose to cable reel or short circuit in length cable. Check wiring.

YES

Measure the A2B signal in the cable reel between 7 and 8 with an ohmmeter. See drawing 1 on page 20.28. Anti-Two-Block switch open = > 1 megohm Anti-Two-Block switch closed = 4700 Ohms + 500 Ohms. Reconnect length cable to slip ring. NO correct?

Replace slip ring.

YES Measure the A2B signal in the boom base box between terminal 5 and 6 with an ohmeter. Anti-Two-Block switch open = > 1 megohm Anti-Two-Block switch closed = 4700 Ohms + 500 Ohms. Reconnect length cable to slip ring. NO correct?

YES NEXT PAGE

20.8

Fault in 7 conductor cable between cable reel and boom base box.

ANTI-TWO-BLOCK PROBLEM PREVIOUS PAGE

Connect wire # 5 back to terminal X1-31 on themain board. 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 Ohms Anti-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 diagram for wires # 5 (+) and # 6 (-). If fault is found check cable.

NO correct?

YES Disconnect X1-31 and X1-32. Check main board function by installing a temporary resistor, 4700 Ohms, between X131 and X1-32 in central unit. With resistor connected alarm should be inactive.

NO

Defect on main board. Replace main board and reset pressure channel.

correct?

Reconnect wire #5 to X1-31 and wire #6 to X1-32.

END

20.9

LENGTH READING PROBLEM PROBLEM 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 counterclockwise until it stops. See drawing 7 on page 20.33.

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?

NO

Replace the gearwheel, clean potentiometer axle. Reset length potentiometer.

YES 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.

correct?

Main board defective. Replace main board and reset pressure channel.

NO

YES NEXT PAGE

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.

NO

Faulty wiring between central unit and length transducer. Check wiring.

correct?

YES Measure signal from length transducer in cable reel at X1-2 and wire #2, the return signal is a current output. Measurement should be in series. Retracted Boom = 0 Potentiometer Turns = 4mA 10 Potentiometer Turns = 20mA

NO correct?

YES

Replace length potentiometer assembly. Remove slip ring body from shaft and remove gear wheel from potentiometer axle. Unscrew mounting plate and 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, turn counterclockwise until it stops. See drawing 7 on page 20.33.

Measure signal from length transducer in central unit. The return signal is a current output and must be measured in series. Connect meter between wire #2 and X1-27. 0 Potentiometer Turns = 4mA 10 Potentiometer Turns = 20mA

See drawing 3 on page 20.29.

NO

Faulty wiring between central unit and length transducer. Check wiring.

correct?

YES NEXT PAGE

20.11

LENGTH READING PROBLEM

PREVIOUS PAGE

Measure length signal of amplified output on analog input module between test point MP0 and X1-3. The measurement should be between 0.5V-4.5V.

0 Potentiometer Turns = 0.5 V (500mV) 10 Potentiometer Turns = 4.5 V Refer to Drawing 5 on page 20.31.

correct?

YES

Main board defective. Replace main board. Reset pressure channel.

NO

Analog Input Module is defective. Replace module.

END

20.12

ANGLE READING PROBLEM PROBLEM Angle Reading Incorrect Crane is not in “Out of Load Chart” condition.

START

Check levelness of the angle sensor in cable reelwith main boom at horizontal remove cover from the cable reel. See drawing 7 on page 20.33.

Readjust the angle sensor to the correct position by loosening the mounting screws and moving the angle sensor. See drawing 7 on page 20.33.

NO correct? YES

Place the boom at 0 o. Check power supply to angle sensor on main board between X126 (+12/24V) and X1-28 (GND) Refer to Drawing 3 on page 20.29.

NO correct?

Main board defective. replace main board and reset pressure channel. Note: Consult factory before replacing main board for further troubleshooting steps.

YES

NEXT PAGE

20.13

ANGLE READING PROBLEM

PREVIOUS PAGE

Measure supply to angle sensor in cable reel at terminal between X1-1 (+12/24V) and X1-3 (GND). See drawing 7 on page 20.33.

NO

Faulty wiring between central unit and angle sensor. Check wiring.

correct? YES

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

NO

Replace angle sensor.

correct? YES

NEXT PAGE

20.14

ANGLE READING PROBLEM PREVIOUS PAGE

Measure signal from angle sensor in central unit. Measurement should be taken in series at X1-29 and wire #4. Boom Angle Signal : 0 Degrees 20 mA 45 Degrees 12 mA 90 Degrees 4 mA

NO

Faulty wiring between central unit and cable reel. Check wiring.

correct? YES

Measure angle signal analog input module between test point MP0 and X1-4. The measurement should be between 0.5 - 4.5V. Boom Angle Signal : 0 Degrees 0.5 Volt 45 Degrees 2.48 Volts 90 Degrees 4.5 Volts See drawing 5 on page 20.31.

NO

Faulty analog input module or CPU module in central unit.

correct?

YES

END

20.15

LOAD READING PROBLEM PROBLEM Load reading incorrect. START Check selected operating mode(code on operating mode switch).

NO

Select operating mode switch to correct position (see operating mode in load chart).

correct?

YES Check boom length reading on display. Reset length potentiometer. With fully retracted boom, turn potentiometer axle counterclockwise until it stops . See drawing 7 on page 20.33.

NO correct? YES Measure radius and check with the displayed radius.

Check if mechanical adjustment of angle transducer is correct. Angle transducer box should in line with boom and adjusted to actual boom angle. See drawing 7 on page 20.33.

NO correct? YES

Check power supply to pressure transducer (rod side). Unplug transducer cable from transducer. Measure voltage at the cable connection between A (+12/24V) and C (ground). Check power supply at main board between X1-20 (+12/24V) and X1-22 (ground) for piston and X1-23 (+12/24V) and X1-25 (ground) for rod side. See drawing 3 on page 20.29.

NO correct? YES

correct?

Fault in pressure transducer. YES Replace the main in central unit. Refer to Drawing on page 15.3.

NO NEXT PAGE

20.16

LOAD READING PROBLEM PREVIOUS PAGE

Measure in series piston side signal, in central unit, remove wire #2 from X1-21. Connect one lead to wire #2 and the other to X1-21. The measurement should be between 4-20mA (4 mA at 0 PSI to 20mA at 4410 PSI). Rod side, remove wire #2 from X1-24. Referto Drawing 9 &10 on pages 20.35 & 20.36.

Measurement is not within 4-20mA. NO Fault in pressure transducer cable. Refer to Drawing 9&10, page 20.35 & 20.36.

NO 4-20mA

correct? YES

YES

Measurement within 4-20mA, but 4mA does not equal 0 PSI. Adjust zero point on pressure transducers at console. Refer to page 17.1.

If transducer(s) are not adjustable, replace pressure transducer(s) and adjust zero point. Refer to page 17.1.

Measure pressure transducer signals on the analog input module between test points, (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.

NO

Replace the analog input module board in central unit.

correct? YES

END

20.17

BAD DATA TRANSFER BETWEEN CONSOLE & CENTRAL UNIT PROBLEM Error Code “E93 / E94” No data transfer to and from console. START

Check the H12 (TXD) LED on the main board ON/OFF. Refer to Drawing 3 on page 20.29. On Make sure that EPROMS are correct and plugged into EPROM MODULE is on main board. Refer to Drawing 4 on page 20.30.

NO correct?

Place EPROM S in correct socket. Refer to Drawing 4 on page 20.30

YES Measure process voltage on the main board in the central unit between MP24 (+5V) and MP0 (GND). Refer to Drawing 3 on page 20.29. NO correct?

Off

Make sure external and internal power supply is correct. Refer to page 20.5.

YES

Turn off system power. Check the continuity of the receive (RXD) and transfer (TXD) wires. Check continuity between: X1-5 main board and X1-3 console X1-6 main board and X1-4 console Refer to Drawings 3&6 on pages 20.29,20.32. NO correct? YES

Check connections and replace cable from central unit to console, if necessary. Refer to Drawing 8 on page 20.34.

NEXT PAGE

20.18

BAD DATA TRANSFER BETWEEN CONSOLE & CENTRAL UNIT

PREVIOUS PAGE

Check if additional ground link between main board terminal X9 and central unit box mounting bracket is in place. Refer to Drawing 3 on page 20.29. Install ground link - single cable minimum of AWG14 (2.0mm2) between terminal X9/2 and central unit box mounting bracket.

NO correct? YES Ensure that cable shields are connected correctly. Refer to connections and wiring diagrams.

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

NO correct? YES Find out which component of the crane electric is spiking out (e.g. dump valve, outrigger relay). Install a diode or varistor across terminals of spiking component. Diode type such as 1N 4001 can be used (watch + and - connection for diode).

END

20.19

INTERFERENCE PROBLEM PROBLEM Interference from crane electric. Error Code “E93 / E94” intermittent. Frozen console displays.

START Check system out; refer to Section 8 - Bad Data Transfer Between Console & Central Unit. NO Replace or repair part which is defective.

correct? YES Check if additional ground like between main board terminal X9 and central unit box mounting bracket is in place. Refer to Drawing 4, “Main Board”, in Section 11.

Install ground link - single cable minimum of AWG14 (2.0mm2) between terminal X9/1 and central unit box mounting bracket. Refer to Drawing 4, “Main Board”, in Section 11.

NO correct? YES Ensure that cable shields are connected correctly. Refer to connections and wiring diagrams, Drawings 9A,B,C in Section 11.

Make correct shield connection. Refer to connection and wiring diagrams, Drawings 9A,9B and 9C in Section 11.

NO correct? YES Find out which component of the crane electric is spiking out (e.g. dump valve, outrigger relay). Install a diode or varistor across terminals of spiking component. Diode type such as 1N 4001 can be used (watch + and - connection for diode). Refer to Drawing 7, “Suppressor Diode”, in Section 11. END

20.20

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 range.

Fallen below the minimum radius or above the angle given in the load chart due to raising the boom too far.

Lower boom back to a radius or angle given in the load chart.

E 02*

Beyond radius or below angle range.

The maximum radius or minimum angle given in the load chart was exceeded due to lowering the boom too far.

Raise boom back to a radius or angle given in the load chart.

E 03*

Prohibited slewing range. (no load area)

Slewing range prohibited with load.

Slew back into admissible range.

E 04*

Operating mode not available.

Operating mode switch in the console set incorrectly. Operating mode is not permissible with actual crane configuration.

Set operating mode switch correctly to the code assigned to the operating mode of the crane.

E 05*

Length range not permitted.

Boom was telescoped too far or not far enough.

Telescope boom to correct length given in the load chart.

Length sensor adjustment changed; i.e. length sensor cable slid off the cable drum.

See page 20.33.

Fallen below the minimum jib angle specified in the respective load chart due to luffing out the jib too far.

Luff in the jib to a radius or angle specified in the load chart.

E 06*

Fallen below angle range with luffing jib operation.

* This error can be corrected by the operator.

20.21

ERROR CODE DISPLAY ERROR DISPLAY

ERROR

CAUSE

E 07

No acknowledgement signal from overload relay (K8).

Overload relay is stuck, defective or not being selected.

E 08

No acknowledgement signal from Anti-Two-Block switch relay (K9).

Anti-Two-Block switch relay is defective or not being selected.

E 11

Fallen below lower limiting value for the measuring channel "length".

E 12

E 13

E 14

Fallen below lower limiting value for the measuring channel "pressure piston side".

Fallen below lower limiting value for the measuring channel "pressure rod side".

Fallen below upper limit value in measuring channel "Force".

ACTION

Cable from central unit to length sensor Check cable. Replace if defective, not connected or water in the necessary. See page 20.33. connectors Length potentiometer defective.

Replace and reset length potentiometer. See page 20.33.

Electronic component in the measuring channel defective on main board.

Replace main board and reset pressure channels.

Cable from central unit to the pressure transducer defective, loose or water in the plug.

Check cable as well as plug. Replace if necessary.

Pressure transducer on piston side defective.

Replace pressure transducer and reset pressure channel.

Electronic component in the measuring channel defective on main board.

Replace main board and reset pressure channels.

Cable from central unit to the pressure transducer defective, loose or water in in the plug.

Check cable as well as plug. Replace if necessary.

Pressure transducer on rod side defective.

Replace pressure transducer and reset pressure channel.

Electronic component in the measuring channel defective on main board.

Replace main board and reset pressure channels.

Cable from central unit to force measuring point defective or water inside the plugs. Force transducer defective. Electronic component in the measuring channel defective.

20.22

Check cable as well as plugs, replace if need be. Replace force transducer. Replace main board and reset pressure channels.

ERROR CODE DISPLAY

ERROR DISPLAY E 15

E 16

ERROR Fallen below lower limiting value for the measuring channel "angle main boom".

Fallen below lower limit value for measuring channel "Luffing Jib Angle".

E 17

CAUSE

ACTION

Cable from central unit to the length/ angle sensor defective or loose or water inside plug.

Check cable. Replace if necessary. See page 20.37.

Angle sensor defective.

Replace angle sensor. and reset adjustment.

Electronic component in the measuring channel defective.

Replace main board and reset pressure channels.

Cable from central unit to angle sensor defective or disconnected or water inside the plug.

Check cable as well as plug, replace if need be.

Angle sensor defective.

Replace angle sensor.

Electronic component in the measuring channel defective.

Replace main board and reset pressure channels.

E 18

Front Stabilizer overloaded

Exceeding capacities allowed for over the front.

Achieve a safe working area Immediately.

E 19

Error in the reference voltage.

Electronic component on the main board defective.

Replace main board and reset pressure channels.

+5 volt supply E 1A E 1B

E 21

Below limiting value for slewing angle 1. Below limiting value for slewing angle 2.

Upper limiting value for the measuring channel "length" exceeded.

Cable from central unit to the slewing angle sensor defective or loose. Slewing angle pot. defective. wiring, (external). Electronic component in the measuring channel defective on main board. Cable from central unit to the length/angle sensor defective or loose. Length potentiometer defective. Electronic component in the measuring channel defective on main board.

20.23

Check wiring, replace if necessary. Replace and reset slewing angle potentiometer. Replace main board and reset pressure channels. Check cable. Replace if necessary. See page 20.37. Replace and reset length potentiometer. See page 20.33. Replace main board and reset pressure channels.

ERROR CODE DISPLAY

ERROR DISPLAY E 22

E 23

E 24

E 25

E 26

ERROR Upper limiting value for the measuring channel "pressure piston side” exceeded.

Upper limiting value for the measuring channel "pressure rod side" exceeded.

Upper limit value in measuring channel "Force" exceeded.

Upper limiting value for the measuring channel "angle main boom" exceeded.

Upper limit value for measuring channel "Luffing Jib Angle" exceeded.

CAUSE

ACTION

Cable from central unit to the pressure transducer defective, loose or water in the plug.

Check cable as well as plug. Replace if necessary.

Pressure transducer on piston side defective.

Replace pressure transducer and reset pressure channels.

Electronic component in the measuring channel defective on main board.

Replace main board and reset pressure channels.

Cable from central unit to the pressure transducer defective, loose or water in the plug.

Check cable as well as plug. Replace if necessary.

Pressure transducer on rod side defective.

Replace pressure transducer and reset pressure channels.

Electronic component in the measuring channel defective. on main board.

Replace main board and reset pressure channels.

Cable between central unit and force measuring point defective or water inside the plug.

Check cable as well as plug, replace if need be.

Force sensor defective.

Replace force sensor.

Electronic component in the measuring channel defective.

Replace main board and reset pressure channels.

Cable from central unit to the length/angle sensor defective or loose. Angle sensor defective. mechanical adjustment. Electronic component in the measuring channel defective on main board. See Error E 16.

Check cable. Replace if necessary.

20.24

Replace angle sensor and reset Replace main board and reset pressure channels. See Error E 16.

ERROR CODE DISPLAY ERROR DISPLAY E 27

ERROR Upper limit value for the measurchannel 7 exceeded.

CAUSE Cable from central unit to the Sensor of channel 7 defective or loose. Sensor of channel 7 defective. Electronic component in the measuring channel 7 defective.

E 29

Error in the reference voltage. -5 volt supply

E 2A E 2B

E 31

E 37

Above limiting value for slewing angle 1. Above limiting value for slewing angle 2.

Error in system program

Error in program run

Check cable. Replace if necessary. Replace angle sensor and reset mechanical adjustment. Replace main board and reset pressure channels.

Supply and Reference voltages on MP10 is more than 3.3V. Electronic component on the main board defective. A/D converter defective. Cable from central unit to the slewing angle sensor defective or loose. Slewing angle pot. defective. wiring, (external). Electronic component in the measuring channel defective on main board.

Check wiring, replace if necessary. Replace and reset slewing angle potentiometer. Replace main board and reset pressure channels.

EPROM with system program defective. Electronic component on the main board defective.

Replace EPROM with system program. Replace main board and reset pressure channels.

EPROM with system program defective. Electronic component on the main board defective.

Replace system program EPROM. Replace main board and reset pressure channels.

CPU is equipped with an incorrect version of system program. CPU is equipped with an incorrect version of system program.

Equip main board with correct version of system or Data EPROM. Equip main board with correct version of system or TLK EPROM. Replace CPU Chip No. 80C31. Replace main board and reset pressure channels. Exchange write/read memory (CMOS-RAM). Replace main board and reset pressure channels.

E 38

Incorrect system program.

E 39

Incorrect system program.

E 41

Error in the external RAM.

RAM in the CPU on the main board defective.

Error in the external write/ read memory (RAM).

Internal defect in digital part of CPU.

E 42

ACTION

20.25

Check supply voltages. Replace main board and reset pressure channels.

ERROR CODE DISPLAY ERROR DISPLAY

ERROR

CAUSE

E 42

Error in the external write/read memory (RAM) part 1.

Internal defect in digital part of CPU.

E 43

Error in the external write/read memory (RAM) part 2.

Internal defect in digital part of CPU.

E 45

Error in internal communications. Error in A/D conversion Malfunction in the monitored write/read memory.

E 46 E 47

Defective electronic

component. Defective electronic component. Internal defect in in digital part of CPU

ACTION Exchange write/read memory (CMOS-RAM). Replace main Board and reset pressure channels. Exchange write/read memory (CMOS-RAM). Replace main Board and reset pressure channels. Replace main board and reset pressure channels. Replace main board and reset pressure channels. Replace main board and reset pressure channels.

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.

E 52

Error in TLK memory.

Data EPROM on the main board defective. Eprom Module not bridge correctly. TLK EPROM on the main

Replace Data EPROM. Make sure BR3 on the main board is installed. 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. Replace EPROM module and reset pressure channels. Write data on serial crane data EEPROM (by means of test program or on line function), then restart the LMI

Crane data EEPROM defective. E 57

E 58

Error in serial crane data EEPROM

Error in the serial analog data EEPROM

E 61

Serial communicate problem

E 63

Digital inputs on buss extension

E 69

Error in serial crane data EEPROM The number of the selected EPROM base and the identical.

Serial crane data EEPROM does not contain valid data.

Memory module defective.

Replace EPROM module and reset pressure channels.

No valid data in the serial analog data EEPROM. LMI main board defective.

Same action as E 57 Replace main board.

Green cable in Buss ext. or module itself.

Check connections Replace module. Replace buss extension

Memory module wrongly bridged. to memory type. Load chart EPROM defective. programming values are not

Bridge memory module acc.

20.26

Replace load chart EPROM.

ERROR CODE DISPLAY ERROR DISPLAY

ERROR

CAUSE

E 71

Incorrect acknowledgment of the 1 relay on the main board. console to central unit.

a.Anti two block relay is stuck or defective b. Two block relay is not being selected due to a break on the main board.

E 72 E 77

Analogous to E 71 for the relays. K2…K7

Analogous to E 71 for the relays K2…K7

E 80

Wipers for slewing potentiometer out of tolerance.

E 84

Wrong rigging condition.

ACTION Replace main board.

Analogous to E 71 for the relays K2…K7. Replace potentiometer.

The selected rigging condition is not contained in the data EPROM.

Select another rigging condition Check the programming in the data EPROM.

E 85

Error in the radius determination.

E 89

Changed of the operating code during lifting a load.

E 91

No data transmission from the console to central unit.

E 92

Error in the data transmission from console to central unit.

E 93

Error in the data transmission from central unit

The computed radius is too small ( negative deflection ) The mode switch was changed during lifting a load. a. Supply voltage of console interrupted. b. Interruption or ground in the line from console to central unit. c. Transmitter/receiver module defective.

a. Temporary interruption of the data line from console electronics to central unit. b. Transmitter/receiver module defective. a. Temporary interruption of the data line from console electronics to central unit. b. Transmitter/receiver module defective.

20.27

Check the programming in the data eprom. Lower the load and set the switch to the correct operating configuration of the crane. a. Check voltage at terminal X1 console electronics. b. Check connection between console and central unit. c. If accidental ground occurs, The transmitter module in the console electronics can be damaged. Replace the console electronics or main board. a. Check connection between console and central unit.

a. Check connection between console and central unit. b. Replace console electronics or main board respectively.

ERROR CODE DISPLAY

ERROR DISPLAY

ERROR

E 94

No data transmission from console to central unit.

E 95

Error in the crane data EPROM

CAUSE

ACTION

a. Interruption or accidental ground in the line from console to CU.

a. Check connection between 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.

Data EPROM defective. Position of jumper for the selection of the type of EPROM is wrong. Electronic component on main board defective.

Replace data EPROM. Check the jumper position. Replace main board and reset pressure channels.

E 96

Error in the internal RAM of the CPU of the console.

CPU or main board of the console defective.

Replace console main board.

E 97

Error in the external RAM of the CPU of the console.

External RAM of the console defective. Electronic component on the main board defective.

Replace console main board. Replace console main board.

E 98

Wrong jumper position in the console.

The jumper position BR9/BR10 in the Check the jumper position. 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 block switch circuit

Short circuit in the anti - two block switch. Short circuit in the cable to the two block switch Electronic component on the analog input module defective

Replace two block switch Replace cable to the two block switch Check analog input module 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

Drawing 3 : Main Board A

B

C

D

E

F

G

H

I

J

K

L

M

-

1

G1

+

KGND KGND

MP 4

+5V

MP 9

C

+6V X15

GND

1

MP 26 GND

AGND

KGND

2

C

MP24

MP23

VBAT

+BATT

+UB1

PWM DC

MP42

2

MP 8

+9V

GND

3

4

5 +UB1 +UB

DI 6

KGND

X12

6

MP41 MP40 V10 H11 V11

H1 H2 H3 H4 H5 H6

DI 1

MP21

5

PFAIL+UB1

DI 1- DI 6 =>

X17

4

power o.k.

X14

3

6

J11

X11

7

7

SP5

X13

TXD

H12

AGND

H10

K8

MP29

10 LEVER LOCKOUT K10

A2B

+UB

2 1

MAIN ON/OFF

KGND

J10 3 4

9

LMI KGND

10

LOAD

+5V/RS232

AGND

9

K9

69 68 67

66 65 64

63 62

61 60 59 58

57 56

55 54

12

KGND

3 1

77 76

F 1

H9 A2B KGND

KGND

+

J4 J3 J2 J1

X1

12

-

11

KGND

F 2

11

X1

13

8

X16

8

KGND MP1 +UBS

36 35 34 33

A

32 31

B

30 29 28 27 26

C

D

25

24 23

E

22 21 20

F

19 18 17

G

16 15 14

13 12

H

LOCATIONS : MP 1 - zone M13 = GND. MP 25 - zone M13 = +UBS MP 8 - zone M2 = +9V MP 9 - zone M2 = +6V MP 4 - zone M1 = +5V MP 26 - zone M1 = GND. MP 23 - zone A2 = VBATT MP 24 - zone D2 = +BATT MP 40 - zone M4 = +UB

I

11

10 9

8

7

J

6

5

K

4

3

2

L

1

13

MP 25

M

LED’S MP 41 - zone M4 = POWER FAIL MP 42 - zone G1 = +5V MP 21 - zone E5 = +5V MP 29 - zone D10 = +5V H1-H6 - zone I5 = DI 1-6

20.29

H 8 - zone M3 - LOAD H 9 - zone E11 - A2B H 10 - zone G9 - MAIN IN/OUT H 11 - zone M3 - POWER H 12 - zone I11 - TXD

Drawing 4 : CPU and Daten EPROM boards

MP7 J1 J13

J12

J2

D3

D1 MP4

D2

X1

D14

X2 D13

P1

SYSTEM D10 J8

D6 J9 MP3 J6 D17

J10

D15

D7

D21

D9 D12

J15

J11

J14

D18

J7

D11 D19

D20

X3

BR6

MP6MP5

EJECT BR5

MP2

A102 CPU

J1

J2

DATA D1 J5 J3

TLK D3 J6

BR 4 3 2 1

X1

A103 DATEN

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

20.30

Drawing 5 : Analog Input Module

+

P7

MP12

1 2

40

AGND

AGND -

P6

MP13

J2

20

P5

16 P4 P3

MP9

J1

MP11

X16

P2

MP10

P1

1 1 2

X1

MP17

BR1

MP0

-

+

MP8

+

+

VREFA

P8

+

MP7 - MP1->

X17

1 2

+

MP16

7

16

6 5 4 3

MP14

2 1

40 1 2 AGND

AGND

BOARD P/N 9-333-103290 The analog input module converts the sensor signals on channels 1 - 7 to signals that will be processed 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 channel signals to 0.5V…. 4.5V, which can be measured on X1:1 through X1:7. The signal voltage can be measured at either point using ground and signal input.

20.31

20.32 J1

J2

1 2 3 4 5 6 7 8

X1

MP 1 +UB

MP 0 GND

Drawing 6 :VIEW OF BACKSIDE OF GRAPHIC CONSOLE

MP 7

MP 6

MP 2 +7V

MP 5 +5V

J4

J5

X5 1 2 3 4

J3

MP 4 -24V

MP 3 -24V

20.33

9333103309

X1

X2 X2

XB2

X2

A

1 3 5

7 (9) 8 (10)

1 2 3

L

1 X3 1 2 3 3 5

ADJUST LENGTH POTENIOMETER WITH BOOM FULLY RETRACTED, TURN THE CENTER SCREW COUNTERCLOCKWISE TO A SOFT STOP.

1 2 3 4 5 6 7 8 S

XA2

Drawing 7 : Length / Angle Transducer

1 2 3 4 5 6 7 8

+UB GND RXD TXD A2B BYPASS A2B BYPASS LMI BYPASS +UB

Drawing 8 :ELECTRICAL WIRING FROM CENTRAL UNIT TO CONSOLE

+UB

GND

CENTRAL UNIT MAIN BOARD

51 52 3 4 5 6 7 8 9 10 8

9

1 2 3

4

5 6

11 12 13 14

8

9 11 12 13 14

4 5 6

7

8 X1

A B C D

1 2 3 4

DI

A2B

10

GND

X7 1 2 3 4

LIGHTBAR

7

LOAD

3

6

A2B

4 5

TXD

2

3

SIG -

+UB

1

2

GND

1

RXD

CONSOLE (1318)

+UB SIG +

20.34

7 10

X8 +UB 1 GND 2

1 2 3

GN/YL

1 2 12 11

51 (GND)

1 2 3

X1

+UB GND

CENTRAL UNIT MAIN BOARD +UBR

Drawing 9 :ELECTRICAL WIRING FROM CENTRAL UNIT TO PRESSURE TRANSDUCER (PISTON)

71 (+UB)

LMI UNLOCK S.

73

20.35 (LMI UNLOCK SOL.) GN/YL

PISTON

+UB

2

3

4

B B

C C

PRESS. TRANS. (PISTON)

A A

1 2 3 4

1

20 21 22

GND

1 2 3

GN/YL

1 2 12 11

51 (GND)

1 2 3

X1

+UB GND

CENTRAL UNIT MAIN BOARD +UBR

Drawing 10 :ELECTRICAL WIRING FROM CENTRAL UNIT TO PRESSURE TRANSDUCER (ROD)

71 (+UB)

LMI UNLOCK S.

73

20.36 (LMI UNLOCK SOL.) GN/YL

ROD

+UB

2

3

4

B B

C C

PRESS. TRANS. (ROD)

A A

1 2 3 4

1

23 24 25

GND

4.7K




RESISTOR

>1> >2> >3> >4> >5> >6> 2

3

1

+UB LEN (GND) 0.0V 3

CORE

SHIELD

6 PIN RECEPTACLE

1 2

ANGLE FORCE 7

A2B SIG. A2B GROUND 5 6

FUSE (4 AMP) FUSE (4 AMP)

NOT USED NOT USED

NOT USED NOT USED CORE

X2

SHIELD X1

7

5 3 1

5 3 1

X3

X4 X2

6

5

4

3 2

1

S 8 7 6 5 4 3 2 1 X1

5 3 1

5 3 1

7 8

RED

BRN

CABLE REEL

ANGLE SIG.

3 4

GND

1 2

+UB

26 27 28 29 30 31 32 33 34 35 36 53 54

GND

CENTRAL UNIT MAIN BOARD

+UB

Drawing 11 :ELECTRICAL WIRING FROM CENTRAL UNIT TO CABLE REEL /ANTI-TWO BLOCK

LENGTH SIG.

20.37 6 PIN RECEPTACLE

1 2 3 4 5 6 7

1 2 3 4 5 6

1 2 3 4 5 6 7

6 SOCKET PLUG

20-38

20-39

P.A.T. – L.M.I MANUAL SECTION 21

DS 350 Graphic Modular (BCS) Console Connections, Wiring Diagrams

HOUSE LOCK PIN SWITCH LMI L/O ALARM (EEC) LEVER LOCKOUT W # 73A SOLENOIDS

D

4

C

3

B

2

A

1

10

CONSOLE BY - PASS KEY

3 4

8 5 4 3

7

7

6

6

+

21.1

AB

A2B

3 4

5

5

4

4

DATA FROM C.U.

3

DATA TO C.U.

2 1

3 (GND) 2 (+24 V)

1

GRAPHIC CONSOLE

4A

13 14 10A

= CONNECTED = WIRES ARE GROUPED TOGETHER

+

K10A

+ +UBS 0V RXD TXD A2B-O A2B-I LOAD-I + +UBS

K9

K8

F2- 10A 11 REL -M 12 REL -A 13 REL -R 14 + +UBS 15 DE 1 16 DE 2 17 DE 3 18 DE 4 19 20 + +UBS I 21 DAV1 U 0V 22 23 + +UBS I 24 DAV2 U 0V 25 + +UBS 26 I 27 LG 1 U 0V 28 I 29 WG 1 U I 30 LG 1 U 31 0V 32 33 + +UBS I 34 S1 DHG 1 U 0V 35 I 36 S2 DHG 2 U 51 + +UB 0V 52 F1 - 4A 53 SI - OUT 54 SI - IN 57 A2B-0 A2B-I 58 LOAD-I 59 60 + +UBS F2-10A 61 SI-REL 62 SI-REL + +UBS 64 0V 65 66 DE 5 67 68 DE 6 69 +UBS + 76 0V 77

K10B

X4 BRN 1 2 WHT PNK 3 GRA 4 5 GRN 6 YEL

WHT WHT BRN BRN

YEL

GRA GRN PNK YEL GRN

3-Pair Twisted Cable

GRA PNK

X2 1 2 GRN 3 YEL 4 5 6 PNK 7 GRA 8 BRN

WHT

BUS EXTENSION

DS350 Graphic Modular BCS Console to C.P.U. Connections

LMI BYPASS KEY SWITCH

+ +24V 0V

MAIN BOARD

LMI

+UBS

+

W # 71K = 24 VOLTS

5

F1

STOP

W # 51AJ = GND

E

1 2 3 4 5 6 7

1 2 3 4 5 6 7 8 9

+UB

X1

1 2

FIVE SECTION BOOM SERVICE SCREEN (RT865BXL - BCS)

PAT

DS 350

!

STOP

STOP

156ft

0335

TARE

!

90.0ft ?

Ramp Seq.

IM Hex Value

1

255

CM Hex Value

OM/Fly Hex Value

0

0

STOP

79.4o

LIM SEL

1

255

0

0

50.8ft MAX

02 73.5oo

38.2 38.2

38.2 38.2

100%

(lbs)

ACT

(lbs)

34.900 100%

i CTRL

100%

STOP

F1

Length of IM

F2

F3

F4

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 the ramping up and ramping down of the output signal to the solenoids. 21.2

P.A.T. – L.M.I MANUAL SECTION 22

DS 350 Graphic Modular (BCS) System Theory & Component Location

DS350 Graphic Modular (BCS) SYSTEM THEORY

DI 1 DI 2 DI 3 DIGITAL DI 4 INPUT DI 5 DI 6 DI 7

DIGITAL INPUTS

BOOM EXTEND BOOM RETRACT

OM / FLY RET. IM RET. IM % RESET

K5 NC

22.1

K6 K7 K5

RxD TxD

AO1

IM 2 WAY SOL. CM 2 WAY SOL.

PRESS. SW. EXTEND PILOT PRESS. PRESS. SW. RETRACT PILOT PRESS. AUTOMODE SWITCH IN CAB

OM 2 WAY SOL.

ON CM SECTION ON IM SECTION ON BASE SECTION ON BASE SECTION

OUT OF SEQ. WARNING LIGHT IN CAB PROP. PRESS. REDUCING VALVE EXT. PROP. PRESS. REDUCING VALVE RET. IM - 2 WAY SOLENOID VALVE

CABLE REEL

DIGITAL OUTPUT K2

CRANE INTERFACE CONNECTOR

PROP. EXT. PROP. RET.

BOOM CONTROL BUS EXTENSION

HOUSE PIN SWITCH

PROX. SW. PROX. SW. PROX. SW. PROX. SW.

CM RET. & % RESET

OUT OF SEQ. WARN.

CENTRAL UNIT

ON RUBBER - OVER FRONT

AUTOMODE ON

K4 K5 NO

CRANE INTERFACE CONNECTOR

ON RUBBER OVER FRONT HOUSE PIN ENGAGED

CM - 2 WAY SOLENOID VALVE OM - 2 WAY SOENOID VALVE

PROP.

ANALOG OUTPUT

AI 1

ANALOG INPUT P1

P2

A1

L1

ANALOG INPUT AI 2 CENTER MID LENGTH SENSOR INNER MID LENGTH SENSOR MAIN BOOM LENGTH SENSOR ANGLE SENSOR ROD PRESS. TRANS. PISTON PRESS. TRANS.

LMI CONSOLE

HOW DOES THE SYSTEM WORK? HYDRAULIC 1. Pilot operated 4 way valve provides oil flow to extend and retract the 3 telescoping cylinders. On this valve are 2 pressure reducing valves electrically operated by the PAT system. Their function is to reduce the pilot pressure when nearing the point a section must stop in order to slow it down smoothly, then they will increase the pilot pressure back 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 and one for retract. These pressure switches tell the PAT which direction has been selected by the operator, so it will know which 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 joystick pressure 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 be released through a .078 orifice. 2. Two - way valves control the oil to each telescope cylinder. One for the pilot pressure to the holding valve and one for the piston side oil to flow. These are operated in pairs only. When a pair of two-way valves are de-energized, that particular telescope cylinder will then operate. The other two pair of two way - valves must be energized to prevent movement of the other two telescope cylinders. These valves are also switched on and off by the PAT system when in Automatic mode. They are controlled by an individual 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 be released back to tank by the way of a .078 orifice. This valve is controlled by the normally closed contacts of the third pressure 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. This valve is electrically operated by the PAT system and is switched on to dump 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 extending when the 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 first begin 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 the 800 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

VIEW B - B

22.5

SS CABLE TO CRANE INTERFACE

CRANE ELECTRIC INTERFACE CONNECTION

3 - PAIR CABLE TO CENTRAL UNIT

A

CABLE ASSY. TO BOOM

CENTRAL UNIT

CABLE ASSY. TO BOOM

A

CABLE ASSY. TO PRESS. TRANSDUCER ( PISTON )

CABLE TO AREA DEFINITION

CABLE ASSY. TO PRESS. TRANSDUCER ( ROD )

CABLE TO CRANE INTERFACE

CABLE ASSY. TO CONSOLE

3 - PAIR CABLE BUS EXTENSION

CABLE ASSY. TO BOOM

FUSE ( 10A)

FUSE ( 4A )

BYPASS KEY SWITCH

P.A.T. - LMI RT865 BXL (BCS) TURNTABLE COMPONENTS BOOM CONTROL BUS EXTENSION

B PAT B

RT865BXL

CONNECTIONS FOR TURNTABLE HARDWARE TO BOOM HARDWARE

19 - pin plug

14 - pin plug

7 - pin plug

RT865BXL (BCS) Central Processing Unit

A 102 CPU MODULE

SYSTEM E-PROM

A 105 SERIAL EXTENSION MODULE SYS

A 103 E-PROM MODULE

DATA

DATA E-PROM

TLK

A 101 MAIN BOARD

TLK E-PROM LMI BYPASS KEY SWITCH

K8 K10 K9

A 106 ANALOG INPUT MODULE RELAYS X1 TERMINAL STRIP FERRITE FILTER

4 AMP

10 AMP

RT865BXL (BCS) Bus Extension A 104 PV EXTENSION MODULE

A102 CPU MODULE

4 AMP FUSE X1 TERMINAL

X1 TERMINAL

A 105 ANALOG INPUT MODULE

2 AMP FUSE

X2 TERMINAL A 101 BUS EXTENSION

K1-K8 RELAYS 22.6

DS350 Graphic Modular BUS EXTENSION BOARDS 8 MP

A 104 PV Extension Module A 105 Analog Input Module

A 102 CPU Module

4

25

2 26

8 72

THIS BOARD IS NOT USED - RT865BXL (BCS)

A 101 Bus Extension 22.7

RT865BXL with Boom Control Turntable Components

22.8

RT865BXL (BCS) Relay Outputs INPUT K1 K2

CU DESCRIPTION TERMINAL A101 BUS NOT USED X1/3 A101 BUS X1/5

NOTES NONE

2 - WAY IM SOLENOID VALVES (2) PILOT PRESSURE PISTON SIDE PRESSURE

OFF = IM EXTENDS OR RETRACTS ON = IM IS NOT ALLOWED TO M OVE

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

K5

A101 BUS X1/14

ANALOG OUTPUT SIGNAL TO PROPORTIONAL EXTEND SOLENOID VALVE

M AXIM UM 800mA TO EXTEND VALVE ONE VALVE FOR ALL SECTIONS

K5

A101 BUS X1/15

ANALOG OUTPUT SIGNAL TO PROPORTIONAL RETRACT SOLENOID VALVE

M AXIM UM 800mA TO RETRACT VALVE ONE VALVE FOR ALL SECTIONS

K6

A101 BUS X1/17

2 - WAY CM SOLENOID VALVES (2) OFF = CM EXTENDS OR RETRACTS PILOT PRESSURE ON = CM IS NOT ALLOWED TO M OVE PISTON SIDE PRESSURE 2 - WAY OM /FLY SOLENOID

K7

A101 MAIN VALVES (2) PILOT PRESSURE X1/20 PISTON SIDE PRESSURE

OFF = OM /FLY EXTENDS OR RETRACTS ON = OM /FLY IS NOT ALLOWED TO M OVE

K8

A101 MAIN LM I CUT OFF INTERNAL RELAY X1/9

CONNECT LM I BYPASS VIA DIODE ASSEM BLY FROM GRAPHIC CONSOLE AND CU KEY SWITCH

K9

A101 MAIN A2B CUT OFF INTERNAL RELAY X1/8

CONNECT A2B BYPASS FROM GRAPHIC CONSOLE

K10

A101 MAIN LM I UNLOCK RELAY OUTPUT X1/12

POWERS THE LM I UNLOCK SOLENOID WHEN NO OVERLOAD, A2B OR ERROR CONDITION

K10

A101 MAIN EXTERNAL ALARM OUTPUT X1/13

USED FOR EEC UNITS ONLY

22.9

DS350 Graphic Modular (BCS) Relay Diagram BUS EXTENSION

6 7 TELE ROD DRAIN

16

8 9 10

A104 X1 1 2 3 4

11 TELE OUT OF SEQUENCE 13 ANALOG SIGNAL

12 13

TELE EXT. PROP. SOL.

17

14

TELE RET. PROP. SOL.

18

15 16

CM TELE

8

17 18 19

OM / FLY TELE TELE PROP. ANALOG GND.

7

20 21 22 23 24 26

H17

>

K2

>

K3 H19

22.10

+24V TELE ROD DRAIN SOL.

2A - F4

>

K4 H20 TELE SEQUENCE

2A - F5

>

K5

NO PROP. EXT. H21 NC PROP. RET.

2A - F6

>

K6 H22

+24V CM 2WAYS

2A - F7

>

K7

+24V OM 2WAYS H23

2A - F8

>

K8 H24 +UB 10 - 35V

27 28

+24V IM 2WAYS H18

+

25

K1

2A - F3

> >

5

> >

9

> >

IM TELE

>

2A - F2

> >

4

> >

3

> >

2

2A - F1

> >

1

> >

X1

KGND

RT865BXL (BCS) DS350Graphic Modular Automode control of two way valves K2 0 1 1 0 0

K6 1 0 1 0 0

K7 1 1 0 0 0

DESCRIPTION IM EXTENDING OR RETRACTING CM EXTENDING OR RETRACTING OM/FLY EXTENDING OR RETRACTING OUT OF SEQUENCE NEUTRAL POSITION

Analog Outputs ANALOG 1 1

CU DESCRIPTION TERMINAL A104 X1/2 Analog GND for proportional extend or retract solenoid valves. A104 X1/1 Analog signal for proportional extend or retract solenoid valves.

Input / Output Logic RT865BXL (BCS) Auto IM Auto IM

Ext. DI 1 1 0

Retr. DI 2 0 1

Relay K2 0 0

Relay K6 1 1

Relay K7 1 1

Relay K5 1 0

2 way IM 0 0

2 way CM 1 1

2 way OM 1 1

analog output 1 1

Auto CM Auto CM Auto OM Auto OM

1 0 1 0

0 1 0 1

1 1 1 1

0 0 1 1

1 1 0 0

1 0 1 0

1 1 1 1

0 0 1 1

1 1 0 0

1 1 1 1

1 0 1 0

0 1 0 1

Man. IM

1

0

0

0

0

0

0

1

1

0

1

0

Man. IM Man. CM

0 1

1 0

0 0

0 0

0 0

0 0

0 1

1 0

1 1

0 0

0 1

1 0

Man. CM Man. OM

0 1

1 0

0 0

0 0

0 0

0 0

1 1

0 1

1 0

0 0

0 1

1 0

Man. 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

Logic 1 ON - 0 OFF

Boom sequence RT865BXL (BCS) Mode B - Mode B - Mode B - Mode B - Mode B - Mode B - Mode B - Mode B - Mode

IM% 0 50 50 75 75 100 100 100

CM% 0 0 50 50 75 75 100 100

22.11

OM% 0 0 0 0 0 0 0 100

FLY% 0 0 0 0 0 0 0 100

Prop. val. Prop. val. EXT. RETR. 1 0 0 1

P.A.T. – L.M.I MANUAL SECTION 23

DS 350 Graphic Modular (BCS) Boom Length Connections & Wiring Diagrams

Boom Control components RT 865BXL 5

DS350 Graphic Modular - BCS

7

7

1

8

PAT PAT PAT

3 5

2

23.1 1

PRE - TENSION (LENGTH SENSOR) SPRING BY ROTATING DRUM (10) REVOLUTIONS COUNTER CLOCKWISE. THEN UNSPOOL THE LENGTH CABLE AND SECURE TO BUSHING ON THE BOOM NOSE PER DETAIL “A”.

2

PRE - TENSION (LENGTH SENSOR) SPRING BY ROTATING DRUM (30) REVOLUTIONS COUNTER CLOCKWISE. THEN UNSPOOL THE LENGTH CABLE AND SECURE TO BUSHING ON THE INNER - MID PER DETAIL “A”.

3

PRE - TENSION (LENGTH SENSOR) SPRING BY ROTATING DRUM (25) REVOLUTIONS COUNTER CLOCKWISE. THEN UNSPOOL THE LENGTH CABLE AND SECURE TO BUSHING ON THE CENTER - MID PER DETAIL “B”

5

REMOVE 1/4 - 20 NUTS ON BOTTOM OF CABLE GUIDE. INSERT CABLE GUIDE SCREWS THRU EXISTING ANGLE BRKT AND SECURE IN PLACE WITH 1/4 - 20 NUTS REMOVED PREVIOUSLY.

7

CENTER LINE OF CABLE GUIDE MUST BE ALIGNED W/ CENTER LINE OF CABLE REEL DRUM.

8

AFTER MACHINE IS CALIBRATED, REMOVE PROTECTIVE PAPER CORROSION INHIBTOR AND ADHERE TO INSIDE HOUSING COVER SURFACE OF CABLE REEL.

Boom Control components RT 865BXL DS350 Graphic Modular - BCS IM length sensor LG321

See detail “A”

See detail “C”

CM length sensor LG321 Boom length & angle sensor LWG309

IM % reset switch

See detail “C”

23.2

PAT PAT PAT

See detail “C”

OM retract and % reset switch

IM retract switch CM retract and % reset switch

See detail “B”

4

PLACE (3) TIE WRAPS, 120 DEGREES APART AROUND BUSHING. WRAP CABLE (8-10) REVOLUTIONS OVER THE TIE WRAPS STARTING FROM THE OUTSIDE AND WORKING INWARD. ALLOW AMPLE CABLE TO REACH JUNCTION BOX. SECURE CABLE WITH (2) ADDITIONAL TIE WRAPS.

6

INSTALL PROXIMITY SWITCH 0.44” FROM TARGET WHEN BOOM SECTIONS ARE FULLY RETRACTED.

16

THIS TARGET IS ONLY INSTALLED IF THE BOOM IS EQUIPPED WITH A BOOM EXTENSION STOP BLOCK.

18

INSTALL PROXIMITY SWITCH 0.13” FROM TARGET WHEN BOOM SECTIONS ARE FULLY RETRACTED.

6

0.44

0.44

16

See detail “A” 0.44 18 3.94 CENTER LINE OF TARGETS & PROXIMITY SW.

23.3

0.13

PAT

DETAIL “A” 1.0

4

DETAIL “C”

1.34

DETAIL “B” To wi be a t l of h ce igne c a nt e d ble r ree line ld rum

4

Boom Control components RT 865BXL DS350 Graphic Modular - BCS

PARTIAL TOP VIEW

19

23.4 CENTER LINE OF CABLE GUIDES

CENTER LINE OF CABLE REEL DRUM

CABLE GUIDES ON THE BASE & INNER MID SECTIONS ASSOCIATED WITH TOP AND MIDDLE CABLE REEL MUST BE ALIGNED WITH CENTER OF CABLE REEL DRUM

19

INSTALL SHIMS AS REQUIRED TO ASSURE CENTER LINE OF CABLE REEL DRUMS ARE PARRALLEL TO BOOM BASE SECTION AND PLUMB WHEN CRANE IS ON A LEVEL \ SURFACE.

P1

J1

AGND

MP14

ERROR CODE

E11 .500v MIN.

MP7 - MP1->

MP16

16

1 2

AGND

1 2

BR1

1

X1

AGND

20 40

23.5

VOLTAGES X1 3 ANALOG INPUT MODULE + 500MV (.500V) = MIN. SIGNAL (RETRACTED BOOM) + 4.50V = MAX. SIGNAL (10 TURNS ON POT) ALL VOTAGES ARE MEASURED WITH REFERENCE TO GND (TERMINAL X1 - 28) ON MAIN BOARD. * THESE MEASUREMENTS ARE MADE IN PARALLEL

X1 26 27 28

WORKING RANGE

- +

MP11

MP10

J2

4.50v MAX. A

ERROR CODE

(GND)

P2

LENGTH

P3

MP9

VREFA

P4

+UB

MP12

P5

Channel # 1 OPERATING WINDOW .0V

MP17

P6 MP13

MP0 MP8

- +

AGND

P7

P8

+

E21 5.0V

Current Based Amplifier All sensing devices used for Analog Inputs now have a current output. (min. signal 4mA, max. signal 20mA) This circuit is measured in series.

1

2 3

E11 / E21 6 Pin

Measure Voltage - Length transducer at X1 1(+) & 3 (-) Range 10V to 30V

GND

Measure Voltage - Length transducer at X1 2(+) & 3 (-) Range 1V to 5.6V

7 8 5 3 1 X2 X4

Measure Amps - Length transducer at X1 2(+) & (-) WIRE 2. Range 4 mA to 20 mA

DS350 GRAPHIC MODULAR BOOM LENGTH MEASURING CHANNEL CHANNEL # 1

+UB

5 3 1

5 3 1 +UB

2

1 OUT

1

CORE

GND

SHIELD

1 OUT

(measurements in cable reel)

5 3 1 X3

S 8 7 6 5 4 3 2 1 X1 6 5 7

4 3 2 1

Plug

1 2 3 4 5 6 7

1 2 3 4 5 6 1 2 3 4 5 6 7

6 Pin

Connector

LMI L/O ALARM (EEC) LEVER LOCKOUT W # 73A SOLENOIDS W # 51AJ = GND

D

4

C

3

B

2

A

1

X1

1 2

1 2 3 4 5 6 7 8 9 10

IS = CUT&INSULATE

7 X2 RED SHEILD

CORE

X1 BRN

SHIELD

A B

CORE

1 2

7

8

6

7

5

X4 5

SIG. 3 +24V 1

23.6

1 2 3 4 3 2

GND SIG. +24V

1

3

1 2

X3 5 3

3 4

7 - PIN PLUG

X1

SIG

1

1

A 1

2

2

B 2

5

3

3

C 3

4

4

4

D 4

3

5

5

E

5

2

2

6

6

F

6

1

1

7

7

G 7

6

3

LG

4.7K

8

GND

CH #1 CH #5

5

IS = CUT&INSULATE

1 2 3 4

1

BOOM LENGTH SIGNAL RETRACTED = 4mA MAX RANGE = 20 mA

BOOM ANGLE SIGNAL 90o = 4mA 0o = 20 mA

OS Connected to strain relief insert

5 6

* NOTE - MAX LENGTH SIGNAL VARIES WITH BOOM, MAX. SIGNAL=20mA IS FOR 10 TURNS ON POT.

7 IS = CUT &INSULATE

4A

LMI BYPASS KEY SWITCH

14 10A

= CONNECTED = WIRES ARE GROUPED TOGETHER

+ +24V

K10A

0V

+ +UBS 0V RXD TXD A2B-O A2B-I LOAD-I + +UBS

K9

K8

F2- 10A 11 REL -M 12 REL -A 13 REL -R 14 + +UBS 15 DE 1 16 DE 2 17 DE 3 18 DE 4 19 20 + +UBS I 21 DAV1 U 0V 22 23 + +UBS I 24 DAV2 U 0V 25 + +UBS 26 I 27 LG 1 U 0V 28 I 29 WG 1 U I 30 LG 1 U 31 0V 32 33 + +UBS I 34 S1 DHG 1 U 0V 35 I 36 S2 DHG 2 U 51 + +UB 0V 52 F1 - 4A 53 SI - OUT 54 SI - IN 57 A2B-0 A2B-I 58 LOAD-I 59 60 + +UBS F2-10A 61 SI-REL 62 SI-REL + +UBS 64 0V 65 66 DE 5 67 68 DE 6 69 +UBS + 76 0V 77

K10B

X4 BRN 1 2 WHT PNK 3 GRA 4 5 GRN 6 YEL

WHT WHT BRN BRN

YEL

GRA GRN PNK YEL GRN

3-Pair Twisted Cable

GRA PNK

X2 1 2 GRN 3 YEL 4 5 6 PNK 7 GRA 8 BRN

WHT

BUS EXTENSION

DS350 Graphic Modular BCS Boom Length to C.P.U. Connections

13

+UBS

MAIN BOARD

WG

GND

X2

F1

+

LWG309 L/A TRANSDUCER

+

5

STOP

W # 71K = 24 VOLTS

E

+UB

HOUSE LOCK PIN SWITCH

RT865BXL (BCS) Cable Reel LWG309 PAT PAT PAT

23.7

Ratio = 3.75 to 1 (PRE - TENSION ON CABLE REEL = 10 REVOLUTIONS COUNTERCLOCKWISE)

XA2

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 S

X2

1 X3 1 2 3 3 5 L

XB2

X2

1 X4 1 2 3 3 5

ADJUST LENGTH POTENIOMETER WITH BOOM FULLY RETRACTED, TURN THE CENTER SCREW COUNTERCLOCKWISE TO A SOFT STOP.

A

X2 X1

9333103309

7 (9) 8 (10)

Complete Assembly Board, Terminal w/ filters Angle Sensor WG103/0007 Length Potentiometer Length Cable (single core, 63M - 206 ft.) Slip Ring Assem. 2-pole

1 1 1

9-333-103394 9-333-103309 9-333-103303 9-333-103308

1

9-333-102382 9-333-102732

DS350 Graphic Modular Boom Length Signal LWG 309

23.8

NO. OF TURNS NO. OF TURNS ON CABLE ON LENGTH REEL POT 0 0 3.75 1 7.5 2 11.25 3 15 4 18.75 5 22.5 6 26.25 7 30 8 33.75 9 37.5 10

SIGNAL AT X1 TERM. SIGNAL ON ANALOG PIN #27 ON C.P.U. MODULE AT X1-3 TERMINAL (X1-28 GND.) 4 mA .5 V 5.5 mA .9 V 7.2 mA 1.3 V 8.7 mA 1.7 V 10.4 mA 2.1 V 12.0 mA 2.5 V 13.6 mA 2.9 V 15.2 mA 3.3 V 16.8 mA 3.7 V 18.4 mA 4.1 V 20 mA 4.5 V

( 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.

CHANNEL # 1

RT865BXL (BCS) Cable Reel LG321 PAT PAT PAT

23.9 XA2

(PRE - TENSION ON CABLE REEL = 25 REVOLUTIONS COUNTERCLOCKWISE)

ADJUST LENGTH POTENIOMETER WITH BOOM FULLY RETRACTED, TURN THE CENTER SCREW COUNTERCLOCKWISE TO A SOFT STOP. Complete Assembly Board, Terminal w/ filters Length Potentiometer Length Cable (eleven core, 25 M - 86 ft.) Slip Ring Assem. 11 pole Junction Box Gear Wheel

1 1

9-333-103621 9-333-101777 9-333-101617

1 1 1

9-333-102490 9-333-102737 9-333-101778 9-333-103752

(CUT CABLE TO SPECIFIED LENGTH)

1 2 3 4 5 6 7 8 S

1 2 3 4 5 6 7 8

Ratio = 2 to 1

X2

1 X3 1 2 3 3 5 L

XB2

X2

1 X4 1 2 3 3 5 A

X2 7 (9) 8 (10)

X1 X1

11 12 13

11 12 13 14 15 16 17 18 19

14 15 16

9333103309

17 18 19

X1

LG 321 CABLE REEL (TO IM) X1

TO JUCTION BOX - IM

14

20

WHT/BLK

19

19

10

BLK

18

18

11

BLK WHT

9

WHT

17

17

GRA

8

GRA

16

16

VIO

7

VIO

15

15

BLU

6

BLU

14

14

5

GRN

13

13

10

GRN YEL

4

YEL

12

12

9

ORG

3

ORG

11

11

T

8 5 14

3

4

3

10

S RED

BRN

1

BRN

8

7

7

X2

6

7

5

6

1

4

LG

23.10

2

1

12

8

5

3

3

2

1

1

X3

X1

BOOM LENGTH SIGNAL RETRACTED = 4 mA MAX RANGE = 20 mA * NOTE - MAX LENGTH SIGNAL VARIES WITH BOOM, MAX SIGNAL 20 mA IS FOR 10 TURNS ON POT.

S 14 - SOCKET PLUG R 14 14 P 13 13 N 12 12 M 11 11 L 10 10 K 9 9 J 8 8 H 7 7 G 6 6 3 F 5 5 E 4 4 D 3 3 1 C 2 2 B 1 1 A

A104 X1

1 2 3 4

3

1 3

3

1

3 5 9 10

12 7

2

1

1 4

2

4

1

= Outer sheild connected to strain relief insert.

3

= Inner sheild cut and insulate.

6 13 14

TO JUCTION BOX - BOOM BASE

2

K3 COM ( +24V ) K3 NO ( +24V TELE ROD DRAIN SOL. ) K3 NC K4 COM K4 NO K4 NC ( TELE OUT OF SEQUENCE ) K5 COM K5 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 +24V GND GND DI 1 ( +24V = TELE EXT. PRESS. SW. ) DI 1 GND DI 2 ( +24V = TELE RET. PRESS. SW. ) DI 2 GND DI 3 ( +24V = AUTO MODE ) DI 3 GND DI 4 ( +24V = OM / FLY RET ) DI 4 GND DI 5 ( +24V = CM RET & % RESET ) DI 5 GND DI 6 ( +24V = IM RET ) DI 6 GND DI 7 ( +24V = IM % RESET ) DI 7 GND

X2 1 BRN 2 WHT GRN 3 YEL 4 ANALOG INPUT 1 (IM LEN.) 5 ANALOG INPUT 2 (CM LEN.) 6 7 PNK 8 GRA

WHT BRN

WHT

YEL GRN

BRN GRA PNK YEL

GRA GRN PNK

X4 1 WHT 2 PNK 3 GRA 4 GRN 5 YEL 6 BRN

MAIN BOARD

DS350 Graphic Modular BCS Inner Mid Cable Reel to Bus Extension Connections

K2 COM ( +24V ) K2 NO ( +24V TO IM 2-WAY SOLS. )

BUS EXTENSION

WHT/BLK

11

13

RED

8 11

PV EXTENSION

20

V U

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 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 60 61 62 63 64 65 66

RT865BXL (BCS) Cable Reel LG321 PAT PAT PAT

23.11

Ratio = 1 to 1 (PRE - TENSION ON CABLE REEL = 30 REVOLUTIONS COUNTERCLOCKWISE) XA2

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 S

X2

1 X3 1 2 3 3 5 L

XB2

X2

1 X4 1 2 3 3 5 A

ADJUST LENGTH POTENIOMETER WITH BOOM FULLY RETRACTED, TURN THE CENTER SCREW COUNTERCLOCKWISE TO A SOFT STOP.

X2 7 (9) 8 (10)

X1 X1

11 12 13

11 12 13 14 15 16 17 18 19

14 15 16

9333103309

17 18 19

Complete Assembly Board, Terminal w/ filters Length Potentiometer Length Cable (eleven core, 33.5 M - 110 ft.) Slip Ring Assem. 11 pole Junction Box Gear Wheel

1 1

9-333-103620 9-333-101777 9-333-101617

1 1 1

9-333-102490 9-333-102737 9-333-101778 9-333-102982

(CUT CABLE TO SPECIFIED LENGTH)

P.A.T. – L.M.I MANUAL SECTION 24

DS 350 Graphic Modular (BCS) Piston & Rod Connections & Wiring Diagrams

LMI L/O ALARM (EEC) LEVER LOCKOUT W # 73A SOLENOIDS W # 51AJ = GND

D

4

C

3

B

2

A

1

X1

1 2

1 2 3 4 5 6 7 8 9

PISTON TRANSDUCER

1

3 4

IS = CUT& INSULATE

B 2

5 1

C 3

1

1 2 3 1 2 3

CH #2

24.1

CH #3 ROD TRANSDUCER

1

DAVS 314

A 1

OS Connected to strain relief insert

B 2 1

C 3

4A

LMI BYPASS KEY SWITCH

14 10A

= CONNECTED = WIRES ARE GROUPED TOGETHER

+ +24V

K10A

0V

+ +UBS 0V RXD TXD A2B-O A2B-I LOAD-I + +UBS

K9

K8

F2- 10A 11 REL -M 12 REL -A 13 REL -R 14 + +UBS 15 DE 1 16 DE 2 17 DE 3 18 DE 4 19 20 + +UBS I 21 DAV1 U 0V 22 23 + +UBS I 24 DAV2 U 0V 25 + +UBS 26 I 27 LG 1 U 0V 28 I 29 WG 1 U I 30 LG 1 U 31 0V 32 33 + +UBS I 34 S1 DHG 1 U 0V 35 I 36 S2 DHG 2 U 51 + +UB 0V 52 F1 - 4A 53 SI - OUT 54 SI - IN 57 A2B-0 A2B-I 58 LOAD-I 59 60 + +UBS F2-10A 61 SI-REL 62 SI-REL + +UBS 64 0V 65 66 DE 5 67 68 DE 6 69 +UBS + 76 0V 77

K10B

X4 BRN 1 2 WHT PNK 3 GRA 4 5 GRN 6 YEL

WHT WHT BRN BRN

YEL

GRA GRN PNK YEL GRN

3-Pair Twisted Cable

GRA PNK

X2 1 2 GRN 3 YEL 4 5 6 PNK 7 GRA 8 BRN

WHT

BUS EXTENSION

DS350 Graphic Modular BCS Piston & Rod Transducers to C.P.U. Connections

13

+UBS

MAIN BOARD

DAVS 314

A 1

F1

+

10

+

5

STOP

W # 71K = 24 VOLTS

E

+UB

HOUSE LOCK PIN SWITCH

AGND

MP14

ERROR CODE

J1

E12 .500v MIN.

MP7 - MP1->

MP16

16

1 2

AGND

1 2

BR1

1

X1

AGND

20 40

24.2

VOLTAGES X1 1 ANALOG INPUT MODULE + 500MV (.500V) = MIN. SIGNAL (ZERO PRESSURE) + 4.50V = MAX. SIGNAL (300 BAR PRESSURE) ALL VOTAGES ARE MEASURED WITH REFERENCE TO GND (TERMINAL X1 - 22) ON MAIN BOARD. * THESE MEASUREMENTS ARE MADE IN PARALLEL

X1 20 21 22 -

WORKING RANGE

- +

MP11

MP10

J2

A

+

4.50v MAX. ERROR CODE

(GND)

P1

(PISTON)

P2

+UB

P3

MP9

VREFA

P4

OUTPUT SIGNAL

MP12

P5

Channel # 2 OPERATING WINDOW .0V

MP17

P6 MP13

MP0 MP8

- +

AGND

P7

P8

E22 5.0V

1

2 3 4

Current Based Amplifier All sensing devices used for Analog Inputs now have a current output. (min. signal 4mA, max. signal 20mA) This circuit is measured in series.

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

1 2 3 4

A B C A B C

Measure resistance - (Hyd) Piston transducer at B (+) & C (-) Range 200 - 300 Ohm PRESS. TRANS. (PISTON)

DS350 GRAPHIC MODULAR PISTON PRESSURE MEASURING CHANNEL CHANNEL # 2

AGND

MP14

ERROR CODE

J1

E13 .500v MIN.

MP7 - MP1->

MP16

16

1 2

24.3

VOLTAGES X1 2 ANALOG INPUT MODULE + 500MV (.500V) = MIN. SIGNAL (ZERO PRESSURE) + 4.50V = MAX. SIGNAL (300 BAR PRESSURE) ALL VOTAGES ARE MEASURED WITH REFERENCE TO GND (TERMINAL X1 - 25) ON MAIN BOARD. * THESE MEASUREMENTS ARE MADE IN PARALLEL

E13 / E23

A

+

4.50v MAX.

AGND

1 2

BR1

1

X1

AGND

20 40

X1 23 24 25 -

WORKING RANGE

- +

MP11

MP10

J2

ERROR CODE

(GND)

P1

(ROD)

P2

+UB

P3

MP9

VREFA

P4

OUTPUT SIGNAL

MP12

P5

Channel # 3 OPERATING WINDOW .0V

MP17

P6 MP13

MP0 MP8

- +

AGND

P7

P8

E23 5.0V

1

2 3 4

Current Based Amplifier All sensing devices used for Analog Inputs now have a current output. (min. signal 4mA, max. signal 20mA) This circuit is measured in series.

(measurements at transducer) Measure Voltage - (Elec) Rod transducer at A (+) & C (-) Range 10V to 30V Measure Voltage - (Elec) Rod transducer at B (+) & C (-) Range 0V

1 2 3 4

A B C A B C

Measure resistance - (Hyd) Rod transducer at B (+) & C (-) Range 200 - 300 Ohm PRESS. TRANS. (ROD)

DS350 GRAPHIC MODULAR ROD PRESSURE MEASURING CHANNEL CHANNEL # 3

DS350 Graphic Modular PRESSURE 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. MEASURING RESISTANCE BETWEEN B ( + ) AND C ( - ) RANGE 200 - 300 Ohm.

+24.0

+0

C

A B

24.4

GRAPHIC MODULAR CONSOLE SPECIAL FUNCTION 0 - SETTING OF TRANSDUCER INPUT

PAT

The first step is to lower the boom all the way down (blocking the boom), shut the engine off then disconnect hydraulic hose from the piston or rod side pressure transducer.

DS 350

!

STOP

STOP

TARE

! LIM

ENTER YOUR SERVICE CODE

SEL

5 5 5 5 5

STOP

+

>

F2

F3

STOP

F1

(1)

i

(2)

CTRL

F4

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 achieve this, 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 press the 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

Now, having successfully entered a valid password, the piston - side 0 - point setting function is activated. 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 - key, the input value is adjusted downwards. When the + and - keys are pressed simultaneously, the 0 - setting occurs automatically. Manual adjustments 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 24.5

PAT

DS 350

!

STOP

0 STOP

TARE

! LIM

0

SEL

STOP

-4%

-2%

0%

+2%

+4%

AUTO 0

CTRL

+

ESC STOP

F1

F2

F3

i

F4

P.A.T. – L.M.I MANUAL SECTION 25

DS 350 Graphic Modular (BCS) Boom Angle Connections & Wiring Diagrams

LMI L/O ALARM (EEC) LEVER LOCKOUT W # 73A SOLENOIDS W # 51AJ = GND

D

4

C

3

B

2

A

1

X1

1 2

1 2 3 4 5 6 7 8 9 10

IS = CUT&INSULATE

7 X2 RED SHEILD

CORE

X1 BRN

SHIELD

A B

CORE

1 2

7

8

6

7

5

X4 5

SIG. 3 +24V 1

25.1

1 2 3 4 3 2

GND SIG. +24V

1

3

1 2

X3 5 3

3 4

7 - PIN PLUG

X1

SIG

1

1

A 1

2

2

B 2

5

3

3

C 3

4

4

4

D 4

3

5

5

E

5

2

2

6

6

F

6

1

1

7

7

G 7

6

3

LG

4.7K

8

GND

CH #1 CH #5

5

IS = CUT&INSULATE

1 2 3 4

1

BOOM LENGTH SIGNAL RETRACTED = 4mA MAX RANGE = 20 mA

BOOM ANGLE SIGNAL 90o = 4mA 0o = 20 mA

OS Connected to strain relief insert

5 6

* NOTE - MAX LENGTH SIGNAL VARIES WITH BOOM, MAX. SIGNAL=20mA IS FOR 10 TURNS ON POT.

7 IS = CUT &INSULATE

4A

LMI BYPASS KEY SWITCH

14 10A

= CONNECTED = WIRES ARE GROUPED TOGETHER

+ +24V

K10A

0V

+ +UBS 0V RXD TXD A2B-O A2B-I LOAD-I + +UBS

K9

K8

F2- 10A 11 REL -M 12 REL -A 13 REL -R 14 + +UBS 15 DE 1 16 DE 2 17 DE 3 18 DE 4 19 20 + +UBS I 21 DAV1 U 0V 22 23 + +UBS I 24 DAV2 U 0V 25 + +UBS 26 I 27 LG 1 U 0V 28 I 29 WG 1 U I 30 LG 1 U 31 0V 32 33 + +UBS I 34 S1 DHG 1 U 0V 35 I 36 S2 DHG 2 U 51 + +UB 0V 52 F1 - 4A 53 SI - OUT 54 SI - IN 57 A2B-0 A2B-I 58 LOAD-I 59 60 + +UBS F2-10A 61 SI-REL 62 SI-REL + +UBS 64 0V 65 66 DE 5 67 68 DE 6 69 +UBS + 76 0V 77

K10B

X4 BRN 1 2 WHT PNK 3 GRA 4 5 GRN 6 YEL

WHT WHT BRN BRN

YEL

GRA GRN PNK YEL GRN

3-Pair Twisted Cable

GRA PNK

X2 1 2 GRN 3 YEL 4 5 6 PNK 7 GRA 8 BRN

WHT

BUS EXTENSION

DS350 Graphic Modular BCS Boom Angle to C.P.U. Connections

13

+UBS

MAIN BOARD

WG

GND

X2

F1

+

LWG309 L/A TRANSDUCER

+

5

STOP

W # 71K = 24 VOLTS

E

+UB

HOUSE LOCK PIN SWITCH

J1

AGND

MP14

ERROR CODE

.500v MIN.

1 2

MP16

16

1 2

25.2

VOLTAGES X1 4 ANALOG INPUT MODULE + 500MV (.500V) = 90o ANGLE MIN. SIGNAL + 2.50V = 45o ANGLE + 4.5 V = 0o ANGLE MAX. SIGNAL ALL VOTAGES ARE MEASURED WITH REFERENCE TO GND (TERMINAL X1 - 28) ON MAIN BOARD. * THESE MEASUREMENTS ARE MADE IN PARALLEL

E15 / E25

X1 26 28 29

WORKING RANGE

AGND

1

BR1

20 40

X1

AGND

E15

MP7 - MP1->

- +

MP11

MP10

J2

4.50v MAX.

ERROR CODE

(90o TO 0o)

P1

ANGLE

P2

(GND)

P3

MP9

VREFA

P4

+UB

MP12

P5

Channel # 5 OPERATING WINDOW .0V

MP17

P6 MP13

MP0 MP8

- +

AGND

P7

P8

+

A

E25 5.0V

Current Based Amplifier All sensing devices used for Analog Inputs now have a current output. (min. signal 4mA, max. signal 20mA) This circuit is measured in series.

SHIELD

1

CORE

2

1

3 4

6 Pin

Plug

(measurements in cable reel)

7 8 5 3 1 X2 X4

Measure Amps - Angle transducer at X1 4(+) & (-) WIRE 4. Range 4 mA to 20 mA

+UB

1 OUT

5 3 1 GND

+UB

GND

Measure Voltage - Angle transducer at X1 2(+) & 3 (-) Range 1V to 5.6V

1 OUT

5 3 1

Measure Voltage - Angle transducer at X1 1(+) & 3 (-) Range 10V to 30V

5 3 1 X3

S 8 7 6 5 4 3 2 1 X1

DS350 GRAPHIC MODULAR BOOM ANGLE MEASURING CHANNEL CHANNEL # 5

6 5 7

4 3 2 1

1 2 3 4 5 6 7

1 2 3 4 5 6 1 2 3 4 5 6 7

6 Pin

Connector

DS350 Graphic Modular Boom Angle Signal ACTUAL BOOM ANGLE IN DEGS. 90o

SIGNAL AT X1 TERM. PIN #29 ON C.P.U. TERMINAL 4.0 mA

SIGNAL ON ANALOG MODULE AT X1-4 (X1-28 GND.) 0.48

85o

4.9 mA

+ .70

o

5.7 mA

+ .92

75o

6.6 mA

+ 1.15

70o

7.4 mA

+ 1.37

o

8.3 mA

+ 1.60

60o

9.2 mA

+ 1.80

80

65

25.3

55

o

10.2 mA

+ 2.04

50

o

11.2 mA

+ 2.26

45o

12.1 mA

+ 2.48

40o

12.9 mA

+ 2.70

35o

13.7 mA

+ 2.92

o

14.7 mA

+ 3.15

25o

15.6 mA

+ 3.38

20o

16.5 mA

+ 3.60

o

17.3 mA

+ 3.82

10o

18.0 mA

+ 4.04

30

15 5

o

19.2 mA

+ 4.27

0

o

20 mA

+ 4.49 CHANNEL #5

CHART SHOWS TYPICAL MILLI-AMP AND VOLTAGE SIGNALS. THESE VALUES ARE TO BE USED AS A REFERENCE ONLY, THE ACTUAL SIGNAL MAY VARY SLIGHTLY.

RT865BXL (BCS) Cable Reel LWG309 PAT PAT PAT

25.4

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

P.A.T. – L.M.I MANUAL SECTION 26

DS 350 Graphic Modular (BCS) Anti - Two - Block Connections & Wiring Diagrams

ANTI - TWO - BLOCK WIRING DIAGRAM 4.7K Ω RESISTOR

To Central Unit 1 2

SHIELD

2

5 3 1

3 4 2

3

1

4 26.1

1 2

7 8 5 3 1 X2 X4

1

A B

1 2 3 4 5 6

5 3 1 X3

1 2 3 4 5 6 7 2

S 8 7 6 5 4 3 2 1 X1 1 2 1 2

3

1

3

1 2

6 5 3

Plug

1 2 3 4 5 6 7

5 3 1 +UB

3

6 Pin

2

GND

1 2

A B

1

GND

CORE

CORE

1 OUT

SHIELD

6 PIN DUMMY PLUG

+UB

A B

1 OUT

!

1

6

6 Pin

1

4 3 21

Connector

1

5 7

ANTI - TWO BLOCK SWITCH

2

1

NO. 1

1 2

3

AUX. BOOM NOSE ANTI - TWO BLOCK SWITCH

PART NO.

QTY

1 2 3 4 5

9-333-102764 9-333-102717 9-333-102666 9-333-102663 9-333-102230

1 1 1 4 1

6

9-333-102765

1

DESCRIP. COMP. ASSEM. 2-POLE JUMPER BAR TAGS, TERMINAL STRIP BLOCK, TERMINAL STRIP SWITCH A2B, WITH RETAINER CRIMP COMP. ASSEM., DUMMY PLUG

NOTES: OUTER SHIELD GROUNDED AT 1 STRAIN RELIEF CONNECTOR 2

CUT AND INSULATE INNER SHIELD

1

SWITCH PREWIRED AND POTTED

!

IMPORTANT CHANGE

HOUSE LOCK PIN SWITCH LMI L/O ALARM (EEC) LEVER LOCKOUT W # 73A SOLENOIDS

D

4

C

3

B

2

A

1

10

CONSOLE BY - PASS KEY

3 4

8 5 4 3

7

7

6

6

+

26.2

AB

A2B

3 4

5

5

4

4

DATA FROM C.U.

3

DATA TO C.U.

2 1

3 (GND) 2 (+24 V)

1

GRAPHIC CONSOLE

4A

13 14 10A

= CONNECTED = WIRES ARE GROUPED TOGETHER

+

K10A

+ +UBS 0V RXD TXD A2B-O A2B-I LOAD-I + +UBS

K9

K8

F2- 10A 11 REL -M 12 REL -A 13 REL -R 14 + +UBS 15 DE 1 16 DE 2 17 DE 3 18 DE 4 19 20 + +UBS I 21 DAV1 U 0V 22 23 + +UBS I 24 DAV2 U 0V 25 + +UBS 26 I 27 LG 1 U 0V 28 I 29 WG 1 U I 30 LG 1 U 31 0V 32 33 + +UBS I 34 S1 DHG 1 U 0V 35 I 36 S2 DHG 2 U 51 + +UB 0V 52 F1 - 4A 53 SI - OUT 54 SI - IN 57 A2B-0 A2B-I 58 LOAD-I 59 60 + +UBS F2-10A 61 SI-REL 62 SI-REL + +UBS 64 0V 65 66 DE 5 67 68 DE 6 69 +UBS + 76 0V 77

K10B

X4 BRN 1 2 WHT PNK 3 GRA 4 5 GRN 6 YEL

WHT WHT BRN BRN

YEL

GRA GRN PNK YEL GRN

3-Pair Twisted Cable

GRA PNK

X2 1 2 GRN 3 YEL 4 5 6 PNK 7 GRA 8 BRN

WHT

BUS EXTENSION

DS350 Graphic Modular BCS Anti - Two Block Connections

LMI BYPASS KEY SWITCH

+ +24V 0V

MAIN BOARD

LMI

+UBS

+

W # 71K = 24 VOLTS

5

F1

STOP

W # 51AJ = GND

E

1 2 3 4 5 6 7

1 2 3 4 5 6 7 8 9

+UB

X1

1 2

Auxiliary Boom Nose

3

2

1

NO.

PART NO.

QTY

1 2

9-333-102238 9-333-102956

1 1

3+

9-333-102768

1

26.3

DESCRIPTION SWITCH, A2B W/O CRIMP CONDUIT 3 FEET (MUST CUT TO LENGTH) JUNCTION BOX ASSEM.

Auxiliary Boom Nose JUNCTION BOX ASSEMBLY

1(BLACK)

1 2(BROWN)

A2B CABLE

3(RED)

1

A

2

B

2 3

Complete Assembly # 9-333-1027678 NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

PART NO.

QTY

9-333-102758 9-333-102764 9-333-101984 9-333-102759 9-333-102663 9-333-102664 9-333-102665 9-333-102666 9-333-102760 9-333-102482 9-333-102612 9-333-102669 9-333-102266 9-333-102480

1 1 1 1 3 1 2 1 1 1 1 4 4 4

DESCRIPTION Junction Box Strain Relief Locknut Mounting rail, terminal strip Block, terminal strip End plate, terminal strip End bracket, terminal strip Tags, terminal strip Connector, cannon 2-pin male recp. Gasket Cover, dust Screw #4 Lockwasher #4 Nut #4 26.4

Folding Extension

4 2

3

26.5 1

NO. 1 2

PART NO. 9-333-102230 9-333-102956

QTY 1 1

3+ 4+

9-333-102996 9-333-102766

1 1

DESCRIPTION Switch, A2B W/O Crimp Conduit 10 feet (must cut to length) Junction box assembly Junction box assembly

Folding Extension JUNCTION BOX ASSEMBLY

1(BLACK)

1 A2B CABLE

2(BROWN)

3(RED)

1

A

2

B

2 3

Complete Assembly # 9-333-102766 NO. 1 2 3 4 5 6 7 8 9 10 11 12 13

PART NO. 9-333-102758 9-333-101995 9-333-102759 9-333-102663 9-333-102664 9-333-102665 9-333-102666 9-333-102760 9-333-102482 9-333-102612 9-333-102669 9-333-102266 9-333-102480

QTY

DESCRIPTION 1 1 1 3 1 2 1 1 1 1 4 4 4

Junction Box Strain Relief Mounting rail, terminal strip Block, terminal strip End plate, terminal strip End bracket, terminal strip Tags, terminal strip Connector, cannon 2-pin male recp. Gasket Cover, dust Screw #4 Lockwasher #4 Nut #4

26.6

Folding Extension JUNCTION BOX ASSEMBLY

Complete Assembly # 9-333-102996 NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

PART NO. 9-333-102758 9-333-101995 9-333-101984 9-333-102664 9-333-102663 9-333-102664 9-333-102665 9-333-103044 9-333-102792 9-333-102482 9-333-102612 9-333-102669 9-333-102266 9-333-102480

QTY

DESCRIPTION 1 1 1 1 3 1 2 1 1 1 1 4 4 4

26.7

Junction Box Strain Relief Locknut Mounting Rail Block, terminal strip End plate, terminal strip End bracket, terminal strip Tags, terminal strip Connector, cannon 2-pin male recp. Gasket Cover, dust Screw #4 Lockwasher #4 Nut #4

P.A.T. – L.M.I MANUAL SECTION 27

DS 350 Graphic Modular (BCS) Digital Inputs

RT865BXL (BCS) MAIN & BUS EXTENSION DIGITAL INPUTS INPUT BUS EXT. 1 2 3

4

5 6 7

CU DESCRIPTION TERMINAL A101 BUS TELE EXTEND (+24V) X1/29 A101 BUS TELE RETRACT (+24V) X1/31 A101 BUS AUTO MODE SELECTED (+24V) X1/33 A101 BUS X1/35 A101 BUS X1/37 A101 BUS X1/39 A101 BUS X1/41

PROX. SWITCH OM/FLY RETRACTED & OM/FLY % RESET (+24V)

NOTES GROVE PRESSURE SWITCH SIGNAL GROVE PRESSURE SWITCH SIGNAL GROVE SELECTOR SWITCH SIGNAL PAT SWITCH ON CM - SIGNAL VIA CM CABLE REEL

PROX. SWITCH CM RETRACTED PAT SWITCH ON BOOM BASE & RESET %(+24V) PROX. SWITCH IM RETRACT PAT SWITCH ON BOOM BASE (+24V) PROX. SWITCH IM % RESET (+24V) PAT SWITCH ON BOOM BASE

INPUT MAIN 2 3

A101 MAIN AREA DEFINATION SWITCH SWIVEL LIMIT SWITCH ON RUBBER X1/17 A101 MAIN HOUSE LOCK PIN SWITCH SIGNAL GROVE LIMIT SWITCH X1/18

27.1

X1

+

DS350 Graphic Modular (BCS) Digital Input Diagram

25 26

+UB 10 - 35V

27 KGND

28 TELE EXT. PRESS. SW. 23 pin plug

TELE RET. PRESS. SW.

4

29 30

5

31 32

HIGH=AUTO / NONE=MANUAL MODE 19 pin plug

PROXY SW.1 OM / FLY RET.

PROXY SW.4 CM RET & % RESET. 14 pin plug

PROXY SW. 2 IM RET. (2 POSITIONS)

6

33 34

6

35 36

12

37 38

7

39 40

PROXY SW.3 IM RESET %. (TOP)

6

41 42 43 44

* TERMINAL # 25 IS + 24V TO PROXY SWITCHES 1,2,3 & 4.

45 46 47

* TERMINAL # 27 IS GND. TO PROXY SWITCHES 1,2,3 & 4.

48 49 50 51 52 53 54 55 56 57 58 59 60

27.2

> > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > >

DE 1

DE 2

DE 3

DE 4

DE 5 DE 6

DE 7

DE 8

DE 9

H1

+24V TELEEXT. PRESS. SW.

H2

+24V TELERET. PRESS. SW. +24V AUTO MODE

H3

H4

+24V OM / FLY RET.

H5

+24V CM RET. & % RESET. +24V IM RET.

H6 +24V IM % RESET.

H7

H8

H9

DE 10 H10 DE 11 H11 DE 12 H12 DE 13 H13 DE 14 H14 DE 15 H15 DE 16 H16

P.A.T. – L.M.I MANUAL SECTION 28

DS 350 Graphic Modular (BCS) Central Unit P.C. Modular Board Layout

P.A.T. DS350 Graphic Modular MAIN BOARD A

B

C

D

E

F

G

H

I

J

K

L

M

-

1

G1

+UB1

PWM DC

MP42

+

KGND

MP 26

KGND

MP 4

+5V

MP 9

C

+6V X15

GND

1

GND

AGND

KGND

2

MP24

MP23

VBAT

+BATT

C

MP 8

2

+9V

GND

3

4

5 +UB1 +UB

DI 6

KGND

X12

6

MP40 V10 H11 V11 MP41

H1 H2 H3 H4 H5 H6

DI 1

MP21

5

PFAIL+UB1

DI 1- DI 6 =>

X17

4

power o.k.

X14

3

6

J11

X11

7

7

SP5

X13

8

X16

8

TXD

H12

K8

10 LEVER LOCKOUT K10

A2B

+UB

MP29

K9 KGND

+

F 1

H9 A2B

69 68 67

66

65 64

63 62

61 60 59 58

57 56

55 54

KGND

3 1

77 76

KGND

KGND

-

11

J4 J3 J2 J1

X1

12

F 2

11

X1

13

AGND

H10

2 1

MAIN ON/OFF

KGND

J10 3 4

9

LMI KGND

10

LOAD

+5V/RS232

AGND

9

12

KGND MP1 +UBS

36 35 34 33

A

32 31

B

30 29 28 27 26

C

D

25 24 23

E

22 21 20

F

19 18 17 16 15 14

G

13 12 11

H

I

10 9

8

7

J

6

5

K

4

3

2

L

1

MP 25

M

LOCATIONS :

LED’S

MP 1 - zone M13 = GND. MP 25 - zone M13 = +UBS CONSOLE, SENSORS, DI’s MP 8 - zone M2 = +9V MP 41 - zone M4 = POWER FAIL MP 9 - zone M2 = +6V MP 42 - zone G1 = +5V MP 4 - zone M1 = +5V MP 21 - zone E5 = +5V MP 26 - zone M1 = GND. MP 29 - zone D10 = +5V MP 23 - zone A2 = VBATT H1-H6 - zone I5 = DI 1-6 MP 24 - zone D2 = +BATT MP 40 - zone M4 = +UB

H 8 - zone M3 - LOAD H 9 - zone E11 - A2B H 10 - zone G9 -MAIN IN/ OUT H 11 - zone M3 - POWER H 12 - zone I11 - TXD

28.1

13

P.A.T. DS350 Graphic Modular EXTENSION BOARDS

MP7 J1 J13

J12

J2

D3

D1 MP4

D2

X1

D14

X2 D13

P1

SYSTEM D10 J8

D6 J9 MP3 J6 D17

J10

D15

D7

D21

D9 D12

J15

J11

J14

D18

J7

D11 D19

D20

X3

BR6

MP6MP5

EJECT BR5

MP2

A102 CPU

J1

J2

DATA D1 J5 J3

TLK D3 J6

BR 4 3 2 1

X1

A103 DATEN

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.

28.2

DS350 Graphic Module Analog Input Module

+

P7

MP12

1 2

40

AGND

AGND -

P6

MP13

J2

20

P5

16 P4 P3

MP9

J1

MP11

X16

P2

MP10

P1

1 1 2

X1

MP17

BR1

MP0

-

+

MP8

+

+

VREFA

P8

+

MP7 - MP1->

X17

1 2

+

MP16

7

16

6 5 4 3

MP14

2 1

40 1 2 AGND

AGND

BOARD P/N 9-333-103290 X1:1-7 X1:8 X1:9 X1:10 X1:11 X1:12-15 X1:16 X1:17 X1:18 X1:19 X1:20

= 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 - P7 = TEMP (0.5V + 10mV/oC) = VREFA = 5.000V reference MP 1 = AGND = AGND (reference GND) MP 8 = + 5V = VREF+ = 5.0V power ADC MP 1 - 7 Input channels 1 - 7 - 0.5V / 4 mA = CH01-04, DIN 1-4 / 10 2.5V / 20mA = CH05, +UBS / 10 MP 14 = + 13V REF 02 = CH06, HESIN(A2B) *4 MP 16 = HESIN input voltage = CH07, +9V *4 MP 17 = app 5.4V clamp for inputs = CH08, VREFA / 2 = 2.500V = UKLEMM, app. VREFA, limits ADC input to 5.0V

28.3

DS350 Graphic Modular (BCS) A 105 Serial Extension Module Part No. 9-333-103292 MP11 +UB1

KGND

MP1

MP10 F5 F4 2A 2A MP15

MP4 H1 H2 MP3

X4 1 2 3 4 5 6

C30 MP0 GND

MP16

MP1

1 2 3 4 5 6 H3

A 101 Bus Extension Module Part No. 9-333-103717 DI 16

DI 9

H9 H10 H11 H12 H13 H14 H15 H16

MP14 ADC

1

2 3

4

5 6

7

8 9

10 11 12

13 14 15

16 17 18

19 20 21

22 23 24

1 2 3 4 5 6 7 8

X2 2A

F25

K1

K2

K3

K4

K5

K6

K7

F1

K8 F8

F2 H17

F3 H18

F4 H19

F5 H20

F6 H21

F7 H22

H23

H24

28.4

25 26 27 28

MP4 MP5 MP6 MP7 MP10 MP11 MP12 MP13 MP 3

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 60

MP 2

MP9

MP 1

61 62 63 64 65 66 MP 8 UREL

MP 0

DI 1

+ 7V

C27

KGND AGND + UB

H8 H7 H6 H5 H4 H3 H2 H1

C93

+5V +14V -14V +REF +REX -10V USIN RIPP

DI 8

DS350 Graphic Modular (BCS) A 102 CPU Module Part No. 9-333-103718

X4 MP4 C38

J3

C37

C32

SLAVE E - PROM

MP2

C33

H1

MP0

MP1

MP3

J1

A 105 Analog Input Module Part No. 9-333-103719

A 104 PV Extension Module Part No. 9-333-103720 X2

X2

P11

MP2

MP3

MP7

MP6

P12 MP0

X1 MP1

1 2 3 4

H1

MP5

28.5

MP4

RT865BXL (BCS) BUS EXTENSION INTERFACE Grove wire number 71H 51AK

Interface connector A

POWER SUPPLY +24V

B

CRANE GND

C

387A 388 239B 242B 243B 244B [507] [505] [338] 323A

D

TELE EXTEND PRESSURE SWITCH (INPUT)

E

TELE RETRACT PRESSURE SWITCH (INPUT)

F

HIGH = AUTO MODE, LOW = MANUAL MODE (INPUT)

G

SELECT OM / FLY IN MANUAL MODE (INPUT)

H

SELECT CM IN MANUAL MODE (INPUT)

J

SELECT IM IN MANUAL MODE (INPUT)

K

3RD WRAP CUT OFF MAIN HOIST RT ONLY

L

3RD WRAP CUT OFF AUX. HOIST RT ONLY

M

3RD WRAP WARNING LIGHT (GND) RT ONLY

N

TELE OUT OF SEQUENCE SIGNAL (RELAY OUTPUT)

O P Q R

238A 1083 255A 257A

S

PROPORTIONAL TELE - SOLENOID GND.

T

TELE ROD DRAIN SOLENOID VALVE SIGNAL

U

PROPORTIONAL TELE - SOLENOID (EXTEND)

V W X

PROPORTIONAL TELE - SOLENOID (RETRACT)

RT865BXL (BCS) MAIN BOARD INTERFACE Grove wire number 71K 51AJ 73A 74 744

Interface connector A

POWER SUPPLY +24V

B

CRANE GND

C

LMI UNLOCK SOLENOIDS

D

LMI LOCK OUT ALARM

E

HOUSE LOCK PIN SWITCH

F G H

28.6

W # 71K = 24 VOLTS

4

C

3

B

2

1 2 3 4 5 6 7 8 9 10

A

1 3 4

5

13 14 10A

= CONNECTED = WIRES ARE GROUPED TOGETHER

+

+ +24V

K10A

0V

+ +UBS 0V RXD TXD A2B-O A2B-I LOAD-I + +UBS

K9

K8

F2- 10A 11 REL -M 12 REL -A 13 REL -R 14 + +UBS 15 DE 1 16 DE 2 17 DE 3 18 DE 4 19 20 + +UBS I 21 DAV1 U 0V 22 23 + +UBS I 24 DAV2 U 0V 25 + +UBS 26 I 27 LG 1 U 0V 28 I 29 WG 1 U I 30 LG 1 U 31 0V 32 33 + +UBS I 34 S1 DHG 1 U 0V 35 I 36 S2 DHG 2 U 51 + +UB 0V 52 F1 - 4A 53 SI - OUT 54 SI - IN 57 A2B-0 A2B-I 58 LOAD-I 59 60 + +UBS F2-10A 61 SI-REL 62 SI-REL + +UBS 64 0V 65 66 DE 5 67 68 DE 6 69 +UBS + 76 0V 77

K10B

X4 BRN 1 2 WHT PNK 3 GRA 4 5 GRN 6 YEL

WHT WHT BRN BRN

YEL

GRA GRN PNK YEL GRN

3-Pair Twisted Cable

GRA PNK

X2 1 2 GRN 3 YEL 4 5 6 PNK 7 GRA 8 BRN

WHT

BUS EXTENSION

DS350 Graphic Modular BCS Crane Interface to Main Board

LMI BYPASS KEY SWITCH

+UBS

MAIN BOARD

28.7 4A

F1

+

W # 51AJ = GND

D

X1

STOP

LMI L/O ALARM (EEC) LEVER LOCKOUT W # 73A SOLENOIDS

1 2

5

+UB

HOUSE LOCK PIN SWITCH

E

X1

9

PV EXTENSION

16 A104 X1

1 2 3 4

13 15 17 18 8 7

+ 24V GND

71H 51AK 387A 388 239B 242B 243B 244B

TELE OUT OF SEQUENCE

323A

TELE PROP. ANALOG GND. TELE ROD DRAIN SOLENOID TELE EXTEND PROP. SOLENOID TELE RETRACT PROP. SOLENOID S/S HARNESS 23 - SOCKET RECEPT

238A 1083 255A 257A

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 1

4 5 6 7 8 9

2 4 5 6

13

1

15 16 17 18 LMI - CRANE INTERFACE 23 - PIN PLUG

= WIRES ARE GROUPED TOGETHER

K3 COM ( +24V ) K3 NO ( +24V TELE ROD DRAIN SOL. ) K3 NC K4 COM K4 NO K4 NC ( TELE OUT OF SEQUENCE ) K5 COM K5 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 +24V GND GND DI 1 ( +24V = TELE EXT. PRESS. SW. ) DI 1 GND DI 2 ( +24V = TELE RET. PRESS. SW. ) DI 2 GND DI 3 ( +24V = AUTO MODE ) DI 3 GND DI 4 ( +24V = OM / FLY RET ) DI 4 GND DI 5 ( +24V = CM RET & % RESET ) DI 5 GND DI 6 ( +24V = IM RET ) DI 6 GND DI 7 ( +24V = IM % RESET ) DI 7 GND

X2 1 BRN 2 WHT GRN 3 YEL 4 ANALOG INPUT 1 (IM LEN.) 5 ANALOG INPUT 2 (CM LEN.) 6 7 PNK 8 GRA

WHT BRN

WHT

YEL GRN

BRN GRA PNK YEL

GRA GRN PNK

X4 1 WHT 2 PNK 3 GRA 4 GRN 5 YEL 6 BRN

MAIN BOARD

DS350 Graphic Modular BCS Crane Interface to Bus Extension

K2 COM ( +24V ) K2 NO ( +24V TO IM 2-WAY SOLS. )

BUS EXTENSION

28.8

TELE EXTEND PRESSURE SW. TELE RETRACT PRESSURE SW. HIGH = AUTO MODE / NONE = MANUAL MODE OM / FLY TELE CM TELE IM TELE

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 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 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 60 61 62 63 64 65 66

P.A.T. – L.M.I MANUAL SECTION 29

DS 350 Graphic Modular (BCS) Troubleshooting Guide

PAT DS350 Graphic Modular (BCS) LOAD MOMENT INDICATOR TROUBLESHOOTING

General Flowchart Lever Lockout Activated Broken Length Cable No Display Anti - Two - Block Length Reading Problem Angle Reading Problem Load Reading Problem Bad Data Transfer Between Console & Central Unit Error Code Displayed

29.1

29.2 29.3 29.4 29.5 29.7 29.10 29.37 29.40 29.42 29.45

GENERAL FLOWCHART

This section explains how to handle a problem that may arise with the P.A.T. Load Moment Indicator 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 which will guide you to one of the more detailed flowcharts shown on pages 35.3 through 35.45.

START

What’s Wrong?

Lever Lockout Activated

Length Cable Problem

No Display

Go to Page 29.3

Go to Page 29.4

Go to Page 29.5

Wrong Length Displayed

Go to Page 29.10

Wrong Angle Displayed

Wrong Load Displayed

Go to Page 29.37 Go to Page 29.40

29.2

No Function Anti-Two-Block Go to Page 29.7

Bad Data Transfer

Error Code Displayed

Go to Page 29.42

Go to Page 29.45

LEVER LOCKOUT ACTIVATED PROBLEM The lever lockout system of the crane is activated. Crane movements “hoist up”, telescope out”, and “boom down” are stopped. Crane is not in overload or two-block condition.

START

Set the override key switch in central unit into upper position to override LMI.

fixed?

YES

NO Does the console indicate Anti-Two-Block warning? NO

YES

Fault in crane electric or hydraulic system.

If console displays is blank, fault is located in power supply, wiring or fuses.

Fault in Anti-Two Block system.

If Load Moment Limit Light is lit, the fault is located in LMI, cables, wiring, fuses or console.

Check lever lockout system in crane

Go to page 29.5

Go to page 29.7

Read error code displayed on console and go to page29.45.

29.3

BROKEN LENGTH CABLE PROBLEM Damaged or broken length cable. STEP

ACTION

1

Cut old cable at cable drum.

2

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

3

Remove cable reel from mounting brackets.

4

Remove damaged length cable, which is mounted to the slip rings in the cable reel, from Terminal X1 and X2 See drawing 1 on page 29.53.

5

Turn the cable reel and open the stain relief attached to the axle in the center of the drum. Pull existing length cable out of the cable reel.

6

Disconnect damaged length cable from Anti-Two-Block switch receptacle at the boom nose.

7

Pull new length cable through the hole, pipe and strain relief and push it through the axle of the reeling drum. Tighten strain relief to ensure sealing.

8

Dismantle length cable near slip ring and reconnect shield to terminal No. X1 and center to No. X2 See drawing 1 on page 29.53.

9

Remount cable reel to the boom. Turn reeling drum clockwise to get rest of new cable onto the drum.

10

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

11

Reconnect new cable to Terminal No. 1 (center) and ground terminal (shield) of receptacle at the boom nose.

12

Reset length potentiometer in length angle transducer (screw is located in center 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.

29.4

NO DISPLAY PROBLEM Blank console display. No warninglight shown. Crane movements stopped.

START Check fuses on CPU box.

correct?

NO

Replace fuses.

YES 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?

NO

Check crane power supply for faulty crane electric or if power supply is too low.

YES

Measure crane voltage on main board terminal strip between X1-3(+24V) and X1-4 (ground). This is a output voltage to the console.

correct?

Defect on main board. Replace main board, see replacement procedure.

NO

YES

NEXT PAGE 29.5

NO DISPLAY continued

PREVIOUS PAGE

Measure voltage in the console between X1-1 (+24V) and X1-2 (ground). Refer to Drawing 6 on page29.57 .

correct?

Check connections of the cable between console and central unit. Replace cable if necessary.

NO

YES

Display is defective. Replace the console.

END

29.6

ANTI-TWO-BLOCK PROBLEM PROBLEM Function of Anti-Two-Block System is faulty. START Check to see whether or not crane is in two-block condition. NO Lower hook down in safe position.

correct? YES

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

NO correct?

Plug appropriate plug into socket of junction box.

YES Measure the resistance at the boom nose box 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 Ohms Switch Open = > 1 Megaohm NO correct? YES NEXT PAGE

29.7

Replace Anti-Two-Block switch.

ANTI-TWO-BLOCK PROBLEM PREVIOUS PAGE

Measure the A2B signal in the cable reel between X1:Brown and X2:Red wires on the slip ring with an ohmmeter. See drawing 1 on page 29.53. Switch closed = 4700 +/- 500 Ohms Switch open = >1 Megohm Reconnect slip ring wires. NO correct?

Fault in wiring cable from junction box at boom nose to cable reel or short circuit in length cable. Check wiring.

YES

Measure the A2B signal in the cable reel between 7 and 8 with an ohmmeter. See drawing 1 on page 20.28. Anti-Two-Block switch open = > 1 megohm Anti-Two-Block switch closed = 4700 Ohms + 500 Ohms. Reconnect length cable to slip ring. NO correct?

Replace slip ring.

YES Measure the A2B signal in the boom base box between terminal 5 and 6 with an ohmeter. Anti-Two-Block switch open = > 1 megohm Anti-Two-Block switch closed = 4700 Ohms + 500 Ohms. Reconnect length cable to slip ring. NO Fault in 7 conductor cable between correct? cable reel and boom base box. YES NEXT PAGE 29.8

ANTI-TWO-BLOCK PROBLEM PREVIOUS PAGE Connect wire # 5 back to terminal X1-31 on the main board. 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 Ohms Anti-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 diagram for wires # 5 (+) and # 6 (-). If fault is found check cable.

NO correct? YES Disconnect X1-31 and X1-32. Check main board function by installing a temporary resistor, 4700 Ohms, between X131 and X1-32 in central unit. With resistor connected alarm should be inactive.

NO

Defect on main board. Replace main board and reset pressure channel.

correct?

Reconnect wire #5 to X1-31 and wire #6 to X1-32.

END

29.9

LENGTH READING PROBLEM PROBLEM Length reading incorrect. Crane is not in “out of load chart” condition. A. Boom Length Percentage Problem START Boom length percentage problem

Switch to Manual Mode and retract the boom completely against the stop block. Check the Percentage indication (1%, 0 %, 0 %)

Wrong?

No

Yes IM and/ or CM retract signal not recognized. Check proximity switch target adjustment. Refer to Drawing on page 23.3. If damage is visible install new switch.

Correct?

Continue to page 29.17

No

Yes Measure the voltage supply to IM switch at terminal 1 (+24V) and 3 (GND) in the length transducer LG321.

NEXT PAGE

29.10

Adjust the target and switch See page 23.3

LENGTH READING PROBLEM A. Boom Length Percentage Problem Cont. PREVIOUS PAGE

Correct?

No

Yes

Measure the voltage at terminal 25 (+24V) and terminal 27 (GND) in the bus extension.

Failure in bus extension. Check connectors, fuses and bus extension power supply.

No

Correct? Yes

Faulty wiring between bus extension and LG 321. Check wiring. Measure voltage at terminal 1 or 2 (+24V) and 5 or 6 (GND) in the switch junction box. See page 29.5.

Correct?

No

Yes Measure voltage at terminal 1 (+24V) and 5 (GND) in the IM junction box. Behind drum.

Correct?

Faulty wiring between length transducer and LG 321 and switch junction box. Check wiring.

No Faulty wiring between length transducer and LG 321 and IM junction box. Check wiring.

Yes NEXT PAGE 29.11

LENGTH READING PROBLEM A. Boom Length Percentage Problem Cont. PREVIOUS PAGE

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?

No

Yes 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.

Correct?

Faulty switch wiring or defective switch. Replace IM reset proximity switch. Adjust switch and target.

No

Yes 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

29.12

Faulty wiring between length transducer and LG 321 and switch junction box. Check wiring.

LENGTH READING PROBLEM A. Boom Length Percentage Problem Cont. PREVIOUS PAGE

Correct?

No

Yes 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

Correct?

Faulty switch. Replace IM retract proximity switch. Adjust switch and target.

No

Yes Measure the CM retract switch signal at terminal 6 (+ 24) and terminal 5 (GND) in the IM junction box. See page 29.5

Correct?

Faulty wiring between length transducer and LG 321 and switch junction box. Check wiring.

No

Yes Measure the CM retract switch signal at terminal 8 (+ 24) and terminal 3 (GND) in the LG321. See page 29.4

NEXT PAGE

29.13

Defective switch. Replace CM retract proximity switch. Adjust switch and target

LENGTH READING PROBLEM A. Boom Length Percentage Problem Cont. PREVIOUS PAGE

Correct?

No

Yes Measure the IM retract switch signal at terminal 39 (+24V) and 27 (GND) in the bus extension. See page 29.3

Correct?

Faulty wiring between length transducer LG321 and switch junction box. Check wiring.

No

Yes Measure the IM reset switch signal at terminal 41 (+24V) and 27 (GND) in the bus extension. See page 29.3

Correct?

Faulty wiring between bus extension and length transducer LG321 and switch junction box. Check wiring.

No

Yes Measure the CM retract switch signal at terminal 37 (+24V) and 27 (GND) in the bus extension. See page 29.3

Correct?

Faulty wiring between bus extension and length transducer LG321 and switch junction box. Check wiring.

No

Yes NEXT PAGE

29.14

LENGTH READING PROBLEM A. Boom Length Percentage Problem Cont. PREVIOUS PAGE Measure OM retract switch power supply at terminal X1/11 (+24V) and X1/7 (GND) in the LG 321 (CM). See page 29.4

Correct?

No

Yes Measure at CM junction box terminal 11 (+24V) and 9 (GND). See page 29.5

Correct?

Faulty wiring between bus extension and length transducer LG321 and switch junction box. Check wiring.

No

Yes Measure OM retract switch signal at CM junction box terminal 10 (+24V) and 9 (GND). See page 29.5

Correct?

Faulty wiring between CM box and length transducer LG321 (CM). Check wiring.

No

Yes Measure signal at terminal X1/8 (+24V) and X1/7 (GND) in the LG 321 (CM). See page 29.4

NEXT PAGE

29.15

Faulty wiring between bus extension and length transducer LG321 (CM). Check wiring.

LENGTH READING PROBLEM A. Boom Length Percentage Problem Cont. PREVIOUS PAGE

Correct?

No

Yes Measure signal at bus extension terminal X1/35 (+24V) and X1/27 (GND). See page 29.3

Correct?

Faulty wiring between CM box and length transducer LG321 (CM). Check wiring.

No

Yes Digital input defective on bus extention. Check LED’s on bus extension. Follow replacement procedures.

END

29.16

Faulty wiring between bus extension and length transducer LG321 (CM). Check wiring.

LENGTH READING PROBLEM B. Boom Out Of Sequence In Automode START Problem: In Automode the boom becomes out of sequence, the warning light is on. Select manual mode. With no load suspended retract the boom completely. Disengage the boom stop block and retract the boom completely. Check the percentage indication. ( 0%, 0%, 0%)

Correct?

No

Yes Inspect the spooling of the length cable on all three drums.

Correct?

Continue with section A.

No

Yes Remove the lid from the length transducers LWG 309 and both LG 321. Carefully reset the length transducer potentiometer. Repeat testing the boom sequence in automode.

NEXT PAGE

29.17

Correct the spooling manually. CAUTION Drum is under tension.

LENGTH READING PROBLEM B. Boom Out Of Sequence In Automode Cont. PREVIOUS PAGE

Failed?

No

Yes In manual mode retract the boom. Disengage the boom stop block to retract all section completely. Re-check the length potentiometer adjustment.

Correct?

END

No

Yes Remove lid from LG321 (IM length) and measure supply voltage at terminal X1/1 (+24V) and X1/3 (GND). See page 29.4

Correct?

Adjust gear assembly and check O-ring in gear wheel. Replace O-ring if wear is visible.

Measure the voltage at terminal X1/25 (+24V) and terminal X1/27 (GND) in bus extension.

No

Yes Failure in bus extension. Check connectors, fuses and bus extension power supply.

No

Correct? Yes

Faulty wiring between bus extension and LG 321 (IM). Check wiring. NEXT PAGE 29.18

LENGTH READING PROBLEM B. Boom Out Of Sequence In Automode Cont. PREVIOUS PAGE Turn the length poteniometer in the LG 321 (IM) counter clockwise to a soft stop. Measure the voltage at terminal X1/2 (1V) and terminal X1/3 (GND). See page 29.4 Switch power off. Remove wire 2 from LG 321 terminal X1/2. Switch power on. Measure electrical current at terminal X1/2 (+ 4mA). Meter - in series.

No

Correct? Yes

Switch power off. Re-connect wire 2 to terminal X1/2. Faulty length sensor unit. Replace length sensor unit.

No

Correct? Yes

Switch power off. Re-connect wire 2 to 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 voltage at terminal X1/2 (5.6V) and terminal X1/3 (GND). See page 29.4 NEXT PAGE

29.19

LENGTH READING PROBLEM B. Boom Out Of Sequence In Automode Cont. PREVIOUS PAGE Switch power off. Remove wire 2 from LG 321 terminal X1/2. Switch power on. Measure electrical current at terminal X1/2 (+ 20mA). Meter - in series.

No

Correct? Yes

Switch power off. Re-connect wire 2 to terminal X1/2. Faulty length sensor unit. Replace length sensor unit.

No

Correct? Yes

Switch power off. Re-connect wire 2 to terminal X1/2.

Faulty wire between length transducer LG 321 and bus extension. Check wiring. Remove lid from LG 321 (CM) and measure supply voltage at terminal X1/1 (+24V) and X1/3 (GND).

Correct?

No

Yes

Faulty wire between length transducer LG 321 (CM) and bus extension. Check wiring.

NEXT PAGE

29.20

LENGTH READING PROBLEM B. Boom Out Of Sequence In Automode Cont. PREVIOUS PAGE Turn the length poteniometer in the LG 321 (CM) counter clockwise to a soft stop. Measure the voltage at terminal X1/2 (1V) and terminal X1/3 (GND). See page 29.4 Switch power off. Remove wire 2 from LG 321 (CM) terminal X1/2. Switch power on. Measure electrical current at terminal X1/2 (+ 4mA). Meter - in series

No

Correct? Yes

Switch power off. Re-connect wire 2 to terminal X1/2. Faulty length sensor unit. Replace length sensor unit.

No

Correct? Yes

Switch power off. Re-connect wire 2 to terminal X1/2.

Faulty wire between length transducer LG 321 (CM) and bus extension. Check wiring. Turn the length poteniometer in the LG 321 (CM) clockwise to a soft stop(10 turns). Measure the voltage at terminal X1/2 (5.6V) and terminal X1/3 (GND). See page 29.4 NEXT PAGE

29.21

LENGTH READING PROBLEM B. Boom Out Of Sequence In Automode Cont. PREVIOUS PAGE Switch power off. Remove wire 2 from LG 321 (CM)terminal X1/2. Switch power on. Measure electrical current at terminal X1/2 (+ 20mA). Meter - in series

No

Correct? Yes

Switch power off. Re-connect wire 2 to terminal X1/2. Faulty length sensor unit. Replace length sensor unit.

No

Correct? Yes

Switch power off. Re-connect wire 2 to terminal X1/2.

Faulty wire between length transducer LG 321 (CM) and bus extension. Check wiring. Remove lid from LWG 309 (OM) and measure supply voltage at terminal X1/1 (+24V) and X1/3 (GND). See page 29.2

Correct?

No

Yes

Faulty wire between length transducer LG 321 (CM) and bus extension. Check wiring.

NEXT PAGE

29.22

LENGTH READING PROBLEM B. Boom Out Of Sequence In Automode Cont. PREVIOUS PAGE Turn the length poteniometer in the LWG 309 (OM) counter clockwise to a soft stop. Measure the voltage at terminal X1/2 (1V) and terminal X1/3 (GND). Switch power off. Remove wire 2 from LWG 309 (OM) terminal X1/2. Switch power on. Measure electrical current at terminal X1/2 (+ 4mA). Meter - in series.

No

Correct? Yes

Switch power off. Re-connect wire 2 to terminal X1/2. Faulty length sensor unit. Replace length sensor unit.

No

Correct? Yes

Switch power off. Re-connect wire 2 to terminal X1/2.

Faulty wire between length transducer LWG 309 (OM) and bus extension. Check wiring. Turn the length poteniometer in the LWG 309 (OM) clockwise to a soft stop(10 turns). Measure the voltage at terminal X1/2 (5.6V) and terminal X1/3 (GND). NEXT PAGE

29.23

LENGTH READING PROBLEM B. Boom Out Of Sequence In Automode Cont. PREVIOUS PAGE Switch power off. Remove wire 2 from LWG 309 (OM)terminal X1/2. Switch power on. Measure electrical current at terminal X1/2 (+ 20mA). Meter - in series.

No

Correct? Yes

Switch power off. Re-connect wire 2 to terminal X1/2. Faulty length sensor unit. Replace length sensor unit.

No

Correct? Yes

Switch power off. Re-connect wire 2 to terminal X1/2.

Faulty wire between length transducer LG 309 (OM) and bus extension. Check wiring. Reset all length transducer potentiometers. Select Boom service screen on console, compare the indicated IM length with the actual IM length. NEXT PAGE

29.24

LENGTH READING PROBLEM B. Boom Out Of Sequence In Automode Cont. PREVIOUS PAGE

Yes

Correct?

Fault is not located in the LMI circuit. Follow the crane service instructions to continue.

END

No

Faulty bus extension module. Contact Technical support for instructions

END

29.25

LENGTH READING PROBLEM C. Outer Mid And Fly Section Are Not Retracted (E83) START

Outer mid and fly sections are not fully retracted.

Switch to manual mode and retract the OM/Fly section fully.

E83 ?

No

Switch to auto mode and contiue normal crane operation

Yes Switch to auto mode and retract the boom (Caution Reduced load chart with E83)

E83 ?

No Defect is not located in LMI circuit. Refer to crane service documentation to continue.

Yes

Check the position of the OM/Fly section

NEXT PAGE

29.26

LENGTH READING PROBLEM C. Outer Mid And Fly Section Are Not Retracted (E83) Cont. PREVIOUS PAGE

Correct?

No

Yes

Switch to auto mode and retract OM section fully.

Check the OM retract proximity switch and target adjustment. Defect is not located in LMI No circuit. Refer to crane service documentation to continue.

Correct? Yes

Switch to auto mode and contiue normal crane operation Correct?

No Adjust the switch and the target.

Yes Measure the voltage at terminal 25 (+24V) and terminal 27 (GND) in the bus extension. See page 29.3

NEXT PAGE

29.27

LENGTH READING PROBLEM C. Outer Mid And Fly Section Are Not Retracted (E83) Cont. PREVIOUS PAGE

Correct?

No

Yes Measure OM retract switch power supply at LG 321 (CM) terminal X1/11 (+24V) and X1/7 (GND) See page 29.4

Correct?

Defective bus extension. Check connectors, fuses and bus extension power supply.

No

Yes Measure OM retract switch signal at CM junction box terminal 10 (+24V) and 9 (GND) See page 29.5

Correct?

Faulty wiring between bus extention and LG 321. Check wiring.

No

Yes Measure signal at LG 321(CM) terminal X1/8 (+24V) and X1/7 (GND). See page 29.4

NEXT PAGE

29.28

Faulty wiring between bus extention and LG 321. Check wiring.

LENGTH READING PROBLEM C. Outer Mid And Fly Section Are Not Retracted (E83) Cont. PREVIOUS PAGE

Correct?

No

Yes Measure signal at bus extension terminal X1/35 (+24V) and X1/27 (GND) See page 29.3

Correct?

Defective wiring between CM junction box and length transducer LG 321(CM). Check wiring.

No

Yes Digital input defective on bus extension. Check LED’s on bus extension. Contact Technical Support for replacement procedure.

END

29.29

Faulty wiring between bus extention and LG 321(CM). Check wiring.

LENGTH READING PROBLEM D. Error In Bus Extension (E61) START E61 Error in the bus extension

Check crane power, battery voltage.

Correct?

No

Yes Measure the power supply at the bus extension terminal X1/26 (+24V) and 28 (GND). See page 29.3

Correct?

Refer to the crane service documentation to correct the power failure.

No

Yes Faulty crane electric wiring. Check wiring.

Check bus extention fuse FX

NEXT PAGE

29.30

LENGTH READING PROBLEM D. Error In Bus Extension (E61) Cont. PREVIOUS PAGE

Correct?

No

Yes Check the bus extension cable wiring and connections between bus extension and central unit.

Correct?

Switch power off. Replace the fuse. Switch power on and check again.

No

Yes If damage is visible replace the cable, otherwise rewire and tighten the connections. CAUTION: Twisted pairs must remain twisted.

Faulty bus extension. Contact Technical Support for replace procedure.

END

29.31

LENGTH READING PROBLEM E. No Tele Function At All In Automode START

Error: No tele-function at all in automode.

Remove load from hook. Make sure no other error or warning is preventing you from extending or retracting the boom. Switch to manual mode and attempt extending and retracting the boom in manual mode.

Correct?

No

Yes

Remove lid from bus extension. Measure crane power supply at terminal X1/26 (+24V) and X1/28 (GND). See page 29.3

Correct?

Malfunction is not related to LMI or boom control extension. Consult the crane service documentation.

No Faulty crane eletric wiring.

Yes Switch to auto mode. Start the engine. Operate the extend control. Measure the extend signal at bus extension terminal X1/29 (+24V) and X1/28 (GND). See page 29.3 NEXT PAGE

29.32

LENGTH READING PROBLEM E. No Tele Function At All In Automode Cont. PREVIOUS PAGE

Correct?

No

Yes Operate the retract control. Measure the retract signal at bus extension terminal X1/31 (+24V) and X1/28 (GND).

Correct?

No

Yes

Select boom service screen on console. Operate the extend control. The ramp value for the appropriate section should increase in steps from 0 to 255.

Correct?

Faulty pilot pressure switch in the tele extend pilot pressure circuit or crane electric harness faulty. Refer to crane documentation.

Faulty pilot pressure switch in the tele extend pilot pressure circuit or crane electric harness faulty. Refer to crane documentation.

No

Yes Select boom service screen on console. Operate the retract control. The ramp value for the appropriate section should increase in steps from 0 to 255. NEXT PAGE

29.33

Faulty digital input 1 on bus extension. Contact Technical Support for replacement procedure.

LENGTH READING PROBLEM E. No Tele Function At All In Automode Cont. PREVIOUS PAGE

Correct?

No

Yes Select manual mode. Retract all sections. Switch power off. Remove wire 2 from the analog output board terminal Faulty digital input 2 on bus A 104 X1/2 (IM). Switch power on. Operate retract and extension. Contact Technical extend control. Measure the electrical current (mA) between Support for replacement procedure. 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.

Correct?

Check the power supply to the analog output module A 104 (IM). Measure at terminal X1/1 (+24V) and X1/4 (GND).

No

Yes Faulty wiring in bus extension. Check wiring.

No

Correct? Yes

Operate retract or extend control. Measure voltage at terminal A 104 X1/2 (>0V) and X1/4

NEXT PAGE

NEXT PAGE

29.34

LENGTH READING PROBLEM E. No Tele Function At All In Automode Cont. PREVIOUS PAGE

PREVIOUS PAGE

Defective analog output board No A 104 (IM). Contact Technical Support for replacement procedures.

Correct? Yes

Refer to drawing of (K2, K6, K7 logic table) to check the two way valve operation.

Re-connect wire 2 to terminal A 104 X1/2. Operate the extend control. Measure at bus terminal X1/14 (>0V) and X1/28 (GND). Operate the retract control. Measure at bus terminal X1/15 (>0V) and X1/28 (GND).

Check fuse F5 in the bus No extension. If blown replace fuse. Check relay K5.

Correct? Yes

Faulty crane wiring or defective valve coil. Contact Technical support .

NEXT PAGE

29.35

LENGTH READING PROBLEM E. No Tele Function At All In Automode Cont. PREVIOUS PAGE

Correct?

No

Yes 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).

Correct?

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.

No

Yes Faulty crane wiring or valve coil. Refer to Crane Service Documentation.

END

29.36

Faulty wiring between bus extension and 2 way valve junction boxes on the IM and CM section. Check wiring.

ANGLE READING PROBLEM PROBLEM Angle Reading Incorrect Crane is not in “Out of Load Chart” condition. START

Check levelness of the angle sensor in cable reelwith main boom at horizontal remove cover from the cable reel.

Readjust the angle sensor to the correct position by loosening the mounting screws and moving the angle sensor.

NO correct? YES

Place the boom at 0 o. Check power supply to angle sensor on main board between X126 (+12/24V) and X1-28 (GND)

NO correct? YES

Main board defective. replace main board and reset pressure channel. Note: Consult factory before replacing main board for further troubleshooting steps.

NEXT PAGE

29.37

ANGLE READING PROBLEM PREVIOUS PAGE

Measure supply to angle sensor in cable reel at terminal between X1-1 (+12/24V) and X1-3 (GND).

NO

Faulty wiring between central unit and angle sensor. Check wiring.

correct? YES

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

NO correct?

Replace angle sensor.

YES

NEXT PAGE

29.38

ANGLE READING PROBLEM PREVIOUS PAGE

Measure signal from angle sensor in central unit. Measurement should be taken in series at X1-29 and wire #4. Boom Angle Signal : 0 Degrees 20 mA 45 Degrees 12 mA 90 Degrees 4 mA

NO

Faulty wiring between central unit and cable reel. Check wiring.

correct? YES

Measure angle signal analog input module between test point MP0 and X1-4. The measurement should be between 0.5 - 4.5V. Boom Angle Signal : 0 Degrees 0.5 Volt 45 Degrees 2.48 Volts 90 Degrees 4.5 Volts

NO

Faulty analog input module or CPU module in central unit.

correct? YES

END

29.39

LOAD READING PROBLEM PROBLEM Load reading incorrect. START Check selected operating mode(code on operating mode switch). NO

Select operating mode switch to correct position (see operating mode in load chart).

correct? YES Check boom length reading on display.

Reset length potentiometer. With fully retracted boom, turn potentiometer axle counterclockwise until it stops .

NO correct? YES Measure radius and check with the displayed radius.

Check if mechanical adjustment of angle transducer is correct. Angle transducer box should in line with boom and adjusted to actual boom angle.

NO correct? YES

Check power supply to pressure transducer (rod side). Unplug transducer cable from transducer. Measure voltage at the cable connection between A (+24V) and C (ground). Check power supply at main board between X1-20 (+12/24V) and X1-22 (ground) for piston and X1-23 (+12/24V) and X1-25 (ground) for rod side.

NO correct? YES

correct?

Fault in pressure transducer. YES

NO NEXT PAGE

Replace the main in central unit. 29.40

LOAD READING PROBLEM PREVIOUS PAGE

Measure in series piston side signal, in central unit, remove wire #2 from X1-21. Connect one lead to wire #2 and the other to X1-21. The measurement should be between 4-20mA (4 mA at 0 PSI to 20mA at 4410 PSI). Rod side, remove wire #2 from X1-24. Measurement is not within 4-20mA. NO Fault in pressure transducer cable. NO 4-20mA

correct? YES

YES

Measurement within 4-20mA, but 4mA does not equal 0 PSI. Adjust zero point on pressure transducers at console.

If transducer(s) are not adjustable, replace pressure transducer(s) and adjust zero point. Refer to page 30.5. Measure pressure transducer signals on the analog input module between test points, (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.

NO

Replace the analog input module board in central unit.

correct? YES END

29.41

BAD DATA TRANSFER BETWEEN CONSOLE & CENTRAL UNIT PROBLEM Error Code “E93 / E94” No data transfer to and from console. START

Check the H12 (TXD) LED on the main board ON/OFF. On Make sure that EPROMS are correct and plugged into EPROM MODULE is on main board.

NO correct?

Place EPROM S in correct socket.

YES Measure process voltage on the main board in the central unit between MP24 (+5V) and MP0 (GND).

NO correct?

Off

Make sure external and internal power supply is correct.

YES Turn off system power. Check the continuity of the receive (RXD) and transfer (TXD) wires. Check continuity between: X1-5 main board and X1-3 console X1-6 main board and X1-4 console

NO correct?

Check connections and replace cable from central unit to console, if necessary.

YES

NEXT PAGE 29.42

BAD DATA TRANSFER BETWEEN CONSOLE & CENTRAL UNIT

PREVIOUS PAGE Check if additional ground like between main board terminal X9 and central unit box mounting bracket is in place. Install ground link - single cable minimum of AWG14 (2.0mm2) between terminal X9/2 and central unit box mounting bracket.

NO correct? YES Ensure that cable shields are connected correctly. Refer to connections and wiring diagrams.

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

NO correct? YES Find out which component of the crane electric is spiking out (e.g. dump valve, outrigger relay). Install a diode or varistor across terminals of spiking component. Diode type such as 1N 4001 can be used (watch + and - connection for diode).

END

29.43

INTERFERENCE PROBLEM PROBLEM Interference from crane electric. Error Code “E93 / E94” intermittent. Frozen console displays.

START Check system out; - Bad Data Transfer Between Console & Central Unit. NO correct?

Replace or repair part which is defective.

YES Check if additional ground like between main board terminal X9 and central unit box mounting bracket is in place. Install ground link - single cable minimum of AWG14 (2.0mm2) between terminal X9/1 and central unit box mounting bracket.

NO correct? YES Ensure that cable shields are connected correctly. Refer to connections and wiring diagrams.

Make correct shield connection. Refer to connection and wiring diagrams

NO correct? YES Find out which component of the crane electric is spiking out (e.g. dump valve, outrigger relay). Install a diode or varistor across terminals of spiking component. Diode type such as 1N 4001 can 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 range.

Fallen below the minimum radius or above the angle given in the load chart due to raising the boom too far.

Lower boom back to a radius or angle given in the load chart.

E 02*

Beyond radius or below angle range.

The maximum radius or minimum angle given in the load chart was exceeded due to lowering the boom too far.

Raise boom back to a radius or angle given in the load chart.

E 03*

Prohibited slewing range. (no load area)

Slewing range prohibited with load.

Slew back into admissible range.

E 04*

Operating mode not available.

Operating mode switch in the console set incorrectly. Operating mode is not permissible with actual crane configuration.

Set operating mode switch correctly to the code assigned to the operating mode of the crane.

E 05*

Length range not permitted.

Boom was telescoped too far or not far enough.

Telescope boom to correct length given in the load chart.

Length sensor adjustment changed; i.e. length sensor cable slid off the cable drum.

See page 35.58

Fallen below the minimum jib angle specified in the respective load chart due to luffing out the jib too far.

Luff in the jib to a radius or angle specified in the load chart.

E 06*

Fallen below angle range with luffing jib operation.

* This error can be corrected by the operator.

29.45

ERROR CODE DISPLAY ERROR DISPLAY

ERROR

CAUSE

E 07

No acknowledgement signal from overload relay (K8).

Overload relay is stuck, defective or not being selected.

E 08

No acknowledgement signal from Anti-Two-Block switch relay (K9).

Anti-Two-Block switch relay is defective or not being selected.

E 11

Fallen below lower limiting value for the measuring channel "length".

E 12

E 13

E 14

Fallen below lower limiting value for the measuring channel "pressure piston side".

Fallen below lower limiting value for the measuring channel "pressure rod side".

Fallen below upper limit value in measuring channel "Force".

ACTION

Cable from central unit to length sensor Check cable. Replace if defective, not connected or water in the necessary. See page 35.58. connectors Length potentiometer defective.

Replace and reset length potentiometer. See page 35.58.

Electronic component in the measuring channel defective on main board.

Replace main board and reset pressure channels.

Cable from central unit to the pressure transducer defective, loose or water in the plug.

Check cable as well as plug. Replace if necessary.

Pressure transducer on piston side defective.

Replace pressure transducer and reset pressure channel.

Electronic component in the measuring channel defective on main board.

Replace main board and reset pressure channels.

Cable from central unit to the pressure transducer defective, loose or water in in the plug.

Check cable as well as plug. Replace if necessary.

Pressure transducer on rod side defective.

Replace pressure transducer and reset pressure channel.

Electronic component in the measuring channel defective on main board.

Replace main board and reset pressure channels.

Cable from central unit to force measuring point defective or water inside the plugs. Force transducer defective. Electronic component in the measuring channel defective.

29.46

Check cable as well as plugs, replace if need be. Replace force transducer. Replace main board and reset pressure channels.

ERROR CODE DISPLAY

ERROR DISPLAY E 15

E 16

ERROR Fallen below lower limiting value for the measuring channel "angle main boom".

Fallen below lower limit value for measuring channel "Luffing Jib Angle".

CAUSE

ACTION

Cable from central unit to the length/ angle sensor defective or loose or water inside plug.

Check cable. Replace if necessary. See page 35.58.

Angle sensor defective.

Replace angle sensor. and reset adjustment.

Electronic component in the measuring channel defective.

Replace main board and reset pressure channels.

Cable from central unit to angle sensor defective or disconnected or water inside the plug.

Check cable as well as plug, replace if need be.

Angle sensor defective.

Replace angle sensor.

Electronic component in the measuring channel defective.

Replace main board and reset pressure channels. .

E 18

Front Stabilizer overloaded

Exceeding capacities allowed for over the front.

Achieve a safe working area Immediately.

E 19

Error in the reference voltage.

Electronic component on the main board defective.

Replace main board and reset pressure channels.

Below limiting value for slewing angle 1. Below limiting value for slewing angle 2.

Cable from central unit to the slewing angle sensor defective or loose. Slewing angle pot. defective. wiring, (external). Electronic component in the measuring channel defective on main board.

Check wiring, replace if necessary. Replace and reset slewing angle potentiometer. Replace main board and reset pressure channels.

Upper limiting value for the measuring channel "length" exceeded.

Cable from central unit to the length/angle sensor defective or loose. Length potentiometer defective.

Check cable. Replace if necessary. See page 35.58.

+5 volt supply E 1A E 1B

E 21

Electronic component in the measuring channel defective on main board.

29.47

Replace and reset length potentiometer. See page 35.58. Replace main board and reset pressure channels.

ERROR CODE DISPLAY

ERROR DISPLAY E 22

E 23

E 24

E 25

E 26

ERROR Upper limiting value for the measuring channel "pressure piston side” exceeded.

Upper limiting value for the measuring channel "pressure rod side" exceeded.

Upper limit value in measuring channel "Force" exceeded.

Upper limiting value for the measuring channel "angle main boom" exceeded.

Upper limit value for measuring channel "Luffing Jib Angle" exceeded.

CAUSE

ACTION

Cable from central unit to the pressure transducer defective, loose or water in the plug.

Check cable as well as plug. Replace if necessary.

Pressure transducer on piston side defective.

Replace pressure transducer and reset pressure channels.

Electronic component in the measuring channel defective on main board.

Replace main board and reset pressure channels.

Cable from central unit to the pressure transducer defective, loose or water in the plug.

Check cable as well as plug. Replace if necessary.

Pressure transducer on rod side defective.

Replace pressure transducer and reset pressure channels.

Electronic component in the measuring channel defective. on main board.

Replace main board and reset pressure channels.

Cable between central unit and force measuring point defective or water inside the plug.

Check cable as well as plug, replace if need be.

Force sensor defective.

Replace force sensor.

Electronic component in the measuring channel defective.

Replace main board and reset pressure channels.

Cable from central unit to the length/angle sensor defective or loose. Angle sensor defective. mechanical adjustment. Electronic component in the measuring channel defective on main board. See Error E 16.

Check cable. Replace if necessary.

29.48

Replace angle sensor and reset Replace main board and reset pressure channels. See Error E 16.

ERROR CODE DISPLAY ERROR DISPLAY E 27

ERROR Upper limit value for the measurchannel 7 exceeded.

CAUSE Cable from central unit to the Sensor of channel 7 defective or loose. Sensor of channel 7 defective. Electronic component in the measuring channel 7 defective.

E 29

Error in the reference voltage. -5 volt supply

E 2A E 2B

E 31

E 37

Above limiting value for slewing angle 1. Above limiting value for slewing angle 2.

Error in system program

Error in program run

ACTION Check cable. Replace if necessary. Replace angle sensor and reset mechanical adjustment. Replace main board and reset pressure channels.

Supply and Reference voltages on MP10 is more than 3.3V. Electronic component on the main board defective. A/D converter defective. Cable from central unit to the slewing angle sensor defective or loose. Slewing angle pot. defective. wiring, (external). Electronic component in the measuring channel defective on main board.

Check supply voltages.

Check wiring, replace if necessary. Replace and reset slewing angle potentiometer. Replace main board and reset pressure channels.

EPROM with system program defective. Electronic component on the main board defective.

Replace EPROM with system program. Replace main board and reset pressure channels.

EPROM with system program defective. Electronic component on the main board defective.

Replace system program EPROM. Replace main board and reset pressure channels.

CPU is equipped with an incorrect version of system program. CPU is equipped with an incorrect version of system program.

Equip main board with correct version of system or Data EPROM. Equip main board with correct version of system or TLK EPROM.

Replace main board and reset pressure channels.

E 38

Incorrect system program.

E 39

Incorrect system program.

E 41

Error in the external RAM.

RAM in the CPU on the main board defective.

Replace CPU Chip No. 80C31. Replace main board and reset pressure channels.

E 42

Error in the external write/ read memory (RAM).

Internal defect in digital part of CPU.

Exchange write/read memory (CMOS-RAM). Replace main board and reset pressure channels.

29.49

ERROR CODE DISPLAY ERROR DISPLAY

ERROR

CAUSE

E 42

Error in the external write/read memory (RAM) part 1.

Internal defect in digital part of CPU.

E 43

Error in the external write/read memory (RAM) part 2.

Internal defect in digital part of CPU.

E 45

Error in internal communications. Error in A/D conversion Malfunction in the monitored write/read memory.

Defective electronic component. Defective electronic component. Internal defect in in digital part of CPU

E 46 E 47

ACTION Exchange write/read memory (CMOS-RAM). Replace main Board and reset pressure channels. Exchange write/read memory (CMOS-RAM). Replace main Board and reset pressure channels. Replace main board and reset pressure channels. Replace main board and reset pressure channels. Replace main board and reset pressure channels.

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.

E 52

Error in TLK memory.

Data EPROM on the main board defective. Eprom Module not bridge correctly. TLK EPROM on the main board defective. Eprom Module not bridge correctly.

Replace Data EPROM. Make sure BR3 on the main board is installed. Replace main board and reset pressure channels.

E 71

Incorrect acknowledgment of the

A2B relay is stuck or defective. A2B Relay on A101 Term. board.

Replace K9 relay.

A2B relay is not being selected due to a break on the terminal board, main board or ribbon cable.

Check terminal board, main board and ribbon cables as well as replace defective part, if necessary.

E 72 – E 77

Analogous to E 71 for relays K2 – K7

Analogous to E 71 for relays K2 – K7

Analogous to E 71 for relays K2 – K7

E 89

Change of the operating code during lifting a load.

The operating mode switch in the console was used during lifting a load.

Lower the load and set the operating mode switch correctly to the code assigned to the actual operating mode of the crane.

29.50

ERROR CODE DISPLAY ERROR DISPLAY E 91

ERROR No data transmission from console to central unit. (See page 35.42)

CAUSE 24V supply of console interrupted.

Check 24V at terminal Xl of console electronics.

Interruption or accidental ground in the line from console electronics to central unit.

Check the connection between console electronics and central unit. If you find an accidental ground, the transmitter module in the console electronics can be damaged. You should, therefore, replace the console electronics. Replace console electronics or main board respectively. Check the connection between console electronics and central unit. Replace console electronics or main board respectively.

Transmitter / receiver module defective. Defective data line from console electronics to central unit. Transmitter / receiver module defective.

E 92

Error in the data transmission from console to central unit. (See page 35.42)

E 93

Error in the data transmission from central unit to console. (See page 35.42)

Defective contact in the line from central unit to console. Transmitter / receiver module defective.

No data transmission from central unit to console. (See page 35.42)

Interruption or accidental ground in the data line from central unit to console.

E 94

ACTION

Check the line to the console. Replace console electronics or main board respectively.

5V supply for the computer in the central unit is missing. 5V supply voltage too low. Transmitter / receiver module defective.

Check the line to the console (in case of accidental ground also replace console electronics). Check the connection to the power supply. Replace power supply module. Replace console electronics or main board respectively.

Data EPROM defective.

Check data EPROM.

Computer module defective.

Replace main board.

Electromagnetic interferences (e.g. when switching contactors or valves).

Eliminate interference source by inverse diodes or varistors.

29.51

ERROR CODE DISPLAY

ERROR DISPLAY E 95

ERROR Error in the crane data EPROM

CAUSE Data EPROM defective. Position of jumper for the selection of the type of EPROM is wrong. Electronic component on main board defective.

ACTION Replace data EPROM. Check the jumper position. Replace main board and reset pressure channels.

E 96

Error in the internal RAM of the CPU of the console.

CPU or main board of the console defective.

Replace console main board.

E 97

Error in the external RAM of the CPU of the console.

External RAM of the console defective. Electronic component on the main board defective.

Replace console main board.

E 98

Wrong jumper position in the console.

Replace console main board.

The jumper position BR9/BR10 in the Check the jumper position. console does not correspond to the actual type of central unit. Electronic component on the main Replace console main board. board defective.

29.52

Drawing 1 : Slip Ring Unit

X2 : RED

X1 : BROWN

4

3

1

2

Drawing 2 : Boom Nose Junction Box

29.53

Drawing 3 : Main Board A

B

C

D

E

F

G

H

I

J

K

L

M

-

1

G1

MP42

+

KGND

MP 26

KGND

GND

MP 9

C

+6V X15

GND

1

MP 4

+5V

MP 8

AGND

KGND

+BATT

C

MP24

MP23

VBAT

2

+UB1

PWM DC

2

+9V

GND

3

4

5 +UB1 +UB

DI 6

KGND

X12

6

MP40 V10 H11 V11MP41

H1 H2 H3 H4 H5 H6

DI 1

MP21

5

PFAIL+UB1

DI 1- DI 6 =>

X17

4

power o.k.

X14

3

6

J11

X11

7

7

SP5

X13

TXD

H12

AGND

H10

K8

MP29

10 LEVER LOCKOUT K10

A2B

+UB

2 1

MAIN ON/OFF

KGND

J10 3 4

9

LMI KGND

10

LOAD

+5V/RS232

AGND

9

K9

F 1

H9 A2B

69 68

67 66 65 64

63 62

61 60 59 58

57 56

55 54

12

KGND

3 1

77 76

KGND

KGND

+

J4 J3 J2 J1

X1

12

-

11

KGND

F 2

11

X1

13

8

X16

8

KGND MP1 +UBS

36 35 34

A

33

32 31

B

30 29 28 27 26

C

D

25 24 23

E

22 21 20

F

19 18 17

G

16 15 14

13 12 11

H

LOCATIONS : MP 1 - zone M13 = GND. MP 25 - zone M13 = +UBS MP 8 - zone M2 = +9V MP 9 - zone M2 = +6V MP 4 - zone M1 = +5V MP 26 - zone M1 = GND. MP 23 - zone A2 = VBATT MP 24 - zone D2 = +BATT MP 40 - zone M4 = +UB

MP 41 - zone M4 = POWER FAIL MP 42 - zone G1 = +5V MP 21 - zone E5 = +5V MP 29 - zone D10 = +5V H1-H6 - zone I5 = DI 1-6

29.54

I

10 9

J

8

7

6

5

K

4

3

2

L

1

MP 25

M

13

Drawing 4 : CPU and Daten EPROM boards

MP7 J1 J13

J12

J2

D3

D1 MP4

D2

X1

D14

X2 D13

P1

SYSTEM D10 J8

D6 J9 MP3 J6 D17

J10

D15

D7

D21

D9 D12

J15

J11

J14

D18

J7

D11 D19

D20

X3

BR6

MP6MP5

EJECT BR5

MP2

A102 CPU

J1

J2

DATA D1 J5 J3

TLK D3 J6

BR 4 3 2 1

X1

A103 DATEN

29.55

Drawing 5 : Analog Input Module

+

P7

MP12

1 2

40

AGND

AGND -

P6

MP13

J2

20

P5

16 P4 P3

MP9

J1

MP11

X16

P2

MP10

P1

1 1 2

X1

MP17

BR1

MP0

-

+

MP8

+

+

VREFA

P8

+

MP7 - MP1->

X17

1 2

+

MP16

7

16

6 5 4 3

MP14

2 1

40 1 2 AGND

BOARD P/N 9-333-103290 X1:1-7 X1:8 X1:9 X1:10 X1:11 X1:12-15 X1:16 X1:17 X1:18 X1:19 X1:20

= ADC INPUT 0.5V/4mA…2.5V/20mA offset adjust with P1-P7 = TEMP (0.5V + 10mV/oC) = VREFA = 5.000V reference = AGND (reference GND) = VREF+ = 5.0V power ADC = CH01-04, DIN 1-4 / 10 = CH05, +UBS / 10 = CH06, HESIN(A2B) *4 = CH07, +9V *4 = CH08, VREFA / 2 = 2.500V = UKLEMM, app. VREFA, limits ADC input to 5.0V

29.56

AGND

Drawing 6 :Console Board

MP 2 +7V

MP 5 +5V MP 0 GND

MP 3 -24V MP 4 -24V

MP 6

MP 7

MP 1 +UB

J2

J5

J1

J4 J3

X1 X5 1 2 3 4

1 2 3 4 5 6 7 8

29.57

Drawing 7 : Length / Angle Transducer

PAT PAT

XA2

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8 S

X2

1 X3 1 2 3 3 5 L

XB2

X2

1 X4 1 2 3 3 5 A

X2 X1

7 (9) 8 (10)

9333103309

ADJUST LENGTH POTENIOMETER WITH BOOM FULLY RETRACTED, TURN THE CENTER SCREW COUNTERCLOCKWISE TO A SOFT STOP.

29.58

Drawing 8 : Suppressor Diode

COMPONENT CAUSING INTERFERENCE

_

+ SUPPRESSOR DIODE

29.59

CABLE ASSY. TO PRESS. TRANSDUCER ( PISTON )

CABLE TO AREA DEFINITION

CABLE TO CRANE INTERFACE

CABLE ASSY. TO CONSOLE

CABLE ASSY. TO BOOM

IN

FUSE ( 10A)

OUT

L/O OVERRIDE

FUSE ( 4A )

NORMAL OPERATION

3 - PAIR CABLE BUS EXTENSION

Drawing 9 : Central Unit Box

CABLE ASSY. TO PRESS. TRANSDUCER ( ROD )

CAUTION: Make sure that + and - diode connections are made as shown to ensure proper polarity.

P.A.T. – L.M.I MANUAL SECTION 30

DS 350 Graphic Modular (BCS) Electrical Diagrams

9 1 2 3 4 5 6 7 10

2

4 1 2 3

2

1

4

1 2 3

4

7

5

6

2

2

2

1

1

1

A B C A B C

A B CD E F TO MAIN BOOM CONNECTOR

NC crane 12 o area definition switch in ele. swivel CRANE SYSTEM AREA DEF. SWITCH ELEC. SWIVEL

GN/YL

FUSE (10 amp)

FUSE (10 amp)

+UBS

LMI BYPASS

FUSE (4 amp)

59 60

61 62

4

3

2

1

10 AMP FUSE LMI BYPASS KEY SWITCH

7 PIN PLUG

+UBE SIG+ SIGGND

744 HOUSE LOCK PIN SW.

74 (LMI L/O ALARM

+UB GND TXD RXD A2B A2B LOAD D1 1 2 3 4

1 2 3 4 5 6 7

A B C A B C V V V

V V V V

1 2 3 4

V V V

NO C

1 2 3 4

A BC D V V V V

1 2 3 4 V V V

73A (LMI UNLOCK SOL.)

A BCD E A BCD E

V V V

X7 1 2 3 4

X8 +UBE 1 GND 2

V V VV V V

1 2 3 4 5 6 7 8 X1

A

5 PIN DEUTSCH 1 2 3 4 PLUG

V V VV V

71K (+UB) 51AJ (GND)

10 8 9

1 2 3 4 5 6 7

V VVV V

V V V V V V V V

30.1

V V

4 5

NOT USED

4 AMP FUSE

CONSOLE (1318) 1 2 3

FUSE (4 amp)

NOT USED

NOT USED

NOT USED

A2B GROUND

A2B SIGNAL

FORCE

ANGLE

GND

LENGTH

+UB

ROD GND

+UB

GND

PISTON

1 2 3

2

1

+UB

DI4

DI2+24V=O/F - RUB.

DI1

GND

+UBS 1

26 27 28 29 30 31 32 33 34 35 36 53 54

OUT

8

23 24 25

IN

5 6

20 21 22

OUT

3 4

14 15 16 17 19

IN

1 2

51 52 3 4 5 6 7 8 9 10

GN/YL

1 2 11 12 13 18

GND +UB GND RXD TXD A2B BYPASS A2B BYPASS LMI BYPASS +UB

+UB

DI 3 (+24V HOUSE PIN ENGAGED)

K10 EXT. HOR. *1

K10 LMI UNLOCK S.

+UB GND K10 (COM) +24V X1

(See Page 36.2)

NOTES: pres. trans. (piston)

pres. trans. (rod)

LIGHTBAR

DS350 GRAPHIC MODULAR B.C.S. CENTRAL UNIT

1

OUTER SHIELD GROUNDED AT STRAIN RELIEF CONNECTOR.

2

INNER SHIELD CUT AND INSULATED

3

INSULATE OUTER SHIELD AND CONNECT TO CHASIS GND. *1) OPTIONAL FOR EXTERNAL HORN (EEC UNITS ONLY)

7 PIN PLUG

A

RT865BXL (BCS) DS350 Graphic Modular

1 2 3 4 5 6 7

Cable Reel to Fly Section V V VV V V A B CD E F A B CD E F V V VV V V

1 2 3 4 5 6 7

1

3

5

30.2

LENGTH ANGLE TRANSDUCER TRANSDUCER

7

8

RED

X2

12345678 BRN

X1 X4

5

7

+ 24V SIG. GND

X3

3

+ 24V SIG. GND

1

5 6

LWG309 (TO NOSE)

123 4

CORE

SHEILD

SHEILD

CORE

3=RED 2=BRN 1=BLK

3 2 1

1234 12 VV A B A B

V V

4.7K

4.7K 1

2

3

TELE RETRACT PROP. SOLENOID

TELE EXTEND PROP. SOLENOID

TELE ROD DRAIN SOLENOID

TELE PROP. ANALOG GND.

9

LMI - CRANE INTERFACE 23 - PIN PLUG

15 16 17 18

13 10 11 12 14 3

S/S HARNESS 23 - SOCKET RECEPT

238A 1083 255A 257A

323A

4 5 6 7 8 9

1 2

6

TELE OUT OF SEQUENCE

A B C D E F G H J K L M N O P Q R S T U V W X 5

IM TELE

A B C D E F G H J K L M N O P Q R S T U V W X 4

CM TELE

OM / FLY TELE

387A 388 239B 242B 243B 244B

71H 51AK

2

HIGH = AUTO MODE / NONE = MANUAL MODE

TELE RETRACT PRESSURE SW.

TELE EXTEND PRESSURE SW.

GND

30.3 + 24V

1 11

16

1

V V V V V V V V V V VV VV VVV V V

8

V V V V V VVVVVVV V V

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

13 17

4 3 2 1

18 8

13 14 7 10 12 14

RT865BXL (BCS) BUS EXTENSION WIRING DIAGRAM

4

1 4

A B C DE FG H J

GND

64 63 27

1 2

A104 X1

PV EXTENSION

K L

3 5 9 10

2

B

(See Page 36.4)

6 7

1 1

2 2

M N P

C

DI 4 ( +24V = OM / FLY RET )

DI 5 ( +24V = CM RET & % RESET )

DI 6 ( +24V = IM RET )

DI 7 ( +24V = IM % RESET )

ANALOG INPUT 2 (CM LEN.)

ANALOG INPUT 1 (IM LEN.)

K7 NO ( +24V TO OM 2-WAY SOLS. )

K7 COM ( +24V )

K6 NC

K6 NO ( +24V TO CM 2-WAY SOLS. )

K6 COM ( + 24V )

K5 NC ( PROP RET )

K5 NO ( PROP EXT )

K5 COM

K4 NC ( TELE OUT OF SEQUENCE )

K4 NO

K4 COM

K2 COM ( +24V ) K2 NO ( +24V TO IM 2-WAY SOLS. ) K3 COM ( +24V ) K3 NO ( +24V TELE ROD DRAIN SOL. ) K3 NC

DI 7 GND

DI 6 GND

DI 5 GND

DI 4 GND

DI 3 GND

DI 2 GND

DI 1 GND

DI 3 ( +24V = AUTO MODE )

DI 2 ( +24V = TELE RET. PRESS. SW. )

DI 1 ( +24V = TELE EXT. PRESS. SW. )

GND

+ 24V

+24V

K7 NC

A 101

41 39 37 35

12

13 3 5 8 9 11

7 15

= WIRES ARE GROUPED TOGETHER

1

2

14 - SOCKET PLUG

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

1

19 - SOCKET PLUG

2

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

(See Page 36.4)

NOTES:

1 OUTER SHIELD GROUNDED AT STRAIN RELIEF CONNECTOR.

2 INNER SHIELD CUT AND INSULATED

B

C

14 - SOCKET PLUG

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

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

V V V V V VVVVVVV V V

V V V V V VVVVVVV V V

RT865BXL (BCS)

19 - SOCKET PLUG

A B C DE FG H J A B C DE FG H J

A B C DE FG H J A B C DE FG H J

DS350 Graphic Modular

5

8

13 14

11

13 14

X2

135

18 19

4 5 6 7

8 9

10

1 2 3

86

4

11 12

9 14 12

13 14

5 10 11

7

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

135

7 8 11 12 13 14 15 16 17

13

18 19

AGND SIG. -5V

3

BRN RED ORG YEL GRN BLU VIO GRA WHT BLK SHD

D

BLK WHT/BLK GRA

VIO

WHT BRN GRN CRE BLK RED PNK YEL BLU

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

GRA

VIO

1 2 3 4 5 6 7 8 9 10 11 12 WHT BRN GRN CRE BLK RED PNK YEL BLU

10 11

WHT/ BLK

1 2 3 4 5 6 7 8 9

BRN RED ORG YEL GRN BLU VIO GRA WHT

LENGTH TRANS.

WHT/ BLK

BRN RED ORG YEL GRN BLU VIO GRA WHT BLK

BLK WHT/BLK

10 11

LENGTH LG321 (TO CM)

1 2 3 4 5 6 7 8 9

LENGTH LG321 (TO IM)

LENGTH TRANS.

BRN RED ORG YEL GRN BLU VIO GRA WHT

30.4

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

7 8 11 12 13 14 15 16 17

1 2

X2

9 10

11 12

K L M N P R S T U V K L M N P R S T U V

X1

4

10

X1

6 7 12

8 9

X3

1 2 3

4 5 6 7

AGND SIG. -5V

F

4 2 3 1

3

K L M N P K L M N P

X3

1 2

SHD

Cable Reels to IM & CM Section

E

VIO YEL PNK RED BLK GRA BLU CRE SHD

E

WHT BRN GRN

JUNCTION BOX (CM) 1 RED 1 RED 2 BLK 1 3 BLK 4 5 GRN 1 GRN 6 WHT 1 7 WHT 8 BLU 9 BLK 10 BRN 11 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 (-)

TIE WRAP USED TO IDENTIFY CABLE

PROXY SW 3 (TOP) (IM % RESET) BRN 1 (+) BLK 4 NO WHT 2 NC BLU 3 (-) IS

PROXY SW 1 (OM/FLY RETR) BRN

1 (+)

BLK WHT IS

BLU

4 NO

O

O

2 NC

O

O

3

(-)

3

IS

30.5

RED YEL BLU VIO GRA BLK CRE PNK

D

JUNCTION BOX (IM) 1 2 3 4 SHD WHT BRN GRN

5 6 7

F

RED BLK GRN WHT

RED = IM CYL (+) BLK = IM PILOT (+) GRN = IM CYL (-) WHT = IM PILOT (-) PROXY SW 4 (CM RETR)

BLU BLK BRN

BRN BLK WHT

WHT IS

BLU IS

1 (+) 4 NO

O

O

2 NC

O

O

3

(-)

4 2 1

6 5 4 3 2 1

O

O

O

O

PROXY SW 2 (BOTTOM) (IM RETR. 2-POSITIONS) BRN 1 (+) BLK O 4 NO WHT O 2 NC BLU 3 (-) IS

O

BLU WHT

BLU BLK

BLK BRN

BRN

WHT JUNCTION BOX BOOM BASE

RT865BXL (BCS) DS350 Graphic Modular Wiring to Proximity Switches

O

P.A.T. – L.M.I MANUAL SECTION 31

DS 350 Graphic Modular (BCS) Service Bulletins & Miscellaneous Information

ERROR-E80-E85-E2D E80 - Slewing pot out of range. E85 - This code has only been seen on the Modular Boom Control System. The error pertains to the internal calculation of radius ( not the displayed radius ). The displayed radius is calculated from the boom length and signals received from the upper cable reel to the C.U. in the cab. The other two length signals as well as all proximity switches inputs are received by the bus extension located on the left turntable upright behind the cab. The bus extension has it’s own processor which performs calculations and transmits data to the processor in the C.U. 1. Negative load display due to the velocity fuse in the piston side transducer port of the lift cylinder. A. The system sees a - 3,000 lb. load display and thinks that the boom must be deflecting backward. This confuses the processor when performing it’s internal calculation of radius. 2. Water in cannon connections located under the base boom. There are two fourteen conductor and one seven conductor cables running to the cable reels on the left side of the base boom section. A. Found water in these connectors which caused length and percentage problems. B. Found twisted wires, pinched wires and in general poor assembly from PAT. Some symptoms of water add poor assembly are that the bus extension may receive low voltage such as +2 volt input for a proximity switch .when the boom is extended. At this time you should see 0 volts and of course when any of the proximity switches see their target you should see 24 volt to the input. When the bus extension processor sees any voltage from these inputs when the sections are extended, the processor gets confused and shows E85. Also the lower two reels length signals may check okay at the reel, but through these connectors the signal changes until the signal reaches the bus extension. 3. On other cause that was found for the E85 is a bad eprom module. There is a small serial eprom ( located in the C.U. ) which contains some calibration factors which are used for calibration purposes. Sometimes this serial eprom loses it’s memory and causes the E85. In this case you must replace the eprom module. The Grove part number is 9-333-103289. E2D - This is an error in the processor board located inside the bus extension box located behind the cab (top left board ) At this time there is no troubleshooting procedure for this board. The board must be replaced to correct this error. The Grove part number is 9-333-103718.

P.A.T. – L.M.I MANUAL 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

iFLEX 5

32-1

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.

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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.

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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 !

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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

Angle Sensor

CAN-Bus Converter

iFLEX5 CU

Pressure Transducer

Cable Reel

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):

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X14 (A2B)

X20 (length)

X21 (angle)

LED

X1 (CAN)

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:

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The angle sensor returns a voltage between 1.875V at 90 degrees and 3.125V at 0 degrees: Angle Sensor Signal on Pin 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.

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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

Length Sensor

CAN-Bus Converter

iFLEX5 CU

The signal runs Pressure Transducer from the length sensor Cable Reel 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 preloading on the reel. Opening the cable reel and locate the length sensor (right) and the CAN-Bus converter board (left):

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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.

Potentiometer

Gear wheel with slip clutch

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.

X14 (A2B)

X20 (length) X21

LED

X1 (CAN)

CAN-Bus electronics in cable reel.

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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 0 0.00 1 0.46 2 0.93 3 1.40 4 1.87 5 2.34 6 2.81 7 3.28 8 3.75 9 4.22 10 4.68

Voltage GND to X20-3 0.16 0.62 1.09 1.56 2.03 2.50 2.97 3.44 3.91 4.38 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.

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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:

(2) PressureMeasuring Cells Pressure Transducer

CAN-Bus Converter

iFLEX5 CU

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.

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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

Slew Potentiomet er with (2) outputs

Current Converter

iFLEX5 CU

Slip Ring Assembly 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.

ANGLE (deg) 0 30.3 60 89.9 120.1 150.1 180 -150.1 -120.1 -90 -60.1 -30 0

SL ANG 1 (mv) 717 1174 1680 2158 2641 3144 3595 3144 2642 2160 1681 1172 718

SL ANG 2 (mv) 2161 2645 3150 3595 3141 2639 2161 1681 1180 718 1168 1680 2161

Modular Slew Pot - Voltage on Service Screen

4000

MILLIVOLTS

3500 3000 2500 2000 1500 Potentiometer 1

1000

Potentiometer 2

500 0 0

Display screen 0 for sensor inputs

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45 45

90 90

135 135

180 225 180 -135 SLEW ANGLE

iFLEX 5

270 -90

315 -45

360 0

32-12

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

mA 2 mA 3

24 20

mA

16 12 8 4 0 0

90

180

270

360

Degrees

(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

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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.

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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.

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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 E62 E63 E64 E65

Error in the CAN bus data transfer for all CAN units Error in the can bus data transfer of the pressure transducer sensor unit Error in the can bus pressure transducer sensor unit Error in the can bus data transfer of the length/angle sensor unit Error in the can bus length/angle sensor unit

Block Diagram

E65

CAN-Bus Converter

E64

E61

iFLEX5 CU

E62

Pressure Transducer

Cable Reel

E63

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 Pin 2 Pin 3 Pin 4 Pin 5

Shield + Ub Ground CAN High 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.

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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.

X14 (A2B)

X20 X21

LE

X1 (CAN)

CAN-Bus electronics in cable reel. If it is not, most likely power is missing. Verify by measurement on connector X1:

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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.

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P.A.T. – L.M.I MANUAL 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.

Press “INFO” To review software version information

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.

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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 Value displayed Value displayed [mV] +/- 10mV

Pressure Transducers 300 bar, type 314 500 1500 2500 3500 4500 Angle Sensor 500 1500 2500 3500 4500 Length Sensor 500 1500 2500 3500 4500

PSI 0 1088 2176 3263 4351

Bar 0 75 150 225 300

degrees 90 67.5 45 22.5 0

boom horizontal

feet 0

fully retracted

boom vertical

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

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Troubleshooting A Sensor Problem Using The Display

SLEW POT SIGNALS: Sig 1 (mA) Reference Angle ±0.03mA 0° 4.00 45° 8.00 90° 12.00 135° 16.00 180° 20.00 -135° 16.00 -90° 12.00 -45° 8.00

Sig 2 (mA) ±0.03mA 12.00 16.00 20.00 16.00 12.00 8.00 4.00 8.00

If the displayed angle is incorrect, please go to section Slewing Sensing

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DRAWINGS COMPONENTS OF THE LMI SYSTEM PAT IFLEX5

PAT

POWER LOCKOUT OTHER 1 Central-Micro-Processor Unit 2 Operating Console 3 Pressure Transducers 4 Length/Angle Sensor 5 Anti Two-Block Switch(es)

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BLOCK DIAGRAM

70 pin Connector RS 485 Serial Interface

Crane Power

Graphic Console

iflex5 Central Unit Lockout

CANBUS

Current 4..20mA

CAN-connector

Slew Sensor

CAN-connector CAN-connector

Dual Pressure

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Length/Angle Sensor

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A2B

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

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Cable Reel (length/angle sensor) Wiring Diagram

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Boom Extension Anti-two Block Wiring Diagram

MAIN CENTRAL UNIT CONNECTOR This is a 70 pass connector.

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ELECTRICAL SYSTEM DIAGRAM BOOM CONTROL SYSTEM

1-1

Central Unit to Crane Interface Wiring Diagram

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Console and Sensor Wiring Diagram

TO LWG520/0002 REFER TO CABLE REEL (LWG520/0002) WIRING DIAGRAM

BOOM BASE CONNECTION TO LG152/0056 REFER TO CABLE REEL (LG152/0056) WIRING DIAGRAM

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Cable Reel (LG152/0056) Wiring Diagram TO LWG520/0002 REFER TO CABLE REEL LWG520/0002 WIRING DIAGRAM

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TO BOOM BASE CONNECTOR REFER TO CONSOLE AND SENSOR WIRING DIAGRAM

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Cable Reel (LWG520/0002) Wiring Diagram

LUFFING JIB CONNECTION REFER TO LUFFING EXTENSION WIRING DIAGRAM

TO PRESSURE TRANSDUCER BLOCK REFER TO CONSOLE AND SENSOR WIRING DIAGRAM

TO LG152/0056 REFER TO CABLE REEL (LG152/0056) WIRING DIAGRAM

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Luffer Extension Wiring Diagram

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

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SPARE PART LISTINGS CENTRAL UNIT, IFLEX5 PART NO. 9333103866 NO. PART NO. 1 9333103890 2 9333103891 3 9333102541 4* 9333103908 5* 9333101978 6* 9333103058 7 9333101591 * ITEM NOT SHOWN

QTY DESCRIPTION 1 CENTRAL UNIT ACCY, GROUNDING KIT 1 BATTERY, LITHIUM 3V 1 KEY SWITCH 1 CENTRAL UNIT COVER iFLEX 1 SCREW SET 1 SPARE KEY 42” GASKET

7 2

1

3

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Spare Part Listings

GRAPHIC CONSOLE ASSY, VERTICAL PART NO. 9333103868 NO. 1 2 3

PART NO. 9333101691 9333103895 9333103892

1 1 1

4 5 6 7 8 9 10

9333103893 9333103894 9333103899 9333103900 9333103901 9333103902 9333103903

1 1 1 1 1 1 1

QTY DESCRIPTION SPARE KEY, GRAPHIC CONSOLE KEYSWITCH, WITH CABLE FRONTFACE WITH DISPLAY, COMPUTER BOARDS, AND LED BOARDS CONNECTION BOARD WITH BUZZER FUSE, 2 AMP AUTO CABLE, 4 POL COMPUTER BRD X1 TO CONN BRD X6,X11 CABLE, 10 POL COMPUTER BRD X2 TO CONN BRD X7 CABLE, 6 POL COMPUTER BRD X10 TO CONN BRD X23 5 LED BOARD, LMI/A2B ALARM LITE 8 LED BOARD, LED’S BY SELECTION BUTTONS

4 9 3 3

5

6 7

1,2

8

10

2

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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

3

2

4 5

8

1 7

9

6

Also see detail on next page.

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Spare Part Listings

8 4 3

5

6

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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

2

4

6

3

9 7 5

10 1

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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

1

9 6

8

13 7 5

3

2

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PRESSURE TRANSDUCER BLOCK, DAV314/0014 PART NO. 9333103870

CABLE ASSEMBLY 11M, PART NO. 9333103872

WIRING HARNESS STANDARD, PART NO. 9333103869

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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

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P.A.T. – L.M.I MANUAL 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.

10

11

Now press the CTRL key. . 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.

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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.

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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 (pistonside, 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 -.

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Service Screen For Sensor Calibration

LENGTH SENSOR CALIBRATION PROCEDURE NOTE: The length sensor can be calibrated for its zero point and its full range. This means, for the correct voltage for retracted boom and for the extended boom. With retracted boom, the potentiometer of the length sensor has to be at its 0 position, which is all the way counter-clockwise. For extended boom, the adjustment is done by software as described in 6 section Length Sensor Adjustment Procedure. The length should be calibrated to be about 0.1 feet (or 0.05m for metric) accurate for retracted and extended lengths. Perform the following steps: Fully retract the main boom and check if indicated length is within 0.1’ of actual retracted boom length. If it is not, adjust length potentiometer as described in 6.3.1. Afterwards always adjust retracted length by software as described in section Length Sensor Adjustment Procedure. Cable Reel LWG508 Adjustment Procedure

Now perform Length Sensor Adjustment Procedure as detailed in section Length Sensor Adjustment Procedure.

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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).

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Service Screen For Sensor Calibration

Cable Reel Length Cable Replacement Procedure Replace length cable using the following procedure: Refer to system electrical wiring diagram and cable reel - parts list 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

13. 14.

15. 16.

Cut old cable at cable drum. Disconnect damaged length cable from junction box at the boom nose. Open cable reel cover and disconnect bus connector. Remove cable reel from mounting brackets. Remove damaged length cable, which is mounted to the slip rings in the cable reel, from slip ring terminal. 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. 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. Reconnect the length cable to the slip ring. Remount cable reel to the boom. Turn reeling drum clockwise to spool the new cable neatly onto the drum. Set pre-load on cable reel by turning the drum counter-clockwise 5 to 8 turns. 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. Connect the length cable into the boom tip junction box. 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. Connect bus connector Follow Length Sensor Adjustment Procedure.

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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.

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Service Screen For Sensor Calibration

Boom up to the next correction angle, 45 degrees (range is 40°- 50°). When the boom angle is within the calibration range, the screen will add the ‘CHANGE’, ‘SET” and ‘OK’ text as shown on the left. Measure the boom angle with the inclinometer and when the boom is positioned in the calibration range, compare the measured angle to the displayed angle. If the indicated angle is within +/- 0.1 degrees of the measured angle, confirm with “OK”. Otherwise, select “SET” to adjust the angle. Once you push ‘SET’ , the screen is going to change to the angle adjustment screen. Use the ‘+’ and ‘-”buttons to adjust the indicated angle to match the measured angle. When the display shows the correct angle, press ‘OK’.

Repeat the above procedure to verify/set the angle at 60° (range 55°- 65°). and 70° (range 65°- 75°). boom angles. Press ESC to leave service screen.

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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.

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P.A.T. – L.M.I MANUAL SECTION 35

Boom Control

IFLEX5 BOOM CONTROL SYSTEM (BCS) RT9000E / RT800E BAS ICS Terminology:

BCS IM CM OM/Fly DI DO PWM 0 1

= boom control system = innermid boom section = center-mid boom section = outer-mid and fly boom section = digital input, refer to table 3 for definitions = digital output, refer to table 4 for definitions = pulse width modulation = off with regard to digital inputs and outputs = 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

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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

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TELE SEQUENCE: RT9000E: Mode “A” - not available RT800E: Mode “A” Mode “B” table1 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 (not selectable, realized by operating mode selection) table 2 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

Note: Retract sequence is opposite of extend sequence. IFLEX5 BCS DIGITAL INPUTS: table 1

Digital Input 6 7 8 9 10 11 16 17 18 19

Description CM (Center-Mid) Retracted (boom proximity switch) IM (Inner-Mid) Retracted (boom proximity switch) Luffing Extension Raise (cab switch) Luffing Extension Lower (cab switch) Luffing Extension Raise (remote switch on ext.) Luffing Extension Lower (remote switch on ext.) “A” Mode (cab switch) Auto Mode (cab switch) Boom Retract (pressure switch) Boom Extend (pressure switch)

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*C.U. X2 Terminal 54 55 56 57 58 59 64 65 66 67

**MP R89 R90 R91 R92 R93 R94 R100 R101 R102 R103

35-3

RT9000E / RT800E IFLEX5 BCS DIGITAL OUTPUTS: table 2 Digital Output 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Description PWM 1 CM Proportional Solenoid +UB CAN bus PWM 2 IM Proportional Solenoid +UB to Slew Potentiometer Electronics PWM 3 Luffing Extension Proportional Solenoid CM Extend Relay K1 Coil in Junction Box PWM 4 Luffing Extension Proportional Solenoid IM Extend Relay K2 Coil in Junction Box Luffing Extension Raise Solenoid External LMI Alarm, Option on Boom Luffing Extension Lower Solenoid Rear Axle Oscillate Signal Tele Rod Drain Solenoid Boom Out of Sequence Lamp Tele Two Stage Relief Solenoid

C.U. X2 Terminal 2 3 4 5 6 7 8 9 14 15 16 17 18 19 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

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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 DO 1

Baugruppencodierung Erweiterung: FF = 11111111 Hubendschalter UNTB/OFFEN/OK/KURZ: 0000 DI 9 X:Exit

Blank:Redraw

S:Slow

DO 16 DI 1

F:Fast

DI 8

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

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C.U. 70-pass connector pins (X2)

Resistor bank to measure digital input (DI) state. Note: must measure on bottom leg of the resistor.

IFLEX5 BCS ANALOG IN PUTS AND PWM OUTPUTS:

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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 1 2 3 5

Description Slew Angle 1 Slew Angle 2 Wind Speed Luffing Extension Offset Angle

PWM 1 2 3 4

Description Center-Mid Tele Output Inner-Mid Tele Output Luffing Extension Raise Output Luffing Extension Raise Output

Note: DO 1 = PWM 1 DO 3 = PWM 2 DO 5 = PWM 3 DO 7 = PWM 4

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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”.

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)

Status No. 1 - 11 29 31 - 41 59 61 - 67 79 81 - 85 99 100 101 102 - 108 110 112 127 200 - 202 210 - 212

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Description Mode B extend Error Mode B extend Mode B retract Error Mode B retract Mode A extend Error Mode A extend Mode A retract Error Mode A retract Manual Mode A neutral or extend Manual Mode B neutral or extend Manual Mode retract at overload, A2B, error condition Mode A, Out of Sequence Mode B, Out of Sequence Mode A or B, neutral position Luffing jib raise Luffing jib lower

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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

boom section percentage 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 (DO13) 0 0

IM retract sw. (DI 7) 1

CM retract sw. (DI 6) 1

Retract pressure sw. (DI 18) 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)

1

1

1

Extend pressure sw. (DI 19)

OM/Fly Percentage

1

>4%

0

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IM rertract sw. (DI 7)

CM retract sw. (DI 6)

1

1

35-9

P.A.T. – L.M.I MANUAL 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.

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P.A.T. – L.M.I MANUAL 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 Fallen below radius E01

Possible Cause

• 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 Radius range • Gone past the maximum exceeded or fallen radius or fallen below the below angle range minimum angle specified in the respective load chart due to luffing down the boom too far Non-permitted slewing • The slewing zone with zone (no load area) load is not permitted Operating mode not • An incorrect operating acknowledged or non mode has been selected permitted slewing zone range or angle range exceeded

E02

E03 E04

Elimination • Luff down the boom to a radius or angle specified in the load chart.

• Luff up the boom to a radius or angle specified in the load chart.

• Slew to permitted area • Set the correct operating mode for the operating configuration in question. Refer to Operator’s Handbook.

• The boom is in a nonpermitted slewing zone

E05

Prohibited length range

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• Slew the boom to a permitted area. Refer to Section 8. • Boom has been extended • Extend/retract boom to the correct length 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 • Length sensor adjustment • Retract boom. Check the prestress of the cable reel has changed, e.g. the (cable must be taut). Open cable slid off the length the length sensor and sensor reel. carefully turn the length sensor pot counterclockwise until the detent by means of a screw driver • Replace the complete clutch • Clutch between length including drive wheel and sensor pot and drive is adjust length sensor pot as defective described above

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Error Code E11

E12

E13

E14

E15

E16

E17

Error

Possible Cause

Elimination

Fallen below lower limit value for measuring channel "length main boom" Fallen below the lower limit value in the measuring channel "pressure piston side"

• Length potentiometer is defective

• Replace length potentiometer, see section Length Sensing

• Pressure transducer is defective.

• Replace pressure transducer, see section Pressure Sensing

Fallen below lower limit value in the measuring channel "pressure rod side" Fallen below lower limit value in measuring channel "force"

• refer to E12

• refer to E12

• Force transducer defective • Electronic component in the measuring channel is defective. • Angle potentiometer defective

• Replace force transducer • Replace sensor unit

• Electronic component in the measuring channel defective. • Angle potentiometer defective

• Replace electronic board, see section Angle Sensing • Refer to E-15

• Electronic component in the measuring channel defective. • Length potentiometer defective

• Refer to E-15

• Replace electronic board, see section Length Sensing • • Check cable as well as plugs, replace, if need be.

Fallen below lower limit value in measuring channel "angle main boom"

Fallen below lower limit value in measuring channel "angle 2"

Fallen below lower limit value "length telescope I (+II)"

E18

Front outrigger overloaded

• Electronic component in the measuring channel defective • 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.

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iFLEX 5

• Replace angle sensor, see section Angle Sensing

• Replace length sensor, see section Length Sensing

37-2

Error Code

E1B

E21

E22

E23

E24

E25

E26

E27

E2A

E2B

E31

Americas Training Grove

Error

Fallen below lower limit value in measuring channel "slewing angle 2" Upper limit value in measuring channel “main boom length” has been exceeded. Upper limit value in measuring channel “pressure piston side” has been exceeded Upper limit value in measuring channel “pressure rod side” has been exceeded. Upper limit value in measuring channel “force” has been exceeded. Upper limit value in measuring channel “main boom angle” has been exceeded. Upper limit value in measuring channel “angle 2” has been exceeded. Upper limit value in measuring channel “length telescope I (+II) has been exceeded. Upper limit value in measuring channel “slewing angle 1” has been exceeded Upper limit value in measuring channel “slewing angle 2” has been exceeded Error in the system program

Possible Cause

Elimination

• Slewing angle • Replace slewing angle potentiometer is defective sensor • Replace sensor unit • Electronic component in the measuring channel defective • refer to E1A • refer to E1A

• refer to E11

• refer to E11

• refer to E12

• refer to E12

• refer to E12

• refer to E12

• refer to E14

• refer to E14

• refer to E15

• refer to E15

• refer to E16

• refer to E16

• refer to E17

• refer to E17

• refer to E1A

• refer to E1A

• refer to E1A

• refer to E1A

• The system program file is defective.

• Upload valid system software

• Flash-EPROM defective

Replace central unit

iFLEX 5

37-3

Error Code E37

Error

Possible Cause

Elimination

Error in the logical program flow

•

•

E38

System program and crane data file do not match.

E39

System program and load chart file do not match

E43

Error in the write/read memory, (RAM) Error in the monitored write/ read memory.

E47

E51

The CRC verification of the monitored write/read memory provides an incoherent result Error in the crane data file

System program file is defective

Upload valid system software

• Flash-EPROM defective • The system program in the LMI does not match to the programming in the crane data file • The system program in the LMI and the programming in the load chart file do not match. • Write/read memory (RAM) or central unit defective. • The CRC sign of the monitored write/read memory is wrong

• Replace central unit • Upload valid system program file or the valid crane data file

• The buffer battery is decharged (< 2V at 1kOhm).

• Replace buffer battery on the central unit.

• Upload valid system program file or the valid load chart file • Replace central unit • Restart the LMI

• Replace central unit • Central unit defective. • No valid data in the crane • Upload valid crane data data file. file • Flash-EPROM defective • No valid data in the load chart file

• Replace central unit • Upload valid load chart file

E52

Error in load chart file.

E56

Error in crane data file.

E57

• Flash-EPROM defective Error in serial crane • Calibration data file does data file. not contain valid data.

• Replace central unit • Upload calibration data file

• Flash-EPROM defective • No valid data in the load chart file

• Replace central unit • Upload valid load chart file

• Base number not programmed

• Program the correct base number (1 for base 1, 2 for base 2)

E60

The number of the selected File base and the programmed value are not identical

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• Flash-EPROM defective • Replace central unit • No valid data in the crane • Restore or upload valid crane data file data file during calibration.

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Error Code

Error

Possible Cause

Elimination

• Load chart file wrongly programmed

E61

Error in the CAN • bus data transfer for all CAN units

• •

E62

E63 E64

E65

Error in the can bus • data transfer of the pressure transducer sensor unit • Error in the can bus • pressure transducer sensor unit Error in the can bus • data transfer of the length/angle sensor unit •

Error in the can bus • length/angle sensor unit •

•

E66

E67

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• Check base programming in the load chart file. CAN Bus cable between • Check the connection between the central unit the central unit and the and the sensor units sensor units defective or (wiring harness). See not connected. section CAN-Bus Communication Short circuit in a CAN Bus • Replace Can Bus cable cable Can bus port in the • Replace the central unit central unit defective • Check the cable to the Cable between the sensor unit (wiring central unit and the harness). See section sensor unit defective or CAN-Bus not connected. Communication Sensor unit is defective • Replace the sensor unit The analog values of the • Replace the sensor unit sensor unit are invalid See section CAN-Bus Communication. • Check the cable to the Cable between the sensor unit. See section pressure transducer and CAN-Bus cable reel defective or not connected. Communication Sensor unit is defective • Replace the electronic board in the cable reel, see section CAN-Bus Communication 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 See E62 • See E62

Error in the can bus • data transfer of the 2nd length/angle sensor unit Error in the can bus • See E63 of the 2nd length /angle sensor unit

iFLEX 5

• See E63

37-5

Error Code E68 E69 E80

E84

E85

Error

Possible Cause

Error in the can bus • See E62 data transfer of the force sensor unit Error in the can bus • See E63 force sensor unit

Elimination • See E62 • See E63

Error in the slewing • The difference between • See section Slewing angle measurement the average of the Sensing slewing angle and one of the wipers of the slewing potentiometer is out of the tolerance Wrong rigging • Select another rigging • The selected rigging condition. condition condition is not contained in the crane data file. • Check the programming in the crane data file. Error in the radius • Check the programming • The computed radius is determination in the crane data file. too small (negative deflection)

E89

Operating mode switchover with load.

E91

No data transmission form the console to the central unit

E92

Error in the data transmission from console to central unit

E93

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

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• The operating mode on the console has been switched over with the boom loaded. • Power supply of the console is interrupted

• Select operating mode without load on the boom

• 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. • Exchange console electronics or CU resp.

• Transmitter/receiver module of console is defective • Loose connection in the line between console electronics and central unit • Transmitter/receiver module is defective • refer to E92

iFLEX 5

• Check power at terminal X1 of the console electronics

• Check the connection between console electronics and central unit • Exchange console electronics or CU resp. • refer to E92

37-6

Error Code E94

E95 E96

E97

EAB

EAC

EAD

EC0

EC1

Error

Possible Cause

Elimination

No data transmission 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). • Exchange console electronics or CU resp. • Exchange CU.

• Transmitter/receiver module is defective • Computer module is defective • Electro-magnetic interferences (e.g. when switching contactors or valves) Error in the console • The console File is File defective. Error in the internal • The CPU of the console RAM of the console. is defective. • The console main board is defective. Error in the external • The external RAM of the RAM of the console console is defective.

• Eliminate the source of interferences by inverse diodes or varistors. • Replace the console software • Replace console electronics.

• Replace the external RAM of the console. • Replace the console electronics. • Replace A2B switch

Short circuit in the A2B switch circuit

• The console main board is defective. • Short circuit in the A2B switch

A2B switch circuit disconnected

• Replace cable to the • Short circuit in the cable A2B switch to the A2B switch • Disconnected cable in the • Connect or replace cable in the A2B switch A2B switch

• Disconnected cable to the • Connect or replace cable to the A2B switch A2B switch No valid A2B switch • Sensor wrong function • Replace A2B switch status • CAN bus delay • Replace cable to the A2B switch Prohibited area • Move boom to permitted • Boom is about to collide area with the engine hood, switch off 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.

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P.A.T. – L.M.I MANUAL 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.

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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.

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P.A.T. – L.M.I MANUAL SECTION 39

SOFTWARE TRANSFER INFORMATIONS INFORMATION

SOFTWARE TRANSFER INSTRUCTIONS FOR THE CONSOLE USING THE FLASH MODULE • • • • • • • • •

Remove the console from the dash by removing 8 mounting screws. Remove four screws from the rear of the console housing, exposing the internal boards. Attach the Console Flash Module to X6 and X7 simultaneously. Power on the system. At power-on if the software in the console does not match that in the Flash Module, an option to update will be presented. This option will disappear after 10 seconds until power is cycled. Immediately after seeing the update option, press and hold the Horn button until it’s light stops blinking. Software is finished updating when the Grove logo appears. Cycle power – if the software is updated correctly the update option will not appear at power-on. Verify software update/version by pressing the Info button three during system operation.

REMOVE FLASH MODULE WHEN FINISHED – IT IS NOT TO REMAIN IN THE CONSOLE! • •

Attach the housing and the four inner screws from the rear of the Console, exposing the internal boards. Insert the console into the dash and mount in place with the 8 screws.

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SOFTWARE TRANSFER INSTRUCTIONS FOR THE IFLASH PALM AND CENTRAL UNIT INTRODUCTION iFLASH allows for transfer data files between the palm and the PC and Palm and iflex system. Data files can not be transferred with the Palm software program „HotSync. IFLASH Desktop iFLASH desktop is the program, which takes care of the data transfer, is provided for communication or the transfer of files between PC and the iFLASH Palm iFLASH Palm iFLASH Palm is the program which runs on the Palm. This program must be transferred to the Palm using Hotsync. Please contact PAT on information on how you can obtain this software.

INSTALLING IFLASH DESKTOP The iFLASH Desktop needs no installation. Just copy to your Desktop or any convenient folder.

INSTALLING IFLASH The iFLASH program must be installed onto the Palm. To install iflash on the Palm, use the hotsync program of the Palm. The file name is iFLASH*.prc. Follow the normal Hotsync procedure for transferring the program from the PC to the Palm. Instructions for Hotsync will be in your Palm documentation or on Palm's web site.

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DATA TRANSFER FROM THE PC TO THE PALM ¾ Palm - Put Palm into the HotSync Cradle and turn it on. ¾ PC - Deactivate HotSync manager. If Hotsync manager is not deactivated, the program will respond with an error, "unable to open specified port…" ¾ PC - Double click on iFLASH Desktop ¾ PC - Select the necessary serial interface (COM1, COM2,...)

¾ PC

¾ PC

- Click on „Add File to Store...“

- Select the file which you want to transfer and click "Open"

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Software Transfer Instructions for the iFLASH Palm and Central Unit

¾ ¾ ¾ ¾ ¾ ¾

Palm Palm Palm Palm PC PC

¾ Palm

- Start iflash - Select File Store. - Select Receive. - palm will show "waiting for connection" - click on OK. - When the transfer is complete the following message will appear.

- "Transfer complete" will show on the palm.

The file should now be stored in the Palm.

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DATA TRANSFER FROM THE PALM TO THE PC ¾ Palm - Put Palm into the HotSync Cradle and turn it on. ¾ PC - Deactivate HotSync manager. If Hotsync manager is not deactivated, the program will respond with an error, "unable to open specified port…" ¾ PC - Double click on iFLASH Desktop ¾ PC - Select the necessary serial interface (COM1, COM2,...)

¾ ¾ ¾ ¾ ¾ ¾

PC - Click on „Refresh File List“ Palm - Start iflash Palm - Select File Store. Palm - Select Send. Palm - palm will show "sending Filelist" PC - When the transfer is complete the window will be updated with the files from the Palm file store.

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Software Transfer Instructions for the iFLASH Palm and Central Unit

¾ Palm ¾ PC

- "Sending complete" will show on the palm. - Select the file you need and click „Retrieve marked File(s)“

After that you will get the following message:

¾ Palm ¾ PC

- select „Receive“. Click „OK“.

Wait until „Transfer completed“ is displayed in the status bar of the Palm. Acknowledge the message on the PC:

The file has been successfully filed in the folder created by the iFLASH Palm Desktop.

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TRANSFERRING SYSTEM, DATA OR TLK FILES FROM THE PALM TO THE IFLEX5 ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾

Connect the Palm with the iFLEX5 via its serial cable. Power the iFLEX system Select iFLASH program Select Settings. Note - The values are saved after the first time. This can be skipped later. Set Speed to: 9600 Set Data Bits to: 8 Set Parity to: N Set Stop Bits to: 1 Select Save. Select Palm to iFLEX Select the file to be transferred from the file selection box. Select Start Transfer

Wait until all bytes have been transferred in the line „Progress“. The data have been successfully transferred to the iFLEX5.

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Software Transfer Instructions for the iFLASH Palm and Central Unit

TRANSFERRING SYSTEM, DATA OR TLK FILES FROM THE IFLEX5 TO THE PALM “ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾

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 Æ

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 Æ

12k_01.BIN and 12k_01.BRN 12k_02.BIN and 12k_02.BRN, etc.

PARAMETER FILES There are several files required for transferring from iflex to palm. These files are called parameter files. You should have a parameter file for each of the file types that you wish to transfer from the iflex to the Palm. These files will have a "adr" extension on the filename. Examples are tlkprom.adr, datprom.adr. These files must be transferred from the PC to the Palm using the file store program. Please contact PAT for information on acquiring these files.

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