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PAT DS350 G Troubleshooting Manual

Boom control for grove crane rt865 bxl, tms 870, tts 870 with 5 section boom
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PAT America, Inc.
Rheinmetall Elektronik
DS350 G BOOM CONTROL
for
GROVE CRANE
RT865 BXL, TMS 870, TTS 870
WITH 5 SECTION BOOM
TROUBLESHOOTING MANUAL
031-300-190-039 Rev. B 04/30/99

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Summary of Contents for PAT DS350 G

  • Page 1 PAT America, Inc. Rheinmetall Elektronik DS350 G BOOM CONTROL GROVE CRANE RT865 BXL, TMS 870, TTS 870 WITH 5 SECTION BOOM TROUBLESHOOTING MANUAL 031-300-190-039 Rev. B 04/30/99...
  • Page 2 Notice The information in this document is subject to change without notice. PAT makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose.

  • Page 3: Table Of Contents

    DS 350 G - Superstructure Components - TMS/ TTS 870 DS 350 G - Superstructure Components - RT 865 BXL 10.1 DS350 G LMI Central unit (751) - TMS/ TTS 870 & RT 865 BXL 10.2 LMI Terminal board - TMS/ TTS 870 & RT 865 BXL 11.1...

  • Page 4: General Information

    RT 865 BXL 031-300-150-659 9-333-103-206 Operator’s Handbook: PAT - Part number 50\350\19_1319e.doc 3. 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.

  • Page 5: Service And Maintenance

    DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 4. 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.

  • Page 6: Boom Control Interface

    PAT Equipment Corporation reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT Equipment Corporation. This drawing is subject to technical modification without prior notice.
  • Page 7 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL Auto mode / Manual mode: The operator selects auto mode or manual mode using the rocker switch in the dash board. Auto mode is the working mode and manual mode is used for rigging or sequencing purpose only.
  • Page 8 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL Length sensors: Three length sensors are mounted to the boom base section to measure the overall length, the inner mid section length and the center mid section length. The software utilizes the signals to calculate the outer mid and fly section length.
  • Page 9 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL Center mid retract and % reset switch: The proximity switch on the inner mid section provides a (+24V) signal to central unit terminal A 114 X1/9 when the center mid section is fully retracted. The signal resets the center mid percentage to 0%.
  • Page 10 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL Output for two- way valves: A pair of two- way valves controls the oil to each tele- cylinder. The relay output K2, K6, K7 operates the pair of two- way valves in automode. The valve need to be de-energized to operate the particular cylinder.
  • Page 11 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL Rod side dump valve: Relay K3 controls the rod side dump valve. The valve dumps the rod side pressure when the controller is in neutral position and during the time the section stops while changing over to another section.

  • Page 12: Boom Sequence

    DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 6. Boom Sequence Main Boom: Mode IM % CM % OM % FLY % Auto B Auto B Auto B Auto B Auto B Auto B Auto B Auto B Mode IM % CM %...

  • Page 13: Boom Control Flow

    DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 7. Boom Control Flow Operator moves controller to extend or retract position. Directional pressure switch transmits signal to B.C.S. B.C.S. checks input for Operation in manual Automode. mode. B.C.S. checks input for A mode or B mode.
  • Page 14 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL Continuation The B.C.S. relays K2, K6, K7 provide power to the 2 way valves allowing oil flow to the selected cylinder. The B.C.S. relay K3 controls the rod side dump valve. Refer to section 5.

  • Page 15: Ramping

    PAT Equipment Corporation reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT Equipment Corporation. This drawing is subject to technical modification without prior notice.

  • Page 16: Ds 350 G - Boom Components And Setup

    PAT Equipment Corporation reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT Equipment Corporation. This drawing is subject to technical modification without prior notice.
  • Page 17 PAT Equipment Corporation reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT Equipment Corporation. This drawing is subject to technical modification without prior notice.

  • Page 18: Length Transducer Adjustment

    PAT Equipment Corporation reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT Equipment Corporation. This drawing is subject to technical modification without prior notice.

  • Page 19: Ds 350 G Superstructure Components - Tms/Tts 870

    PAT Equipment Corporation reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT Equipment Corporation. This drawing is subject to technical modification without prior notice.

  • Page 20: Ds 350 G Superstructure Components - Rt 865 Bxl

    PAT Equipment Corporation reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT Equipment Corporation. This drawing is subject to technical modification without prior notice.

  • Page 21: Ds350 G Lmi Central Unit (751) - Tms/ Tts 870 & Rt 865 Bxl

    PAT Equipment Corporation reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT Equipment Corporation. This drawing is subject to technical modification without prior notice.

  • Page 22: Lmi Terminal Board - Tms/ Tts 870 & Rt 865 Bxl

    PAT Equipment Corporation reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT Equipment Corporation. This drawing is subject to technical modification without prior notice.

  • Page 23: Wiring Schematic - Tms/ Tts 870

    PAT Equipment Corporation reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT Equipment Corporation. This drawing is subject to technical modification without prior notice.
  • Page 24 PAT Equipment Corporation reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT Equipment Corporation. This drawing is subject to technical modification without prior notice.
  • Page 25 PAT Equipment Corporation reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT Equipment Corporation. This drawing is subject to technical modification without prior notice.
  • Page 26 PAT Equipment Corporation reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT Equipment Corporation. This drawing is subject to technical modification without prior notice.
  • Page 27 PAT Equipment Corporation reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT Equipment Corporation. This drawing is subject to technical modification without prior notice.

  • Page 28: Wiring Schematic - Rt 865 Bxl

    PAT Equipment Corporation reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT Equipment Corporation. This drawing is subject to technical modification without prior notice.
  • Page 29 PAT Equipment Corporation reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT Equipment Corporation. This drawing is subject to technical modification without prior notice.
  • Page 30 PAT Equipment Corporation reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT Equipment Corporation. This drawing is subject to technical modification without prior notice.
  • Page 31 PAT Equipment Corporation reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are confidential and are not to be used or reproduced without the written consent of PAT Equipment Corporation. This drawing is subject to technical modification without prior notice.

  • Page 32: Boom Length Percentage Error

    DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 12. 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%)? The LMI does not recognize the one or more reset switch signals.
  • Page 33 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 12. Continuation Continuation Is the voltage correct? Keep the inner mid section retracted. Measure the inner mid reset switch signal Faulty voltage supply wiring to at terminal 3 (24V) and 5 (GND) in the switch.Refer to section 11.
  • Page 34 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 12. Continuation Continuation Is the voltage correct? Measure the IM reset switch signal at Faulty wiring in cable terminal 15 (24V) and 14 (GND) in the connecting the junction box boom base junction box.
  • Page 35 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 12. Continuation Continuation Is the voltage correct? Measure the CM reset switch signal at Defective CM reset switch. terminal 10 (24V) and 9 (GND) in the length Replace proximity switch. sensor LG221.
  • Page 36 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 12. Continuation Continuation Is the voltage correct? Faulty wiring in cable Measure the CM reset switch signal at connecting the boom base central unit terminal A114 9 (24V) and junction box with the LG221. A104 36 (GND).
  • Page 37 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 12. Continuation Continuation Is the voltage correct? Faulty wiring in cable Measure voltage supply to CM switch at connecting the central unit and terminal 7 (+24V) and 5 (GND) in the inner the boom base junction box.
  • Page 38 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 12. Continuation Continuation Is the voltage correct? Faulty wiring in cable Measure the CM reset switch signal at connecting the the center mid terminal 10 (24V) and 9 (GND) in the junction box and the LWG 221.
  • Page 39 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 12. Continuation Continuation Is the voltage correct? Faulty wiring in cable Measure the OM reset switch signal at connecting the boom base central unit terminal A104 78 (24V) and junction box with the LWG 221. A104 36 (GND).

  • Page 40: Main Boom Length Error

    DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 13. 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? CAUTION: High tension on cable reel drum! Continue...
  • Page 41 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 13. Continuation Continuation the adjustment corrected the boom length indication? Continue Check the power supply to the length sensor. Measure with the power supply voltage at central unit terminal A104 on page 40 X1/11(-5V) and A104 X1/8(GND).
  • Page 42 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 13. Continuation Continuation Is the voltage correct (-5V)? Faulty wiring between Verify the length sensor signal. central unit and length Measure the voltage at the length transducer. Check transducer (LG 208) terminal 1 (GND) wiring, junction boxes and 2 (-500mV) with fully retracted and connectors for...
  • Page 43 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 13. Continuation Continuation Is the voltage correct (-500mV)? Check the wiring that connects the Main board component defective. LG 208 with the central unit. Inspect the Contact authorized service dealer for cable and connectors.
  • Page 44 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 13. Continuation Continuation the voltage decreasing from -500mV to -4.5V ? Check the wiring between length Main board component defective. transducer LG 208 and central unit. Contact authorized service dealer for Inspect cable connectors and junction main board replacement procedure.
  • Page 45 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 13. Continuation Continuation Is the voltage correct? [O turns = - 500mV 10 turns= - 4.5V] Defective length potentiometer assembly. Replace and Refer to page 18 and reset length adjust length potentiometer. Refer to drawing on page transducer.

  • Page 46: Inner Mid Length Error

    DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 14. Inner Mid Length Error 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 indicated correctly? Continue with B...
  • Page 47 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 14. Continuation Continuation the adjustment corrected the inner mid length indication? Continue Check the power supply to the length sensor. Measure with B the power supply voltage at central unit terminal A104 on page 46 X1/11(-5V) and A104 X1/8(GND).
  • Page 48 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 14. Continuation Continuation Is the voltage correct (-5V)? Faulty wiring between Verify the length sensor signal. central unit and length Measure the voltage at the length transducer. Check transducer (LG 221) terminal 1 (GND) wiring, junction boxes and 2 (-500mV) with fully retracted and connectors for...
  • Page 49 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 14. Continuation Continuation Is the voltage correct (-500mV)? Check the wiring that connects the Main board component defective. LG 221 with the central unit. Inspect the Contact authorized service dealer for cable and the connections.
  • Page 50 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 14. Continuation Continuation the voltage decreasing from -500mV to -4.5V ? Check the wiring between length Main board component defective. transducer LG 221 and central unit. Contact authorized service dealer for Inspect cable connectors and junction main board replacement procedure.
  • Page 51 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 14. Continuation Continuation Is the voltage correct? [O turns = - 500mV 10 turns= - 4.5V] Defective length potentiometer Refer to page18 and reset length assembly. Replace and adjust length transducer.

  • Page 52: Center Mid Length Error

    DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 15. Center Mid Length Error 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? Continue...
  • Page 53 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 15. Continuation Continuation the adjustment corrected the center mid length indication? Check the power supply to the length sensor. Measure Continue the power supply voltage at central unit terminal A104 with B X1/11(-5V) and A104 X1/8(GND).
  • Page 54 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 15. Continuation Continuation Is the voltage correct (-5V)? Faulty wiring between Verify the length sensor signal. central unit and length Measure the voltage at the length transducer. Check transducer (LWG 221) terminal 1 wiring, junction boxes (GND) and 2 (-500mV) with fully and connectors for...
  • Page 55 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 15. Continuation Continuation Is the voltage correct (-500mV)? Check the wiring that connects the Main board component defective. LWG 221 with the central unit. Inspect Contact authorized service dealer for the cable and the connections.
  • Page 56 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 15. Continuation Continuation the voltage decreasing from -500mV to -4.5V ? Check the wiring between length Main board component defective. transducer LWG 221 and central unit. Contact authorized service dealer for Inspect cable connectors and junction main board replacement procedure.
  • Page 57 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 15. Continuation Continuation Is the voltage correct? [O turns = - 500mV 10 turns= - 4.5V] Defective length potentiometer Possible main board defect. Contact assembly. Replace and adjust length authorized service dealer for further potentiometer.

  • Page 58: No Extend Or Retract Function In Automode

    DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 16. No Extend or Retract Function in Automode Boom does not extend or retract in automode. Switch to manual mode and extend or retract the boom manually. Does the boom extend or retract? Switch to automode.
  • Page 59 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 16. Continuation Continuation Switch to automode. Start the engine and operate the retract control. Measure the voltage at central unit terminal A104 X1/40 (24V) and A104 X1/39 (GND) while operating the extend control. Is the voltage correct? Select the service screen on the Faulty wiring to retract pressure switch or...

  • Page 60: Out Of Sequence Warning

    DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 17. Out of Sequence Warning Boom sections are out of sequence (Automode). Follow the instruction in section 12. Is the problem corrected? Follow the instruction in section 13. Is the problem corrected? Continue on next page 031-300-190-039 Rev.
  • Page 61 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 17. Continuation Continuation Follow the instruction in section 14. Is the problem corrected? Follow the instruction in section 15. Is the problem corrected? Continue on next page 031-300-190-039 Rev. B 4/30/99...
  • Page 62 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 17. Continuation Continuation With outer mid section completely retracted check the adjustment for the OM retract switch target. Refer to section 9.1. Is the switch and target adjusted correctly? Measure switch signal at central unit terminal Adjust OM retract A104 X1/ 76 (24V) and...
  • Page 63 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 17. Continuation Continuation Faulty wiring. Check the voltage at terminal 17 (24V) and 13 (GND) in boom base junction box. Refer to section 9.and 11. Have you located a wiring fault? Correct the wiring Measure switch signal at...
  • Page 64 DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 17. Continuation Continuation 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? Retract all boom section in Defective OM retract manual mode and let the switch.

  • Page 65: Additional Error Codes - Operational

    DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 18.1 Additional Error Codes - Operational Error code Description Solution Front Stabilizer overloaded Achieve a safe working area immediately. The outer mid section and fly section Select manual mode. are not fully retracted while the center Manually retract the outer mid and fly section mid section or the inner mid section until fully retracted.

  • Page 66: Additional Error Codes -System

    DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 18.2 Additional Error Codes - System Error code Description Solution E 47 Processor can not locate analog Analog output circuit defective. Replace output circuit for center mid section module. Ribbon cable (DS 350G only) defective or bad connection.

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