3B6 SLIM Programming manual

SLIM
Troubleshooting Manual
Rev 9 1-4-13
Software TXW003TME
Enter
ACT
a
r
h
l
STOP
Index
+
-
0 43.5
1.1 10.2
34.1 6 1 68
7055 Morning Dove Way, Roscoe, IL 61073
Phone [phone]
www.controlsystemsw.com : [e-mail]

3B6 Troubleshotting Manual
WARNING
The SLIM system is an LMI, with Range limiting
features.
The system should be checked for the shutoff
functions prior to programming the Operating mode
and confirming by trying to move the boom functions
to ensure the shutoff is disabled.
A full check confirming all features on the system are
functioning properly prior to lifting any loads!
To obtain the optimum performance from this system
we recommend that you read and understand this
manual before using the system.
WARNING
For proper use of the system, carefully read and understand this page.
MAINTENANCE The SLIM system power cable must be
disconnected when welding, battery replacement, charging or jump
starting the battery. Failure to comply will result in serious damage to
the system.
MACHINE WASHING If washing the machine with a high pressure power washer, you
must protect all the system components from direct spraying to
avoid damage to the components.
Failure to comply with the above warnings will result in voiding the warranty!
Introduction

WARRANTY
THERE ARE NO WARRANTIES, EXPRESSED OR IMPLIED, MADE BY EITHER THE
DISTRIBUTOR OR THE MANUFACTURER ON NEW 3B6 SYSTEMS AND
COMPONENTS, EXCEPT THE MANUFACTURER’S WARRANTY AGAINST DEFECTS,
MATERIAL AND WORKMANSHIP SET OUT BELOW.
NEW EQUIPMENT WARRANTY
“The manufacturer warrants each new product made by the manufacturer to be free from
defects in material and workmanship, its obligation and liability under this warranty being
limited to replacing free of charge at its factory any part proving defective under normal use
and service within twelve (12) months from the date of initial sale, providing the product is
on record with the manufacturer as being installed by the distributor. If the product is not on
record as being installed by the distributor, the manufacturer will consider the date of
shipment from the factory as the date of initial sale. This warranty is in lieu of all other
warranties, expressed or implied and the obligation and liability of the manufacturer under
this warranty shall not include any transportation or other charges or the cost of installation
or any liability for direct, indirect or consequential damages or delay resulting from the
defect. Any operation beyond rated capacity or the improper use of the product or the
substitution upon it of parts not approved by the manufacturer shall void this warranty. This
warranty covers only the products of 3B6. The products of other manufacturers are covered
only by such warranties as made by their manufacturers.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESSED
OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE, AND OF ANY OTHER OBLIGATIONS OR
LIABILITY OF THE PART OF THE MANUFACTURER, AND 3B6 NEITHER ASSUMES
NOR AUTHORIZES ANY OTHER PERSON TO ASSUME FOR IT ANY OTHER LIABILITY
IN CONNECTION WITH SUCH EQUIPMENT.
3B6 Troubleshooting Manual

Table of Contents
4
System Layout Page 5
System Wiring Diagram Page 6
Warning Messages Page 7
Alarm Messages Page 8-10
Angle (Alarm 2 or 3) Page 12
Length (Alarm 4 or 5) Page 13
Piston pressure sensor ( Alarm 8 or 9) Page 14
Rod pressure sensor ( Alarm 10 or 11) Page 15
Alarms 16 - 72 Page 16
A2B ( Alarm 60) Page 17
Cable reel repair Page 18-24
Angle-Length adjustments Page 25
Rotation Potentiometer replacement Page 26-30
Cylinder Topping/ Rigging and Travel mode Page 31
3B6 Troubleshooting Manual

System Layout
5
3B6 Troubleshooting Manual
4
4
J4 J5
2
1
CV.SL.HC036T / T104435
45.90.0404A0.01T / T104429
43.31.2100A0.01T / T104434
3B6 Part No./ Terex part No.QuantityRef. Description
1
1MAINUNIT SLIM
1CABLEREEL
1
2
3AV45.60.0126.01 / T10443024
8 0 .S L .H C 0 3 6 0 .0 1
T R O N O F .
0 9 / 0 2 / 2 0 0 9
L A Y O U T
A3
S L I M .H C 3 6
S L I M .H C 3 6 .F 1 1 / 1
G E R A N E O A .
00
0
46.12.0100XX.01T / T1044325 46.80.0000XX.01 / T10474716
3
7
17 30.35.77226T / T104436
X1
X2
21 polemale connector socket
21 polefemale connector plug HDP24-18-21PN HDP26-18-21SN
DTM04-6P
DTM06-6S
PX0732S
6 pole connector
X1
X2
X10
X8
X7
X9
X7 X8
X6
X5
X4
X3
4 pole connector
4 pole connector
3 pole connector
3 pole connector
6 pole connector
6 pole connector
PX0731P
DTM06-4S
DTM04-4P
DT06-6S
DTM06-2S2 pin connector
1
0 1 SWIVEL PLATE A2BN2SP1 / T106332
/ T106274
80.SL.HC0360.01/ T106274
CV6x0.35sch
21' (7m)
CV6x0.35sch
5' (1.5m)
CV16xsch
5' (1.5m)
CV14xsch
5' (1.5m)
CV4x0.50sch
3' (1m)
CV4xsch
(pot suppliedlength)
CV4x0.50sch
2' (0.61m)
CV4x0.50sch
2' (0.61m)
CV4x0.50sch
6' (1.8m)
CV6x0.35sch
4' (1.2m)
X12
X11 3 pole connector 3 pole connector DT04-3P
DT06-3S
WIRE HARNESS
PRESSURETRANSDUCER
LIMIT SWITCH
WEIGH
POTENTIOMETER
8 1 PROXIMITYSWITCH Y11KIBM18PS
ROD
4
PISTON
4
3' (1m)
CV4x0.50sch
X11 X12
8
PROXIMITY
SWITCH
SUPPLY
INPUTS
OUTPUTS
X9 X4
X3
DN1
X10
CABLEREEL
X15
6
AC156A/230V
EN418
IP66
VDE0660
0
5
X14
CV4x0.50sch
2' (0.61m)

6
3B6 Troubleshooting Manual
Wiring Diagram
+VB -VB
0.5mm² 0.5mm²
(8)AGND (5)AI1 (13)AI0
16 14 15
+VP
(2)+VB (9)-VB
4x0,5
4x0,5
Boom Cylinder
Green White Brown
OUT +VB GND
123
P
123
OUT GND
P
+VB
4
Green White Brown
Rod Side Piston Side
2A
43.31.2100A0.01 - SLIM
-VB
+VB
-VB
+VB
( 10 ) CAN 1L ( 3 ) CAN 1H
4 3
2
1
DN1
DO0
0.25mm² (11)DO0
OUT0
2 1
(+10-30V)
9
123 123
Pressure Transducers:
123456789
101112131415161718
1234567
14 13 12 11 10 9 8
J5 J4
Brown/Yellow (Lock Relay Verification)
DN1: SUB-D 9 Way Connector Female
NOTE:
DO2
0.25mm² (12)DO2
OUT2 7
Blue/Red (Output Right Rotation Lock)
DO3
0.25mm² (4)DO3
OUT3 6
Pink/Gray (Output Left Rotation Lock)
(12)AI5/INP5
OUT1
GND
+5V
Brown 1
Green 2
White 3
Yellow 4
OUT2
Potentiometer
(14)AI2/INP212 (6)AI3/INP311
1
2
3
Angle Sensor
A2BN2B
ASA-CBL3W/XX
WIRE COLOR SIGNAL
BROWN +VB
GREEN
WHITE -VB
CAN L
CAN HYELLOW
AN1
AGND
+5V
SIGNAL
WHITE
GREEN
BROWN
WIRE COLOR
J8
J3
J8
J3
R=120 ohm1/4W
POT.
1
2
3
CAN L
AGND
AN1
+5
CAN H
- VB
+ VB
A2B return
A2B supply
(15) AI4/INP4
17
AV45.60.0126.01
30.35.77226
(7)+5VA
13
Rotation Sensor Supply Verification
Cable Reel
45.90.0404A0.01
(3)DO18
DO1
OUT1
White/Green (External Buzzer)
0.25mm²
X1
Brown
White
Gray
Yellow
Green
Yellow
Green
RED
WHITE
2
5
1
7
X2
Grey White Purple Green/Grey Green Black/White Red Black/Brown Blue Pink/Grey Pink Yellow Grey/Pink Green/White Blue/Red
X2
X1
Black Brown
+VB Blue GND OUT
S
Black
19
A
Green Brown White
4x0,5
B
C
(13) AI7
Y11KIBM18PS
Proximity Switch
8
8 0 .S L .H C 0 3 6 0 .0 1
T R O N O F .
0 9 / 0 2 / 2 0 10
E X T E R N A L W I R I N GS
A3
S L IM . H C 3 6
S L IM . H C 3 6 .C 1 1 / 1
G E R A N E O A .
00
0
Purple wire from J4
18 Green/White (16) +15V
Black
White
Brown
Green Yellow
1
2
3
4
SLIM Rev 6 9-29-10

WARNING CODES
7
3B6 Troubleshooting Manual
WARNING 5
Rope overload Exceeded single line pull of wire
rope Increase reeving
Reduce weight
WARNING 6
Exceeded load
program change
Suspended load when changing
program Lower load to ground to change program
WARNING 7
Rigging & Travel Rigging & Travel mode selected N/A
WARNING 8
Pre-warning
rotation
Rotation approaching limit range Increase Boom angle above
10 degrees
WARNING 9
Rotation limit
stop
Exceeded rotation limits Increase Boom angle above
10 degrees
Rotate opposite direction
WARNING 10
5 vdc supply
rotation pot fault
5vdc supply is low to rotation pot Check wiring
Check harness to pot
Replace pot
WARNING 11
Virtual wall Angle
preset limit
Preset for virtual wall exceeded Increase boom angle
Reset ISAAC angle setting,
page 14 operator manual
WARNING 12
Virtual wall
radius exceeded
Preset for Virtual wall exceeded Decrease radius
Reset ISAAC radius setting,
page 14 operator manual
WARNING 13
Virtual wall
Height exceeded
Preset for Virtual wall exceeded Decrease height
Reset ISAAC height setting,
page 14 operator manual
WARNING 15
Virtual Wall
Rotation min
exceeded
WARNING 16
Virtual Wall
Rotation min
exceeded
Preset for Virtual wall exceeded
Preset for Virtual wall exceeded
Increase Rotation min
Reset ISAAC ROT MIN
setting, see page 14 operator
manual
Decrease Rotation Max
Reset ISAAC ROT MAX
setting. See page 14 operator
manual

Alarm/Fault codes
8
3B6 Troubleshooting Manual
MESSAGE CAUSE SOLUTION
ALARM 1
Memory Data
Fault
Internal memory fault Cycle system power, if
continued Contact Service
ALARM 2
Angle sensor 1
reading lower
than minimum
 Potentiometer inside Reel is faulty.
Possible lack of continuity in
wires
carrying the signals
Fault in Display unit connector
Angle out of adjustment
Check Wiring from cable reel
to
Display Unit
Check 12vdc supply to angle
pot in cable reel
Replace pot if damaged
Check CAN BUS lines
ALARM 3
Angle sensor 1
reading higher
than maximum
Potentiometer inside reel is faulty.
Lack of continuity in wiring
Fault in display unit connector
Angle out of adjustment
Check Wiring from cable reel
to display unit
Check 12vdc supply to angle
sensor
Replace pot if damaged
Check CAN BUS lines
Call Service
ALARM 4
Length Sensor 1
reading lower
than minimum
Potentiometer inside reel is faulty.
Lack of continuity in wiring
Fault in display unit connector
Length out of adjustment
Check Wiring from cable reel
to display unit
Check 5 vdc supply to length
sensor
Replace pot if damaged
Adjust length pot values fully
retracted 0.250vdc
Check CAN BUS lines
Call Service
ALARM 5
Length Sensor 1
reading higher
than maximum
Potentiometer inside reel is faulty.
Lack of continuity in wiring
Fault in display unit connector
Length out of adjustment
Check Wiring from cable reel
to display unit
Check 5 vdc supply to length
sensor
Replace pot if damaged
Adjust length pot values fully
retracted 0.250 vdc
Check CAN BUS lines
Call Service

MESSAGE CAUSE SOLUTION
ALARM 8
Piston pressure
sensor output
lower than
minimum
Piston Pressure sensor faulty.
 Lack of continuity in wiring
Moisture in connector.
Sensor broken or disconnected
Check for15vdc supply
Check for output 0.5 vdc
Check for moisture or fluid.
 Check connector and wiring
•Replace Transducer if faulty
ALARM 9
Piston pressure
sensor output
higher than
maximum
Piston Pressure sensor faulty.
 Lack of continuity in wiring
Moisture in connector.
Sensor broken or disconnected
Check for15vdc supply
Check for output 0.5 vdc
Check for moisture or fluid.
 Check connector and wiring
•Replace Transducer if faulty
ALARM 10
Rod pressure
sensor output
lower than
minimum
 Rod Pressure sensor faulty.
 Lack of continuity in wiring
Moisture in connector.
Sensor broken or disconnected
Check for15vdc supply
Check for output 0.5 vdc
Check for moisture or fluid.
 Check connector and wiring
•Replace Transducer if faulty
ALARM 11
Rod pressure
sensor output
higher than
maximum
 Rod Pressure sensor faulty.
 Lack of continuity in wiring
Moisture in connector.
Sensor broken or disconnected
Check for15vdc supply
Check for output 5.5 vdc
Check for moisture or fluid.
 Check connector and wiring
•Replace Transducer if faulty
ALARM 16
Shutoff output
fault.
 Lack of continuity in wiring
Fault internal SLIM
Shutoff solenoid
Check for12vdc supply
 Check connector and wiring
ALARM 22
Internal WDO
fault
 Faulty display  Check wiring of display
and harness
ALARM 41
CRC Error
EPROM SW
Internal fault SLIM display Cycle power on SLIM display
Call Service
ALARM 42
CRC Error in
program
Internal fault SLIM display
Cycle power on SLIM display Call Service
ALARM 43
CRC Error in
Load chart
ALARM 50
Cable reel
CANBUS
Internal fault SLIM display
Faulty wiring from display to cable
reel
Cycle power on SLIM display
Call Service
Check wiring and CAN line for
120 ohm resistor.
3B6 Troubleshooting Manual
Alarm/Fault codes
9

Alarm/Fault codes
10
3B6 Troubleshooting Manual
ALARM 60
A2B condition Approaching A2B condition Lower hook block. Check A2B switch cable
ALARM 61
Overload SWL
110%
Exceeded 110% SWL Reduce SWL
ALARM 62
Overload SWL
115%
Exceeded 115% SWL Reduce SWL
ALARM 63
Overload SWL
120%
Exceeded 120% SWL Reduce SWL
ALARM 64
Bypass enabled Faulty wiring System bypassed Check wiring from harness to bypass
ALARM 70
Rotation pot
ADC value
Faulty wiring
Internal fault rotation pot Check wiring from harness to rotation pot
Call Service
ALARM 71
Rotation prox
switch
 Faulty mechanical hardware
Internal fault SLIM display
Check wiring from harness to
rotation pot
Check pot hardware
ALARM 72
Rotation sensor
malfunction
Faulty wiring
Defective rotation sensor Check wiring from harness to rotation sensor
Call Service

11
System Alarm Codes
Alarm 1 Memory Data fault (SLIM Display)
1. Cycle power on the display and check wiring for damage.
2. CALL SERVICE
NOTE
Do not check wiring for output from any can bus component when power is applied to
the system. Damage to the system will be the result
3B6 Troubleshooting Manual
Enter
ACT
a
r
h
l
STOP
Index
+
-
Alarm 6
1.1 10.2
34.1 6 1 68
The SLIM system will automatically alert the operator by Audible and or Visual alarm
codes on the display of a condition. When in a alarm condition the Length and
Height indicator are blanked out to display the message.

12
Fig 4
System Alarm Codes
Alarm Code 2 or 3 ( Angle Sensor)
This code is caused by the output voltage of the angle sensor is lower (code 2) than the
minimum or higher (code 3) than the maximum voltage.
Actions to take; Level the machine, Fully retract the boom and lower the angle to zero
degrees using a angle finder to determine zero degrees. All wire color is the
connection cable coming from turret. See figure 3.
1. Remove the cover of the cable reel using a m3 allen wrench and check the +12.00vdc
(Typically the voltage is about 11.95vdc) supply voltage (Brown wire) and the ground
wire (white wire). See Fig 3. If the voltage is ok continue to step 2, if not check the
wiring from the cable reel to the display for damage.
2. Check the 120 ohm resistor (with no power on) between the yellow and green wires
inside the cable reel (CAN BUS lines). If the wiring is ok, loosen the three screws (Fig
4) on the angle pot and adjust the pot until the display indicates what the angle finder
indicates. Check the high angle setting at 75 degrees for accuracy.
3. If adjusting the angle pot and the angle does not change on the display, change the
angle pot and set the angle sensor by the display.
4. Call for service if angle is still incorrect or to set angle sensor.
Fig 3
3B6 Troubleshooting Manual

13
Fig 6
System Alarm Codes
Alarm Code 4 or 5 ( Length Sensor)
This code is caused by the output voltage of the length sensor is lower (code 4 ) than the
minimum, higher (code 5 ) than the maximum voltage or higher than the actual value.
Actions to take; Level the machine, Fully retract the boom and lower the angle to zero
degrees. Length indication is in percentage of length 0-100%
1. Check the cable is spooling properly on the drum. If cable is built up on one side of
drum correct it and adjust the roller guide on the cable reel to correct.
2. Remove the cover of the cable reel using a m3 allen wrench and check the +12.00vdc
(Typically the voltage is about 11.94vdc) supply voltage (Brown wire) and the ground
wire (white wire). See Fig 5. If the voltage is ok continue to step 2, if not check the
wiring from the cable reel to the display for damage.
3. Check the output of the length sensor. The output of the length sensor when the boom
is fully retracted should be approximately .250vdc.( wire), (tolerance .246 to .254vdc is
OK). If it is higher or lower check the wiring first for damage. If the wiring is ok, press
down on the length pot swing arm(Fig 6) and adjust the gear until the display indicates
what the minimum boom length for that model of machine. Check the voltage and
record this for later use.
4. If adjusting the length gear assembly and the length does not change on the display,
remove the output wire and check if the voltage changes, if not change the length pot
and adjust the length.
5. If still incorrect call service to set length sensor in display
Fig 5
3B6 Troubleshooting Manual

14
System Alarm Codes
Alarm Code 8 or 9 ( Piston Pressure Sensor)
This code is caused by the output voltage of the piston pressure sensor is lower (code 8) than
the minimum or higher (code 9) than the maximum voltage.
Actions to take; Fully retract the boom and lower the angle to zero degrees. Piston
pressure sensor is located on the top side of the lift cylinder. See figure 7.
1. Using your finger lift the lock tab on the sensor connector and switch the connector and
see if the code changes to the opposite sensor, if it does check the wiring from the
display to the sensor and check that air is not creating the code by bleeding the sensor
or hydraulic fluid is in the connector.
2. Check the supply voltage and ground at the connector end. See figure 7. If the code
does not change and wiring is ok bleed pressure sensor or replace it.
3. Supply voltage for pressure sensors is 15vdc, Output with no load should be around .70
to .90vdc
4. Call for service if code is still present.
Fig 7
PIN 3 Wires
1 +15vdc
2 output signal 0,5 .. 5,5 V
3 GND
3B6 Troubleshooting Manual
1 2 3

15
System Alarm Codes
Alarm Code 10 or 11 ( Rod Pressure Sensor)
This code is caused by the output voltage of the rod pressure sensor is lower (code 10) than
the minimum or higher (code 11) than the maximum voltage.
Actions to take; Fully retract the boom and lower the angle to zero degrees. Rod pressure
sensor is located inside the turret area on the control valve line. See figure 8.
1. Using your finger lift the lock tab on the connector and switch the connector and see if
the code changes to the opposite sensor, if it does check the wiring from the display to
the sensor and check that air is not creating the code by bleeding the sensor or hydraulic
fluid is in the connector.
2. Check the supply voltage and ground at the connector end. See figure 8. If the code
does not change and wiring is ok bleed pressure sensor or replace it.
3. Supply voltage for pressure sensors is 15vdc, Output with no load should be around .50
to .70vdc
4. Call for service if code is still present.
Fig 8
PIN 3 Wires
1 +15vdc
2 output signal 0,5 .. 5,5 V
3 GND
3B6 Troubleshooting Manual
1 2 3

16
System Alarm Codes
ALARM 16 Shutoff output circuit not verified
Faulty wiring
Internal fault SLIM display Check wiring from harness to shutoff valves
Call Service
ALARM 22 Output supply not verified
Check wiring from harness to shutoff valves
Call Service
ALARM 41 CRC Error in SW running
Internal fault SLIM display
Cycle power on SLIM display, Call Service
ALARM 42 CRC Error EPROM SW program
Internal fault SLIM display
Cycle power on SLIM display, Call Service
ALARM 43 CRC Error in EPROM load chart pages
Internal fault SLIM display Cycle power on SLIM display, Call Service
ALARM 50 Cable reel CANBUS lost
Check +12 vdc inside cable reel
Check wiring from harness to cable reel
Check angle sensor is functioning
Check for 120 ohm resistor between CAN H and CAN L lines
ALARM 60 A2B Condition
Faulty wiring
Check wiring from harness to Cable reel and A2B switch
ALARM 61, 62, or 63 LMI Overload
Exceeded rated capacity, Reduce capacity or radius
Cylinder topped
ALARM 64 Bypass enabled
Faulty wiring
Check wiring from harness to bypass
Call Service
Alarm 70 Rotation pot ADC value
Check wiring to rotation pot
Alarm 71 Rotation prox switch
Check wiring to pot
Check mechanical hardware on pot.
Alarm 72 Rotation pot malfunction
Check wiring to pot
Check voltage supply to pot +5vdc
Check pot output with boom directly over rear should be around +2.50 vdc
Check display diagnostics P10
Replace pot
3B6 Troubleshooting Manual

17
System Fault Conditions
A-2-B alarm ( Alarm 60)
This code is caused by an open circuit in the A-2-B switch.
Actions to take; Fully retract the boom and lower the angle to zero degrees.
1. Check if the machine is in a A-2-B condition, lower hook block.
2. Check if the cable or connectors are damaged between the switch to the display.
3. Remove the four screws in the switch cover and check the micro-switch for continuity.
or +12vdc supply voltage.
4. Check for moisture, dry and seal connector.
5. Replace the switch or cable.
6. Call for service if code is still present.
Fig 9
3B6 Troubleshooting Manual
The circuit is supplied at 10-30 vdc.
A-2-B wire terminal Connector terminal
Yellow wire 22 N 4.7k resistor inline
White wire 21 L
Cable reel end.
Cable reel wires Connector wire terminals
Red wire N
White wire L

18
Cable replacement
Fully retract the boom and lower to zero degrees angle. Remove the black connector from the
end of the cable to reuse it later (Fig 14). Then we will need to remove the cable reel from the
boom of the machine in order to replace the cable. Remove the four bolts from the bracket and
set the reel on a surface that will not damage it (Fig 15).
Fig 14
Fig 15
Remove all tension from the cable reel to avoid injury or damage to
the spring package of the cable reel.
3B6 Troubleshooting Manual

19
Cable replacement
Remove all the cable from the cable reel drum and push up the cable protective loom and
cut it off at the back side of the cable reel (Fig 16). Lay the cable reel on its mounting
bracket to access the front area (Fig 17).
Fig 16
Fig 17
3B6 Troubleshooting Manual

20
Cable replacement
Remove three self locking nuts using a 10mm wrench (Fig 18). Carefully remove the plastic
slip ring cover cap (Fig 19). You may require using a flat tip screwdriver to pry it . Insert the
tip of the screwdriver just enough to catch the side of the cap. DO NOT INSERT IT TO
DEEP OR YOU CAN DAMAGE THE SLIPRING!
Fig 18
Fig 19
Using the screwdriver tip to carefully pry up the cap to access the wiring. Use the hardware as
a lever for the screwdriver.
3B6 Troubleshooting Manual