PAT DS350 G Programming manual

031-300-190-039 Rev. B 04/30/99
PAT America, Inc.
Rheinmetall Elektronik
DS350 G BOOM CONTROL
for
GROVE CRANE
RT865 BXL, TMS 870, TTS 870
WITH 5 SECTION BOOM
TROUBLESHOOTING MANUAL

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL
031-300-190-039 Rev. B 04/30/99
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.
PAT shall not be liable for errors contained herein
or for incidental or consequential damages in
connection with the furnishing, performance
or use of this manual.
This document contains proprietary information
which is protected by copyright. All rights are
reserved. No part of this document may be
photocopied, reproduced, or translated to
another language without prior consent of PAT.

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL
031-300-190-039 Rev. B 4/30/99
TABLE OF CONTENTS
Section Content Page
1 General Information 1
2 Reference Material 1
3 Warnings 1
4 Service and Maintenance 2
5 Boom Control Interface 3
6 Boom Sequence 9
7 Boom Control Flow 10
8 Ramping 12
9.1 DS 350 G - Boom Components and Setup 13
9.2 Length Transducer Adjustment 15
9.3 DS 350 G - Superstructure Components - TMS/ TTS 870 16
9.4 DS 350 G - Superstructure Components - RT 865 BXL 17
10.1 DS350 G LMI Central unit (751) - TMS/ TTS 870 & RT 865 BXL 18
10.2 LMI Terminal board - TMS/ TTS 870 & RT 865 BXL 19
11.1 Wiring Schematic - TMS/ TTS 870 20
11.2 Wiring Schematic - RT 865 BXL 25
12 Boom Length Percentage Error 29
13 Main Boom Length Error 37
14 Inner Mid Length Error 43
15 Center Mid Length Error 49
16 No Extend or Retract Function in Automode 55
17 Out of Sequence Warning 57
18.1 Additional Error Codes - Operational 62
18.2 Additional Error Codes -System 63

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL
031-300-190-039 Rev. B 4/30/99
1
1. General Information
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. Reference Material
Parts & Installation Manual:
Crane Model PAT- Part number Grove- Part number
TMS/ TTS 870 031-300-150-662 9-333-103129
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. The boom control extension controls the
sequence of the boom during operation. It still remains the operator’s responsibility to 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 continuing 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.

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL
031-300-190-039 Rev. B 4/30/99
2
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. 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 hoist cylinder(s) and the connecting hoses for oil
leakage.
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.

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL
031-300-190-039 Rev. B 4/30/99
3
5. Boom Control Interface
LMI Circuit
Boom
control
circuit
Digital
Input
Relays
output
Analog input
Analog output
Crane interface
connector
Crane interface
connector
P-switch extend pilot pressure
P-switch retract pilot pressure
Automode switch in cabin
Front O/R pressure switch
Prox.switch on base section
Prox.switch on IM section
Boom retract
Boom extend
Auto mode on
House lock engaged
Inner mid retracted
Center mid retracted & 0%
IM 2- way valve
Rod side dump
valve
Tele out of
sequence
Proportional
output / extend
Prop.
K2 K3
K4
K5
K6 K5
Proportional
output / retract
2- way valves (inner mid)
Rod side dump valve
Out of sequence warning light
pressure reducing valve/
retract
pressure reducing valve/
extend
Center mid length sensor
Main boom length sensor
Main boom angle sensor
Rod pressure transducer
Piston pressure transducer
LMI Console
870 - LMI (751)
DI 1 DI 2 DI 3
DI 7
DI 6
DI 11
Inner mid length sensor
CM 2- way valve
OM 2- way valve
K7
2- way valves (center mid)
2- way valves (outer mid)
K5
DI 8
DI 9
Auto mode A *
Front O/R overloaded
DI 4 OM/Fly retracted & 0%
Inner mid 0%
DI 5
Area def. switch *
Prox.switch on base section
Prox.switch on CM section
House lock switch (EEC units) *
Automode A selector switch
* = RT 865BXL only
Drawing 1.
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.

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL
031-300-190-039 Rev. B 4/30/99
4
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.
Pilot pressure switch signal / Analog output signal:
Two pressure switches in the pilot pressure circuit are used to distinguish between boom
extend or boom retract. The two circuits are wired through the crane interface connector into
the DS 350 G central unit.
When the operator extends the boom, the pressure switch signal at central unit terminal
A101-X1/38 changes from 0V to +24V. The boom control logic allows electrical current to
flow to the extend pressure reducing valve coil. The minimum current equals 0 mA with the
control in neutral position. The maximum current output equals 800 mA.
To measure the coil current while extending, remove wire #20from central unit terminal
A101-X1/63. Connect the Amp-meter in series with wire #20 to terminal X1/63.
When the operator retracts the boom, the pressure switch signal at central unit terminal
A101-X1/40 changes from 0V to +24V. The boom control logic allows electrical current to
flow to the retract pressure reducing valve coil. The minimum current equals 0 mA with the
control in neutral position. The maximum current output equals 800 mA.
To measure the coil current while retracting, remove wire #21 from central unit terminal
A101-X1/64. Connect the Amp-meter in series with wire #21 to terminal X1/64.

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL
031-300-190-039 Rev. B 4/30/99
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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.
Disengage the boom stop to retract the boom completely.
With retracted main boom the overall boom length signal is -500 mV (A101-X1/10). Use the
test pin MP 15 (AGND) or terminal A101-X1/8 (AGND) for reference ground. Disengage the
boom stop to retract the boom completely.
With retracted main boom the inner mid section length signal is -500 mV (A101-X1/24). Use
the test pin MP 15 (AGND) or terminal A101-X1/8 (AGND) for reference ground.
With retracted main boom the center mid section length signal is -500 mV (A101-X1/73). Use
the test pin MP 15 (AGND) or terminal A101-X1/8 (AGND) for reference ground.
Keep the cable on the length transducer drum spooled properly. A poorly spooled cable may causes the boom to
become out of sequence. If the boom becomes out of sequence, select manual mode and correct the length by
operating individual sections. Once the sections are sequenced again the operator may return to the automode.
Refer to section 9.1 for boom components installation and set up.
Inner mid retract and % reset switch:
The reset- proximity switch on the base section provides a (+24V) signal to central unit
terminal A 104 X1/80 when the inner mid section is retracted against the boom stop. The
signal resets the inner mid percentage to 1%.
The retract- proximity switch on the base section provides a (+24V) signal to central unit
terminal A 104 X1/78 when the inner mid section is fully retracted (disengage the boom stop).

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL
031-300-190-039 Rev. B 4/30/99
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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%.
Refer to Parts & Installation Manual and follow the installation instructions for switch and target adjustment.
Outer mid/ fly retract and % reset switch:
The proximity switch on the center mid section provides a (+24V) signal to central unit
terminal A 114 X1/76 when the outer mid and fly section is fully retracted. The signal resets
the outer mid/ fly percentage to 0%.
Refer to Parts & Installation Manual and follow the installation instructions for switch and target adjustment.
System inputs:
DI # Description Central Unit
Terminal
Signal
(DI=on)
1 MB Pressure switch - boom extend A104 - X1/38 +24V
GND A104 - X1/37 0V
2 MB Pressure switch -boom retract A104 - X1/40 +24V
GND A104 - X1/39 0V
3 MB Automode switched on A104 - X1/42 +24V
GND A104 - X1/41 0V
4 MB Outer mid/ fly retract and % switch A104 - X1/76 +24V
GND A104 - X1/75 0V
5 MB Inner mid retract switch A104 - X1/78 +24V
GND A104 - X1/77 0V
6 MB Inner mid % reset switch A104 - X1/80 +24V
GND A104 - X1/79 0V
1 EX House lock engaged (RT 865 BXL-- Europe) * A114 - X1/1 +24V
GND A114 - X1/2 0V
2 EX Automode A = on; Automode B = off * A114 - X1/3 +24V
GND A114 - X1/4 0V
3 EX + Ub (24V) A114 - X1/5 +24V
Front outrigger overload (GND) A114 - X1/6 0V
4 EX Area def. switch (RT 865 BXL) * A114 - X1/7 +24V
GND A114 - X1/8 0V
5 EX Center mid retract and % reset switch A114 - X1/9 +24V
GND A114 - X1/10 0V
Note: MB = main board * = RT 865 BXL only
EX = extension board

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL
031-300-190-039 Rev. B 4/30/99
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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. The valves for the sections that are not selected are powered
to prevent movement of the other cylinders.
Mode Relay K2
[V]
IM 2 way
valves
Relay K6
[V]
CM 2 way
valves
Relay K7
[V]
OM 2 way
valves
A104-X1/54 A104-X1/66 A104-X1/69
Auto IM 0 0 24 1 24 1
Auto CM 24 1 0 0 24 1
AutoOM 241241 0 0
Manual IM 0 0 * 0 1 * 0 1 *
Manual CM 0 1 * 0 0 * 0 1 *
Manual OM 0 1 * 0 1 * 0 0 *
Error(Auto) 241241241
Neutral (Auto) 24 1 24 1 24 1
Note: * = powered directly from the section selector switch in the cabin.
Relay outputs:
Relay Fuse Description Central Unit
Terminal
Signal
K1 F2 not used
not used
K2 F3 Inner mid two way- valves A104 - X1/54 +24V
GND A104 - X1/3 0V
K3 F4 Rod side dump valve A104 - X1/57 +24V
GND A104 - X1/3 0V
K4 F5 Tele out of sequence - Warning light in cabin A104 - X1/61 +24V
GND A104 - X1/3 0V
K5 F6 Signal from analog output board A104 - X1/62 0-800mA
K5 Directs the analog signal to the extend valve A104 - X1/63 0-800mA
K5 Directs the analog signal to the retract valve A104 - X1/64 0-800mA
K6 F7 Center mid two way- valves A104 - X1/66 +24V
K6 GND A104 - X1/3 0V
K7 F8 Outer mid two way- valves A104 - X1/69 + 24V
GND A104 - X1/3 0V
K8 none Internal LMI use (overload, error) A104 - X1/44 + 24V
K9 none Internal LMI use (A2B) A104 - X1/46 + 24V
K10 external Motion cut (Bosch relay) A104 - X1/48 + 24V

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL
031-300-190-039 Rev. B 4/30/99
8
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.
Controller Relay K3
A101 x1/ 57
Extend on 0V
Retract on 0V
Neutral +24V
Retracted/ retract on +24V

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL
031-300-190-039 Rev. B 4/30/99
9
6. Boom Sequence
Main Boom:
Mode IM % CM % OM % FLY %
AutoB0000
Auto B 50 0 0 0
Auto B 50 50 0 0
Auto B 75 50 0 0
Auto B 75 75 0 0
Auto B 100 75 0 0
Auto B 100 100 0 0
Auto B 100 100 100 100
Mode IM % CM % OM % FLY %
Auto A * 0 0 0 0
Auto A * 0 100 0 0
Auto A * 0 100 100 100
Auto A * 100 100 100 100
*= Mode A not available on RT 865 BXL
Extensions:
Mode IM % CM % OM % FLY %
Auto0000
Auto 100 0 0 0
Auto 100 100 0 0
Auto 100 100 100 100

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL
031-300-190-039 Rev. B 4/30/99
10
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
Automode.
Operation in manual
mode.
off
B.C.S. checks input for
A mode or B mode.
on
B.C.S. checks the
retract and % reset
switch and boom
length. Refer to section
6 for sequencing
information.
Console displays
length and % of each
section.
correct
B.C.S. defaults into a
rigging mode, console
displays error code or
dashboard warning
light indicates "out of
sequence". Refer to
section 16 for BCS
error codes
incorrect
continue on next
page
Drawing 2a.

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL
031-300-190-039 Rev. B 4/30/99
11
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.
The B.C.S. analog
output signal opens the
pressure reducing
valves (proportional
valves).
Continuation
While estending and
retracting the B.C.S.
monitors each section
length.
The B.C.S. controls the
speed and sequence of each
boom section.
correct
incorrect
Out of sequence warning and lock
out.Operate in manual mode to re-
sequence the boom. Reference
section 9.1 for boom components
and setup.
Drawing 2b.

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL
031-300-190-039 Rev. B 4/30/99
12
8. Ramping
Drawing 3.
Ramp value: A hex value in the software which determines the output current to the proportional valve.
Max. ramp value: The maximum hex value (hex 255) equals to 800 mA valve (pressure reducing valve). This
current is required to open the valve for maximum tele speed.
Min. ramp value: The minimum hex value that is required to move a section in the ramping area. These values
may differ for each ramping area.
Change over: The previous section comes to a complete stop and the next section ramps up (accelerates
speed).
IM: Inner Mid Section
CM: Center Mid Section
OM/Fly: Outer Mid Section & Fly
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.
Ramp
Value
Boom
Length
Boom
Section A
-e.g. IM-
Boom
Section B
-e.g. CM-
Max. Ramp
Value
Max. Ramp
Value
Change
Over
Min. Ramp
Value
Ramp down
Ramp up

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL
031-300-190-039 Rev. B 4/30/99
13
9.1 DS 350 G - Boom Components and Setup
Outer mid
retract and %
reset switch
Center mid
retract and %
reset switch
Inner mid
retract switch
Inner mid %
reset switch
Inner mid length
sensor LG 221
Center mid
length and
angle sensor
LWG 221
Overall boom
length sensor
LG 208
1
3
2
4
4
5
7
7
8 / 9
Drawing 4.
1. Pre-tension the cable reel spring by rotating drum (16) revolution counterclockwise. If replacing the LG 208
un-spool the length cable and secure to bushing on the boom nose as noted in the installation drawing. Zero
the length potentiometer as described on page 18.
2. Pre-tension the cable reel spring by rotating drum (35) revolution counterclockwise. If replacing the LG 221
un-spool the length cable and secure to bushing on the boom nose as noted in the installation drawing. Zero
the length potentiometer as described on page 18.
3. Pre-tension the cable reel spring by rotating drum (30) revolution counterclockwise. If replacing the LWG 221
un-spool the length cable and secure to bushing on the boom nose as noted in the installation drawing. Zero
the length potentiometer as described on page 18.
4. Run cable through the cable guides. Remove 1/4-20 nuts on bottom of cable guide, insert cable guide
screws through existing angle bracket and secure in place with 1/4-20 nuts removed previously.
5. Center line of cable must be aligned with center line of cable drum. See partial top view.
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.

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL
031-300-190-039 Rev. B 4/30/99
14
1. Place tie wrap, 120 degree apart around the bushing. Wrap cable (8-10) revolutions over the tie wraps
starting from the outside and working inward. Allow ample cable to reach the junction box. Secure with (2)
additional tie wraps. See page 17.
2. Check proximity switch installation (0.44 inch from target) when boom sections are fully retracted.
3. This target is only installed if the boom is equipped with a boom extension stop block.
4. Check this proximity switch installation (0.13 inch from target) when boom sections are fully retracted.
This proximity switch
is used to sense the
inner mid section fully
retracted.
This proximity
switch is used to
reset the inner mid
percentage.
This proximity
switch is used to
sense the center
mid section fully
retracted.
3.94”
0.44”
0.44”
0.44”
Partial top view
To be aligned
with center line
of cable reel
drum.
6
1.34”
Drawing 5.
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.

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL
031-300-190-039 Rev. B 4/30/99
15
9.2 Length Transducer Adjustment
Drawing 6.
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.

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL
031-300-190-039 Rev. B 4/30/99
16
9.3 DS 350 G Superstructure Components - TMS/TTS 870
Drawing 7.
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.

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL
031-300-190-039 Rev. B 4/30/99
17
9.4 DS 350 G Superstructure Components - RT 865 BXL
Drawing 8.
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.