PAT DS 350 Programming manual

PAT America, Inc.
Rheinmetall Elektronik
DS350 MODULAR
BOOM CONTROL EXTENSION
For
GROVE CRANE RT865 BXL
TROUBLESHOOTING MANUAL
P/N 031-300-190-047 Rev0 2/17/99

DS350GM - BOOM CONTROL EXTENSION RT 865BXL
031-300-190-047 Rev0 02/17/1999
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.

DS350GM - BOOM CONTROL EXTENSION RT 865BXL
031-300-190-047 Rev0 02/17/1999
TABLE OF CONTENTS
GENERAL INFORMATION 1
REFERENCE MATERIAL 2
SERVICE AND MAINTENANCE 3
1. TROUBLESHOOTING
1.1 Boom Control Interface 4
1.2 Getting Started 5
1.3 Boom length percentage problem 6
1.4 Boom out of sequence in Automode 16
1.5 E83 - Outer mid and fly section are not retracted 26
1.6 E61 - Error in the bus extension 31
1.7 No tele function at all in automode 33
2. REFERENCE DRAWINGS AND INSTRUCTIONS
2.1 Proximity switch location and adjustment 39
2.2 RT865BXL Boom - LMI Hardware 40
2.3.1 Length transducer- Inner mid section 41
2.3.2 Length transducer- Center mid section 42
2.4 Length angle transducer- Overall boom length 43
2.5 Length transducer adjustment 44
2.6 RT 865BXL Turntable - LMI Hardware 45
2.7 Boom control - bus extension 46
2.8 Electric schematic - Central unit 47
2.9 Electric schematic - Bus extension 48
2.10 Electric schematic - Turntable 49
2.11 Electric schematic - Lower 50
2.12.1 Electric schematics - Boom 51
2.12.2 Electric schematics - Boom 52
2.13 Console - Boom control data display - 53
2.14 Relay output logic for the two-way-valves 54

DS350GM - BOOM CONTROL EXTENSION RT 865BXL 1
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GENERAL INFORMATION
This troubleshooting manual is designed to assist a service of maintenance person in
identifying LMI (Load Moment Indicator) problem areas or malfunctions. A digital
voltmeter with the capability to also measure current will be required. Regular
maintenance and service tools will also be required.
NOTE: Knowledge of how to use a voltmeter to measure both voltage and current is
assumed.
For system operation refer to the operator’s handbook for the console. This may differ
from crane manufacturer and model.
Section 2 provides the drawings and reference material that will used in the
troubleshooting flowcharts of this manual. Use the reference drawings in conjunction
with the flowcharts to help understand the operation of the system.
The PAT LMI DS 350 Modular with Boom Control Extension has been designed to
provide the crane with the essential information required to operate the machine within
the designed parameters.
Using different sensing devices, the DS 350 LMI monitors various crane functions and
provides the operator with a continuous display of the crane’s capacity. The display
continually changes as the crane moves through the motions needed to make a lift.
The DS 350 Modular LMI provides the operator with information regarding the boom
length and boom angle of the main boom, working radius rated load and the total
calculated weight being lifted by the crane.
If non-permitted conditions are approached, the DS 350 LMI will warn the operator by
sounding an audible alarm and lighting a warning light. In addition the LMI system has
the capability to provide a signal to the solenoids and thereby locking out those
functions that may aggravate the crane’s condition.

DS350GM - BOOM CONTROL EXTENSION RT 865BXL 2
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WARNING
The DS 350 load moment indicator (LMI) with boom control extension is an operational
aid that warns the crane operator when approaching an overload condition, a two block
condition and an out of boom sequence condition.
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.
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.
It still remains the operator’s responsibility to verify the operation and to select the
correct mode during crane operations.
The DS 350 Modular 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
Proper functioning depends upon proper daily inspection and observance of the
operating instructions provided with the crane and load moment indicator.
The manual mode is a rigging mode. Lifting loads in manual mode 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.
REFERENCE MATERIAL
Document PAT- Part number Grove- Part number
Parts & Installation Manual 031-300-150-713 9-333-103628
Operator’s Handbook 50\350\19_1319e.doc

DS350GM - BOOM CONTROL EXTENSION RT 865BXL 3
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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, non-expert personnel shall perform no other
repairs.

DS350GM - BOOM CONTROL EXTENSION RT 865BXL 4
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1.1 BOOM CONTROL INTERFACE
DS 350 Modular
Central Unit
Boom
Control Bus
Extension
Digital
Input
Digital 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
Prox.switch on CM section
Prox.switch on base section
Prox.switch on IM section
Boom retract
Boom extend
Automode on
OM/Fly retracted
Inner mid retracted
Center mid retracted & % reset
Out of sequence warning
Prop.extend
IM- 2way solenoids
Prop.
K4
K5
NO
K5
NC
K2 K3
K4
K5
Prop. retract
Out of sequence warning
light in cabin
Proportional pressure
reducing valve extend
Proportional pressure reducing valve retract
IM- 2way solenoid valve
Inner Mid length sensor
Main boom length sensor
Angle sensor
Rod pressure transducer
Piston pressure transducer
LMI Console
DI 1 DI 2
DI 3 DI 4
DI 5 DI 6
AO1
Prox.switch on base section
DI 7 Inner mid % reset
House pin switch
House pin engaged
DI 3
Digital Inputs
Analog input
CM- 2way solenoids
CM- 2way solenoid valve
AI
1
L1A1P2
P1
RxD
TxD
On rubber - over front switch
DI 2
on rubber over front
OM- 2way solenoids
Cable reel
OM- 2way solenoid valve
Center Mid length sensor
AI
2

DS350GM - BOOM CONTROL EXTENSION RT 865BXL 5
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1.2 GETTING STARTED
This section explains how to handle a problem that may arise with the PAT DS 350 Modular LMI boom
control extension. The procedures are given in flowchart format for the following sections. Start with the
general flowchart below which will guide you to one of the detailed flowcharts shown in Sections 1.1 to 1.7.
The drawings that are referenced in these sections can be found in Section 2.1 to 2.13.
Start
Boom length %
problem
No tele function at all in
automode
Boom out of sequence
in Auto mode
E61
Error in the boom
control extension
Start with section 1.3 Start with section 1.4 Start with section 1.6
Start with section 1.7
E83
Outer mid/ fly section is
not fully retracted or
center mid section is
not fully extended.
Start with section 1.5

DS350GM - BOOM CONTROL EXTENSION RT 865BXL 6
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1.3 BOOM LENGTH PERCENTAGE PROBLEM
Wrong?
Boom length percentage problem
Continue with section 1.4
Yes
No
IM and/ or CM retract signal not recognized. Check
proximity switch target adjustment. Refer to
section 2, drawing 2.1. If damage is visible install
new switch.
Switch to Manual Mode and retract the boom
completely against the stop block.
Check the percentage indication (1%,0%,0%).
Measure the voltage supply to IM switch at terminal
1(+24V) and 3 (GND) in the length transducer
LG 321 . Refer to section 2, drawing 2.3 and 2.8 to
2.12
Continue on next
page
Correct?
Yes
Adjust the target and switch.
Refer to section 2, drawing 2.1
No
Start

DS350GM - BOOM CONTROL EXTENSION RT 865BXL 7
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Correct?
Yes
No
Continue on next
page
Yes
No
Continuation
Correct?
Measure the voltage at terminal
25(+24V) and terminal 27 (GND) in the
bus extension unit.
Failure in bus extension.
Check connectors, fuses
and bus extension power
supply. Refer to section 2,
drawing 2.7 and 2.9.
Faulty wiring between bus
extension and LG 321.
Check wiring. Refer to
section 2, drawing 2.7 to
2.12.

DS350GM - BOOM CONTROL EXTENSION RT 865BXL 8
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Correct?
Faulty wiring between length
transducer LG 321 and switch
junction box. Check wiring.
Yes
No
Measure the voltage at terminal 1 (+24V) and 5
(GND) in the inner mid junction box.
Refer to section 2, drawing 2.2 and 2.12.
Measure voltage at terminal 1or 2 (+24V) and
5 or 6 (GND) in the switch junction box. Refer to
section 2, drawing 2.2 and 2.12.
Measure the IM reset switch signal at terminal 3
(+24V) and 5 (GND) in the proximity switch junction
box. Refer to section 2, drawing 2.2 and 2.12.
Continue on next
page
Correct?
Yes
Faulty wiring between length
transducer LG 321 and inner
mid junction box. Check wiring.
No
Continuation

DS350GM - BOOM CONTROL EXTENSION RT 865BXL 9
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Correct?
Faulty switch wiring or
defective switch. Replace IM
reset proximity switch. Adjust
switch and target. Refer to
section 2, drawing 2.1.
Yes
No
Measure the IM reset switch signal at wire 2
(+24V)(fast-on connector) and terminal 3 (GND) in the
length transducer LG321. Refer to section 2, drawing
2.3 and 2.12.
Measure the IM retract switch signal at terminal 4
(+24V) and 5 (GND) in the switch junction box.
Refer to section 2, drawing 2.2 and 2.12.
Continue on next
page
Correct?
Yes
Faulty wiring between length
transducer LG 321 and switch
junction box. Check wiring.
No
Continuation

DS350GM - BOOM CONTROL EXTENSION RT 865BXL 10
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Correct?
Faulty switch. Replace IM
retract proximity switch. Adjust
switch and target. Refer to
section 2, drawing 2.1.
Yes
No
Measure the IM retract switch signal at wire 4 (+24V)
(fast-on connector) and 3 (GND) in the length
transducer LG321. Refer to section 2,
drawing 2.3 and 2.12.
Measure the CM retract switch signal at terminal 6
(+24V) and 5 (GND) in the inner mid junction box.
Refer to section 2, drawing 2.2 and 2.12.
Correct?
Yes
Faulty wiring between length
transducer LG 321 and switch
junction box. Check wiring.
No
Continuation
Correct?
Defective switch. Replace CM
retract proximity switch. Adjust
switch and target. Refer to
section 2, drawing 2.1.
Yes
Measure the CM retract switch signal at terminal 8
(+24V) and 3 (GND) in the length transducer LG321.
Refer to section 2, drawing 2.2, 2.3 and 2.12 .
Continue on next
page
No
Yes

DS350GM - BOOM CONTROL EXTENSION RT 865BXL 11
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Correct?
Faulty wiring between length
transducer LG 321 and switch
junction box.
Check wiring.
Yes
No
Measure the IM retract switch signal at terminal 39
(+24V) and 27 (GND) in the bus extension. Refer to
section 2, drawing 2.7 and 2.9.
Measure the IM reset switch signal at terminal 41
(+24V) and 27 (GND) in the bus extension. Refer to
section 2, drawing 2.7 and 2.9.
Continue on next
page
Correct?
Yes
No
Continuation
Faulty wiring between bus
extension and length
transducer LG 321. Check
wiring.

DS350GM - BOOM CONTROL EXTENSION RT 865BXL 12
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Correct?
Faulty wiring between bus
extension and length
transducer LG 321. Check
wiring.
Yes
No
Measure the CM retract switch signal at terminal 37
(+24V) and 27 (GND) in the bus extension. Refer to
section 2, drawing 2.7 and 2.9.
Measure OM retract switch power supply at terminal
X1/11 (+24V) and X1/7 (GND) in the LG 321 (CM).
Refer to section 2, drawing 2.2 and 2.8 to 2.12.
Continue on next
page
Correct?
Yes
No
Continuation

DS350GM - BOOM CONTROL EXTENSION RT 865BXL 13
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Correct?
Faulty wiring between bus
extension and length
transducer LG 321(CM). Check
wiring.
Yes
No
Measure at CM junction box terminal 11 (+24V) and 9
(GND) . Refer to section 2, drawing 2.2 and 2.12.
Measure OM retract switch signal at CM junction
box terminal 10 (+24V) and 9 (GND). Refer to
section 2, drawing 2.2 and 2.8 to 2.12.
Continue on next
page
Correct?
Yes
No
Continuation
Faulty wiring between CM
junction box and length
transducer LG 321(CM). Check
wiring.

DS350GM - BOOM CONTROL EXTENSION RT 865BXL 14
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Correct?
Faulty wiring between bus
extension and length
transducer LG 321(CM). Check
wiring.
Yes
No
Measure signal at terminal X1/8 (+24V) and X1/7
(GND) in the LG 321(CM). Refer to section 2, drawing
2.2 and 2.12.
Measure signal at bus extension terminal X1/35
(+24V) and X1/27 (GND). Refer to section 2,
drawing 2.7 and 2.9.
Continue on next
page
Correct?
Yes
No
Continuation
Faulty wiring between CM
junction box and length
transducer LG 321(CM). Check
wiring.

DS350GM - BOOM CONTROL EXTENSION RT 865BXL 15
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Digital input defective on bus extension. Check
LED's on bus extension. Contact authorized service
for the replacement procedure.
Correct?
Faulty wiring between bus
extension and length
transducer LG 321(CM). Check
wiring.
Yes
No
Continuation
End

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1.4 BOOM OUT OF SEQUENCE IN AUTOMODE
Correct?
Problem:
In Auto Mode the boom becomes out of
sequence, the warning light is on.
Continue with section 1.3
-Boom length (%) error-
Yes
No
Inspect the spooling of the length cable on both drums.
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
(should be 0%,0%,0%).
Remove the lid from the length (angle) transducer
LG 321 and LWG 309. Carefully reset the length
transducer potentiometer. Refer to section 2,
drawing 2.5 for instruction. Repeat testing the boom
sequence in automode.
Continue on next
page
Correct?
Yes
Correct the spooling manually.
CAUTION:
Drum is under tension.
No
Start

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Failed?
Yes
No
In manual mode retract the boom. Disengage the boom stop block to
retract all section completely. Re-check the length potentiometer
adjustment. Refer to section 2, drawing 2.5.
Remove lid from LG321(IM length) and measure
supply voltage at terminal X1/1 (+24V) and X1/3
(GND).
Continue on next
page
Correct?
Yes
Adjust gear assembly and check O-ring
in gear wheel. Replace O-ring if wear is
visible.
No
Continuation
End