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3B6 SLIM, Troubleshooting Manual, Page: 31 / 31

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3B6 SLIM Troubleshooting Manual Download Page 31

31 

AUTO DIAGNOSTIC 

Cylinder topping  

3B6 

 

 

 

Rigging & Travel 

 
In the event the cylinder is topped the system detects a shutoff condition due to the piston 
pressure has exceeded the calibration data inside the system. In order to boom the machine 
back down out of the upper stops, you must select the Rigging and Travel mode to allow this or 
bypass the system using the bypass key switch. 
 
Once the unit has reset to the normal operating condition select the proper program for 
operation. 

Summary of Contents for SLIM

Page 1: ...hooting Manual Rev 9 1 4 13 Software TXW003TME Enter AC T a r h l S TO P Index 0 43 5 1 1 10 2 34 1 6 1 68 7055 Morning Dove Way Roscoe IL 61073 Phone 815 270 0088 www controlsystemsw com waynem controlsystemsw com ...

Page 2: ... 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...

Page 3: ...itial 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 prod...

Page 4: ... 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 ...

Page 5: ...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 2S 2 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 supplied length CV4x0 50sch 2 0 61m CV4x0 50sch 2 0 61m...

Page 6: ...I2 INP2 12 6 AI3 INP3 11 1 2 3 Angle Sensor A2BN2B ASA CBL3W XX WIRE COLOR SIGNAL BROWN VB GREEN WHITE VB CAN L CAN H YELLOW 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 DO1 8 DO1 OUT1 White Gr...

Page 7: ...otation 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 Virtu...

Page 8: ...ustment 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 Re...

Page 9: ...ture 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 ...

Page 10: ... 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 malfuncti...

Page 11: ...mponent when power is applied to the system Damage to the system will be the result 3B6 Troubleshooting Manual Enter AC T a r h l S TO P 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 ...

Page 12: ...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 in...

Page 13: ... 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 pr...

Page 14: ...tor 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 ...

Page 15: ...tor 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 ...

Page 16: ...t 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 wir...

Page 17: ...n 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 inl...

Page 18: ... 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 ...

Page 19: ...ble 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 ...

Page 20: ...y 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 ...

Page 21: ...can remove the existing cable Remove the four Phillips head screws noting the color code and location on the slip ring Cut the ring terminals off Fig 20 Fig 20 Wiring code Collector Bottom White Middle Red Top Blue Shield base 3B6 Troubleshooting Manual ...

Page 22: ...ble Fig 21 Strip back one end of the replacement cable the same length as the old cable or approximately 12 inches and feed it through the cable reel drum access hole from the inside of the drum area and then into the base connector and up into the slip ring collector Fig 22 Fig 22 3B6 Troubleshooting Manual ...

Page 23: ...the pg connector strain relief nut Cut off any access wire inside the slip ring and install the ring terminal and connect the wire to the proper terminal of the slip ring collector Tighten the phillips screws and replace the cap and self locking nuts 3B6 Troubleshooting Manual Wiring code Collector Bottom White Middle Red Top Blue Shield base ...

Page 24: ...ace a tie wrap on the cable at the roller guide on the reel and install it back on the boom Feed the cable through the boom to the boom tip and connect the strain relief and the black connector The tension on the reel should be between 2 5 wraps 3B6 Troubleshooting Manual Tie wrap Cable Guide Connector Strain relief at boom tip area Cable routing ...

Page 25: ...ates zero degrees on the display Tighten the screws and check it at other angles for accuracy Angle sensor ASA 25 3B6 Troubleshooting Manual Check the voltage output of the length pot is approximately 250vdc wire tolerance of 246 to 254 with fully retracted boom if not adjust the length gear assembly until it is Check the length indication on the display If it is correct extend the boom and check ...

Page 26: ...ot Replacement Drive Assembly Collar Rotation pot 26 3B6 Troubleshooting Manual Loosen the top side set screws on the collar Swing the boom centered directly over the rear of the Machine Location is inside turret ...

Page 27: ... Manual Remove the bracket with pot and collar attached Loosen set screws on collar and remove Remove the pot hardware and set aside for reinstallation later Remove the hardware attaching the bracket and pot bracket Set aside for reinstalling later ...

Page 28: ...eplacement 28 3B6 Troubleshooting Manual Reassemble pot bracket assemble and tighten Hardware Pot wire direction should match photo Assemble new pot to collar and then tighten the collar set screws down Shaft recess ...

Page 29: ...ust the pot collar until the display read out is indicating an average of 180 degrees Now tighten the set screws on the drive assembly Now check the rotation stop points Install the hardware back into place and tighten Do not tighten the top set screws on Drive assembly at this time ...

Page 30: ...button and scroll to page P10 of the auto diagnostics the RA is the channel we will adjust the pot to read 180 degrees average between the two outputs of channel A and B when the boom is directly over the rear of the machine and tighten the set screws on the upper drive assembly and then tighten the drive assembly set screw Example Channel A is 179 6 channel B is 181 8 Average is around 180 degree...

Page 31: ...the piston pressure has exceeded the calibration data inside the system In order to boom the machine back down out of the upper stops you must select the Rigging and Travel mode to allow this or bypass the system using the bypass key switch Once the unit has reset to the normal operating condition select the proper program for operation ...

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