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  DS350GM - BOOM CONTROL EXTENSION RT 865BXL

3

031-300-190-047 Rev0 02/17/1999

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.

Summary of Contents for DS 350

Page 1: ...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...

Page 2: ...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 per...

Page 3: ...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 Lengt...

Page 4: ...p 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 wi...

Page 5: ...t 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 su...

Page 6: ...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...

Page 7: ...set 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 p...

Page 8: ...low 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...

Page 9: ...et 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...

Page 10: ...ntinuation 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...

Page 11: ...ion 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 sign...

Page 12: ...easure 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 term...

Page 13: ...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 a...

Page 14: ...asure 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...

Page 15: ...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 term...

Page 16: ...ing 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...

Page 17: ...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 secti...

Page 18: ...7 Rev0 02 17 1999 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...

Page 19: ...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...

Page 20: ...lock 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 X...

Page 21: ...Check wiring Refer to section 2 drawing 2 8 to 2 12 Yes No Continue on next page Yes No Continuation Correct Measure the voltage at terminal X1 25 24V and terminalX1 27 GND in the bus extension Refer...

Page 22: ...t terminal X1 2 4mA and X1 3 GND Switch power off Re connect wire 2 to terminal X1 2 Faulty length sensor unit Replace length sensor unit Refer to section 2 drawing 2 3 Turn the length potentiometer i...

Page 23: ...2 Defective length sensor unit Replace length potentiometer assembly Refer to section 2 drawing 2 3 Turn the length potentiometer in the LG 321 IM clockwise to a soft stop 10 turns Measure the voltag...

Page 24: ...t terminal X1 2 4mA and X1 3 GND Switch power off Re connect wire 2 to terminal X1 2 Faulty length sensor unit Replace length sensor unit Refer to section 2 drawing 2 3 Turn the length potentiometer i...

Page 25: ...2 Defective length sensor unit Replace length potentiometer assembly Refer to section 2 drawing 2 3 Turn the length potentiometer in the LG 321 IM clockwise to a soft stop 10 turns Measure the voltag...

Page 26: ...rical current at terminal X1 2 4mA and X1 3 GND Switch power off Re connect wire 2 to terminal X1 2 Defective length sensor unit Replace length sensor unit Refer to section 2 drawing 2 4 Turn the leng...

Page 27: ...1 2 Defective length sensor unit Replace length sensor unit Refer to section 2 drawing 2 4 Turn the length potentiometer in the LWG 309 clockwise to a soft stop 10 turns Measure the voltage at LWG 309...

Page 28: ...XL 25 031 300 190 047 Rev0 02 17 1999 Fault is not located in the LMI circuit Follow the crane service instructions to continue End Continuation Correct Yes No Faulty bus extension module Contact PAT...

Page 29: ...Switch to automode and continue normal crane operation Yes No Switch to automode and retract the boom Caution Reduced load chart with E83 Switch to manual mode and retract the outer mid section fully...

Page 30: ...t page Correct Yes No Continuation Switch to manual mode and retract the outer mid section fully Adjust the switch and the target Refer to section 2 drawing 2 1 Correct Defect is not located in LMI ci...

Page 31: ...and 2 8 to 2 12 Continue on next page Correct Yes No Continuation Defective bus extension Check connectors fuses and bus extension power supply Refer to section 2 drawing 2 7 and 2 9 Faulty wiring bet...

Page 32: ...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 an...

Page 33: ...Rev0 02 17 1999 Digital input defective on bus extension Check LED s on bus extension Contact authorized service for the replacement procedure Correct Defective wiring between bus extension and lengt...

Page 34: ...ension Refer to the crane service documentation to correct the power failure Yes Check crane power battery voltage No Start No Measure the power supply at the bus extension terminal X1 26 24V and 28 G...

Page 35: ...nnections between bus extension and central unit End Correct Yes If damage is visible replace the cable otherwise rewire and tighten the connections Caution Twisted pairs must remain twisted No Contin...

Page 36: ...n Yes No Remove lid from bus extension enclosure Measure crane power supply at terminal X1 26 24V and X1 28 GND Refer to section 2 drawing 2 6 2 7 and 2 8 2 12 Remove load from hook Make sure no other...

Page 37: ...and 2 8 2 12 Faulty pilot pressure switch in the tele extend pilot pressure circuit or crane electric harness faulty Refer to crane documentation Switch to auto mode Start the engine Operate the exten...

Page 38: ...ection should increase in steps from 0 to 255 continue on next page Correct Yes Faulty digital input 1 on bus extension Contact authorized service to obtain replacement instructions Continuation Refer...

Page 39: ...should increase from 0 mA to approximately 800 mA Note In the ramping area the value may be 800 mA continue on next page Correct Yes Check the power supply to the analog output module A104 IM Measure...

Page 40: ...al A104 X1 2 Operate the extend control Measure at bus terminal X1 14 0V and X1 28 GND Operate the retract control Measure at bus terminal X1 15 0V and X1 28 GND Continuation Correct Defective analog...

Page 41: ...n box No Continuation In the bus extension Check fuse F2 for relay K2 IM 2 way valve Check fuse F6 for relay K6 CM 2 way valve Check fuse F7 for relay K7 OM 2 way valve Replace if blown Refer to secti...

Page 42: ...DS350GM BOOM CONTROL EXTENSION RT 865BXL 39 031 300 190 047 Rev0 02 17 1999 2 1 DRAWING PROXIMITY SWITCH LOCATION AND ADJUSTMENT...

Page 43: ...DS350GM BOOM CONTROL EXTENSION RT 865BXL 40 031 300 190 047 Rev0 02 17 1999 2 2 DRAWING RT 865BXL BOOM LMI HARDWARE...

Page 44: ...EXTENSION RT 865BXL 41 031 300 190 047 Rev0 02 17 1999 2 3 1 DRAWING LENGTH TRANSDUCER INNER MID SECTION Terminal X1 Gearwheel Length potentiometer Slipring assembly To19 pin connector connecting boo...

Page 45: ...0 047 Rev0 02 17 1999 2 3 2 DRAWING LENGTH TRANSDUCER CENTER MID SECTION To center mid junction box To19 pin connector connecting boom and superstructure Drawing 2 3 2 LG 321 Center mid section Termin...

Page 46: ...47 Rev0 02 17 1999 2 4 DRAWING LENGTH ANGLE TRANSDUCER OVERALL LENGTH Slipring assembly Terminal X1 Length potentiometer Angel sensor To boom nose junction box To 7 pin connector connecting boom with...

Page 47: ...DS350GM BOOM CONTROL EXTENSION RT 865BXL 44 031 300 190 047 Rev0 02 17 1999 2 5 DRAWING LENGTH TRANSDUCER ADJUSTMENT Drawing 2 5 Length transducer adjustment...

Page 48: ...7 Rev0 02 17 1999 2 6 DRAWING RT 865 BXL TURNTABLE LMI HARDWARE Pressure Transducers Console Central unit Boom control bus extension Connect the turntable hardware with the boom hardware Crane electri...

Page 49: ...865BXL 46 031 300 190 047 Rev0 02 17 1999 2 7 DRAWING BOOM CONTROL BUS EXTENSION Analog output module Analog input module Drawing 2 7 Boom control bus extension Bus extension Terminal X1 CPU Module Re...

Page 50: ...WING ELECTRIC SCHEMATIC CENTRAL UNIT To bus extension To 8 pin crane electric connector To area def switch interface To console To piston side pressure transducer To rod side pressure transducer To 7...

Page 51: ...48 031 300 190 047 Rev0 02 17 1999 2 9 DRAWING ELECTRIC SCHEMATIC BUS EXTENSION To 23 pin crane interface connector To 14 pin boom base connector To 19 pin boom base connector To central unit Drawing...

Page 52: ...GM BOOM CONTROL EXTENSION RT 865BXL 49 031 300 190 047 Rev0 02 17 1999 2 10 DRAWING ELECTRIC SCHEMATIC TURNTABLE To bus extension Drawing 2 10 Electrical Schematic Turntable To central unit To central...

Page 53: ...047 Rev0 02 17 1999 2 11 DRAWING ELECTRIC SCHEMATIC LOWER To length angle transducer LWG 309 Boom base connector Console Connector for optional lightbar Drawing 2 11 Electrical Schematic Lower To cent...

Page 54: ...0GM BOOM CONTROL EXTENSION RT 865BXL 51 031 300 190 047 Rev0 02 17 1999 2 12 1 DRAWING ELECTRIC SCHEMATIC BOOM Drawing 2 12 1 Electrical Schematic Boom To bus extension To pair of inner mid two way va...

Page 55: ...BOOM CONTROL EXTENSION RT 865BXL 52 031 300 190 047 Rev0 02 17 1999 2 12 2 DRAWING ELECTRIC SCHEMATIC BOOM To bus extension Drawing 2 12 2 Electrical Schematic Boom To central unit To pairs of two wa...

Page 56: ...865BXL 53 031 300 190 047 Rev0 02 17 1999 2 13 DRAWING CONSOLE BOOM CONTROL DATA DISPLAY Press the two outer keys simultaniously to view the boom control data Press again to hide the data Drawing 2 13...

Page 57: ...2 on bus extension IM two way valves 6 Relay K6 on bus extension CM two way valves 7 Relay K7 on bus extension OM two way valves Table A K2 K6 K7 out of sequence 0 0 0 IM ext ret 0 1 1 CM ext ret 1 0...

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