PAT DS350 G Troubleshooting Manual Download

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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

Summary of Contents for DS350 G

Page 1: ...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...

Page 2: ...e 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 furni...

Page 3: ...5 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...

Page 4: ...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 op...

Page 5: ...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 sha...

Page 6: ...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 tr...

Page 7: ...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...

Page 8: ...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 s...

Page 9: ...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 3...

Page 10: ...r Auto 24 1 24 1 24 1 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 n...

Page 11: ...p 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...

Page 12: ...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 Au...

Page 13: ...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 di...

Page 14: ...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 len...

Page 15: ...se 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 O...

Page 16: ...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 co...

Page 17: ...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 u...

Page 18: ...tment 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...

Page 19: ...ts 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...

Page 20: ...ts 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...

Page 21: ...ermial board Diode extension board Real time clock Timer board with e prom sockets Diode extension board Key to open central unit enclosure Drawing 9 PAT Equipment Corporation reserves proprietary rig...

Page 22: ...K6 K7 K5 K3 K4 K1 K9 K8 K10 X1 X1 X1 X1 X1 X1 K2 X1 X1 X1 Drawing 10 PAT Equipment Corporation reserves proprietary rights to this drawing and to the data shown there on The drawing and data are confi...

Page 23: ...TS 870 Drawing 11 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 with...

Page 24: ...TS 870 Drawing 11 2 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 with...

Page 25: ...TS 870 Drawing 11 3 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 with...

Page 26: ...TS 870 Drawing 11 4 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 with...

Page 27: ...TS 870 Drawing 11 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 with...

Page 28: ...BXL Drawing 12 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...

Page 29: ...BXL Drawing 12 2 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...

Page 30: ...BXL Drawing 12 3 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...

Page 31: ...a Logger Connection Drawing 12 4 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 re...

Page 32: ...LMI does not recognize the one or more reset switch signals Check proximity switch target adjustment as per section 9 1 If damage is visible install new switch Keep the boom stop block latched Switch...

Page 33: ...ulty voltage supply wiring to switch Refer to section 11 Replace defective cables Yes No Keep the inner mid section retracted Measure the inner mid reset switch signal at terminal 3 24V and 5 GND in t...

Page 34: ...ocate the fault Yes Continuation Is the voltage correct Faulty wiring in cable connecting the junction box with the length sensor Refer to section 11 to locate the fault Yes No Measure the IM reset sw...

Page 35: ...Refer to section 11 to locate the fault Yes Continuation Is the voltage correct Defective CM reset switch Replace proximity switch Yes No Measure the CM reset switch signal at terminal 10 24V and 9 GN...

Page 36: ...e the fault Yes Continuation Is the voltage correct Faulty wiring in cable connecting the boom base junction box with the LG221 Refer to section 11 to locate the fault Yes No Measure the CM reset swit...

Page 37: ...correct Faulty wiring in cable connecting the central unit and the boom base junction box Refer to section 11 to locate the fault Yes No Measure voltage supply to CM switch at terminal 7 24V and 5 GN...

Page 38: ...Yes Continuation Is the voltage correct Faulty wiring in cable connecting the the center mid junction box and the LWG 221 Refer to section 11 to locate the fault Yes No Measure the CM reset switch si...

Page 39: ...ate the fault Yes Continuation Is the voltage correct Faulty wiring in cable connecting the boom base junction box with the LWG 221 Refer to section 11 to locate the fault Yes No Measure the OM reset...

Page 40: ...carefully Let the drum rewind slowly and spool the cable manually back on the drum Check the roller guides for correct adjustment Refer to section 9 1 No In manual mode retract all boom sections Pull...

Page 41: ...nt procedure Yes Continuation Has the adjustment corrected the boom length indication Yes No Check the power supply to the length sensor Measure the power supply voltage at central unit terminal A104...

Page 42: ...Yes Continuation Is the voltage correct 5V Yes Verify the length sensor signal Measure the voltage at the length transducer LG 208 terminal 1 GND and 2 500mV with fully retracted boom Check the length...

Page 43: ...ain board component defective Contact authorized service dealer for the board replacement procedure Yes No Check the wiring that connects the LG 208 with the central unit Inspect the cable and connect...

Page 44: ...oard component defective Contact authorized service dealer for main board replacement procedure Yes No Check the wiring between length transducer LG 208 and central unit Inspect cable connectors and j...

Page 45: ...B 4 30 99 42 13 Continuation Continuation Is the voltage correct O turns 500mV 10 turns 4 5V Refer to page 18 and reset length transducer Continue with section 14 Yes No Defective length potentiomete...

Page 46: ...le carefully Let the drum rewind slowly and spool the cable manually back on the drum Check the roller guides for correct adjustment Refer to section 9 1 No In manual mode retract all boom sections Pu...

Page 47: ...procedure Yes Continuation Has the adjustment corrected the inner mid length indication Yes No Check the power supply to the length sensor Measure the power supply voltage at central unit terminal A10...

Page 48: ...correct 5V Yes Verify the length sensor signal Measure the voltage at the length transducer LG 221 terminal 1 GND and 2 500mV with fully retracted boom Check the length signal in the central unit Meas...

Page 49: ...00mV Main board component defective Contact authorized service dealer for the board replacement procedure Yes No Check the wiring that connects the LG 221 with the central unit Inspect the cable and t...

Page 50: ...5V Main board component defective Contact authorized service dealer for main board replacement procedure Yes No Check the wiring between length transducer LG 221 and central unit Inspect cable connec...

Page 51: ...Continuation Is the voltage correct O turns 500mV 10 turns 4 5V Refer to page18 and reset length transducer Possible main board defect Contact authorized service dealer for further assistance Yes No...

Page 52: ...e carefully Let the drum rewind slowly and spool the cable manually back on the drum Check the roller guides for correct adjustment Refer to section 9 1 No In manual mode retract all boom sections Pul...

Page 53: ...rocedure Yes Continuation Has the adjustment corrected the center mid length indication Yes No Check the power supply to the length sensor Measure the power supply voltage at central unit terminal A10...

Page 54: ...orrect 5V Yes Verify the length sensor signal Measure the voltage at the length transducer LWG 221 terminal 1 GND and 2 500mV with fully retracted boom Check the length signal in the central unit Meas...

Page 55: ...500mV Main board component defective Contact authorized service dealer for the board replacement procedure Yes No Check the wiring that connects the LWG 221 with the central unit Inspect the cable and...

Page 56: ...5V Main board component defective Contact authorized service dealer for main board replacement procedure Yes No Check the wiring between length transducer LWG 221 and central unit Inspect cable conne...

Page 57: ...99 54 15 Continuation Continuation Is the voltage correct O turns 500mV 10 turns 4 5V Possible main board defect Contact authorized service dealer for further assistance Yes No Defective length poten...

Page 58: ...re Refer to section 9 3 10 1 and 10 2 No Switch to manual mode and extend or retract the boom manually Does the boom extend or retract Yes Continue on next page Yes Faulty wiring to extend pressure sw...

Page 59: ...tage correct Switch to automode Start the engine and operate the retract control Measure the voltage at central unit terminal A104 X1 40 24V and A104 X1 39 GND while operating the extend control Selec...

Page 60: ...0 190 039 Rev B 4 30 99 57 17 Out of Sequence Warning Is the problem corrected Boom sections are out of sequence Automode Yes Is the problem corrected No Continue on next page Follow the instruction i...

Page 61: ...S870 RT865 BXL 031 300 190 039 Rev B 4 30 99 58 17 Continuation Is the problem corrected Yes Is the problem corrected No Continue on next page Follow the instruction in section 14 Follow the instructi...

Page 62: ...Continue on next page With outer mid section completely retracted check the adjustment for the OM retract switch target Refer to section 9 1 Measure switch signal at central unit terminal A104 X1 76...

Page 63: ...n next page Faulty wiring Check the voltage at terminal 17 24V and 13 GND in boom base junction box Refer to section 9 and 11 Measure switch signal at LWG 221 terminal 10 24V and 9 GND Yes No Continua...

Page 64: ...Is the voltage correct Yes No Check the signal at terminal 10 24V and 9 GND in CM junction box Refer to section 9 1 and 11 Retract all boom section in manual mode and let the system reset boom percent...

Page 65: ...g light in console and reduced capacity chart rigging mode Select manual mode Manually retract the outer mid and fly section until fully retracted Return to auto mode Check fly section cable adjustmen...

Page 66: ...ing manual and identify the correct location for the data eprom E70 No or wrong return signal from digital input extension module to processor Digital input circuit defective Replace module Ribbon cab...

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