Pat 2 Manual

LEVEL II
VE
RO
G
T
PA
DS350 GRAPHIC
(BOOM CONTROL SYSTEM)
DS350 GRAPHIC
MODULAR
DS350 GRAPHIC
MODULAR
iFLEX5 SYSTEM
P.A.T. - L.M.I.
SYSTEM MANUAL
P.A.T. - L.M.I. LEVEL II

MANUAL INDEX
DS350 Graphic (BCS)
Section
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Description
DS350 Graphic Console Descriptions
Connections & Wiring Diagram,
DS350 Graphic (BCS) Hydraulic, Electrical
Theory & Component Location
DS350 Graphic (BCS) Boom Length
Connections & Wiring Diagrams
DS350 Graphic (BCS) Piston, Rod Connections
& Wiring Diagrams
DS350 Graphic (BCS) Boom Angle
DS350 Graphic (BCS) Anti - Two - Block
DS350 Graphic (BCS) Digital Inputs
DS350 Graphic (BCS) Central Unit P.C. Board
Layout
DS350 Graphic (BCS) Basic Adjustments
and Checks.
DS350 Graphic (BCS) Main Board and
Transducer Replacement Procedure
DS350 Graphic (BCS) Troubleshooting Guide
Appendix: Boom Length Troubleshooting
DS350 Graphic (BCS) Electrical Diagrams
DS350 Graphic (BCS) Service Bulletins
& Miscellaneous Information

MANUAL INDEX
DS350 Graphic Modular
Section
Description
14.
DS350 Graphic Modular Console Connections,

Wiring Diagram
15.
DS350 Graphic Modular Central Unit P.C. Board

Layout
16.
DS350 Graphic Modular Boom Length

17.
DS350 Graphic Modular Piston, Rod Connections

& Wiring Diagrams
18.
DS350 Graphic Modular Boom Angle Connection

& Wiring Diagrams
19.
DS350 Graphic Modular Anti - Two - Block

20.
DS350 Graphic Modular Troubleshooting Guide

MANUAL INDEX
DS350 Graphic Modular (BCS)
Section
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Description
DS350 Graphic Modular (BCS) Console
Connections, Wiring Diagrams
DS350 Graphic Modular (BCS) Component
Location
DS350 Graphic Modular (BCS) Boom Length
DS350 Graphic Modular (BCS) Piston, Rod
DS350 Graphic Modular (BCS) Boom Angle
DS350 Graphic Modular (BCS) Anti - Two - Block
DS350 Graphic Modular (BCS) Digital Inputs
DS350 Graphic Modular (BCS) Central Unit P.C.
Modular Board Layout
DS350 Graphic Modular (BCS) Troubleshooting
Guide
DS350 Graphic Modular (BCS) Electrical Diagrams
DS350 Graphic Modular (BCS) Service Bulletins
& Miscellaneous Information

MANUAL INDEX
iFLEX5 System
Section
Description
32.
iFLEX5 Service Information
33.
Troubleshooting a Sensor Problem Using the Display
34.
Service Screen for Sensor Calibration
35.
Boom Control
36.
Luffing Boom Extension
37.
Error Code Listing
38.
Troubleshooting Moisture
39.
Software Transfer Instructions Information

This presentation and all information contained herein are confidential and proprietary
information of Grove Worldwide and as such, no usage or reproduction of this
information shall be done without the express written permission of Grove Worldwide.
The information in this manual is subject to change without notice.
3/22/04
P.A.T. L.M.I
MANUAL
SECTION 1
DS 350 GRAPHIC CONSOLE

DESCRIPTION, CONNECTIONS
& WIRING DIAGRAM
PAT
LOAD MOMENT INDICATOR
PAT
DS 350
STOP
STOP
156ft
0335
TARE
90.0ft
?
79.4
LIM
SEL
50.8ft
STOP
MAX
(lbs)
02 73.5oo
ACT
(lbs)
34.900
100%
100%
CTRL
100%
STOP
F1
F2
F3
F4
DS 350 / 1319 GRAPHIC

OPERATORS HANDBOOK
1.1
NOTICE:
The information in this document is subject to change without notice.
This document was created for training purposes only and should not
be a replacement for the original P.A.T.-L.M.I. operators handbook
for your specific system and crane.
1.2
P.A.T. LOAD MOMENT INDICATOR

1. GENERAL INFORMATION
The PAT Load Moment Indicator 1) (LMI) has been designed to provide the crane operator with the
essential information required to enable the machine to be used within its design parameters.
Using various sensing devices, the Load Moment Indicator monitors various crane functions and provides
the operator with a continuous reading of the cranes capacity. The readings continuously change as the
crane moves through the motions needed to make the lift.
The LMI provides the operator with information regarding the length and angle of the boom, tip height,
working radius, rated load and the total calculated weight being lifted by the crane.
If non permitted conditions are approached, the Load Moment Indicator will warn the operator by
sounding an audible alarm, lighting a warning light and locking out those functions that may aggravate
the cranes condition.
1)LOAD MOMENT: Generally the product of a force and its moment arm: specifically, the product
of the load and the load radius. Used in the determination of the lifting capacity of a crane.
2. WARNINGS
The LMI is an operational aid which warns a crane operator of approaching overload conditions and
also warns of overhoist conditions which could cause damage to equipment and personnel..
The device is not, and shall not, be a substitute for good operator judgment, experience and use
of accepted safe crane operating procedures.
The responsibility for the safe operation of the crane 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 in this manual to ensure that he knows the operation and limitations of the
indicator and crane.
Proper functioning is dependent upon proper daily inspection and observations of the operating
instructions set forth in this manual. We draw your attention to section 5 of this manual.
WARNING
The display will only aid the operator when the LMI is properly programmed and the
proper load capacity chart and operating code are selected for the crane configuration
being utilized. To prevent property damage or serious bodily injury or death to
personnel, ensure the LMI is properly programmed before operating the crane.
1.3
WARNING
This system is equipped with an override key on the central microprocessor unit. This key switch bypasses control lever lockout function of load moment indicator device. The switch may
only be used by authorized personnel during emergency situations. Failure to follow this instruction may result in property
damage and/or personal injury.
NORMAL OPERATION
L/O OVERRIDE
3. SYSTEM DESCRIPTION
The PAT load Moment Indicator consists of a central micro processor unit, operating console, length/angle
sensor, pressure transducers and anti-two-block switches.
The system operates on the principle of reference/actual comparison. The actual value, resulting from the
force or pressure measurement is compared with the reference data, stored in the central processor
memory and evaluated in the micro processor. When limits are reached, an overload warning signal is
generated at the operators console. At the same time, the dangerous crane movements, such as hoist up,
telescope out and boom down, will be stopped.
The fixed data regarding the crane, such as load capacity charts, boom weights, centers of gravity and
dimensions are stored in memory chips in the central processor unit. This data is the reference information
used to calculate the operating conditions.
Boom length and boom angle are registered by the length/angle sensor, mounted inside the cable reel
which is mounted on the boom. The boom length is measured by the cable reel cable which also serves
as an electrical conductor for the anti-two-block switches.
The crane load is measured by pressure transducers attached to the piston and rod side of the lift cylinders.
1.4
VE
GRO
NOTE:
If PAT System is to be used in
conjunction with a jib having an
existing Grove/Krueger Anti-TwoBlock system, a special connector
cable is required. Consult Grove
customer services for requirement.
3
4
5
CONSOLE
4
2
1 ANTI-TWO-BLOCK SWITCHES
2 PRESSURE TRANSDUCERS
3 LENGTH/ANGLE SENSOR-ANTITWO-BLOCK CABLE REEL
4 OPERATING CONSOLE
5 CENTRAL MICRO PROCESSOR UNIT
1.5
3.2 SYSTEM FUNCTION

The PAT Load Moment Indicator (LMI) works with a user guide system that simplifies the operation
of the crane and the LMI system. The system run during the start up phase is shown in the following
block diagram.
After ignition of the engine the system starts with an
automatic test of all lamps, the audible alarm and the
complete LMI system.
Start
Self check of
LMI System
Error?
Error code
yes
no
yes
In case of system malfunction an error code number

will be displayed on the console.
Within
2 hours?
After restarting the engine within 2 hours, the system

will by-pass Pre-Setup.
no
Basic system information for crane operator will be

displayed.
Interactive
INPUT
operating mode
Experienced operators who are familiar with the LMI

system can by-pass the info run.
Interactive
INPUT
reevings
Inputs
OK?
The system will display information and directions

which the operator will follow by using the respective
function of the key.
no
The system is in the programming procedure. The operator

has to set the LMI to the configuration of the crane.
yes
Ready for
Operation
The system is ready for operation.
4 SYSTEMS OPERATION
During the startup phase the crane operator will receive information about the function and meaning of the various elements of
the console. This process will also remind the crane operator to follow the respective operating instructions.
During the pre-setup phase the crane operator will receive general information about his responsibility by operating the crane.
If the operator is experienced and totally familiar with the function and operation of the system he can go directly to the
programming procedure at the end of this PRE-SETUP phase.
When the crane engine is restarted after less than approximately two hours, the PRE-SETUP and Information Run
will be skipped.
4.1 Pre-Setup
The PRE-SETUP is a simple step by step procedure. The information will be displayed until a button is pressed to call for the
next info step. The PRE-SETUP is followed by the Info Run or by the programming phase.
1.6
4.1 Pre-Setup cont.

Before operating the machine you must be aware of some safety precautions, on some systems these precautions
will be included in the normal Pre-Setup display screen after you have selected the language (DS350GW &DS350GWV).
FIND OPERATOR
MANUALS
READ AND UNDERSTAND
* PUSH INFO
Prior to operating, the operator shall carefully and thoroughly read and understand
the crane load capacity charts and the information contained in the manuals for the
crane and the LMI, to ensure that the operator knows the operation and limitations
of the crane and the LMI.
THE LMI SYSTEM IS AN

OPERATIONAL AID
WHICH CAN FAIL
* PUSH INFO
The load moment indicator (LMI) is a system which supports an operator in his
action to operate the crane.
But the system cannot be 100% fail-safe and not all causes for danger can be
recognized at the same time.
CONSULT AND OPERATE

ACCORDING TO IN CAB
LOAD CAPACITY CHARTS
* PUSH INFO
For the loading capacity of the crane only the load capacity charts are relevant. The
operator shall also observe the operating instructions in the load capacity charts.
The load values in the load capacity chart shall under no circumstances be
exceeded. It is essential to select the correct operating code number which is
also printed in the load capacity chart.
The operator is entirely responsible for safe crane operation.

YOU ARE ALWAYS
RESPONSIBLE FOR
YOUR LIFT OPERATIONS
* PUSH INFO
IF IN DOUBT CONSULT
THE OPERATOR MANUALS
BEFORE OPERATING THE
CRANE
* PUSH INFO
He has to make sure that the crane is in good condition and that he works on a firm
and level supporting surface. The operator shall fully acquaint himself with the
most recent government regulations and industry standards relevant to safe craning
operations.
If there is anything unclear or if there are doubts about operating the crane or LMI,
the operator shall consult the operator manuals before operating the crane.
1.7
4.2 Operating Console

The console has 3 functions:
Inputs by the crane operator (operator mode, reeving)
Input of geometry limit values and signalization of exceeded limit values
Display of important data and information
The operators console is mounted in the cranes cab in the operators field of vision. For a better
identification of displays and operating elements, they are continuously back lit during operation.
4.3 Control Identification

This unit contains a display and different controls which are described as follows:
Fig.2: Operating Console
PATDS 350
12
STOP
Legend to Fig. 2 :
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
F1
F2
F3
F4
LC Display Area
Load Moment Limit Light
Load Moment Prewarning Light
Alarm Light Anti - Two - Block
Override Key Warning Light
Button Alarm Stop
Button and Control Light TARE
Button and Control Light LIMITS
Button and Control Light SELECT
OPERATION MODE
Button and Control Light INFO
Button and Control Light CONTROL
Audible Alarm
By-Pass Key Switch
Button and Control Light By-Pass
ANTI - TWO - BLOCK
Button and Control Light By-Pass
LMI SHUT-OFF FUNCTION
Button Function 1
Button Function 2
Button Function 3
Button Function 4
STOP
7
3
TARE
!
8 LIM
9 SEL
STOP
14
STOP
15
F1
13
1.8
F2
F3
F4
10
11
CTRL
1.
2.
3.
STOP
The LC display visualizes graphical symbols, text and numerical values.

Depending on the selected operating mode the corresponding information is
indicated on the display.
The red Load Moment Limit Light warns the operator that a rated load condition
has been reached (at 100 % of the crane rating). It lights up when the load on the
crane reaches the crane load capacity. The audible alarm also sounds when this
condition has been reached.
The following crane movements will be stopped concurrently: hoist up,
telescope out, boom down. On units with luffing jib, in addition to the above
lockouts, the luffing hoist down will be stopped.
The yellow Load Moment Prewarning Light will light up when the load on the
crane enters the defined prewarning area (between 90 and 100 % of crane rating).
It indicates that an overload condition is approaching.
This means for the operator to continue his crane operation with extreme caution.
The definition and setting of the prewarning area is linked to the data EPROM
used in the central unit.
The red Anti-Two-Block Warning Light will light up when the Anti-Two-Block
limit switch contacts open, indicating that a two-blocking condition is
approaching. At the same time the audible alarm will sound.
The following crane movements will be stopped concurrently: hoist up,
telescope out, boom down. On units with luffing jib, in addition to the above
lockouts, the luffing hoist down will be stopped.
4.
5.
STOP
STOP
6.
The red Override Key Warning Light flashes when the bypass key switch
is turned and the button is pushed. This switch deactivates the cut-off function
of the LMI.
WARNING
Should the red override key warning light continue to flash (with the by-pass
key switch in the neutral position) , the LMI override key switch located
on the central processing unit (CPU) has been positioned in the lockout override
position. This key switch continually by-passes the control lever lockout
function of the load moment indicator device.
The Alarm Stop Button allows the audible alarm to be silenced for
approximately 15 seconds by pressing this button.
The Tare Button is used to indicate the net load on the display. Net load is the
actual load, less lifting tackle and hook block. The Tare Button has to be
activated before lifting.
7.
TARE
After pushing the Tare Button before lifting, the display of actual load will be
set to zero (taring). After pushing the tare button the display shows max. load,
net load and radius. Net load display is blinking and set to zero. After lifting a
load the net load display shows the net load (pay load).
The net load display will change to the normal working display when the
boom radius is changed (either by angle or length).
1.9
8.
9.
LIM
This button will be used for future functions:

- Slewing Angle Limitation
- Tip Height Limitation
- Radius Limitation
Boom AngleLimitation is used.
SEL
If, during the crane operation, you wish to change the crane
configuration, this button can be pushed for quick setting
without having to go through the whole LMI programming
procedure again. (ie. Hoist Reeving, Hoist, Extension)
10.
CTRL
11.
PAT
12.
13.
B
With the system being ready for operation, this function serves
to display the system configuration.
The display shows the crane symbol representing the adjusted
configuration (marked in black), the extended operating code
number and the reeving number.
This function serves for the contrast adjustment of the LC display.
The last adjustment is stored and does not have to be repeated at
every system start.
The AUDIBLE ALARM sounds during the following

conditions: overload condition, approaching two- block condition,
preset limits reached, malfunction of the LMI, operating error.
The alarm can be temporarily silenced by pushing button (6).
When turned to position B the KEY SWITCH serves to release the function :
- deactivate the cut-off function of the LMI
- deactivate the cut-off function of the
anti-two-block switch
It can be operated only by using the matching key
WARNING
Since buttons (14) and (15) deactivate the cut-off function of the LMI system
/ the anti-two-block system, the following instructions must be obeyed.
- The by-pass function shall be used with discretion, as unwarranted use
of it to override the control lever lockout system can result in harm to the
crane and danger to property and persons.
- Never use the by-pass function to either overload or operate the crane in
a non permissible range.
1.10
14.
15.
STOP
This button can be operated only if key switch is turned to

position B.
After pushing this button, the cut-off function of the
anti-two-block switch is deactivated.
The Override Key Warning Light (13) flashes to indicate that
the cut-off function is deactivated.
This button can be operated only if key switch is turned to
position B.
After pushing this button, the cut-off function of the
LMI switch is deactivated.
The Override Key Warning Light (13) flashes to indicate that
the cut-off function is deactivated.
1.11
5. Daily Inspection & Observations

Prior to operating the crane, the following electrical connections must be checked to ensure that the system
is properly connected for the crane configuration.
Machines with only a Main Hoist

If the crane works only with the boom and without boom extension or jib, no additional connections are
necessary. However, be sure the weight of the anti-two-block switch is properly installed on the main hoist
load line. With even parts of hoisting line, the weight shall be attached to the dead-end line. With odd parts
of hoist line, the weight shall be attached to the line of lowest speed.
If the crane works with boom extension or jib, the connecting cable shall be installed between the junction
box on the boom extension or jib and the boom junction box. The weight attached to the main hoist anti-twoblock switch shall be removed. In that case the anti-two-block switch has to be locked with the red
Anti-Two-Block Retainer, which is fixed with a red lanyard at the anti-two-block switch
(shown in Fig. 1-4). Then the weight shall be reattached to the boom extension or jib anti-two-block.
WARNING
Failure to re-position the anti-two-block switch weight will prevent the
overhoist system from functioning properly. No weight shall be on the main
hoist anti-two-block switch when the boom extention or jib is being used.
Machines with Main and Auxiliary Hoists

If the boom extention or jib is not in the operating position, the by-pass plug shall be installed in the main
boom junction box. The weight of the main hoist anti-two-block switch shall be installed.
If the boom extension or jib is in the operating position, the connecting cable shall be installed between the
junction boxes on the boom extension or jib and the main boom. Weights shall also be attached to the
anti-two-block switches on both the main boom and boom extension or jib.
If the boom extension or jib is in the operating position and no load line is being used on main boom, to
prevent injury or damage to equipment, the weight shall be removed from main boom switch. In that
case the anti-two-block switch has to be locked with the red Anti-Two-Block Retainer, which is fixed
with a red lanyard at the anti-two-block switch.
Installation of Anti-Two-Block Retainer in Locking Position

Procedure (see Fig. 1 and 2):
1. Pull the cable out of the switch and bend back parallel to the boom and hold (1).
2. Slide the retainer from left side with its slot over the cable between the crimped stop
and the switch (2). Push firmly straight onto the cable guide of the Anti-Two-Block
switch (3).
3. Straighten the cable completely into the slot and release the cable (4).
4. Turn the flag of the retainer for best
visibility for the operator (5).
1.12
3
1
5
2
4
Fig. 1 : Setting of Anti-Two-Block
Retainer in Locking Position
Fig. 2 : Retainer in Locking Position
Removal and Storage of the Anti-Two-Block Retainer

Procedure (see Fig. 3 and 4):
1. Pull the cable out of the switch (1) and bend back parallel to the boom and hold (2).
2. Move the retainer down (3) and then left (4) to remove it from the Anti-Two-Block
switch. Release the cable.
3. For storage slide the retainer from right side (5) over the Anti-Two-Block switch unti
the clips (A) lock into the holes (B).
1.13
B
A
3
1
4
2
Fig. 3 : Removal of the Anti-TwoBlock Retainer
Fig. 4 : Retainer in Storage Position
Pre-Operation Inspection and Calibration Verification

After the electrical connections have been checked to insure that the system is properly connected for
the crane configuration, the following checks shall be made:
1. Check the electrical wiring connecting the various parts of the system for
physical damage.
2. Check the anti-two-block-switches and weights for free movement.
3. Check the spring-loaded cable reel to be sure it is free rotate, has tension and the cable
is reeled properly.
4. Check mechanical installation and electrical connection of the force transducer(s) on
jibs where applicable.
WARNING
The following test shall be performed with care to prevent
damage to the machine or injury to personnel. Proper functioning
of the system requires successful completion of these test before
operating the machine.
1.14
If the operator cannot see the load handling device approaching the boom nose, he shall have an assistant
(signal person) watch the load handling device. The operator shall be prepared to stop the machine
immediately should the LMI system not function properly as indicated by lighting the red warning light,
sounding the alarm and locking the crane movements, hoist up, telescope out and boom down.
Check the anti-two-block alarm light and the audible alarm by performing one of the following test:
1. By manually lifting the weight attached to the anti-two-block switches. When the
weight is lifted, the audible alarm should sound, the anti-two-block alarm light
should light.
2. Slowly raise the main boom load handling device to create a potential two -block
condition. When the load handling device lifts the weight, the audible alarm
should sound, the anti-two-block light should light and the motion of the load
handling device should be stopped. Lower the load handling device slightly to
eliminate this condition.
3. Slowly lower the boom to create a potential two -block condition. When
the load handling device lifts the weight, the audible alarm should sound,
the anti-two-block light should light and the boom lowering function
should be stopped. Lower the load handling device slightly to eliminate
this condition.
4. Slowly extend (telescope) the main boom to create a potential two -block
condition. When the load handling device lifts the weight, the audible alarm
should sound, the anti-two-block light should light and the boom telescope out
function should be stopped. Lower the load handling device slightly to
eliminate this condition.
If the light and audible alarm do not function as described

and the crane movements are not stopped, the system is
not working properly. The malfunction shall be corrected
before operating the crane.
5. If the crane is equipped with a boom extension or jib, repeat the test procedure
for the boom extension or jib anti-two-block switch.
6. Check that the display of the main boom length agrees with the actual boom length.
1.15
7. Check that the display of the main boom angle agrees with the actual boom angles.
8. Check that the display of the operating radius of the crane agrees with the actual radius.
9. Check the load display by lifting a load of known weight. The accuracy of the load
indication shall be within the tolerance of SAE J159.
Operation
After being properly programmed, the LMI is operational. Therefore, the operator shall be thoroughly
familiar with all controls of the LMI and he shall properly set each switch before operating the crane.
All settings shall be checked by lifting a load of known weight and comparing the load to the information
displayed on the LMI.
Rated loads include the weight of the hook block, slings, and auxilliary load handling devices. Their
combined weights shall be subtracted from the listed load capacities as stated on the load capacity
chart to obtain the net load to be lifted.
WARNING
If any of the displays reflect a deviation between displayed and
actual values an authorized PAT service representative shall
be called for repair of the system or reverification of the cranes
LMI calibration.
WARNING
Any structural modifications or changes to the crane shall
require reverification of the cranes LMI calibration.
6. 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 lift cylinder(s) and the connecting hoses for oil
leakage.
6. Check mechanical installation and electrical connection of force transducer(s) on jibs
where applicable.
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.
1.16
7. Troubleshooting
General
In case of a malfunction of the system, the display (1) will indicate a code which identifies the system
malfunction.
The error codes listed in the Malfunction Table will identify various faults which can occur with the LMI.
Following the Malfunction Table there is information which will explain each fault and describe the action
which shall be taken to correct the fault.
Faults within the electronic microprocessor shall be repaired by factory trained service personnel. When
these faults occur, the competent service organization shall shall be contacted.
Malfunction Table
Error Code
E01
E02
E03
E04
E05
E06
Error
Fallen below the radius or above angle range
Radius range exceeded or fallen below angle range
Boom position is out of the permissible working area
Operating mode not existing
Prohibited length range
Radius range exceeded or fallen below jib angle range
NOTE:
If there is any Error Code displayed on the console which is not listed in the Malfunctions Table you shall
call the Local Distributor.
Operating Errors
Malfunctions in the system which are caused by range exceedings or operating errors by the crane operator
himself are indicated on the display together with an explanation. These error codes are E01, E02, E03, E04,
E05 and E06 and they can normally be eliminated by the crane operator himself.
1.17
ERROR 01
E01: ABOVE ANGLE
RANGE
ANGLE = 80.0 o
E01: FALLEN BELOW

RADIUS RANGE
RADIUS = 27.4 ft
Cause:
Fallen below the minimum radius
or above the angle given in the
load capacity chart due to raising
the boom too far.
Elimination:
Lower boom back to a radius or
angle given in the load capacity
chart.
ERROR 02
E02: BELOW ANGLE
RANGE
ANGLE = 25.0 o
E02: RADIUS RANGE

EXCEEDED
RADIUS = 75.6 ft
Cause:
The maximum radius or minimum
chart was exceeded due to lowering the boom too far.
Elimination:
Raise boom back to a radius or
chart.
ERROR 03
E03: NO - LOAD AREA
Cause:
Boom position is out of the permissible working area (over front)
Elimination:
Move boom back to permissible working area. See lifting
diagram in the load capacity
charts.
1.18
ERROR 04
E04: OPERATING MODE
NOT AVAILABLE
SEE LOAD CAPACITY
CHART * PUSH INFO
Cause: 1
Operating mode switch in the console set incorrectly.
Elimination:
Set operating mode switch correctly to the code assigned to the
operating mode of the crane.
Cause: 2
Elimination:
Operating mode is not permissible Be sure crane is set up according
with the actual crane configuration, to proper operating configurboom position or area definition.
ations.
ERROR 05
E05: LENGTH RANGE
NOT PERMITTED
LENGTH = 75.3 ft
Cause: 1
Elimination:
Boom was telescoped too far or not Telescope boom to correct
far enough, i.e. load curves for on length, given in the load capacity
rubber, you may only operate up to chart.
a certain maximum or minimum
boom length or with load curves
for jibs where you have to telescope
the main boom to a certain length.
Cause: 2
Length sensor adjustment changed
i.e. length sensor cable slid off the
length sensor drum.
Elimination:
For elimination refer to service
manual.
1.19
ERROR 06
E06: RADIUS RANGE
EXCEEDED
RADIUS = 96.6 ft
E06: BELOW JIB ANGLE

RANGE
JIB ANGLE = 15.0o
Cause:
The minimum angle or maximum
radius of the luffing fly jib given in
the load capacity chart was exceeded
due to lowering the jib too far.
Elimination:
Raise jib back to an angle given
in the load capacity chart.
Lightbar
The P.A.T. Lightbar is a supplementary indicator for the standard P.A.T. Load Moment Indicator systems.
It displays the load moment in form of a bargraph. The lightbar is located in the operators cab in front of
the operator.
DIM
STOP
This indicator display how much of the crane capacity is being used. As the crane is moved through its
various motions, the bargraph will constantly change.
The range of the bargraph is divided into three areas:
- the green area is the normal working area,
- the yellow prewarning area shows the remaining portion of the rated load capacity and
the bargraph indicates the approach to the overload condition,
- the red area shows that the maximum rated load capacity is exceeded.
NOTE: Operating within the red area is not permitted.

Brightness adjustment:
In order to adapt the P.A.T. Lightbars brightness to the lighting conditions of the environment a DIMswitch is installed on the right hand side of the display. When actuating the DIM-switch the brightness
increases. After having exceeded the maximum brightness value the display turns back to the minimum
brightness value.
1.20
CONSOLE MEASUREMENT:
CONNECTION BOARD W/VOLTMETER ON X1:30 & X1:33
VOLTMETER SHOULD MEASURE +24V BETWEEN CONNECTIONS
X1 - 33 (NEGATIVE) AND X1 - 30 (POSITIVE).
H8
V2
X3
H7
A2B K9
LMI K8
SHUT
OFF
SHUT
OFF
H4
H1
V8
OUT OF
SEQUENCE
OUTER
MID
V11
R15
V1
K7
R16
R9
V5
K4
K1
+24.0
R10
R3
R4
R17
R18
H10
H5
H3
R13
K6
R14
R11
R12
R7
V3
R8
K10
LEVER
LOCKOUT
K2
R5
R2
R6
F4
IM
X1
77 76 75
K3
67 66 65 64 63 62 61 60
X1
80 79 78
V6
D
RO
F5
F6
X1
R1
49 48 47
SE
F7
K5
4W
70 69 68
CM
OM
F8
V7
ROD
DRAIN
X4
V9
4 - WAY
CENTER
MID
V10
X1
H2
INNER
MID
H6
8 10 12 14 16 18 20 22 24 26 28 71 72 73 74
H9
X1
7 9 11 13 15 17 19 21 23 25 27 29
F1
X1
2 4 6
1 2 3 4
1 3 5
X4
F3
F2
59 58 57 56 55 54 53
X1
52 51 50
X1
43 42 41
40 39 38
X1
37 36 35 34 33 32 31 30
46 45 44
X1
1.21
80
79
78
77
76
75
74
73
72
71
70
69
68
67
66
65
64
63
62
61
60
59
58
57
56
55
54
53
52
51
50
49
DS350 Graphic
Console to C.P.U.
Connections
6
5
LMI BY - PASS
KEY
14
o o
o o
13
LMI BUTTON
BY - PASS
A2B BUTTON
BY - PASS
CONSOLE
BY-PASS
KEY
DI (8)
LMI (7)
A2B (6)
COMM. (5)
DATA FROM C.U.
RXD (4)
DATA TO C.U.
TXD (3)
2
1
2
3
4
1
GND (2)
+24V (1)
1.22
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
DE 6
LENGTH
RESET SW.
DE 5
CM / IM
RET. SW.
DE 4
OM / FLY
RET. / % SW.
-5V
-SIG
GND
86
K7 = OM / FLY
- 2 WAY
o
30
o o
87A
87
85
F8
86
o
o30
o
K6 = CM 2 - WAY
87A
87
85
F7
86
o
30
o o
K5 = 4 - WAY
DIREC. VALVE
87A
87
85
F6
86
o
30
o o
K4 = TELE OUT
OF SEQ.
87A
87
85
F5
86
o
30
o o
K3 = ROD
DRAIN SOL.
87A
87
85
F4
86
o
o30
o
K2 = IM 2 - WAY
87A
87
85
F3
86
K1= NOT USED
o
30
o o
87A
87
85
F2
87A
87
.
.
o
30
o oK10
o o o K9
o o o K8
SIG
0-SIG
86
K10
UB
UB
DE 3
AUTO MODE
SW. ON
DE 2
PRESS. SW.
BOOM RET.
DE 1
PRESS. SW.
BOOM EXT.
0 (UB)
0 (UB)
RXD
TXD
UB
-SIG
+SIG
-SIG
0 (UB)
85
A2B
COMPARATOR
-9V
+9V
-5V
GND
-SIG
-5V
+5V
GND
-SIG
-5V
+5V
GND LEN.(OA)
-5V
ANGLE
GND
X4
0(UB)
+UB
4
3
2
1
)
)
)
)
0 (UB) / GND
+24 V
FIVE SECTION BOOM SERVICE SCREEN

(TMS/TTS 870 & RT865BXL)
PAT
DS 350
STOP
STOP
156ft
0335
TARE
90.0ft
?
Ramp Seq.
CM Hex Value
IM Hex Value
79.4
255
SEL
OM/Fly Hex Value
STOP
LIM
255
50.8ft
MAX
02
38.2
38.2
38.2
38.2
100%
(lbs)
73.5oo
ACT
(lbs)
34.900
100%
i
CTRL
100%
STOP
F1
Length of IM
F2
F3
F4
Tot. Length
minus IM
To activate service screen press and hold F1 & F4 until screen

appears in lower left corner. The ramping value will indicate the
ramping up and ramping down of the output signal to the
solenoids.
1.23
P.A.T. L.M.I
MANUAL
SECTION 2
DS 350 GRAPHIC BCS

HYDRAULIC, ELECTRICAL THEORY
& COMPONENT LOCATION
DS350 GRAPHIC with BOOM CONTROL SYSTEM

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. 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 operators responsibility to
select 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 he continues 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.
2.1
Boom control information flow
Operator moves
control to extend or
retract position.
Directional pressure
switch transmits signal
to B.C.S.
B.C.S. checks input for

Automode.
off
Operation in manual
mode - no control
output.
correct
Console displays
length and % of each
section.
on
B.C.S. checks input for

A mode or B mode and
prepares the control
logic for that mode.
B.C.S. checks the

retract and % reset
switches on the boom
and obtains the length
signals.
incorrect
B.C.S. defaults into a

rigging mode, console
displays error code or
dashboard warning
light indicates "out of
sequence".
continue on next page
2.2
TMS,TTS 870 & RT 865 BXL
B.C.S. activates relays

to power up valves.
This enables the oil to
flow into the cylinder.
B.C.S. switches relay

to correct position for
the rod side dump
valve
B.C.S. ramps up the

analog output current
for the pressure
reducing valves
(proportional valves)
The pressure reducing

valves open linear an
the pilot pressure
increases until
maximum pressure is
obtained.
continue on next page
2.3
TM9150, TM9100
continuation
B.C.S. senses the

boom length and
calculates the
percentage of each
section while extending
or retracting.
incorrect
correct
B.C.S. starts the ramp down

process when approaching a
change over point.The
analog output current
decreases and slows down
the section.
Out of sequence
warning and lock out.
TMS/TTS 870 & RT 865 BXL
At the change over point the

B.C.S. changes relay
combination to close the flow to
the actual cylinder and enable
flow to the next cylinder.
The B.C.S. ramps up the

analog signal by a linear
current increase of the
pressure reducing valves.
The section speeds up to
its maximum speed.
2.4
TM9150 & TM9100
Why use electrical boom control ?

Hose reel not required (TMS/TTS 870, RT 865 BXL).
Hydraulic flow is routed internally of the cylinder.
Trombone Concept.
Enables selected sequencing of the boom to improve utilization of the
crane.
Mode A:
Increased stability. The heavy IM (inner mid section) remains retracted until the
CM (center mid section) and OM/Fly (outer mid and fly section) becomes fully
extended. This enables a better load chart for the boom between fully retracted
and extended.
Mode B:
Increased structural capacity. The stronger sections IM & CM extends in a
programmed sequence keeping the weaker section OM & Fly fully or partially
retracted.
Model
TM 9150
TM 9100
TMS 870
TTS 870
RT 865 BXL
2.5
Mode
B
A, B
A, B
A, B
B
WHERE ARE THE CONTROLS?

PILOT CONTROL
Standard joystick or foot operated treadle valve.
The following switches are located inside, and on the upper right hand side of the cab directly above the
window.
MANUAL / AUTO (See page 2.7)

AUTO MODE is to be used when lifting loads per the load chart.
MANUAL MODE is used primarily to put the boom back into synchronization or, for rigging and
maintenance purposes. Loads cannot be lifted while on manual mode as the capacity is reduced greatly
by the PAT to limit loads to that which would normally be seen during rigging and / or maintenance.
When changing boom modes, always try to do so with boom full retracted or full extended. This will
prevent you from having to select manual mode to desynchronize the boom.
SECTION SELECTOR (See page 2.7)

THE SECTION SELECTOR switch is used to select which section will be extended or retracted, and can
only operate when in manual mode.
INDICATOR LIGHTS (See page 2.7)

THE INDICATOR LIGHTS tell the status when in manual mode as to which boom section has been
selected for operation, and that the electric coils to that section have been energized.
BOOM NOT SYNCHRONIZED LIGHT (See page 2.7)

THE BOOM NOT SYNCHRONIZED LIGHT will illuminate to indicate a boom section. or several boom
sections are at least 3% out of synchronization. At this point the load would have to be set down, and the
manual controls operated to reset the boom.
2.6
2.7
CENTER
MID
ON
INNER
MID
CENTER
MID
BOOM
MODE
INNER
MID
ON
OUTER
MID
FLY
BOOM TELE
SECTION SELECT
OUTER MID
FLY
ON
M
A
N
U
A
L
A
U
T
O
BOOM
NOT
SYNC
B
BOOM
TELE MODE
BOOM
TELESCOPE
SYSTEM
WHERE ARE THE COMPONENTS LOCATED ?

VALVES S / S
Pressure reducing valve ( 800 P.S.I. ) and rod side dump lie within the turntable uprights. This is also
where the test port is located for settings the pressure reducing valve and the sequence valve.
The 4 - way directional valve and piston dump valve lie outside the turntable uprights on the right side of
the superstructure.
The Sequence valve lies just below the 4 - way valve , also on the right side of the superstructure.
SWITCHES S / S
On the 4 - way valve are the 3 pressure switches which control the opening of the dump valves and the
direction of movement inputs to the PAT system.
PAT BOX S / S
Inside the PAT box we have the relays labeled to correspond to the function they control.
One item of importance here is the numbers 1 through 7 along the left side of the relays controlling the
boom. These numbers indicate the fuse number that corresponds to the valve the relay controls. When
troubleshooting any problems, it's always a good idea to check these fuses first.
VALVES IN BOOM
The 2 way valves for the inner mid are mounted in the rear of the inner mid as shown. Piston flow is to
the lower left side, while pilot flow is to the upper right.
The 2 way valves for the outer and center mid are mounted in the rear of the center mid.
Piston flow for the center mid is to the lower right, while the piston flow to the outer mid is to the upper
right.
Pilot flow to the outer mid is to the upper left, while the pilot flow to the center mid is to the lower left.
Wire colors to the valves are shown to the right.
SWITCHES ON BOOM
Four Proximity switches are mounted on the left side of the boom. Each of the switches are adjusted to
indicate to the PAT system that all the boom sections have been fully retracted.
CABLE REELS ON BOOM
Three cable reels are mounted on the left side of the boom. The top reel is the basic L.M.I. reel with the
small thin cable for A2B.
The other two reels have a large cable installed and are primarily used to provide power to the 2 way
valves inside the boom. They also pickup inputs from two of the proximity switches to send back to the
PAT system.
2.8
2.9
SEQUENCE
VALVE
1000 PSI
TELE
EXTEND
TMS / TTS 870 & RT865BXL

with Boom Control
Turntable Components
P.A.T. DS350 GRAPHIC

C.P.U. BOARD LOCATION
TMS870/TTS870
(5 section boom)
THIRD WRAP
K11
K12
MH
AH
VALVE CONTROL
BOARD
A111
DIGITAL INPUT
EXTENSION BOARD
A112
DECODER
BOARD
A110
DIODE
BOARD
A113
X1 TERMINAL
BOARD A104
2.10
MAIN
BOARD
A101
2.11
(BOTTOM VIEW
OF C.P.U.)
CABLE ASSY TO BOOM
PRES. TRAN. CABLE ASSY (ROD)
DATA LOGGER DOWNLOAD RECEPT.

(DATA LOGGER OPTIONAL)
KEY BYPASS SWITCH
FUSE (2A)
CRANE INTERFACE CABLE
FUSE (10A)
CABLE ASSY TO BOOM
CABLE ASSY TO CONSOLE
PRES. TRAN. CABLE ASSY (PISTON)
TMS / TTS870 Central Processing Unit

5 - Section Boom
2.12
(BOTTOM VIEW
OF C.P.U.)
CABLE ASSY TO BOOM
PRES. TRAN. CABLE ASSY (ROD)
AREA DEF CABLE
DATA LOGGER DOWNLOAD RECEPT.

(DATA LOGGER OPTIONAL)
KEY BYPASS SWITCH
FUSE (2A)
CRANE INTERFACE CABLE
FUSE (10A)
CABLE ASSY TO BOOM
CABLE ASSY TO CONSOLE
PRES. TRAN. CABLE ASSY (PISTON)
RT865BXL Central Processing Unit
INNER MID
PILOT
INNER MID
RED
GREEN
CYL
CABLE
INNER MID
BLACK
WHITE
PILOT
INNER MID
CYLINDER
OUTER MID
PILOT
OUTER MID
CYLINDER
CENTER MID
CYLINDER
CENTER MID
PILOT
OUTER MID
BLACK
WHITE
CYL
B
CENTER MID
RED
GREEN
CYL
OUTER MID
BLACK
WHITE
PILOT
C
CENTER MID
RED
GREEN
PILOT
2.13
2.14
See detail
A
See detail
C
IM % reset
switch
PAT
See detail
C
CM retract and %
reset switch
IM retract
switch
PAT
OM retract and %
reset switch
See detail
C
IM length sensor
LG221
DS350 Graphic - BCS
Boom Control components

TMS/TTS 870 and RT 865BXL
PAT
Boom length sensor

LG208
CM length and angle sensor

LWG221
2.15
PRE - TENSION (LENGTH SENSOR) SPRING

BY ROTATING DRUM (35) REVOLUTIONS COUNTER
CLOCKWISE. THEN UNSPOOL THE LENGTH CABLE
AND SECURE TO BUSHING ON THE INNER - MID
PER DETAIL A.

AND SECURE TO BUSHING ON THE CENTER - MID
PER DETAIL B
PAT
PAT

AND SECURE TO BUSHING ON THE BOOM NOSE
PER DETAIL A.
PAT
REMOVE 1/4 - 20 NUTS ON BOTTOM OF CABLE GUIDE.

INSERT CABLE GUIDE SCREWS THRU EXISTING ANGLE
BRKT AND SECURE IN PLACE WITH 1/4 - 20 NUTS
REMOVED PREVIOUSLY.
CENTER LINE OF CABLE GUIDE MUST BE ALIGNED W/ CENTER
LINE OF CABLE REEL DRUM.
AFTER MACHINE IS CALIBRATED, REMOVE PROTECTIVE PAPER
CORROSION INHIBTOR AND ADHERE TO INSIDE HOUSING COVER
SURFACE OF CABLE REEL.
DS350 Graphic - BCS

2.16
0.13
18
See detail
A
See detail
B
0.44
3.94
16
1.34
PAT
DETAIL C
CENTER LINE OF
TARGETS &
PROXIMITY SW.
0.44
0.44
18
16
1.0
To
wi be a
t
of h c e ligne
n
ca
bl e t e r l d
ree ine
ld
rum
DETAIL B
DETAIL A
INSTALL PROXIMITY SWITCH 0.13 FROM

TARGET WHEN BOOM SECTIONS ARE
FULLY RETRACTED.
THIS TARGET IS ONLY INSTALLED IF THE

BOOM IS EQUIPPED WITH A BOOM
EXTENSION STOP BLOCK.

FULLY RETRACTED.
PLACE (3) TIE WRAPS, 120 DEGREES

APART AROUND BUSHING. WRAP CABLE
(8-10) REVOLUTIONS OVER THE TIE WRAPS
STARTING FROM THE OUTSIDE AND
WORKING INWARD. ALLOW AMPLE CABLE
TO REACH JUNCTION BOX. SECURE CABLE
WITH (2) ADDITIONAL TIE WRAPS.
2.17
CABLE GUIDES ON THE BASE & INNER MID

SECTIONS ASSOCIATED WITH TOP AND
MIDDLE CABLE REEL MUST BE ALIGNED WITH
CENTER OF CABLE REEL DRUM
CENTER LINE OF CABLE GUIDES
19
19
CENTER LINE OF
CABLE REEL DRUM
INSTALL SHIMS AS REQUIRED TO ASSURE

CENTER LINE OF CABLE REEL DRUMS ARE
PARRALLEL TO BOOM BASE SECTION AND
PLUMB WHEN CRANE IS ON A LEVEL \
SURFACE.
PARTIAL TOP VIEW
DS350 Graphic - BCS

HOW DOES THE SYSTEM WORK?

HYDRAULIC
1. Pilot operated 4 way valve provides oil flow to extend and retract the 3 telescoping cylinders. On this
valve are 2 pressure reducing valves electrically operated by the PAT system. Their function is to reduce
the pilot pressure when nearing the point a section must stop in order to slow it down smoothly, then they
will increase the pilot pressure back to normal once the next section begins to move allowing for a smooth
transition.
Directional pressure switches
In each of the pilot pressure lines is a normally open pressure switch, one for extend and one for retract.
These pressure switches tell the PAT which direction has been selected by the operator, so it will know
which section is next to go out or in and when the pilot pressure is to be reduced and returned to normal.
Third switch pressure
A third pressure switch ( normally closed ) mounted near the top of the 4 way valve monitors joystick
pressure directly on the main spool for extend. When no pressure is evident, or the controller is in neutral,
the switch is closed , and the piston side dump valve is energized allowing piston side pressure to be
released through a .078 orifice.
2. Two - way valves control the oil to each telescope cylinder. One for the pilot pressure to the holding
valve and one for the piston side oil to flow. These are operated in pairs only. When a pair of two-way
valves are de-energized, that particular telescope cylinder will then operate. The other two pair of two
way - valves must be energized to prevent movement of the other two telescope cylinders. These valves
are also switched on and off by the PAT system when in Automatic mode. They are controlled by an
individual selector switch when in the Manual mode.
Two - way valves are normally open, so that in the event of an electrical malfunction, the boom could
always be telescoped in for repair.
Piston side dump valve
In the piston side, there is a piston side dump valve which allows piston side oil to be released back to
tank by the way of a .078 orifice. This valve is controlled by the normally closed contacts of the third
pressure switch and dumps to tank, when the controller is in neutral and pilot pressure has decayed.
Rod side dump valve

In the rod side, there is a rod side dump valve which allows rod side oil to be released back to tank. This
valve is electrically operated by the PAT system and is switched on to dump rod side pressure when the
controller is in neutral.
2.18
Sequence valve
The sequence valve maintains pressure on the rod side to prevent the cylinders from extending when
the trombone tubes are pressurized.
* If the boom sections drift back in momentarily after the controller is released, this is a good indication
the sequence valve is defective.
* To adjust or check for proper adjustment:
1. Install gauge into test port between pressure reducing valve and sequence valve.
2. Select manual mode.
3. Select either inner mid or center mid section.
4. Extend the boom section and monitor pressure while boom is extending. If it does not
read 1,000 P.S.I., adjust valve accordingly.
Pressure reducing valve
The pressure reducing valve is used to flood the rod side whenever the telescope cylinders first
begin to extend.
* If the boom sections take off with a jump, this is a good indication the pressure reducing valve
is defective.
1. Always be sure to check setting of the sequence valve first.
2. Gauge should still be in test port from checking sequence valve.
3. With manual mode still selected.
4. Select either the inner mid or center mid section chosen.
5. Extend the section completely until it bottoms out.
6. Release controller or treadle valve to neutral (this allows oil to drain off).
7. Then operate controller or treadle valve to extend and note pressure reading, it should
read 800 P.S.I. if it does not, adjust pressure reducing valve accordingly.
Check valve
The purpose of the check valve, is to prevent high pressure oil from flowing back through the
800 P.S.I. pressure reducing valve when trying to retract.
2.19
ELECTRIC
Automatic Mode
Proportional voltage is sent by the PAT system to the coils on the 4 - way valve, either to the extend or
the retract side as determined by the pressure switches in the joystick lines an the K-5 relay in the PAT
system. The current is applied gradually and removed gradually by the PAT system to assure smooth
starts and transitions between boom section change over.
Extending the inner mid
The proportional output building up while extending the inner mid followed by full current and a fully
open valve while extending, followed by a decrease in current during the change over to the center mid.
Once all the 2 way valves for the appropriate sections have changed over and the rod and piston side have
dumped momentarily, the current will be reapplied proportionally to allow a smooth start of the center
mid. K-5 relay remains energized during the entire process. This is because the operator never left off on
the controller and the extend pressure switch always remained in the on position.
Retracting the inner mid
While retracting the inner mid, followed by full current and a fully open valve while extending, followed
by a decrease in current during the change over to the center mid. Once all the 2 way valves for the
appropriate sections have changed over the piston side dump valve stayed energized before, during , and
after the change over took place, while the rod side dump valve energized briefly during the change over.
This was because we were retracting, and no pilot pressure was seen on the extend side, and therefore our
normally closed pressure switch kept the piston side dump valve energized and K - 5 relay which directs
the proportional voltage never energized. This is a default mode so that if there is an electrical problem
current could always be applied to the retract side to bring in the boom in for repairs.
Manual Mode
Extending the inner and center mid
Any time manual mode is selected voltage to the proportional solenoids is at maximum voltage. This
means the 4 way valve will respond directly to the input from the controller, without the ramp up and
ramp down feature as provided when under control by the PAT system. The 2 way valves for the
appropriate sections are controlled by the manual switch. Although it is not required to release the
controller to neutral when changing boom sections, it is preferred. When releasing the controller to
neutral the rod side and piston side will drain, which will allow for a smooth transition between boom
sections when on manual mode. Note that K-5 relay never energizes, now that we are in manual mode
both coils on the 4 - way valve will remain energized with full voltage.
Retracting the inner and center mid
Anytime manual mode is selected voltage to the proportional solenoids is at maximum voltage.
The two way valves for the appropriate sections are controlled by the manual switch. The rod side valve
energizes briefly as we stop controller input to change sections, and the piston side dump valve is not
energized during retraction.
2.20
OM 2 - WAYS
CM 2 - WAYS
ANALOG SIG. - RET. VALVE
ANALOG SIG. - EXT. VALVE
SIG. ANALOG OUTPUT BOR.
TELE OUT OF SEQ.
ROD SIDE DUMP

IM 2-WAYS
F2
GND
+24 V
10 A
3
2
1
DE 5
CM / IM
RET. SW.
DE 4
OM / FLY
RET. / % SW.
-5V
-SIG
GND
86
o
30
o o
K7 = OM / FLY
- 2 WAY
87A
87
DS350 Graphic
X1 Terminal Board
85
F8
86
o
o30
o
K6 = CM 2 - WAY
87A
87
85
F7
86
o
30
o o
K5 = 4 - WAY
DIREC. VALVE
87A
87
85
F6
86
o
30
o o
K4 = TELE OUT
OF SEQ.
87A
87
85
F5
86
o
30
o o
K3 = ROD
DRAIN SOL.
87A
87
85
F4
86
K2 = IM 2 - WAY
o
o30
o
87A
87
85
F3
86
K1= NOT USED
o
30
o o
87A
87
85
F2
87A
87
.
.
o
30
o oK10
o o o K9
o o o K8
SIG
0-SIG
86
K10
UB
UB
DE 3
AUTO MODE
SW. ON
DE 2
PRESS. SW.
BOOM RET.
DE 1
PRESS. SW.
BOOM EXT.
0 (UB)
0 (UB)
RXD
TXD
UB
-SIG
+SIG
-SIG
0 (UB)
85
A2B
COMPARATOR
-9V
+9V
-5V
1
2
3
4
GND
-SIG
-5V
+5V
GND
X5
-SIG
-5V
40
COND.
+5V
GND LEN.(OA)
-5V
X6
ANGLE
26
COND.
GND
X4
0(UB)
+UB
2.21
4
3
2
1
)
)
)
)
X4
MEMORY
EXTENSION
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
LENGTH
RESET SW.
MEASURE
PINS
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
DE 6
2X SERIAL
INTERFACE
F1
2A
80
79
78
77
76
75
74
73
72
71
70
69
68
67
66
65
64
63
62
61
60
59
58
57
56
55
54
53
52
51
50
49
X1
(
(
(
3
2
1
X7
0 (UB) / GND
+24 V
X9
BR14
w
w
w
PILOT
w
TEST PORT
800 PSI
ROD
DRAIN
TO DUAL RETURN
MANIFOLD
PISTON
DRAIN
.078
w
P1
w
PRESSURE
SWITCH
EXTEND
P2
TO CASE
DRAIN
MANIFOLD
RET
EXT
PRESSURE
SWITCH
EXTEND
EXT
B A P1 D
RET
B A
49.9
GPM
P1
GP
220300
3650
w
w
3800
SEQUENCE
VALVE
WITH CHECK
1000 PSI
1500
3000
w
LS
TELE
P2
LIFT
OPEN
PRESSURE
SWITCH
RETRACT
OUT
TO DRAIN MANIFOLD
2.22
PILOT
800 PSI
K3
ROD
DRAIN
w
PRESSURE
SWITCH
EXTEND
P2
NO
TO CASE
DRAIN
MANIFOLD
DI 1
RET
NC
EXT
PRESSURE
SWITCH
EXTEND
EXT
P1 D
RET
49.9
GPM
P1
GP
K5
220300
3650
w
3800
K5
3000
SEQUENCE
VALVE
WITH CHECK
1000 PSI
PISTON
DRAIN
.078
TO DUAL RETURN
MANIFOLD
P1
1500
w
LS
TELE
P2
DI 2
LIFT
NO
OUT
PRESSURE
SWITCH
RETRACT
TO DRAIN MANIFOLD
2.23
CYLINDER FULLY RETRACTED
w
2.24
PILOT
DS350 GRAPHIC BOOM CONTROL SYSTEM B MODE

Ramping
value
1
255
CENTER MID
INNER MID
50
40
3
Proportional
solenoid
valve 1
Proportional solenoid
valve 2
4 sec.
0
40
47
50
2 sec.
RT 865BXL
TTS/TMS 870
1
2
Maximum Ramping value

-valve fully open-
Minimum ramping
value CM
Time based ramping up

i.e. 12 cycles = 6 seconds
Maximum Ramping value

-valve fully open-
Ramping down
Minimum ramping
value IM
Change over point

-Ramping value 0-valve closed-
2.25
Length
[%]
DS350 GRAPHIC BOOM CONTROL SYSTEM

AUTOMATIC MODE
EXTEND
INNER MID
EXTEND
CENTER MID
PROPORTIONAL
OUTPUT
PROPORTIONAL VALVE
START
OM
2 WAYS
CM
2 WAYS
CHANGE OVER
CLOSED
OPEN
CLOSED
OPEN
CLOSED
IM
2 WAYS
OPEN
OPEN
OPEN
ROD
DRAIN
OPEN
CLOSED
K5
RELAY
OPEN
CLOSED
OPEN
PISTON
DRAIN
STOP
OPEN
CLOSED
OPEN
CLOSED
EXTEND
2.26

AUTOMATIC MODE
RETRACT
INNER MID
RETRACT
CENTER MID
PROPORTIONAL
OUTPUT
PROPORTIONAL VALVE
START
CHANGE OVER
STOP
CLOSED
OM
2 WAYS
OPEN
CLOSED
CM
2 WAYS
OPEN
CLOSED
IM
2 WAYS
OPEN
OPEN
OPEN
ROD
DRAIN
OPEN
CLOSED
OPEN
CLOSED
PISTON
DRAIN
K5
RELAY
2.27

MANUAL MODE
EXTEND
INNER MID
EXTEND
CENTER MID
PROPORTIONAL VALVE
START
CHANGE OVER
STOP
CLOSED
OM
2 WAYS
OPEN
CLOSED
CM
2 WAYS
OPEN
CLOSED
IM
2 WAYS
OPEN
OPEN
OPEN
ROD
DRAIN
OPEN
CLOSED
CLOSED
OPEN
PISTON
DRAIN
OPEN
OPEN
CLOSED
OPEN
CLOSED
K5
RELAY
2.28

MANUAL MODE
RETRACT
INNER MID
RETRACT
CENTER MID
PROPORTIONAL VALVE
START
CHANGE OVER
STOP
OM
2 WAYS
CLOSED
CM
2 WAYS
OPEN
CLOSED
IM
2 WAYS
OPEN
OPEN
OPEN
ROD
DRAIN
OPEN
CLOSED
OPEN
CLOSED
PISTON
DRAIN
K5
RELAY
2.29
DS350 GRAPHIC (BCS)

Automode control of two way valves
K2
0
1
1
0
0
K6
1
0
1
0
0
K7
1
1
0
0
0
DESCRIPTION
IM EXTENDING OR RETRACTING
CM EXTENDING OR RETRACTING
OM/FLY EXTENDING OR RETRACTING
OUT OF SEQUENCE
NEUTRAL POSITION
Rod side dump valve logic TMS/TTS 870 and RT 865 BXL
Note: K3 is energized in neutral controller position or during the change over transition
while both section do not move.
DI 1
EXTEND SELECT
0
0
0
0
0
0
0
0
1
1
1
1
DI 2
RETRACT
SELECT
0
0
0
0
1
1
1
1
0
0
0
0
DI 4
OM/FLY
RETRACTED
0
0
1
1
0
0
1
1
0
0
1
1
DI 5
IM & CM
RETRACTED
0
1
0
1
0
1
0
1
0
1
0
1
Analog Outputs
ANALOG
1
1
CU
DESCRIPTION
TERMINAL
A111 X1/5 Analog GND for proportional extend or retract solenoid valves.
A111 X1/6 Analog signal for proportional extend or retract solenoid valves.
2.30
K3
ROD DRAIN
SOLENOID
1
1
1
1
0
0
0
0
0
0
0
0
DS350 GRAPHIC (BCS)

Input Output Logic TMS/TTS 870 AND RT 865 BXL
Mode
Ext. auto IM
Ret. auto IM
Ext. auto CM
Ret. auto CM
Ext. auto OM
Ret. auto OM
Ext.
DI 1
1
0
1
0
1
0
Ext. manual IM
Ret. manual IM
Ext. manual CM
Ret. manual CM
Ext. manual OM
Ret.manual OM
neutral
Retr.
DI 2
0
1
0
1
0
1
1
0
1
0
1
0
0
Relay
K2
0
0
1
1
1
1
0
1
0
1
0
1
0
Relay
K6
1
1
0
0
1
1
0
0
0
0
0
0
0
Relay
K7
1
1
1
1
0
0
0
0
0
0
0
0
0
Relay
K5
1
0
1
0
1
0
0
0
0
0
0
0
0
2 way
IM
0
0
1
1
1
1
0
0
0
0
0
0
0
2.31
2 way
CM
1
1
0
0
1
1
0
0
1
1
1
1
0
2 way
OM
1
1
1
1
0
0
1
1
0
0
1
1
0
analog
output
board
1
1
1
1
1
1
1
1
1
1
0
0
0
Prop.Valve
ext.
1
0
1
0
1
0
0
0
0
0
0
0
0
Prop Valve
retr.
0
1
0
1
0
1
1
0
1
0
1
0
0
0
1
0
1
0
1
0
DS350 GRAPHIC (BCS)

Boom sequence TMS/TTS 870, RT 865 BXL Main Boom
Mode
AUTO B
AUTO B
AUTO B
AUTO B
AUTO B
AUTO B
AUTO B
AUTO B
IM %
0
50
50
75
75
100
100
100
CM %
0
0
50
50
75
75
100
100
OM %
0
0
0
0
0
0
0
100
FLY %
0
0
0
0
0
0
0
100
AUTO A
AUTO A
AUTO A
AUTO A
0
0
0
100
0
100
100
100
0
0
100
100
0
0
100
100
Boom sequence TMS/TTS 870, RT 865 BXL, TM 9100 AND TM9150 boom extensions
Mode
AUTO
AUTO
AUTO
IM %
100
100
100
CM %
0
100
100
OM %
0
0
100
2.32
FLY %
0
0
100
PAT DS350 Graphic (BCS) NOTES

1. Tolerance on boom lengths is 3 % before the PAT system recognizes the boom as being out of
sequence.
2. Total time between boom section change over that boom sections actually stop moving is two
seconds.
3. Ramping down begins at 10 % prior to change over boom length.
4. Ramping value of 255 is a Pat calibration number, which also equates to 800 milliamps.
5.
800 milliamps at the Proportional coils results in full pilot flow to valve.
6. Wire 239 to the Proportional coils is ground, but must never be grounded to crane ground, as it is also
an analog signal to the PAT as well.
7.
E-07 error code is generated from voltage noise created across the extend and retract pressures
switches. Suppression diodes have been installed from input to ground
(# 38 to # 37 ) to clip the spikes.
8.
Resistance of a good proportional coil is 20 ohms, + or - 2 ohms.
9. 4 proximity switches located on left side of boom indicate to the PAT that boom sections are fully
retracted, at which time the PAT will automatically reset the retracted boom length percentage as
shown:
OM / Fly
Mid
IM
IM
0%
0%
1%
0 % ( with boom stop pulled down )
10. Pilot pressure switch signal / Analog output signal

Two pressure switches (1-extend & 1-retract) wired through crane interface connector.
Extending the boom: Pressure switch signal changes from 0V to +24V, electrical flows to extend.
Min. current =0mA, max. current=800mA(measure coil current while extending, meter in series
wire #20 & A 104 X1-63.
Retracting the boom: Pressure switch signal changes from 0V to +24V, electrical flows to
retract. Min. current =0mA, max. current=800mA(measure coil current while retracting, meter in
series wire #21 & A 104 X1-64.
11. If the PAT will not permit loads to be picked off the first column of the load chart , the problem is
likely to be:
a. the inner mid is between fully retracted with the stops out, and fully retracted with the stops in.
or
b. the inner mid proximity switches are out of adjustment.
2.33
HELPFUL HINTS
CHECKING THE COILS IN THE TWO WAY VALVES FOR CONTINUITY
1. Select manual mode
2. Select individual sections to operate.
3. If there is continuity in the wiring to the valve, the section lights will illuminate.
CHECKING THE BOOM LENGTH SIGNALS

Three length sensors are located on the side of the boom ,(Overall length, Inner Mid &
Center Mid) the software utilizes the signals to calculate the outer mid & fly section
length.
Disengage the boom stop, retract the boom:
Overall boom length signal -500mV (A 104 X1-10 using MP 15 or X1-8 GND)
Inner Mid length signal -500mV (A 104 X1-24 using same GND)
Center Mid length signal -500mV (A 104 X1-73 using same GND)
CHECKING PROXIMITY SWITCH INPUTS

Four proximity switches are used to tell the system if all sections are fully retracted.
Inner mid retract & percentage reset switch:
Reset proximity switch provides +24V signal to A 104 X1-80 when retracted against
boom stop.
Center mid retract & percentage reset switch:
Reset proximity switch provides +24V signal to A 114 or A 112 X1-9.
Outer mid / fly retract & percentage reset switch:
Reset proximity switch provides +24V signal to A 104 X1-76.
Retract proximity switch provides a +24V signal to A 104 X1-78 when boom stop
is disengage.
2.34
P.A.T. L.M.I
MANUAL
SECTION 3
DS 350 GRAPHIC BCS

BOOM LENGTH CONNECTIONS
& WIRING DIAGRAMS
80
79
78
77
76
75
74
73
72
71
70
69
68
67
66
65
64
63
62
61
60
59
58
57
56
55
54
53
52
51
50
49
DS350 Graphic
Boom Length to C.P.U.
Connections
LG 208 CABLE REEL
(TO NOSE)
17
18
R.F.
FILTERS
10
9
6
7
6
A
B
CORE
1
2
1 2 3
3
4
2
LG
4.7K
SHIELD
1
PIN 1 & 5 = GND
PIN 3 & 6 = -5V
PIN 2 = LENGTH SIGNAL
5
6
1
2
BOOM LENGTH SIGNAL

RETRACTED = -0.500V
MAX RANGE = -4.5V
* NOTE - MAX LENGTH SIGNAL
VARIES WITH BOOM
MAX VOLTAGE - 4.5V IS
FOR 10 TURNS ON POT.
Boom Base
Junction Box
1
A 1
B 2
C 3
3
2
1
TERMINALS :
1-2 & 4-5
ARE JUMP
TOGETHER
3.1
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
DE 6
LENGTH
RESET SW.
DE 5
CM / IM
RET. SW.
DE 4
OM / FLY
RET. / % SW.
-5V
-SIG
GND
86
o
30
o o
K7 = OM / FLY
- 2 WAY
87A
87
85
F8
86
K6 = CM 2 - WAY
o
o30
o
87A
87
85
F7
86
o
30
o o
K5 = 4 - WAY
DIREC. VALVE
87A
87
85
F6
86
K4 = TELE OUT
OF SEQ.
o
30
o o
87A
87
85
F5
86
o
30
o o
K3 = ROD
DRAIN SOL.
87A
87
85
F4
86
K2 = IM 2 - WAY
o
o30
o
87A
87
85
F3
86
K1= NOT USED
o
30
o o
87A
87
85
F2
87A
87
.
.
o
30
o oK10
o o o K9
o o o K8
SIG
0-SIG
86
K10
UB
UB
DE 3
AUTO MODE
SW. ON
DE 2
PRESS. SW.
BOOM RET.
DE 1
PRESS. SW.
BOOM EXT.
0 (UB)
0 (UB)
RXD
TXD
UB
-SIG
+SIG
-SIG
0 (UB)
85
A2B
COMPARATOR
-9V
+9V
-5V
GND
-SIG
-5V
+5V
GND
-SIG
-5V
+5V
GND LEN.(OA)
-5V
ANGLE
GND
X4
0(UB)
+UB
4
3
2
1
)
)
)
)
0 (UB) / GND
+24 V
DS350 Graphic
Connections
LWG 221 CABLE REEL
(TO CM)
20
19
18
17
16
TERMINALS FOR
PROX. SWITCHES
SEE PG. 12.1-12.4
15
14
13
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
Boom Base
Junction Box
12
11
10
A 1
2 10 H 8
8
7
C 3
13 6
D 4
LG
WG
6
5
4
13
80
79
78
77
76
75
74
73
72
71
70
69
68
67
66
65
64
63
62
61
60
59
58
57
56
55
54
53
52
51
50
49
TERMINALS :
1-2 & 4-5
ARE JUMP
TOGETHER
PIN 1 & 5 = GND

PIN 3 & 6 = -5V
PIN 4 = ANGLE SIGNAL
BOOM LENGTH SIGNAL

RETRACTED = -0.500V
MAX RANGE = -4.5V
ANGLE SIGNAL
0 DEG. = -3.125V
45 DEG. = -2.50V
90 DEG. = -1.875V
VARIES WITH BOOM
3
4
1
3.2
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
DE 6
LENGTH
RESET SW.
DE 5
CM / IM
RET. SW.
DE 4
OM / FLY
RET. / % SW.
-5V
-SIG
GND
86
K7 = OM / FLY
- 2 WAY
o
30
o o
87A
87
85
F8
86
o
o30
o
K6 = CM 2 - WAY
87A
87
85
F7
86
o
30
o o
K5 = 4 - WAY
DIREC. VALVE
87A
87
85
F6
86
o
30
o o
K4 = TELE OUT
OF SEQ.
87A
87
85
F5
86
o
30
o o
K3 = ROD
DRAIN SOL.
87A
87
85
F4
86
o
o30
o
K2 = IM 2 - WAY
87A
87
85
F3
86
K1= NOT USED
o
30
o o
87A
87
85
F2
87A
87
.
.
o
30
o oK10
o o o K9
o o o K8
SIG
0-SIG
86
K10
UB
UB
DE 3
AUTO MODE
SW. ON
DE 2
PRESS. SW.
BOOM RET.
DE 1
PRESS. SW.
BOOM EXT.
0 (UB)
0 (UB)
RXD
TXD
UB
-SIG
+SIG
-SIG
0 (UB)
85
A2B
COMPARATOR
-9V
+9V
-5V
GND
-SIG
-5V
+5V
GND
-SIG
-5V
+5V
GND LEN.(OA)
-5V
ANGLE
GND
X4
0(UB)
+UB
4
3
2
1
)
)
)
)
0 (UB) / GND
+24 V
80
79
78
77
76
75
74
73
72
71
70
69
68
67
66
65
64
63
62
61
60
59
58
57
56
55
54
53
52
51
50
49
DS350 Graphic
Connections
LG 221 CABLE REEL
(TO IM)
20
19
18
17
16
15
14
TERMINALS FOR
PROX. SWITCHES
SEE PG. 12.1-12.4
13
Boom Base
Junction Box
12
11
10
9
8
A 1
G 7
C 3
7
6
5
LG
4
3
TERMINALS :
1-2 & 4-5
ARE JUMP
TOGETHER
PIN 1 & 5 = GND

PIN 3 & 6 = -5V
7
BOOM LENGTH SIGNAL
RETRACTED = -0.500V
MAX RANGE = -4.5V
VARIES WITH BOOM
3
1
3.3
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
DE 6
LENGTH
RESET SW.
DE 5
CM / IM
RET. SW.
DE 4
OM / FLY
RET. / % SW.
-5V
-SIG
GND
86
K7 = OM / FLY
- 2 WAY
o
30
o o
87A
87
85
F8
86
o
o30
o
K6 = CM 2 - WAY
87A
87
85
F7
86
o
30
o o
K5 = 4 - WAY
DIREC. VALVE
87A
87
85
F6
86
o
30
o o
K4 = TELE OUT
OF SEQ.
87A
87
85
F5
86
o
30
o o
K3 = ROD
DRAIN SOL.
87A
87
85
F4
86
o
o30
o
K2 = IM 2 - WAY
87A
87
85
F3
86
K1= NOT USED
o
30
o o
87A
87
85
F2
87A
87
.
.
o
30
o oK10
o o o K9
o o o K8
SIG
0-SIG
86
K10
UB
UB
DE 3
AUTO MODE
SW. ON
DE 2
PRESS. SW.
BOOM RET.
DE 1
PRESS. SW.
BOOM EXT.
0 (UB)
0 (UB)
RXD
TXD
UB
-SIG
+SIG
-SIG
0 (UB)
85
A2B
COMPARATOR
-9V
+9V
-5V
GND
-SIG
-5V
+5V
GND
-SIG
-5V
+5V
GND LEN.(OA)
-5V
ANGLE
GND
X4
0(UB)
+UB
4
3
2
1
)
)
)
)
0 (UB) / GND
+24 V
3.4
(3 TURNS OF CABLE REEL = 1 TURN OF LENGTH POT. = 0.4V)

CHART SHOWS TYPICAL VOLTAGE SIGNALS.
THESE VOLTAGES ARE TO BE USED AS A REFERENCE ONLY, THE ACTUAL SIGNAL MAY VARY SLIGHTLY.
FOR SPECIFIC BOOM LENGTH VOLTAGES, CHECK VOLTAGES AT MP 6 OR X1-10 AND COMPARE WITH
TEST DATA IN CENTRAL UNIT.
CHANNEL # 1
NO. OF TURNS
NO. OF TURNS
"INPUT" SIGNAL AT "OUTPUT" SIGNAL AT
ON CABLE REEL ON LENGTH POT. TERM. X1-10 IN C.U. MP 6 TEST POINT ON
MAIN BOARD IN C.U.
0
0
-0.5V
0.5V
3
1
-0.9V
0.9V
6
2
-1.30V
1.30V
9
3
-1.70V
1.70V
12
4
-2.10V
2.10V
15
5
-2.50V
2.50V
18
6
-2.90V
2.90V
21
7
-3.30V
3.30V
24
8
-3.70V
3.70V
27
9
-4.10V
4.10V
30
10
-4.50V
4.50V
PAT DS350Graphic(BCS)
MAIN BOOM LENGTH SIGNAL VOLTAGE
X1
CABLE REEL
ASSY
0.0V
(GND)
ERROR
CODE
FIXED
RESISTOR
3 : 1 RATIO
ZERO ADJUSTMENT
RETRACTED BOOM
3.5
PRELOAD SPRING
30 REVOLUTIONS
COUNTERCLOCKWISE
(CENTER REEL)
CH. #1
OPERATING
WINDOW
0
1
2
3
4
5
6
7
8
9
10
LENGTH SENSOR
10 K /10 TURNS
.0V
E 11
.500V MIN.
WORKING
RANGE
ERROR
CODE
- 500MV (-.500V)
MINIMUM SIGNAL
(RETRACTED BOOM)
4.50V MAX.
E 21
5.0V
10
AMP
TO A/D
CONVERTER
MP 6
TEST POINT
- 4.50V
MAXIMUM SIGNAL
(10 TURNS ON POT)
MP 6 VOLTAGES
+ 500MV (.500V) = MIN. SIGNAL
(RETRACTED BOOM)
+4.50V = MAX. SIGNAL
(10 TURNS ON POT)
ALL VOLTAGES ARE MEASURED WITH
REFERENCE TO GND (TERMINAL X1-8 ON A104OR MP 15
ON MAIN BOARD).
CABLE REEL TERMINAL
X1
CENTRAL UNIT
TERMINAL BOARD
WIRE NUMBER
TEST POINT
ON MAIN BOARD
FIXED
RESISTOR
11
-5V
X1
P.A.T. DS350 Graphic (BCS)

BOOM LENGTH MEASURING CHANNEL
CHANNEL # 1
LENGTH MEASUREMENT:
CABLE REEL W/VOLTMETER ON 1 & 2
W/VOLTMETER ON 1 & 3
WITH THE BOOM FULLY RETRACTED THE VOLTMETER SHOULD
MEASURE -0.50 VOLTS BETWEEN CONNECTIONS 1 (GND) AND
2 (SIGNAL VOLTAGE).
VOLTMTER SHOULD MEASURE -5.0 VOLTS BETWEEN
CONNECTIONS 1 (GND) AND 3 (SUPPLY VOLTAGE).
-0.50
-5.00
1
2 3 4 5 6 7 8 9 10111213 1415 16
3.6
PAT
PAT
ADJUST TOP OF ANGLE SENSOR

PARALLEL WITH BOOM.
1
2 3 4 5 6 7 8 9 101112 131415 16
ADJUST LENGTH POTENIOMETER

WITH BOOM FULLY RETRACTED,
TURN THE CENTER SCREW COUNTERCLOCKWISE TO A SOFT STOP.
3.7
LENGTH MEASUREMENT:
VOLTMETER SHOULD MEASURE -5.0 VOLTS BETWEEN CONNECTIONS
X1 - 8 (NEGATIVE) AND X1 - 11 (POSITIVE).
H8
V2
X3
H7
A2B K9
LMI K8
SHUT
OFF
SHUT
OFF
H4
H1
V8
R15
V5
OUT OF
SEQUENCE
OUTER
MID
V11
K7
K4
R9
R10
R16
V1
K1
R3
R4
R17
R18
H10
H5
H6
H3
R14
R8
R5
V3
K10
LEVER
LOCKOUT
K2
R2
R6
F4
67 66 65 64 63 62 61 60
IM
X1
77 76 75
D
RO
F5
X1
80 79 78
X1
R1
49 48 47
Q
F6
R7
SE
F7
R12
4W
70 69 68
CM
OM
F8
R11
K3
INNER
MID
R13
K5
V6
ROD
DRAIN
K6
X1
H2
V7
4 - WAY
X4
V9
CENTER
MID
V10
8 10 12 14 16 18 20 22 24 26 28 71 72 73 74
H9
X1
7 9 11 13 15 17 19 21 23 25 27 29
F1
-5.00
X1
2 4 6
1 2 3 4
1 3 5
X4
F3
F2
59 58 57 56 55 54 53
X1
52 51 50
X1
43 42 41
40 39 38
X1
37 36 35 34 33 32 31 30
46 45 44
X1
3.8
LENGTH MEASUREMENT:
WITH BOOM FULLY RETRACTED THEVOLTMETER SHOULD MEASURE
-0.50 VOLTS BETWEEN CONNECTIONS X1 - 8 (NEGATIVE)
AND X1 - 10 (POSITIVE).
H8
V2
X3
H7
A2B K9
LMI K8
SHUT
OFF
SHUT
OFF
H4
H1
V8
K7
V5
OUT OF
SEQUENCE
OUTER
MID
V11
R15
V1
K4
R9
R10
R16
K1
R3
R4
R17
R18
H10
H5
H3
R13
K6
R14
R11
R12
R7
V3
R8
K10
LEVER
LOCKOUT
K2
R5
R2
R6
F4
IM
X1
77 76 75
K3
67 66 65 64 63 62 61 60
X1
80 79 78
V6
D
RO
F5
F6
X1
R1
49 48 47
SE
F7
K5
4W
70 69 68
CM
OM
F8
V7
ROD
DRAIN
X4
V9
4 - WAY
CENTER
MID
V10
X1
H2
INNER
MID
H6
8 10 12 14 16 18 20 22 24 26 28 71 72 73 74
H9
X1
7 9 11 13 15 17 19 21 23 25 27 29
F1
-0.50
X1
2 4 6
1 2 3 4
1 3 5
X4
F3
F2
59 58 57 56 55 54 53
X1
52 51 50
X1
43 42 41
40 39 38
X1
37 36 35 34 33 32 31 30
46 45 44
X1
3.9
P.A.T. L.M.I
MANUAL
SECTION 4
DS 350 GRAPHIC BCS

PISTON, ROD
CONNECTIONS &
WIRING DIAGRAMS
80
79
78
77
76
75
74
73
72
71
70
69
68
67
66
65
64
63
62
61
60
59
58
57
56
55
54
53
52
51
50
49
DS350 Graphic
Piston Pressure
Transducer to C.P.U.
Connections
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
14
o o
o o
13
PRESSURE TRANSDUCER
PISTON SIDE
DAVS
4
3
2
1
4.1
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
DE 6
LENGTH
RESET SW.
DE 5
CM / IM
RET. SW.
DE 4
OM / FLY
RET. / % SW.
-5V
-SIG
GND
86
K7 = OM / FLY
- 2 WAY
o
30
o o
87A
87
85
F8
86
o
o30
o
K6 = CM 2 - WAY
87A
87
85
F7
86
o
30
o o
K5 = 4 - WAY
DIREC. VALVE
87A
87
85
F6
86
o
30
o o
K4 = TELE OUT
OF SEQ.
87A
87
85
F5
86
o
30
o o
K3 = ROD
DRAIN SOL.
87A
87
85
F4
86
o
o30
o
K2 = IM 2 - WAY
87A
87
85
F3
86
K1= NOT USED
o
30
o o
87A
87
85
F2
87A
87
.
.
o
30
o oK10
o o o K9
o o o K8
SIG
0-SIG
86
K10
UB
UB
DE 3
AUTO MODE
SW. ON
DE 2
PRESS. SW.
BOOM RET.
DE 1
PRESS. SW.
BOOM EXT.
0 (UB)
0 (UB)
RXD
TXD
UB
-SIG
+SIG
-SIG
0 (UB)
85
A2B
COMPARATOR
-9V
+9V
-5V
GND
-SIG
-5V
+5V
GND
-SIG
-5V
+5V
GND LEN.(OA)
-5V
ANGLE
GND
X4
0(UB)
+UB
4
3
2
1
)
)
)
)
0 (UB) / GND
+24 V
4.2

THESE VOLTAGES ARE TO BE USED AS A
REFERENCE ONLY, THE ACTUAL SIGNAL
MAY VARY SLIGHTLY.
PAT DS350Graphic (BCS)

PISTON PRESSURE
TRANSDUCER
VOLTAGE SIGNALS
0
145
290
435
580
725
870
1015
1160
1305
1450
1595
1740
1885
2030
2175
2320
2465
2610
2755
2900
3045
3190
3335
3480
3625
3770
3915
4060
4205
4350
PRESSURE
(P.S.I.)
"INPUT" SIGNAL AT
TERM. X1-21 IN
CENTRAL UNIT
0 MV.
-33.3 MV.
-66.6 MV.
-99.9 MV.
-133.3 MV.
-166.6 MV.
-199.9 MV.
-233.2 MV.
-266.6 MV.
-299.9 MV.
-333.2 MV.
-366.5 MV.
-399.9 MV.
-433.2 MV.
-466.5 MV.
-499.8 MV.
-533.1 MV.
-566.5 MV.
-599.8 MV.
-633.1 MV.
-666.4 MV.
-699.7 MV.
-733.1 MV.
-766.4 MV.
-799.7 MV.
-833.1 MV.
-866.3 MV.
-899.7 MV.
-932.9 MV.
-966.3 MV.
-999.9 MV.
CHANNEL # 2
"OUTPUT" SIGNAL AT MP 4
TEST POINT ON MAIN
BOARD IN C.U.
0.5 V.
0.63 V.
0.77 V.
0.89 V.
1.03 V.
1.17 V.
1.29 V.
1.43 V.
1.53 V.
1.69 V.
1.83 V.
1.97 V.
2.09 V.
2.23 V.
2.36 V.
2.49 V.
2.63 V.
2.76 V.
2.89 V.
3.03 V.
3.16 V.
3.29 V.
3.43 V.
3.56 V.
3.69 V.
3.83 V.
3.96 V.
4.09 V.
4.23 V.
4.36 V.
4.50 V.
4.3
300 BAR MAX.

(4410 PSI)
DAVS 301
PRESSURE TRANSDUCER
(PISTON SIDE)
TEST POINT
ON MAIN BOARD
WIRE NUMBER
CENTRAL UNIT
TERMINAL BOARD
PRESSURE
FROM PISTON SIDE
OF LIFT CYLINDERS
X1
D
C
B
18
X1
19
20
21
AMP
P4
0.0V
(GND)
- 5.0V
TO A/D
CONVERTER
5.0V
MP 4 VOLTAGES
MP 4
TEST POINT
E 22
4.50V MAX.
.500V MIN.

(300 BAR PRESSURE)
REFERENCE TO GND (TERMINAL X1-19 A104 OR MP 15
ON MAIN BOARD.)

(ZERO PRESSURE)
ERROR
CODE
WORKING
RANGE
E 12
.0V

PISTON PRESSURE MEASURING CHANNEL
CHANNEL # 2
ERROR
CODE
P4 ZERO POINT
ADJUSTMENT
+ 5.0V
OUTPUT SIGNAL :
ZERO PRESSURE = 0.000V
MAX. PRESSURE = -1.0V
(+ / - 25 MV)
X1
CH. #2
OPERATING
WINDOW
PISTON TRANSDUCER MEASUREMENT:

W/VOLTMETER ON X1:20 & X1:19
VOLTMETER SHOULD MEASURE +5.0 VOLTS BETWEEN CONNECTIONS
X1:18 (+5.0V) & X1: 19 (GROUND)
VOLTMETER SHOULD MEASURE -5.0 VOLTS BETWEEN CONNECTIONS
X1:20 (-5.0V) & X1: 19 (GROUND)
H8
V2
H4
V1
A2B K9
LMI K8
SHUT
OFF
SHUT
OFF
H1
V5
OUT OF
SEQUENCE
V8
R17
R18
H10
8 10 12 14 16 18 20 22 24 26 28 71 72 73 74
H9
X1
7 9 11 13 15 17 19 21 23 25 27 29
F1
X1
2 4 6
1 3 5
+5.00
V3
K10
LEVER
LOCKOUT
4.4
X1
-5.00
X1
P.A.T. DS350
Graphic
E12 ERROR CODE

The following step - by - step procedures, with illustrations,
are designed to assist in eliminating error code E12. Since
various problems can cause an E12, these procedures will
check out the complete piston pressure transducer system.
4.5
TERMINAL BOARD
ERROR CODE 12, DRAWING #1
1.
LOWER BOOM ALL THE WAY DOWN, SHUT OFF ENGINE. DISCONNECT
HYDRAULIC HOSE FROM LIFT CYLINDER TO THE PISTON SIDE
PRESSURE TRANSDUCER SO THAT NO HYDRAULIC PRESSURE IS APPLIED
TO TRANSDUCER.
2.
CONNECT A DIGITAL VOLTMETER NEGATIVE (-) LEAD TO X1 - 19 AND

POSITIVE (+) LEAD TO X1 - 21 ON TERMINAL BOARD IN THE P.A.T. CENTRAL
UNIT VOLTAGE SHOULD BE .000 VOLT +/- .025 VOLT. THIS IS THE OUTPUT
SIGNAL FOR THE PISTON PRESSURE TRANSDUCER. RECORD THIS VOLTAGE
VDC.
H8
V2
A2B
V1
K9
SHUT
OFF
H4
7 9 11 13 15 17 19 21 23 25 27 29
H9
LMI K8
SHUT
OFF
H1
V8
V5
OUT OF
SEQUENCE
X1
PISTON PRESSURE TRANSDUCER

OUTPUT SIGNAL = .000 VOLT
+/- .025V AT ZERO HYDRAULIC
PRESSURE.
R17
R18
H10
H3
V7
ROD
DRAIN
4 - WAY
V9
X1
X1
V3
H2
V6
K10
LEVER
LOCKOUT
INNER
MID
H5
X1
8 10 12 14 16 18 20 22 24 26 28 71 72 73 74
F1
2 4 6
1 3 5
.000
X1
R2
4.6
R1
4.7
TERMINAL BOARD
5.
IF UNABLE TO ADJUST VOLTAGE AT MP4 TO .500V (500MV) WITH POT

P4, DISCONNECT THE SIGNAL WIRE FROM TERMINAL X1 - 21 ON
TERMINAL BOARD AND CONNECT A JUMPER WIRE BETWEEN TERMINAL
X1 - 21 AND X1 - 19.
6.
TRY READJUSTING POT P4 FOR .500V (500MV) AT MP4 WITH JUMPER

WIRE IN PLACE. IF STILL UNABLE TO ADJUST VOLTAGE THE MAIN BOARD
IS DEFECTIVE. REPLACE MAIN BOARD. IF VOLTAGE CAN BE ADJUSTED
WITH JUMPER WIRE IN PLACE, PRESSURE TRANSDUCER OR CABLE IS
DEFECTIVE.
H8
V2
A2B
V1
K9
SHUT
OFF
H4
7 9 11 13 15 17 19 21 23 25 27 29
H9
LMI K8
SHUT
OFF
H1
V8
V5
OUT OF
SEQUENCE
X1
DISCONNECT
FROM X1 - 21
R17
R18
H10
H3
V7
ROD
DRAIN
4 - WAY
V9
X1
JUMPER
WIRE
X1
V3
H2
V6
K10
LEVER
LOCKOUT
INNER
MID
H5
X1
8 10 12 14 16 18 20 22 24 26 28 71 72 73 74
F1
2 4 6
1 3 5
X1
R2
4.8
R1
PRESSURE TRANSDUCER PLUG

ERROR CODE 12, DRAWING# 4
7. IF VOLTAGE COULD BE ADJUSTED TO .500V (500 ) MV AT TEST POINT

MP 4 IN STEP 6, REFER TO DRAWING # 4 TO CHECK THE +5 VOLT &
-5 VOLT REFERENCE VOLTAGES AT PISTON PRESSURE TRANSDUCER
PLUG.
CONNECT DIGITAL VOLT METER NEGATIVE (-) LEAD TO TERMINAL B.
CONNECT POSITIVE (+) LEAD TO TERMINAL A, VOLTAGE SHOULD BE
+5.00 VDC. CONNECT POSITIVE (+) LEAD TO TERMINAL C, VOLTAGE
SHOULD BE -5.00 VDC. IF INCORRECT CHECK CABLE CONNECTIONS IN
CENTRAL UNIT AND CHECK CABLE FOR DEFECTS. IF CORRECT
REPLACE PRESSURE TRANSDUCER.
C
B
A D
4.9
80
79
78
77
76
75
74
73
72
71
70
69
68
67
66
65
64
63
62
61
60
59
58
57
56
55
54
53
52
51
50
49
DS350 Graphic
Rod Pressure
Transducer to C.P.U.
Connections
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
14
o o
o o
13
PRESSURE TRANSDUCER
ROD SIDE
DAVS
4
3
2
1
4.10
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
DE 6
LENGTH
RESET SW.
DE 5
CM / IM
RET. SW.
DE 4
OM / FLY
RET. / % SW.
-5V
-SIG
GND
86
K7 = OM / FLY
- 2 WAY
o
30
o o
87A
87
85
F8
86
o
o30
o
K6 = CM 2 - WAY
87A
87
85
F7
86
o
30
o o
K5 = 4 - WAY
DIREC. VALVE
87A
87
85
F6
86
o
30
o o
K4 = TELE OUT
OF SEQ.
87A
87
85
F5
86
o
30
o o
K3 = ROD
DRAIN SOL.
87A
87
85
F4
86
o
o30
o
K2 = IM 2 - WAY
87A
87
85
F3
86
K1= NOT USED
o
30
o o
87A
87
85
F2
87A
87
.
.
o
30
o oK10
o o o K9
o o o K8
SIG
0-SIG
86
K10
UB
UB
DE 3
AUTO MODE
SW. ON
DE 2
PRESS. SW.
BOOM RET.
DE 1
PRESS. SW.
BOOM EXT.
0 (UB)
0 (UB)
RXD
TXD
UB
-SIG
+SIG
-SIG
0 (UB)
85
A2B
COMPARATOR
-9V
+9V
-5V
GND
-SIG
-5V
+5V
GND
-SIG
-5V
+5V
GND LEN.(OA)
-5V
ANGLE
GND
X4
0(UB)
+UB
4
3
2
1
)
)
)
)
0 (UB) / GND
+24 V
4.11
0
145
290
435
580
725
870
1015
1160
1305
1450
1595
1740
1885
2030
2175
2320
2465
2610
2755
2900
3045
3190
3335
3480
3625
3770
3915
4060
4205
4350
PRESSURE
(P.S.I.)
"INPUT" SIGNAL AT
TERM. X1-16 IN
CENTRAL UNIT
0 MV.
-33.3 MV.
-66.6 MV.
-99.9 MV.
-133.3 MV.
-166.6 MV.
-199.9 MV.
-233.2 MV.
-266.6 MV.
-299.9 MV.
-333.2 MV.
-366.5 MV.
-399.9 MV.
-433.2 MV.
-466.5 MV.
-499.8 MV.
-533.1 MV.
-566.5 MV.
-599.8 MV.
-633.1 MV.
-666.4 MV.
-699.7 MV.
-733.1 MV.
-766.4 MV.
-799.7 MV.
-833.1 MV.
-866.3 MV.
-899.7 MV.
-932.9 MV.
-966.3 MV.
-999.9 MV.
CHANNEL # 3
TEST POINT ON MAIN
BOARD IN C.U.
0.5 V.
0.63 V.
0.77 V.
0.89 V.
1.03 V.
1.17 V.
1.29 V.
1.43 V.
1.53 V.
1.69 V.
1.83 V.
1.97 V.
2.09 V.
2.23 V.
2.36 V.
2.49 V.
2.63 V.
2.76 V.
2.89 V.
3.03 V.
3.16 V.
3.29 V.
3.43 V.
3.56 V.
3.69 V.
3.83 V.
3.96 V.
4.09 V.
4.23 V.
4.36 V.
4.50 V.

THESE VOLTAGES ARE TO BE USED AS A
REFERENCE ONLY, THE ACTUAL SIGNAL
MAY VARY SLIGHTLY.

ROD PRESSURE
TRANSDUCER
VOLTAGE SIGNALS
4.12
300 BAR MAX.

(4410 PSI)
DAVS 301
PRESSURE TRANSDUCER
(ROD SIDE)
TEST POINT
ON MAIN BOARD
WIRE NUMBER
CENTRAL UNIT
TERMINAL BOARD
PRESSURE
FROM ROD SIDE
OF LIFT CYLINDERS
X1
D
C
B
13
X1
14
15
16
AMP
P5
0.0V
(GND)
- 5.0V
TO A/D
CONVERTER
5.0V
MP 5 VOLTAGES
MP 5
TEST POINT
E 23
4.50V MAX.
.500V MIN.

(300 BAR PRESSURE)
REFERENCE TO GND (TERMINAL X1-14 A104 OR MP 15)
ON MAIN BOARD.

(ZERO PRESSURE)
ERROR
CODE
WORKING
RANGE
E 13
.0V

ROD PRESSURE MEASURING CHANNEL
CHANNEL #3
ERROR
CODE
P5 ZERO POINT
ADJUSTMENT
+ 5.0V
OUTPUT SIGNAL :
ZERO PRESSURE = 0.000V
MAX. PRESSURE = -1.0V
(+ / - 25 MV)
X1
CH. #3
OPERATING
WINDOW
ROD TRANSDUCER MEASUREMENT:

W/VOLTMETER ON X1:15 & X1:14
VOLTMETER SHOULD MEASURE +5.0 VOLTS BETWEEN CONNECTIOS
X1:13 (+5.0V) & X1: 14 (GROUND)
VOLTMETER SHOULD MEASURE -5.0 VOLTS BETWEEN CONNECTIOS
X1:15 (-5.0V) & X1: 14 (GROUND)
-5.00
H8
V2
H4
V1
A2B K9
LMI K8
SHUT
OFF
SHUT
OFF
H1
V5
OUT OF
SEQUENCE
V8
R17
R18
H10
8 10 12 14 16 18 20 22 24 26 28 71 72 73 74
H9
X1
7 9 11 13 15 17 19 21 23 25 27 29
F1
X1
2 4 6
1 3 5
+5.00
V3
K10
LEVER
LOCKOUT
4.13
X1
X1
P.A.T. DS350
Graphic
E13 ERROR CODE

The following step - by - step procedures, with illustrations,
are designed to assist in eliminating error code E13. Since
various problems can cause an E13, these procedures will
check out the complete rod pressure transducer system.
4.14
TERMINAL BOARD
1.
LOWER BOOM ALL THE WAY DOWN, SHUT OFF ENGINE. DISCONNECT
HYDRAULIC HOSE FROM LIFT CYLINDER TO THE ROD SIDE
PRESSURE TRANSDUCER SO THAT NO HYDRAULIC PRESSURE IS APPLIED
TO TRANSDUCER.
2.
CONNECT A DIGITAL VOLTMETER NEGATIVE (-) LEAD TO X1 - 19 AND

POSITIVE (+) LEAD TO X1 - 16 ON TERMINAL BOARD IN THE P.A.T. CENTRAL
UNIT VOLTAGE SHOULD BE .000 VOLT +/- .025 VOLT. THIS IS THE OUTPUT
SIGNAL FOR THE ROD PRESSURE TRANSDUCER. RECORD THIS VOLTAGE
VDC.
2 4 6
1 3 5
X1
H8
V2
A2B
V1
K9
SHUT
OFF
H4
LMI K8
SHUT
OFF
H1
V8
OUT OF
SEQUENCE
V5
R17
R18
H10
H3
.000
X1
V3
H2
V6
K10
LEVER
LOCKOUT
INNER
MID
V7
ROD
DRAIN
4 - WAY
V9
8 10 12 14 16 18 20 22 24 26 28 71 72 73 74
H9
7 9 11 13 15 17 19 21 23 25 27 29
ROD PRESSURE TRANSDUCER

X1
+/- .025V AT ZERO
X1 HYDRAULIC
PRESSURE.
F1
H5
X1
R2
4.15
R1
4.16
TERMINAL BOARD
5.
IF UNABLE TO ADJUST VOLTAGE AT MP5 TO .500V (500MV) WITH POT

P5, DISCONNECT THE SIGNAL WIRE FROM TERMINAL X1 - 16 ON
TERMINAL BOARD AND CONNECT A JUMPER WIRE BETWEEN TERMINAL
X1 - 16 AND X1 - 19.
6.
TRY READJUSTING POT P5 FOR .500V (500MV) AT MP5 WITH JUMPER

WIRE IN PLACE. IF STILL UNABLE TO ADJUST VOLTAGE THE MAIN BOARD
IS DEFECTIVE. REPLACE MAIN BOARD. IF VOLTAGE CAN BE ADJUSTED
WITH JUMPER WIRE IN PLACE, PRESSURE TRANSDUCER OR CABLE IS
DEFECTIVE.
A2B
V1
K9
SHUT
OFF
H4
LMI K8
SHUT
OFF
H1
V8
OUT OF
SEQUENCE
V5
H10
H3
V3
H2
V6
K10
LEVER
LOCKOUT
INNER
MID
V7
ROD
DRAIN
4 - WAY
V9
X1
JUMPER
WIRE X1
R17
R18
H5
X1
8 10 12 14 16 18 20 22 24 26 28 71 72 73 74
H8
V2
7 9 11 13 15 17 19 21 23 25 27 29
H9
DISCONNECT
X1
FROM X1 - 16
2 4 6
1 3 5
F1
X1
R2
4.17
R1

ERROR CODE 13, DRAWING# 4
7. IF VOLTAGE COULD BE ADJUSTED TO .500V (500 ) MV AT TEST POINT

MP 5 IN STEP 6, REFER TO DRAWING # 4 TO CHECK THE +5 VOLT &
-5 VOLT REFERENCE VOLTAGES AT ROD PRESSURE TRANSDUCER
PLUG.
CONNECT DIGITAL VOLT METER NEGATIVE (-) LEAD TO TERMINAL B.
+5.00 VDC. CONNECT POSITIVE (+) LEAD TO TERMINAL C, VOLTAGE
SHOULD BE -5.00 VDC. IF INCORRECT CHECK CABLE CONNECTIONS IN
CENTRAL UNIT AND CHECK CABLE FOR DEFECTS. IF CORRECT
REPLACE PRESSURE TRANSDUCER.
C
B
A D
4.18
P.A.T. L.M.I
MANUAL
SECTION 5
DS 350 GRAPHIC BCS

BOOM ANGLE
CONNECTIONS &
WIRING DIAGRAMS
80
79
78
77
76
75
74
73
72
71
70
69
68
67
66
65
64
63
62
61
60
59
58
57
56
55
54
53
52
51
50
49
DS350 Graphic
Boom Angle to C.P.U.
Connections
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
14
o o
o o
13
CABLE REEL
17
R.F.
FILTERS
18
10
9
8
7
A
B
1
2
5
4
1 2 3
3
4
2
LG
4.7K
CORE
WG
6
SHIELD
2
1
PIN 1 & 5 = GND

PIN 3 & 6 = -5V
PIN 4 = ANGLE SIGNAL
3
2
4
1
BOOM LENGTH SIGNAL

RETRACTED = -0.500V
MAX RANGE = -4.5V
ANGLE SIGNAL
0 DEG. = -3.125V
45 DEG. = -2.50V
90 DEG. = -1.875V
VARIES WITH BOOM
5.1
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
DE 6
LENGTH
RESET SW.
DE 5
CM / IM
RET. SW.
DE 4
OM / FLY
RET. / % SW.
-5V
-SIG
GND
86
K7 = OM / FLY
- 2 WAY
o
30
o o
87A
87
85
F8
86
o
o30
o
K6 = CM 2 - WAY
87A
87
85
F7
86
o
30
o o
K5 = 4 - WAY
DIREC. VALVE
87A
87
85
F6
86
o
30
o o
K4 = TELE OUT
OF SEQ.
87A
87
85
F5
86
o
30
o o
K3 = ROD
DRAIN SOL.
87A
87
85
F4
86
o
o30
o
K2 = IM 2 - WAY
87A
87
85
F3
86
K1= NOT USED
o
30
o o
87A
87
85
F2
87A
87
.
.
o
30
o oK10
o o o K9
o o o K8
SIG
0-SIG
86
K10
UB
UB
DE 3
AUTO MODE
SW. ON
DE 2
PRESS. SW.
BOOM RET.
DE 1
PRESS. SW.
BOOM EXT.
0 (UB)
0 (UB)
RXD
TXD
UB
-SIG
+SIG
-SIG
0 (UB)
85
A2B
COMPARATOR
-9V
+9V
-5V
GND
-SIG
-5V
+5V
GND
-SIG
-5V
+5V
GND LEN.(OA)
-5V
ANGLE
GND
X4
0(UB)
+UB
4
3
2
1
)
)
)
)
0 (UB) / GND
+24 V
5.2
"INPUT" SIGNAL AT TERM. B

IN CANNON PLUG AND
TERM. X1-9 IN C.U.
-1.87
-1.93
-2.00
-2.07
-2.14
-2.21
-2.28
-2.35
-2.42
-2.49
-2.56
-2.63
-2.70
-2.77
-2.84
-2.91
-2.98
-3.05
-3.12
CHANNEL # 5
TEST POINT ON MAIN
BOARD IN C.U.
+.48
+.70
+.92
+1.15
+1.37
+1.60
+1.80
+2.04
+2.26
+2.48
+2.70
+2.92
+3.15
+3.38
+3.60
+3.82
+4.04
+4.27
+4.49

THESE VOLTAGES ARE TO BE USED AS A REFERENCE ONLY, THE ACTUAL SIGNAL
MAY VARY SLIGHTLY.
90 DEGS.
85 DEGS.
80 DEGS.
75 DEGS.
70 DEGS.
65 DEGS.
60 DEGS.
55 DEGS.
50 DEGS.
45 DEGS.
40 DEGS.
35 DEGS.
30 DEGS.
25 DEGS.
20 DEGS.
15 DEGS.
10 DEGS.
5 DEGS.
0 DEGS.
ACTUAL
BOOM ANGLE

BOOM ANGLE SIGNAL VOLTAGE
X1
TERMINAL STRIP
IN JUNCTION BOX
14 SOCKET PLUG JUNCTION

BOX BOOM BASE
TEST POINT
ON MAIN BOARD
WIRE NUMBER
CENTRAL UNIT
TERMINAL BOARD
CABLE REEL TERMINAL
ANGLE SENSOR
0o
90o
BOOM ANGLE SENSOR

PENDULUM
5.3
13
(PART OF THE ANGLE

POTENTIOMETER)
FIXED
RESISTOR
X1
3 11
4 9
A 1 8
AMP
5.0V
4.50V MAX.
.500V MIN.
TO A/D
CONVERTER
MP 8
TEST POINT
E 25
WORKING
RANGE
E 15
MP 8 VOLTAGES
ERROR
CODE
ERROR
CODE
.0V
-5V
+ 500MV (.500V) = 90o ANGLE MIN. SIGNAL

+ 2.50V = 45o ANGLE
+4.50V = 0o ANGLE MAX. SIGNAL
REFERENCE TO GND (TERMINAL X1-8 A104 OR MP 15
ON MAIN BOARD.)
0.0V
(GND)

BOOM ANGLE MEASURING CHANNEL
CHANNEL # 5
MAXIMUM SIGNAL
-3.125V = 0o ANGLE
MINIMUM SIGNAL
-1.875V = 90o ANGLE
(PART OF THE ANGLE

POTENTIOMETER)
FIXED
RESISTOR
X1
CH. #5
OPERATING
WINDOW
P.A.T. L.M.I
MANUAL
SECTION 6
DS 350 GRAPHIC BCS

ANTI - TWO - BLOCK
CONNECTIONS &
WIRING DIAGRAMS
6.1
4.7K
A
B
1
2
1
2
1 2 3
3
SHIELD
LENGTH
CABLE
4
2
CORE
SHIELD
A2B
L.M.I.
CONSOLE
BYPASS KEY
BLUE
WEIGHT
ASSY
A2B
SWITCH
ASSY
18
17
7
6
+SIG
OUTPUT
CENTRAL UNIT TERMINAL

BOARD
1
X1
UB
+24V
SOME MODELS USE MULTIPLE

SOLENOID VALVES.
86
87
K9
87A
V3
85
K8
LMI OVERLOAD
A2B
ELECTRONICS V2
6
K9
7
34 0- SIG
35
30
45
44
46
47
48
- # - WIRE NUMBER
X1
FROM
CRANE SUPPLY
+24V
X1
49
PAT DS350 Graphic LMI

ANTI TWO BLOCK &
SHUTOFF CKT.
14 SOCKET
PLUG
10
14
13
F2-10A
LMI
BYPASS
KEY
(CU)
73
R.F.
FILTERS
CABLE REEL
SLIP
RINGS
3 GREY
2
2
4 VIOLET
1
3 RED
LEVER LOCKOUT
SOLENOID VALVE *
UB
+24V
K10
30
DRAWING 1:
BOOM TIP JUNCTION BOX W/VOLTMETER ON 1 & 2 TURN POWER OFF OR
DISCONNECT X1:35 ON CONNECTION BOARD IN CENTRAL UNIT.
MEASURE THE RESISTANCE BETWEEN TERMINALS 1 & 2.
A2B SWITCH CLOSED = 4700 +/- 500 OHMS
A2B SWITCH OPEN = GREATER THAN 1 MEGOHM
1
2
4.70
6.2
DRAWING 2:
TURN POWER OFF OR DISCONNECT X1:35 ON CONNECTION BOARD IN
CENTRAL UNIT. MEASURE RESISTANCE BETWEEN X2:RED & X1:BROWN.
A2B SWITCH CLOSED = 4700 (+/-500) OHMS
A2B SWITCH OPEN = GREATER THAN 1 MEGAOHM
X2 RED
SHEILD
X1 BROWN
CORE
4.70
X2 : RED
X1 : BROWN
6.3
DRAWING 3:
CABLE REEL W/VOLTMETER ON 7 & 8. TURN POWER OFF OR DISCONNECT X1:35
ON CONNECTION BOARD IN CENTRAL UNIT, MEASURE THE RESISTANCE
BETWEEN TERMINALS 7 & 8.
A2B SWITCH CLOSED = 4700 (+/- 500) OHMS
4.70
1 2 3 4 5 6 7 8 9 101112131415 16
6.4
DRAWING 4:
BOOM BASE JUNCTION BOX W/VOLTMETER ON 5 & 6 TURN POWER OFF OR
DISCONNECT X1:35 ON CONNECTION BOARD IN CENTRAL UNIT.
MEASURE THE RESISTANCE BETWEEN TERMINALS 5 & 6.
A2B SWITCH OPEN = GREATER THAN 1 MEGAOHM
3
4
5
6
7
6.5
4.70
DRAWING 5:
TURN POWER OFF TO CENTRAL UNIT. MEASURE THE RESISTANCE
BETWEEN X1:34 & X1:35.
LMI K8
SHUT
OFF
H1
V8
OUT OF
SEQUENCE
OUTER
MID
V11
K7
R16
R9
V5
K4
K1
R10
R3
R4
R17
R18
H10
H3
R13
R11
R12
R7
V6
K3
R8
R5
F4
X1
77 76 75
K10
LEVER
LOCKOUT
K2
R2
R6
67 66 65 64 63 62 61 60
IM
RO
F5
F6
X1
80 79 78
V3
R1
49 48 47
SE
70 69 68
F7
K5
4W
4.70
R14
CM
OM
F8
K6
V7
ROD
DRAIN
X4
V9
4 - WAY
CENTER
MID
V10
X1
H2
INNER
MID
H5
H6
X1
71 72 73 74
A2B K9
SHUT
OFF
H4
R15
V1
X1
X1
8 10 12 14 16 18 20 22 24 26 28
H8
V2
H7
7 9 11 13 15 17 19 21 23 25 27 29
F1
H9
X3
X1
2 4 6
1 2 3 4
1 3 5
X4
F3
F2
59 58 57 56 55 54 53
X1
52 51 50
X1
43 42 41
40 39 38
X1
37 36
35 34 33 32 31 30
46 45 44
X1
6.6
DRAWING 6:
CONNECTION BOARD W/TEMPORARY 4.7k RESISTOR INSTALLED
TURN POWER OFF TO CENTRAL UNIT. INSTALL THE RESISTANCE BETWEEN
X1:34 & X1:35. TURN POWER ON TO CENTRAL UNIT AND THE A2B ALARM
SHOULD BE INACTIVE.
X3
R15
K4
R16
R9
R10
K1
R3
71 72 73 74
K7
8 10 12 14 16 18 20 22 24 26 28
LMI K8
SHUT
OFF
7 9 11 13 15 17 19 21 23 25 27 29
A2B K9
SHUT
OFF
2 4 6
1 3 5
1 2 3 4
F1
R4
K10
K6
K5
K3
LEVER
LOCKOUT
K2
X4
R13
R14
R11
R12
R7
R8
R5
R2
R6
R1
49 48 47
F8
70 69 68
80 79 78
77 76 75
F7
F6
F5
F4
67 66 65 64 63 62 61 60
43 42 41
40 39 38
37 36
F3
F2
59 58 57 56 55 54 53
35 34 33 32 31 30
4.70k
6.7
52 51 50
46 45 44
P.A.T. L.M.I
MANUAL
SECTION 7
DS 350 GRAPHIC BCS

DIGITAL INPUTS
DS350 GRAPHIC (BCS)

Digital Inputs
INPUT
1
CU
DESCRIPTION
TERMINAL
A104
TELE EXTEND (+24V)
X1/38
NOTES
GROVE PRESSURE SWITCH SIGNAL
A104
X1/40
TELE RETRACT (+24V)
A104
X1/42
AUTO MODE SELECTED (+24V)
GROVE SELECTOR SWITCH SIGNAL
A104
X1/76
PROX. SWITCH OM/FLY RETRACTED PAT SWITCH ON CM - SIGNAL VIA CM

& OM/FLY % RESET (+24V)
CABLE REEL
A104
X1/78
PROX. SWITCH CM/IM RETRACTED

(+24V)
PAT SWITCH ON BOOM BASE
A104
X1/80
PROX. SWITCH IM % RESET (+24V)
E1
A112/A114 HOUSE LOCK PIN SWITCH SIGNAL

X1/1
GROVE LIMIT SWITCH (RT865BXL ONLY)
E2
A112/A114 AUTO MODE A = ON

X1/3
AUTO MODE B = OFF
GROVE SELECTOR SWITCH SIGNAL (NOT

FOR RT865BXL)
E3
A112/A114 FRONT O/R OVERLOAD

X1/6
(GROUND SIGNAL)
GROVE FRONT O/R SWITCH SIGNAL (NOT

FOR RT865BXL)
E4
A112/A114 AREA DEFINATION SWITCH

X1/7
ON RUBBER
SWIVEL LIMIT SWITCH (RT865BXL ONLY)
E5
A112/A114 PROX. SWITCH CM RETRACTED &

X1/9
CM % RESET (+24V)
PAT SWITCH ON IM - SIGNAL VIA IM

CABLE REEL
7.1
P.A.T. L.M.I
MANUAL
SECTION 8
DS 350 GRAPHIC BCS

CENTRAL UNIT,
P.C. BOARD LAYOUT
& CONNECTIONS

5 - Section Boom - Main Board
Power Supply Test Points:

MP 1 = +5V
MP 2 = -5V
MP 11 = Ground H-4
MP 12 = +5V
MP 13 = Digital Ground
MP 15 = Analog Ground
MP 19 = -5V
Analog Measuring Channels / Test Points:

Ch. 1 Boom Length - MP 6 / P6(Do Not Adjust)
Ch. 2 Piston Pressure - MP 4 / P4
Ch. 3 Rod Pressure - MP 5 / P5
Ch. 5 Bom Angle - MP 8 / P8(Do Not Adjust)
E-1
E-4
B-7
B-7
E-1
E-1
8.1
G-3
G-4
G-3
G-2
DS350 GRAPHIC BCS

X1 Terminals A104 Board
X1 TERM.
DESCRIPTION
X1 TERM.
DESCRIPTION
1,2
3,4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
24
25
26
27
28
29
30
31
32
33,36
34
35
37
38
39
40
41
42
24V Battery - Input

GND () Battery - Input
F1 (2 amp) GND
F1 (2 amp) Load Side ub
GND (Inner Shield Connection)
GND
Boom Angle Signal
Boom Length Signal
-5Volt Supply/Length/Angle Transducer
+5Volt Supply/Piston Pressure Transducer
GND
-5Volt/Rod Pressure Transducer
Rod Pressure Signal
+5Volt Supply/Piston Pressure Transducer
GND
-5Volt Supply/Piston Pressure Transducer
Piston Pressure Signal
Length (I/M) Signal
-5Volt Supply / Length Sensor
+9 Volt Supply/Force Transducer
-9 Volt Supply/Force Transducer
+ Force Signal
- Force Signal
24V (ub)
TXD Data Transmit to Console
RXD Data Received from Console
GND (oub)
0 Signal A2B
A2B Signal
Digital Input 1 (-)
Digital Input 1 (+) Tele Ext. Press. SW.
Digital Input 2 (-)
Digital Input 2 (+) Tele Retr. Press. SW.
Digital Input 3 (-)
8.2
Digital Input 3 (+) Auto Mode
43
44
+C/M Prox. Switch

LMI Shut-off Signal
(LMI By Pass Key)
+24V (ub) from F1 (2amp)
(LMI By Pass Key)
A2B Shut off Signal
(A2B By Pass Key)
+24V Battery from F2 (10 amp)
Output to Lever Lockout
K10 LMI Lockout Alarm
Not Used
K2 +24V
K2 (NO) I/M 2 way valve
Not Used
K3 +24V
K3 (NO) Tele Rod Drain Sol.
Not Used
K4 +24V
Not Used
K4 (NO) Tele out of Seq. Sol.
K5 +24V
K5 (NO) Extend
K5 (NC) Retract
K6 +24V
K6 (NO) C/M 2 way valve
Not Used
K7 +24V
K7 (NO) O/M - Fly 2 way valve
Not Used
Length Signal C/M
-5V
Digital Input 4 GND
Digital Input 4 Prox. Switch
O/M Fly Retract
Digital Input 5 GND
CM/IM Retract
Digital Input 6 GND
Length Reset
45
46
47
48
49
50,51,52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70,71,72
73
74
75
76
77
78
79
80

5 - Section Boom - X1 Terminal Board (A104)
V1
K9
A2B
LMI K8
SHUT
OFF
X3
H7
H4
H1
V8
OUT OF
SEQUENCE
OUTER
MID
V11
R15
SHUT
OFF
K7
R16
R9
V5
K4
K1
R10
R3
R4
R17
R18
H10
H6
H3
R13
R11
R12
R7
V6
K3
R8
R5
X1
77 76 75
K10
LEVER
LOCKOUT
K2
R2
R6
F4
64 63 62 61 60
IM
67 66 65
F5
D
RO
F6
X1
80 79 78
V3
R1
49 48 47
Q
SE
F7
K5
4W
70 69 68
R14
CM
OM
F8
K6
V7
ROD
DRAIN
X4
V9
4 - WAY
CENTER
MID
V10
X1
H2
INNER
MID
H5
X1
71 72 73 74
H8
V2
X1
X1
8 10 12 14 16 18 20 22 24 26 28
H9
7 9 11 13 15 17 19 21 23 25 27 29
F1
X1
2 4 6
1 2 3 4
1 3 5
X4
F3
F2
59 58 57 56
X1
55 54 53
52 51 50
X1
43 42 41
40 39 38
37 36 35
34 33 32 31 30
46 45 44
X1
X1
8.3
DS350 GRAPHIC (BCS)

Relay Outputs
INPUT
K1
DESCRIPTION
CU
TERMINAL
NOT USED
A104
X1/52
NOTES
NONE
K2
A104
X1/54
2 - WAY IM SOLENOID VALVES (2)

PILOT PRESSURE
PISTON SIDE PRESSURE
OFF = IM EXTENDS OR RETRACTS ON = IM IS

NOT ALLOWED TO MOVE REFER TO TRUTH
TABLE 1
K3
A104
X1/57
TELE ROD DRAIN VALVE
OFF = BOOM IS EXTENDING OR RETRACTING

AND IS NOT FULLY RETRACTED
ON = BOOM IS IN NEUTRAL POSITION OR FULLY
RETRACTED
K4
A104
X1/61
TELE OUT OF SEQUENCE
PROVIDES SIGNAL TO GRV WARNING LIGHT
K5
A104
X1/62
ANALOG OUTPUT SIGNAL FROM

ANALOG BOARD
ANALOG OUTPUT TO PROPORTIONAL SOLENOID

VALVES, EXTEND & RETRACT, RELAY K5
SELECTS EXTEND OR RETRACT
K5
A104
X1/63
ANALOG OUTPUT SIGNAL TO

PROPORTIONAL EXTEND SOLENOID
VALVE
MAXIMUM 800mA TO EXTEND VALVE ONE

VALVE FOR ALL SECTIONS
K5
A104
X1/64
MAXIMUM 800mA TO RETRACT VALVE ONE

PROPORTIONAL RETRACT SOLENOID VALVE FOR ALL SECTIONS
VALVE
K6
A104
X1/66
2 - WAY CM SOLENOID VALVES (2)

PILOT PRESSURE
K7
A104
X1/69
2 - WAY OM/FLY SOLENOID VALVES OFF = OM/FLY EXTENDS OR RETRACTS ON =

(2) PILOT PRESSURE PISTON SIDE OM/FLY IS NOT ALLOWED TO MOVE
PRESSURE
K8
A104
X1/44
LMI CUT OFF INTERNAL RELAY
CONNECT LMI BYPASS VIA DIODE ASSEMBLY

FROM GRAPHIC CONSOLE AND CU KEY SWITCH
K9
A104
X1/46
A2B CUT OFF INTERNAL RELAY
CONNECT A2B BYPASS FROM GRAPHIC

CONSOLE
K10
A104
X1/48
LMI UNLOCK RELAY OUTPUT
POWERS THE LMI UNLOCK SOLENOID WHEN NO

OVERLOAD, A2B OR ERROR CONDITION
K10
A104
X1/49
EXTERNAL ALARM OUTPUT
USED FOR EEC UNITS ONLY
8.4
OFF = CM EXTENDS OR RETRACTS ON = CM IS

NOT ALLOWED TO MOVE

5 - Section Boom - Diode Board(A113)
24 000 35 0003
PAT BS Z:E
XD1
12 11 10
XC1
8
X1
XB1
5
XA1
2 1
X1

5 - Section Boom - Valve Control Board (A111)
MP11
MP4 MP5
MP6 MP7
..
J3
..
X3
MP10
J1
X2
..
J2 3
MP3MP2 MP8
MP1
X1
F1
8.5

5 - Section Boom - Digital Input
Extention Board (A112)
X2/IN X3/OUT
MP5
MP1
+5V
MP4
MP2
MP3
MP6
GND
C11 C12
MP0
H12
H11
H10
H9
H8
H7
H6
H5
H4
H3
7 8
H13
H2
H14
4 5
H15
H1
1 2 3
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
H16
1
30
25
15
20
8.6
10
DS350 GRAPHIC (BCS)

PAT - GROVE Interface
Grove wire
number
Interface
connector
Description
71
51
73
387
388
239
242
243
244
[507]
[505]
[338]
323
[74]
[744]
240
147
238
1083
255
257
POWER SUPPLY +24V
CRANE GND
LMI UNLOCK SOLENOID (RELAY OUTPUT)
TELE EXTEND PRESSURE SWITCH (INPUT)
TELE RETRACT PRESSURE SWITCH (INPUT)
HIGH = AUTO MODE, LOW = MANUAL MODE (INPUT)
SELECT OM / FLY IN MANUAL MODE (INPUT)
SELECT CM IN MANUAL MODE (INPUT)
SELECT IM IN MANUAL MODE (INPUT)
3RD WRAP CUT OFF MAIN HOIST RT ONLY
3RD WRAP CUT OFF AUX. HOIST RT ONLY
3RD WRAP WARNING LIGHT (GND) RT ONLY
TELE OUT OF SEQUENCE SIGNAL (RELAY OUTPUT)
ADDITIONAL EXTERNAL ALARM (RT ONLY EEC)
HOUSE LOCK PIN SWITCH - PICK & CARRY
AUTO MODE A = HIGH, AUTO MODE B = LOW (INPUT)
FRONT OUTRIGGER OVERLOAD (INPUT)
PROPORTIONAL TELE - SOLENOID GND.
TELE ROD DRAIN SOLENOID VALVE SIGNAL
PROPORTIONAL TELE - SOLENOID (EXTEND)
PROPORTIONAL TELE - SOLENOID (RETRACT)
W
X
8.7
IS
TELE RETRACT PROP SOL
TELE EXT PROP SOL
A111
1
X1
2 3
13 14 15 20 21
23 - SOCKET RECEPT
S/S HARNESS (REF)
TMS/TTS 870
INTERFACE
TELE PROP ANALOG GND
56 57 1 2 3 4 48 38 40 42 36 37 39 41 75 77 79 59 61 49 62 63 64
TELE ROD DRAIN SOL
7 19 10 11 12
240
147
238
1083
255
257
FRONT O/R OVERLOAD
6 9
HIGH SIGNAL = AUTO MODE A

NO SIGNAL = AUTO MODE B
323
To Boom Base
Junction Box
4
TELE OUT OF SEQ.
B
3
CM TELE
IM TELE
8 10 2 3 5 7 11 12 13 14 1
OM/FLY TELE
TELE RETRACT PRESS. SW.
HIGH=AUTO / NONE=MANUAL
7 8
TELE EXT. PRESS. SW.
8.8
1
5 6
LMI UNLOCK SOLS
K7 (COM) +24V
68 69
GND
A113
4
X1
71
51
73
387
388
239
242
243
244
K6 (COM) +24V
K6 (NO) +24V TO CM 2-WAY SOLS
65 66
+24V
K2 (COM) +24V
K2 (NO) +24V TO IM 2-WAY SOLS
53 54
4 5 6
18
LMI - CRANE INTERFACE

23 - PIN PLUG
1 2 3 4 5 6 7 8 9 101112 13 14 15 16 17 1819 20 2122 23 24 25

A B C D E F G H J KLM N O P Q R S T UV W X
16
5
6 9 10
DI E5 GND
DI E5 (+24V=CM RET)
DI E3 (GND=FRONT O/R OL)
A114
3 4
X1
DI E3 (+24V)
[ +24=MODE A
0V=MODE B
DI E2 GND
DI E2
A1 (PROP)
AGND
GND
GND
+24V
+24V
K5 (NC) OUTPUT TO RET PROP
K5 (COM)
K5 (NO) OUTPUT TO EXT PROP
K10 (NC) +24V TO LMI L/O ALARM
K4 (COM) +24V
K4 (NC) +24V TO TELE OUT OF SEQ
DI 6 GND
DI 4 GND
DI 5 GND
DI 2 GND
DI 3 GND
DI 1 GND
DI GND
DI 2 (+24V=TELE RET PRES SW)

DI 3 (+24V=AUTO MODE
DI 1 (+24V=TELE EXT PRES SW)
K3 (NO) +24V TO TELE ROD DRAIN

+24V
+24V
GND
GND
K10 (NO) +24V TO LMI UNLOCK SOLS
K3 (COM) +24V
K7 (NO) +24V TO OM/FLY 2-WAY SOLS
+24V
IS
CONTINUED FROM PAGE 12.1

22 47
DI EXTENSION BOARD
24 350 300 301
9 10 11 12
7
12
9
8
17 22 23 24 25
P.A.T. L.M.I
MANUAL
SECTION 9
DS 350 GRAPHIC BCS

BASIC ADJUSTMENTS
& CHECKS
MODEL:
S/N:
PAT DS35O Graphic (BCS)

"BASIC ADJUSTMENTS AND VOLTAGE CHECKS"
1. Crane Supply Voltage @ Xl -1 ( + ) & Xl -4(GND) =
VDC
2. Supply Voltage to Main Board @ Xl -1 ( + ) & Xl -3 (GND) =
VDC
3. Main Board Power Supply ( Reference Voltages +/- 50 MV) :

(For MP Locations Refer To Page 8.33 )
+ 9V @ MP 14=
- 9V @ MP 16=
+ 5V @ MP 17=
- 5V @ MP 19=
+5V @ MP 1=
-5V @ MP 2=
VDC MP 15 Ground - Force Transducer

VDC MP 15 Ground - Force Transducer
VDC MP 15 Ground - Internal to Board
VDC MP 15 Ground - Jib Angle, Length /
Angle Rod, Piston
VDC MP15 Ground - Piston & Rod
Pressure
+5V @ MP 18=
+5V @ MP 12 =
+12V @ MP 21=
+ 6V @ MP 20 =
4.
5.
6.
Boom Length: (MP 15 Ground for Meter)

Fully Retracted
Ft.
Fully Extended
Ft.
- 5 Volt Reference Voltage
VDC @ X1-10
VDC @ X1-10
VDC @ X1-11
Boom Angle: (MP 15 Ground for Meter)

Minimum Angle
Degs.
Maximum Angle
Degs.
VDC @ X1-9
VDC @ X1-9
VDC @ X1 -11
Pressure Transducers: (MP 15 Ground for Meter)

Piston Zero Point
VDC @ X1-21
VDC @ MP 4
Rod Zero Point
VDC @ X1-16
VDC @ MP 5
+5 Volt Reference Voltage
@ X1-13 & 18
@ X1-15 & 20
9.1
VDC @ MP 6
VDC @ MP 6
VDC @ MP 8
VDC @ MP 8

5 - Section Boom - Main Board (A101)

MP 1 = +5V
MP 2 = -5V
MP 11 = Ground H-4
MP 12 = +5V
MP 19 = -5V

E-1
E-4
B-7
B-7
E-1
E-1
9.2
G-3
G-4
G-3
G-2
P.A.T. L.M.I
MANUAL
SECTION 10
DS 350 GRAPHIC BCS

MAIN BOARD & TRANSDUCER
REPLACEMENT PROCEDURE
P.AT DS350 Graphic

TMS/TTS 870 & RT865BXL
Instructions for replacement of the Main P.C. Board, Pressure Transducer.

A digital voltmeter is required to make adjustments on the main board.
Voltmeter should be set on a range that will display three digits to the right
of the decimal point (i.e. 2VDC).
When the main board in the central unit or pressure transducers are replaced,
the zero point for rod and piston pressure transducer channels must be
checked and readjusted with no hydraulic pressure applied to the pressure
transducers
A. Check the zero pressure output signals for the rod and the
piston pressure transducer on the terminal board inside central
processing unit. Terminal X1/16 for rod signal and terminal
X1/21 for piston signal. Signal voltage should be .000 volt
+/- .025 volts.
B. Refer to instructions on pages 10.3 and 10.4 for adjustment of
pressure channel zero points.
If the main board is replaced, the data and system EPROM must be removed
from the old board and installed on the new board. Refer to page 10.5 for
EPROM location.
10.1
TERMINAL BOARD
V2
V1
K9
SHUT
OFF
LMI K8
SHUT
OFF
H1
OUT OF
SEQUENCE
V5
PISTON PRESSURE TRANSDUCER

+/- .025V AT ZERO HYDRAULIC
PRESSURE.
R17
R18
H10
H3
V7
ROD
DRAIN
4 - WAY
V9
.000
X1
V3
H2
V6
K10
LEVER
LOCKOUT
INNER
MID
H5
8 10 12 14 16 18 20 22 24 26 28 71 72 73 74
7 9 11 13 15 17 19 21 23 25 27 29
H8
V8
2 4 6
1 3 5
H9
H4
X1
ROD PRESSURE TRANSDUCER

X1
X1 HYDRAULIC
+/- .025V AT ZERO
PRESSURE.
.000
F1
A2B
X1
R2
10.2
R1
10.3
10.4
10.5
P.A.T. L.M.I
MANUAL
SECTION 11
DS 350 GRAPHIC BCS

TROUBLESHOOTING
GUIDE
GENERAL FLOWCHART
This section explains how to handle a problem that may arise with the P.A.T. Load Moment
Indicator System - P.A.T. DS350. The procedures are easy to follow and are given in
flowcharts on the following pages. Start with general flowchart below which will guide you
to one of the more detailed flowcharts shown on pages 11.2-11.40.
START
Whats Wrong?
Lever Lockout
Activated
Length Cable
Problem
Go to Page 11.2
Go to Page 11.3
Wrong Length
Displayed
Go to Page 11.10
Wrong Angle
Displayed
Go to Page 11.32
No Display
Go to Page 11.4
No Function
Anti-Two-Block
Go to Page 11.7
Wrong Load
Displayed
Bad Data Transfer Console/CPU
Interface Problem
Go to Page 11.35
Go to Pages 11. 38
Go to Page 11.40
Error Code
Displayed
Go to Page 11.41
11.1
LEVER LOCKOUT ACTIVATED

PROBLEM
The lever lockout system of the crane is activated.
Crane movements hoist up, telescope out, and
boom down are stopped. Crane is not in overload
or two-block condition.
START
Set the override key switch in central unit into upper

position to override LMI.
fixed?
YES
NO
Does light in console indicate
Anti-Two-Block warning?
NO
Fault in crane electric

or hydraulic system.
Check lever lockout

system in crane
YES
If console display is
blank, fault is located
in power supply,
wiring or fuses.
Fault in Anti-Two
Block system.
If Load Moment Limit

Light (7) displays fault
is located in LMI,
cables, wiring, fuses or
console.
Go to Page 11.4
Go to Page 11.7
Read error code displayed on console

display (1) and go to
Page11.41.
11.2
BROKEN LENGTH CABLE

PROBLEM
Damaged or broken length cable.
STEP
ACTION
Cut old cable at cable drum.
Open cable reel cover and disconnect wiring from terminal block. Pull 7- conductor
cable out of strain relief.
Remove cable reel from mounting brackets.
Remove damaged length cable, which is mounted to the slip rings in the cable reel,
from Terminal X1 and X2. Refer to Drawing on Page 11.49.
Turn the cable reel and open the stain relief attached to the axle in the center of the drum.
Pull existing length cable out of the cable reel.
Disconnect damaged length cable from Anti-Two-Block switch receptacle at the boom nose.
7
Pull new length cable through the hole, pipe and strain relief and push it through the axle of
the reeling drum. Tighten strain relief to ensure sealing.
Dismantle length cable near slip ring and reconnect shield to terminal No. X2 and center to
No. X1. Refer to Drawing on Page 11.49.
Remount cable reel to the boom. Turn reeling drum clockwise to get rest of new cable
onto the drum.
10
Set preload on cable reel by turning the drum counter-clockwise (see page 2.15 - pre-tension).
11
Reconnect new cable to Terminal No. 1 (center) and ground terminal (shield) of receptacle
at the boom nose.
12
Reset length potentiometer in length angle transducer (screw is located in center of

white gear): with boom fully retracted, turn potentiometer carefully counter-clockwise
until it stops. Check function of Anti-Two-Block switch. Recheck length and angle display.
Refer to drawing 6 on page 11.53.
11.3
NO DISPLAY
PROBLEM
Blank console display.
No warninglight shown.
Crane movements stopped.
START
Check fuses on CPU box.
correct?
NO
Replace fuses.
YES
Measure crane voltage on terminal board (terminal block X1) between Pin 2 (+24V) and
Pin 4 (ground). Refer to Drawing 3,
Terminal Board, on page 11.50.
Note: If crane voltage is measured below 18V
system will switch off.
correct?
NO
Check crane power supply for faulty crane

electric or if power supply is too low.
YES
Measure crane voltage on terminal board (terminal block X4) between Pin 2 (+24V) and
Pin 3 (ground). Refer to Drawing 3,
Terminal Board, on page 11.50.
correct?
Defect on terminal board. Diode D4,

inductance L1 or capacitor C1 is faulty.
These items cant be replaced, change
terminal board. Refer to Drawing 3,
Terminal Board on page 11.50.
NO
YES
NEXT PAGE
11.4
NO DISPLAY
continued
PREVIOUS PAGE
Measure crane voltage on main

board (terminal block X1) between
Pin 1 (+24V) and Pin 3 (ground).
Refer to Drawing 4, Main Board,
on page 11.51.
correct?
Faulty wiring or connectors

between terminal board and
main board. Check wiring
and connections.
NO
YES
Measure voltages out of power supply

between:
MP 15 = ground (analog) and MP 1 = +5V
MP 15 = ground (analog) and MP 2 = -5V
MP 13 = ground (digital) and MP 12 = +5V
MP= Measuring Points on Main Board. Refer
to Drawing 4, Main Board, on page 11.51.
correct?
Short circuit in external

wiring. Check external
wiring of system for defects.
NO
YES
NEXT PAGE
11.5
NO DISPLAY
continued
PREVIOUS PAGE
Disconnect ribbon cables from X2 and X3

of main board. Measure voltages out of
power supply between:
MP 13 = ground (digital) and MP 12 = +5V
MP= Measuring Points on Main Board. Refer
to Drawing 4, Main Board, on page 11.51.
correct?
Defective power supply on

main board. Replace main
board and reset pressure
channels - see Section 10.
NO
YES
Measure voltage at console terminal

block between Pin 1 = (+24V) and
Pin 2 = (crane ground). Refer to
Drawing 5, Console Board, on
page 11.52.
correct?
Fault in wiring between terminal

block X1 and console board.
Check wiring. Refer to Drawing 5,
Console Board, on page 11.52.
NO
YES
Replace console board.
END
11.6
ANTI-TWO-BLOCK PROBLEM
PROBLEM
Function of Anti-Two-Block System is faulty.
START
Check to see whether or not crane is in two-block condition.
NO
Lower hook down in safe position.
correct?
YES
Check if jumper / dummy plug is

plugged into receptacle at boom
nose.
NO
correct?
Plug appropriate plug into

socket of junction box.
YES
Remove jumper / dummy plug and check
function of anti-two-block switch with
ohmmeter between terminals 1 and 2
in the receptacle.Switch closed=4700 + 500 Ohms
(weight installed) Switch open => 1 Megaohm
(weight removed)
Safe Condition = 0 ohm
Block-To-Block = > 1 megaohm
NO
correct?
YES
NEXT PAGE
11.7
Replace Anti-Two-Block switch.
PREVIOUS PAGE
Disconnect wire from terminal block X1, Pin 35 in

central unit. Measure between Pin 1 and Pin 2 of
receptacle at boom nose with ohmmeter.
Switch closed = 0 Ohm
Switch open = >1 Megohm
NO
correct?
Fault in wiring cable from Anti-Two-Block

switch to junction box at boom nose or short
circuit in length cable. Check wiring.
YES
For next measurement reconnect jumper / dummy

plug, then disconnect length cable from slip rings
7 / 8 in cable reel. With ohmmeter, measure
between center and shield of length cable.
Anti-Two-Block switch open = > 1 megohm
Anti-Two-Block switch closed = 4700 Ohms
+ 500 Ohms.
Reconnect length cable to slip ring.
Faulty wiring between receptacle at

boom nose and cable reel or damaged
length cable. Check out wiring. In
case of damaged length cable,
replace length cable
NO
correct?
YES
NEXT PAGE
11.8
PREVIOUS PAGE
Check Anti-Two-Block signal in central unit.

With ohmmeter measure between wire disconnected from terminal block X1, Pin 35 and Pin 34.
+ 500 Ohms
Anti-Two-Block switch open = > 1 Megohm.
Faulty wiring between cable reel and

central unit. Check Ten Pin Receptacle,
using same measurements as in previous
step. See cranes specific wiring diagram
for wires # 5 (+) and # 6 (-). If fault is
found check cable.
NO
correct?
YES
Check main board function by installing a

temporary resistor, 4700 Ohms, at terminnal
block X1 between 35 and 34 in central. With
resistor connected alarm should be inactive.
NO
If problem still exist, replace

main board and reset pressure channel.
correct?
YES
END
11.9
BOOM LENGTH PERCENTAGE PROBLEM

A.
Boom Length Percentage Error

Boom length
percentage error
Keep the boom stop block

latched. Switch to Manual
Mode and retract the boom
completely.
Is the
percentage reading
(1%, 0%, 0%)?
Yes
No
Continue to Page 11.15
The LMI does not recognize the one or

more reset switch signals. Check
proximity switch target adjustment ,
If damage is visible install new switch.
Measure voltage supply to IM switch at

terminal 1 or 2 (+24V) and 5 or 6 (GND)
in the junction box at the front of the
boom base.
Is the
Voltage
Correct?
No
Yes
Keep the inner mid section retracted.
Measure the inner mid reset switch signal
at terminal 3 (24V) and 5 (GND) in the
junction box at the front of the boom base
section.
Next Page
Faulty voltage supply wiring to

switch. Replace defective
cables.
11.10

Previous Page
Is the
voltage
correct ?
No
Yes
Measure the IM reset switch signal at

terminal 5 (24V) and 9 (GND) in the length
sensor LG221.
Is the
Voltage
Correct ?
Defective IM reset switch.

Replace proximity switch.
No
Yes
Measure the IM reset switch signal at
terminal 15 (24V) and 14 (GND) in the
boom base junction box.
Is the
voltage
correct?
Faulty wiring in cable

connecting the junction box
with the length sensor.
No
Yes
Measure the IM reset switch signal at central unit

terminal A104 80 (24V) and A 101 36 (GND).
Is the
voltage
correct?
Faulty wiring in cable connecting

the length sensor LG221 and the
No
Yes
Measure the CM reset switch signal at
terminal 10 (24V) and 9 (GND) in the length
sensor LG221.
Defective CM reset switch

Next Page
11.11

Previous Page
Is the
voltage
correct ?
No
Yes
Is the
voltage
correct ?

the junction box with the length
sensor.
No
Yes
central unit terminal Al14-9 (24V) and
A l04-36 (GND).
Is the
voltage
correct ?

connecting the boom base
junction box with the LG221.
No
Yes
Measure voltage supply to OM switch at
terminal 11 (+24V) and 9 (GND) in the center
mid junction box.
Is the
voltage
correct ?

the central unit and the boom
base junction box.
No
Yes
Measure voltage supply to CM switch at
terminal 7 (+24V) and 5 (GND) in the inner
mid junction box.
Next Page

connecting the central unit and
the boom base junction box.
11.12

Previous Page
Is the
voltage
correct ?
No
Yes
Keep the outer mid (OM) section retracted.
Measure the OM reset switch signal at terminal
10 (24V) and 9 (GND) in the center mid junction
box .
Is the
voltage
correct ?
Faulty voltage supply wiring to switch.

Replace defective cables.
No
Yes
length- angle sensor LWG221.
Is the
voltage
correct ?

connecting the center mid junction
box and the LWG 221.
No
Yes
Measure the OM reset switch signal at


the junction box with the length
sensor.
Next Page
11.13

Previous Page
Is the
voltage
correct ?
No
Yes
Measure the OM reset switch signal at
central unit terminal Al04-78 (24V) and
Al04-36 (GND).

connecting the boom base
junction box with the LWG 221.
Is the
voltage
correct ?
Defective digital input 4, 5 on main board or

digital input 5 on extension board. Contact
service dealer to obtain replacement
instructions.

the central unit and the boom
base junction box.
11.14

B.
Main Boom Length Error

Main boom length error
In manual mode retract all

boom sections. Pull the boom
stop and retract the inner mid
section completely.
Is the
main boom length
indicated correctly?
Yes
No
CAUTION: High tension on cable reel drum!
CAUTION: To avoid length potentiometer damage. do not
turn the length potentiometer past the stop.
Is the
length cable
spooled properly on
the LG 208
drum ?
Continue
with *
on page 11.17
No
Yes
With all sections completely
retracted, un-spool the length
cable carefully. Let the drum
rewind slowly and spool the
cable manually back on the
drum. Check the roller guides
for correct adjustment.
Reset the length potentiometer.
Has
the adjustment
corrected the boom length
indication.
Yes
Continue
with *
on page 11.17.
No
Next Page
11.15

Previous Page
Check the power supply to the length sensor. Measure

the power supply voltage at central unit terminal Al04
Xl /l1(-5V) and Al04 Xl/8(GND).
Is the voltage
correct (-5V) ?
No
Yes
Possible short or wiring fault between

central unit and cable reel. Measure with
the DVM at the length transducer (LG 208)
terminal 1(GND) and 3 (-5V)
Is the voltage
correct (-5V) ?
Main board component defective

Contact authorized service dealer
for the board replacement procedure.
No
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.
Is the voltage
correct ?
(-500mV)
Faulty wiring between

central unit and length
transducer. Check
wiring, junction boxes
and connectors for faulty wiring.
No
Yes
Check the length signal in the central unit.
Measure the signal at central unit terminal
A104 Xl/10(-5OOmV) and Al 04 Xl/8(GND)
with fully retracted boom.
Next Page
11.16
Defective length potentiometer.

Replace length potentiometer
assembly. For instruction how to
change the length potentiometer
assembly refer to Section 3.
Previous Page
Is the voltage
correct ?
(-500mV)
Yes
No
Check the wiring that connects the
LG 208 with the central unit. Inspect the
cable and connectors.
Have you
found any wiring
faults ?
Main board component defective.

Contact authorized service dealer for
the board replacement procedure.
Yes
No
Connect the voltmeter central unit
terminal A104 X1/10 (signal) and
A104 Xl/8 (GND). Use a small
screwdriver to turn the length
potentiometer carefully clockwise.
The voltage should decrease
from -500mV to -4.5V.
Is the voltage
decreasing from
-500mV to
-4.5V ?
Correct the wiring problem.
Yes
No
cable and connectors.

Contact authorized service dealer for
the board replacement procedure.
Next Page
11.17
Previous Page
Have you
found any wiring
faults ?
Yes
No
Connect the voltmeter central unit
terminal 2 (signal) and terminal
1 (GND). Use a small in the
cable reel. Carefully turn the length
potentiometer clockwise.
The voltage should decrease
from -500mV to -4.5V.
Is the
voltage correct?
(0 turns = -500mV
10 turns = -4.5 V)
Yes
No
Defective length potentiometer assembly.

Replace and adjust length potentiometer.
Reset length transducer.

Continue with section 14.
11.18

C. Inner Mid Length Error
section completely.
Is the
inner mid boom length Yes
indicated correctly?
Continue
with *
CAUTION : High tension on cable reel drum ! on page 11.21
CAUTION : To avoid length potentiometer damage,
do not turn the length potentiometer past the stop.
No
Is the
length cable
spooled properly on
the 221
drum?
No
Yes

retracted, un - spool the length
rewind slowly and spool the
cable manually back on the
drum. Check the roolerguides
for correct adjustment.
Has
the adjustment
corrected the inner mid
length indication?
Continue
with *
on page 11.21
the power supply voltage at central unit terminal A104
X1/11 (-5V) and A104 X1/8 (GND)
Next Page
11.19

Previous Page
Is the voltage
correct (-5V)?
No
Yes
central unit and cable reel. Measure with
the DVM at the length transducers (LG 221)
terminal 1 (GND) and 3 (-5V)
Is the voltage
correct (-5V)?

Contact authorized service dealer
for the board replacement
procedure.
No
Yes
Faulty wiring between
central unit and length
transducer. Check
wiring, junction boxes
and connectors for
faulty wiring.

transducer (LG 221) terminal 1 (GND)
and 2 (-500mV) with fully retracted
boom.
Is the voltage
correct (-500mV)?
No
Yes
Check the length signal in the central unit.
A104 X1-24 (-500mV) and A104 X1-8
(GND) with fully retracted boom.

assembly.
Next Page
11.20

Previous Page
Is the voltage
correct (-500mV)?
Yes
No
cable and the connections.
Have you found

any wiring faults?

See section 10 for replacement procedure.
Yes
No
Connect the voltmeter to central unit
terminal A104 X1-24 (signal) and
A104 X1-8 (GND).
Turn potentiometer clockwise
0 turns = -500mV, 10 turns = -4.5V.
*
Is
the voltage
decreasing from
-500mV to
- 4.5V?
Yes
No
Check the wiring between length
transducer LG 221 and central unit
Inspect cable connectors and junction
boxes.

Next Page
11.21

Previous Page
Have you found

any wiring faults?
Yes
No
Connect the voltmeter to terminal 2 (signal)
and terminal 1 (GNU) in the cable reel.
Turn length potentiometer clockwise.
0 turns = - 500mV, 10 turns = -4.5V
Is the
voltage correct?
0 turns = -500mV
10 turns = - 4.5V
Yes
No
Defective length potentiometer

assembly. Replace and adjust length
potentiometer.
Reset length
transducer. Possible main board defect.
11.22

D. Center Mid Length Error
section completely.
Is the
center mid
length indicated
correctly?
Yes
Continue
with *
on page 11.25
No
CAUTION: High tension on cable reel drum.

CAUTION:
To avoid length potentiometer damage, do not
Is the
turn the length potentiometer past the stop.
length cable
No
spooled properly on
the LWG 221
drum?
Yes
Has
the adjustment
corrected the center mid
length indication?

retracted, un-spooled the length
rewind slowly and spool the cable
manually back on the drum.
Check the roller guides for
correct adjustment.
Yes
Continue
with *
on page 11.25
No

the power supply voltage at central unit terminal A 104
X1-11 (-5V) and A104 X1-8 (GND).
Next Page
11.23

Previous Page
Is the voltage
correct (-5V)?
No
Yes
central unit and cable reel. Measure at
the length transducer, terminal 1
(GND) and 3 (-5V).
Is the voltage
correct (-5V)?

Follow board replacement procedure.
No
Yes
transducer, terminal 1 (GND)
and 2 (-500mV) with fully
retracted boom.
Is the voltage
correct (-500mV)?
Faulty wiring between central

unit and length transducer.
Check wiring, junction boxes and
connectors for faulty wiring.
No
Yes
A 104 X1-73 (-500mV) and A 104 X1-8
(GND) with fully retracted boom.

assembly.
Next Page
11.24

Previous Page
Is the voltage
correct (-500mV)?
Yes
No
Have you found

any wiring faults?

Yes
No
Connect the voltmeter central unit terminal

A 104 X1-73 (signal) and A 104 X1-8 (GND).
Turn length potentiometer clockwise.
0 turns = -500mV, 10 turns = -4.5V.
*
Is
the voltage
decreasing from
-500mV to
-4.5V?
Yes
No

See section 10 for
replacement procedure.
Next Page
11.25

Previous Page
Have you found

any wiring faults?
Yes
No
Connect the voltmeter to terminal 2

(signal) and terminal 1 (GND) in the
cable reel. Turn the length potentiometer
clockwise. 0 turns = -500mV, 10 turns = -4.5V.
Is the
voltage correct?
0 turns = -500mV
10 turns = - 4.5V
Yes
No
Defective length potentiometer

assembly. Replace and adjust length
potentiometer.
Possible main board defect.

Follow main board replacement procedure.
11.26

E. No Extend or Retract Function in Automode
Switch to manual mode and extend

or retract the boom manually.
Does the
boom extend or
retract?
No
Yes
Switch to automode. Start the engine and operate the
extend control. Measure the voltage at central unit
terminal A 104 X1-38 (24V) and A 104 X1-37 (GND)
while operating the extend control.
Is the
voltage
correct?
Defect in crane electric or hydraulic circuit.

Reset crane fuse breaker. Check LMI fuses
in the central unit enclosure.
No
Yes
Switch to automode. Start the engine and operate the
retract control. Measure the voltage at central unit
terminal A 104 X1-40 (24V) and A 104 X1-39 (GND)
while operating the extend control.
Is the
voltage
correct?
Faulty wiring to extend pressure switch or

defective pressure switch. Correct the
wiring and replace the switch if defective.
No
Yes
Select the service screen on the console
by pressing the two outer keys (F1 & F4)
simultaneously. The ramping value for the selected
section shall increase from 0 to 255. The ramping
value remains 0 in the neutral position.
Faulty wiring to retract pressure switch or

defective pressure switch. Correct the wiring
and replace the switch if defective.
Next Page
11.27

Previous Page
Is the
ramping value
increasing?
No
Yes
Continue to troubleshoot the wiring to
the 2 way value and the hydraulic
circuit.
Check ribbon cable connection in

central unit and wiring in the central unit.
11.28

F. Out of Sequence Warning
Boom sections are out of sequence
(Automode)
Follow instructions in
section A.
Is the
problem
corrected?
Yes
End
No
section B.
Is the
problem
corrected?
Yes
End
No
section C.
Is the
problem
corrected?
Yes
End
No
section D.
Is the
problem
corrected?
No
Yes
End
Next Page
11.29

Previous Page
With outer mid section completely retracted

check the adjustment for the OM retract switch
target.
Is the
switch and
target adjusted
correctly?
No
Yes
Measure the switch signal
at central unit.
A 104 X1-76 (24V) and
A 104 X1-36 (GND)
Is the
voltage
correct?
Adjust OM retract
switch and target.
Yes
No
Faulty wiring. Check the voltage at terminal

17 (24V) and 13 (GND) in the boom base
junction box.
Have you
found a
fault in
the wiring?
No
Next Page

See main board replacement
procedure.
Yes
Correct the wiring

between boom base
junction box and central
unit.
11.30

Previous Page
Measure switch signal at

LWG 221 terminal 10
(24V) and 9 (GND)
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.
Is the
voltage
correct?
Correct the wiring between LWG 221

and boom base junction box. Refer to
section 9 and 11.
No
Yes
Retract all boom section in
manual mode and let the system
reset boom percentage.
Recheck.
Defective OM retract switch.

Refer to section 9 & 11.
End
11.31
ANGLE READING PROBLEM

PROBLEM
Angle Reading Incorrect
Crane is not in Out of Load Chart condition.
START
Check levelness of the angle sensor

in cable reelwith main boom at
horizontal remove cover from the
cable reel. Refer to Page 11.53, Angle
/ Length Sensor Adjustment Procedure.
NO
correct?
YES
Readjust the angle sensor to the correct

position by loosening the mounting
screws and moving the angle sensor.
Refer to Page 11.53, Angle /
Length Sensor Adjustment Procedure.
Check power supply to angle

sensor on Terminal Board,
Terminal X1, Pin 8 (ground)
and Pin 11 (-5V) +/- 50mv.
Refer to Drawing 3 Terminal
Board on page 11.50.
NO
correct?
YES
Main board defective. replace main board and

reset pressure channel. Refer to Section 10 of
this Manual.
Note: Consult factory before replacing main
board for further troubleshooting steps.
NEXT PAGE
11.32
PREVIOUS PAGE
Measure supply to angle sensor in cable

reel at terminal between Pin 5 (ground)
and Pin 6 (-5V) +/- 50mv.
Refer to Drawing 6, Length / Angle Transducer on page 11.53.
NO
correct?
Faulty wiring between central unit and

angle sensor. Check wiring.
YES
Measure signal from angle sensor in cable

reel at terminal between Pin 4 (signal) and
Pin 5 (ground).
Boom Angle Signal Voltages:
0 Degrees
-3.12 Volts
45 Degrees
-2.49 Volts
75 Degrees
-2.07 Volts
For more detailed signal voltages refer
to : Boom Angle Signal Voltage Chart
in Section 5.
NO
correct?
YES
Remove wire # 4 from Terminal, in thecable

reel, and recheck the boom angle signal
voltages at terminal # 4 in cable reel.
If the signal is correct the problem is in the
wiring between the cable reel and the central
unit or the main board is defective.
If the signal is incorrect the angle sensor is
defective. Replace the angle sensor and adjust
according to instructions on page 11.53
NEXT PAGE
11.33

PREVIOUS PAGE
Measure signal from angle sensor in cable

reel at terminal between Pin # 9 (signal) and
Pin # 8 (ground).
0 Degrees
-3.12 Volts
45 Degrees
-2.49 Volts
75 Degrees
-2.07 Volts
in Section 5.
NO
correct?

cable reel. Check wiring.
YES
Measure angle signal of amplified output on

main board between test point MP 15(ground)
and MP 8 (angle signal).
Note: Negative signal at terminal X1 Pin 9
will be converted into positive signal at MP 8.
0 Degrees
+4.49 Volts
45 Degrees
+2.48 Volts
75 Degrees
+1.15 Volts
in Section 5.
reset pressure channel. Refer to Section 10 of
the System Manual.
NO
correct?
YES
END
11.34
LOAD READING PROBLEM

PROBLEM
Load reading incorrect.
START
Check selected operating mode(code
on operating mode switch).
NO
correct?
Select operating mode switch to correct position

(see operating mode in load chart).
YES
Check boom length reading on display.
NO
correct?
Reset length potentiometer. With fully retracted

boom, turn potentiometer axle counterclockwise
until it stops
YES
Measure radius and check with the
displayed radius.
NO
correct?
Check if mechanical adjustment of angle transducer

is correct. Angle transducer box should in line with
boom and adjusted to actual boom angle.
YES
Check power supply to pressure transducer (rod
side). Unplug transducer cable from transducer.
Measure on terminal board at terminal block X1.
Measure between Pin 14 (ground) and Pin 15
(-5V). Measure between Pin 14 (ground) and Pin
13 (+5V).
Power supply on main board defected. Check
power supply out and measure between test
point MP15 = ground and MP18 = +5V and
between test point MP15 = ground and MP2 =
-5V. If incorrect, replace main board and reset
pressure channel.
NO
correct?
YES
NEXT PAGE
11.35

PREVIOUS PAGE
Check power supply to pressure transducer

(piston side). Unplug transducer cable from
transducer. Measure on terminal board at terminal block X1. Measure between Pin 19
(ground) and Pin 20 (-5V). Measure between
Pin 19 (ground) and Pin 18 (+5V).
NO
correct?
YES
Power supply on main board defective. Check

power supply and measure between test point
MP 15 = ground and MP 18 = +5V and between
test point MP 15 = ground and MP 2 = -5V. If
incorrect, replace main board and reset pressure
channels.
Check power supply at transducer plugs. Measure between B = ground and A = +5V. Measure between B = ground and C = -5V.
NO
Faulty wiring. Check wiring (pressure

transducer cable).
correct?
YES
Plug transducer cable back into transducer.

Check out signal from transducer. Measure
between B = ground and D = signal in
transducer plug. Signal = 0 to -1V (+/- 20mV).
NO
correct?
Transducer defective - replace transducer.
YES
NEXT PAGE
11.36

PREVIOUS PAGE
Plug transducer cables back into transducer.
Check transducer signals in central unit. Disconnect wire # 4 of transducer cable from
terminal block X1, Pin 21 (signal piston side).
Disconnect wire # 4 of transducer cable from
terminal block X1, Pin 16 (signal rod side).
Measure transducer signals (0....-1V) between
Pin 19 (ground) and wire # 4 (piston and rod
side transducer cable).
NO
correct?
Faulty wiring. Check wiring (pressure transducer

cable). Transducer defective-replace transducer
and reset pressure channel as described below.
YES
Reconnect wire # 4 from transducer cables
back to terminal X1, Pin 16 (rod side) and
terminal X1, Pin 21 (piston side).
Without pressure in hoses, check 0 point
adjustment on main board by disconnecting
hydraulic hoses from transducer. Measure
between test point MP 15 (ground) and test
point MP 4. Signal should be 0.50V
(piston side). Measure between test point
MP 15 (ground) and test point MP 5. Signal
should be 0.50V (rod side).
NO
correct?
YES
Measure voltage between test point MP 15

(ground) and test point MP 4 and reset with
P4 to 0.50V (piston side).
Measure voltage between test point MP 15
(ground) and test point MP 5 and reset with
P5 to 0.50V (rod side).
If not resettable, replace transducer.
END
11.37
BAD DATA TRANSFER BETWEEN CONSOLE & CENTRAL UNIT

PROBLEM
Error Code E93 / E94
No data transfer to and from console.
START
Make sure that Data EPROM is plugged into

main board socket D5 and System EPROM is
plugged into main board socket D4. Check
that EPROMS are inserted with notch on
EPROM to matching notch on socket.
NO
Place EPROM in correct socket.
correct?
YES
Check supply crane voltage for console in central

unit at terminal board (block X1) between Pin 33
(ground) and Pin 30 (+24V). Make sure external
and internal power supply is correct.
NO
correct?
YES
Defective internal power supply. Replace main

board and reset pressure channel.
or
Defect in terminal board. Replace terminal board.
NEXT PAGE
11.38
PREVIOUS PAGE
Check power supply to console between console

terminal # 2 = ground (KM) and terminal # 1 =
+24V.
NO
Faulty wiring in cable from central

unit to console. Replace cable.
correct?
YES
Ensure that wires are properly connected between terminal block X1 Pin 31 and console
terminal Pin 4 and between terminal block X1
Pin 32 and console terminal Pin 3.
NO
correct?
Defective electronic components on main board

and / or console board. Replace console board
and / or replace main board.
YES
END
11.39
INTERFERENCE PROBLEM
PROBLEM
Interference from crane electric.
Error Code E93 / E94 intermittent.
Frozen console displays.
START
Check system out; Pg. 11.38&39 - Bad Data
Transfer Between Console & Central Unit.
NO
Replace or repair part which is defective.
correct?
YES
Check if additional ground like between main
board terminal X9 and central unit box mounting
bracket is in place.
NO
correct?
Install ground link - single cable minimum of

AWG14 (2.0mm2) between terminal X9/1 and
central unit box mounting bracket.
YES
Ensure that cable shields are connected correctly.
Refer to connections and wiring diagrams.
Make correct shield connection.

Refer to connection and wiring diagrams.
NO
correct?
YES
Find out which component of the crane electric
is spiking out (e.g. dump valve, outrigger relay).
Install a diode or varistor across terminals of
spiking component. Diode type such as 1N 4001
can be used (watch + and - connection for diode).
END
11.40
ERROR CODE DISPLAY
PROBLEM
Error code displayed. Lever lockout activated.
Warning lights on.
ERROR
DISPLAY
ERROR
CAUSE
ACTION
E 01*
Below radius or above angle

range.
Fallen below the minimum

radius or above the angle given
in the load chart due to raising
the boom too far.
Lower boom back to a radius

or angle given in the load
chart.
E 02*
Beyond radius or below

angle range.
The maximum radius or

minimum angle given in the
load chart was exceeded due
to lowering the boom too far.
Raise boom back to a radius

chart.
E 03*
Prohibited slewing range.

(no load area)
Slewing range prohibited

with load.
Slew back into admissible

range.
E 04*
Operating mode not available.
Operating mode switch in the

console set incorrectly.
Operating mode is not permissible with actual crane
configuration.
Set operating mode switch

correctly to the code assigned
to the operating mode of the
crane.
E 05*
Length range not permitted.
Boom was telescoped too

far or not far enough.
Telescope boom to correct

length given in the load chart.
Length sensor adjustment

changed; i.e. length sensor
cable slid off the cable drum.
See Section No. 3
Fallen below the minimum jib

angle specified in the
respective load chart due to
luffing out the jib too far.
Luff in the jib to a radius or

angle specified in the load
chart.
E 06*
Fallen below angle range with

luffing jib operation.
* This error can be corrected by the operator.
11.41
ERROR CODE DISPLAY

ERROR
DISPLAY
ERROR
CAUSE
ACTION
E 07
No acknowledgment signal
from overload relay (K8).
Overload relay is stuck,

defective or not being selected.
Replace relay.
E 08
No acknowledgment signal
from Anti-Two-Block switch
relay (K9).
Anti-Two-Block switch relay

is defective or not being
selected.
Replace relay.
E 11
Fallen below lower limiting

value for the measuring
channel "length".
E 12
E 13
E 14

channel "pressure piston side".

channel "pressure rod side".
Fallen below upper limit value

in measuring channel "Force".
Cable from central unit to length sensor Check cable. Replace if

defective, not connected or water in the necessary. See Section 3.
connectors
Length potentiometer defective.
Replace and reset length

potentiometer. See Section 3.
Electronic component in the

measuring channel defective on
main board.
Replace main board and

reset pressure channels.
See Section 10.
Cable from central unit to

the pressure transducer
defective, loose or water in
the plug.
Check cable as well as plug.

Replace if necessary.
See Section 10.
Pressure transducer on
piston side defective.
Replace pressure transducer

and reset pressure channel.
See Section 10.

measuring channel defective
on main board.

See Section 10.

in the plug.

See Section 10.
Pressure transducer on rod

side defective.

See Section 10.
Electronic component in
the measuring channel defective
on main board.

See Section 10.

force measuring point defective
or water inside the plugs.
Force transducer defective.
measuring channel defective.
11.42
Check cable as well as plugs,

replace if need be.
Replace force transducer.
Replace main board and reset
pressure channels. Section 10
ERROR CODE DISPLAY
ERROR
DISPLAY
E 15
E 16
ERROR
channel "angle main boom".
Fallen below lower limit

value for measuring channel
"Luffing Jib Angle".
CAUSE
ACTION
Cable from central unit to the length/

angle sensor defective or loose or
water inside plug.
Check cable.
See Section 5.
Angle sensor defective.
Replace angle sensor.

and reset adjustment.


See Section 10.
Cable from central unit

to angle sensor defective
or disconnected or water
inside the plug.
Check cable as well as plug,

replace if need be.


pressure channels.
See Section 10.
E 18
Front Stabilizer overloaded
Exceeding capacities allowed for over

the front.
Achieve a safe working area

Immediately.
E 19
Error in the reference voltage.
Electronic component on
the main board defective.

pressure channels.
See Section 10.
Bad power supply on

main board.
Check wiring, replace if

need be.
Bad force transducer

wiring, (external).
Check force transducer cable,

replace if need be.
Cable from central unit to the

length/angle sensor defective
or loose.
Length potentiometer
defective.
Check cable. Replace if

necessary. See Section 3.
potentiometer.

on main board.

See Section 10.
+5 volt supply
E 20

-9 volt supply
E 21
Upper limiting value for the

measuring channel "length"
exceeded.
11.43
ERROR CODE DISPLAY
ERROR
DISPLAY
E 22
E 23
E 24
E 25
E 26
ERROR
measuring channel "pressure
piston side exceeded.

rod side" exceeded.
Upper limit value in measuring

channel "Force" exceeded.

measuring channel "angle
main boom" exceeded.
Upper limit value for

measuring channel "Luffing
Jib Angle" exceeded.
CAUSE
ACTION

pressure transducer defective,
loose or water in the plug.

See Section 10.
Pressure transducer on piston

side defective.

and reset pressure channels.
See Section 10.

on main board.

See Section 10.


See Section 10.

side defective.
See Section 10.


on main board.

See Section 10.
Cable between central unit and

or water inside the plug.

replace if need be.
Force sensor defective.
Replace force sensor.

See Section 7.
or loose.
mechanical adjustment.
on main board.
See Error E 16.

pressure channels.
11.44
Check cable.
See Section 5.
Replace angle sensor and reset
pressure channels.
See Section 10.
See Error E 16.
ERROR CODE DISPLAY

ERROR
DISPLAY
E 29
ERROR
Error in the reference
voltage.
-5 volt supply
E 31
E 37
Error in system program
Error in program run
CAUSE
Supply and Reference voltages on
MP10 is more than 3.3V
EPROM with system

program defective.
EPROM with system program
defective.
Electronic component on the main
board defective.
ACTION
Check supply voltages.
pressure channels.
See section 10.
Replace EPROM with system
program.
pressure channels.
See section 10.
Replace system program
EPROM.
pressure channels.
See section10.
E 38
Incorrect system program.
CPU is equipped with an

incorrect version of system
program.
Equip main board with

correct version of system
EPROM.
E 41
Error in the external RAM.
RAM in the CPU on the

main board defective.
Replace CPU Chip No.

80C31. Replace main
channels. See Section 10.
E 42
Error in the external write/

read memory (RAM).
Internal defect in
digital part of CPU.
Exchange write/read memory

(CMOS-RAM).
pressure channels.
See Section 10.
E 45
Error in internal
communications.
Defective electronic
component.
E 47
Malfunction in the
monitored write/read
memory.
Internal defect in
in digital part of CPU

See Section 10.
pressure channels.
See Section 10.
E 48
Malfunction in the monitored
Inter defect in digital part of CPU

pressure channels.
See section 10
E 51
Error in data memory.
Data EPROM on the main

board defective.
Replace Data EPROM.

Make sure BR3 on the main
board is installed.
See Drawing 4 on page 11.51.
11.45
ERROR CODE DISPLAY
ERROR
DISPLAY
ERROR
CAUSE
ACTION
E 60
Error in EPROM
DATA-EPROM is not plugged into

the correct socket or location is not
programmed correctly in the EPROM.
Properly install DATA-EPROM

See page 11.51
E 70
Error in return signal
No or wrong return signal from digital

input extension module to processor.
E 71
Incorrect acknowledgment of the

A2B Relay on A101 Term. board.
A2B relay is stuck or defective.
Ribbon cable defective or bad

Connection. Replace cable.
Digital input circuit defective.
Replace module.
Decoder circuit defective.
Replace decoder module.
Replace K9 relay. See page
11.50
A2B relay is not being selected due to

a break on the terminal board, main
board or ribbon cable.
E 72 E 77
Analogous to E 71 for relays

K2 K7

K2 K7
Check terminal board, main

board and ribbon cables as well
as replace defective part, if
necessary.
K2 K7
E 80
Error in return signal
No or wrong return signal from analog

output extension module to processor.
(for inner mid)
Ribbon cable defective or bad

Connection. Replace cable.
Analog output circuit defective.
Replace module.
Decoder circuit defective.
Replace decoder module.
E 83
Boom not synchronized.
The outer mid and fly section are not

fully retracted while the center mid
section or the inner mid section
retracts or extends.
Select manual mode, manually

retract the outer mid and fly
section until fully retracted.
Return to auto mode.
Check fly section cable
adjustment. The fly section
shall not be extended when
center mid section is fully
retracted.
11.46
ERROR CODE DISPLAY

ERROR
DISPLAY
ERROR
CAUSE
ACTION
E 89
Change of the operating code

during lifting a load.
The operating mode switch in the

console was used during lifting
a load.
Lower the load and set the

operating mode switch correctly
to the code assigned to the
actual operating mode of the
crane.
E 91
No data transmission from

console to central unit.
(See page 11.38 - 11.40)
24V supply of console

interrupted.
Check 24V at terminal Xl of

console electronics.
Interruption or accidental
ground in the line from
console electronics to
central unit.
Check the connection between

console electronics and
central unit. If you find an
accidental ground, the
transmitter module in the
console electronics can be
damaged. You should,
therefore, replace the console
electronics.
Replace console electronics
or main board respectively.
console electronics and central
unit.
E 92
E 93
E 94
Error in the data transmission

from console to central unit.
(See page 11.38 - 11.40)
Transmitter / receiver module

defective.
Defective data line
from console electronics to
central unit.
Transmitter / receiver
module defective.

from central unit to console.
(See page 11.38 - 11.40)
Defective contact in the line

module defective.

central unit to console.
(See page 11.38 - 11.40)
ground in the data line from
Check the line to the console.

5V supply for the computer

in the central unit is missing.
5V supply voltage too low.
module defective.
Check the line to the console

(in case of accidental ground
also replace console
electronics).
Check the connection to the
power supply.
Replace power supply module.
Data EPROM defective.
Check data EPROM.
Computer module defective.
Replace main board.
Electromagnetic interferences
(e.g. when switching
contactors or valves).
Eliminate interference source

by inverse diodes or varistors.
11.47
ERROR CODE DISPLAY
ERROR
DISPLAY
E 95
ERROR
Error in the crane data EPROM
CAUSE
ACTION

Position of jumper for the selection
of the type of EPROM is wrong.
Electronic component on main board
defective.
Replace data EPROM.

Check the jumper position.
pressure channels.
E 96
Error in the internal RAM of the

CPU of the console.
CPU or main board of the console

defective.
Replace console main board.
E 97
Error in the external RAM of the

CPU of the console.
External RAM of the console

defective.
board defective.
E 98
Wrong jumper position in the

console.
The jumper position BR9/BR10 in the Check the jumper position.

console does not correspond to the
actual type of central unit.
board defective.
11.48
Drawing 1 : Slip Ring Unit
X2 : RED
X1 : BROWN
Drawing 2 : Boom Nose Junction Box
11.49
Drawing 3 : Terminal Board
X3
H7
A2B K9
LMI K8
SHUT
OFF
SHUT
OFF
H4
H1
V8
OUT OF
SEQUENCE
OUTER
MID
V11
R15
V1
K7
R16
R9
V5
K4
K1
R10
R3
R4
R17
R18
H10
H3
R13
R14
R11
R12
K3
R8
R5
K10
LEVER
LOCKOUT
K2
R2
R6
F4
67 66 65 64 63 62 61 60
IM
X1
77 76 75
V6
D
RO
F5
X1
80 79 78
V3
R1
49 48 47
Q
F6
R7
SE
F7
K5
4W
70 69 68
CM
OM
F8
V7
ROD
DRAIN
K6
4 - WAY
X4
V9
CENTER
MID
V10
X1
H2
INNER
MID
H5
H6
X1
71 72 73 74
H8
V2
X1
X1
8 10 12 14 16 18 20 22 24 26 28
H9
7 9 11 13 15 17 19 21 23 25 27 29
F1
X1
2 4 6
1 2 3 4
1 3 5
X4
F3
F2
59 58 57 56 55 54 53
X1
52 51 50
X1
43 42 41
40 39 38
X1
37 36 35 34 33 32 31 30
46 45 44
X1
11.50
Drawing 4 : Main Board

MP 1 = +5V
MP 2 = -5V
MP 11 = Ground H-4
MP 12 = +5V
MP 19 = -5V

E-1
E-4
B-7
B-7
E-1
E-1
11.51
G-3
G-4
G-3
G-2
Drawing 5 :Console Board
MP 2
+7V
MP 5
+5V
MP 0
GND
MP 3
-24V
MP 4
-24V
MP 6
MP 7
MP 1
+UB
J2
J5
J1
J4
J3
X1
X5 1 2 3 4
1 2 3 4 5 6 7 8
11. 52
Drawing 6 : Length / Angle

Transducer
PAT
PAT
1
2 3 4 5 6 7 8 9 101112 131415 16

11.53
Drawing 7 : Suppressor Diode
COMPONENT
CAUSING
INTERFERENCE
+
SUPPRESSOR DIODE
CAUTION: Make sure that + and - diode connections are

made as shown to ensure proper polarity.
Drawing 8 : Central Unit Box
FUSE (10A)
FUSE (2A)
OVERRIDE
KEY SWITCH
(BOTTOM VIEW
OF C.P.U.)
11.54
NORMAL
OPERATION
OUT
L/O
OVERRIDE
IN
P.A.T. L.M.I
MANUAL
SECTION 11
APPENDIX
DS 350 GRAPHIC BCS

BOOM LENGTH
TROUBLESHOOTING
PROCEDURE
5 Section Boom
Problem :
Outer Mid section and Fly will not extend.
Reason:
Center Mid section indicates 96% - 97% extention on the PAT even though boom Section is fully
extended.
Findings:
Cable reels are spooling properly.
Switch to manual mode and retract all sections with the boom stop pulled.
Boom percentages should indicate a 0% - 0% - 0%
If not check the proximity switches
Proximity switches are all four being made when boom is fully retracted to reset zero point with
swingaway stop pulled down.
Proxy switch
Terminal to check in reference to Ground( X1/ 36)
OM/Fly Retracted
A 104 X 1/76
CM Retracted
A 114 X 1/9
IM+CM Retracted
A 104 X 1/78
The red LED will be illuminated
when switch is on.
IM % Reset
A 104 X 1/80
All four should have a minimum of
20 volts
If still not correct
Reset the length potentiometers by turning them counterclockwise until they stop with the boom fully
retracted.
Press the outer two keys simultaneously ( F1& F4 on the PAT console) to obtain the length indication for
the inner mid and center mid.
With the boom stop disengaged the total length retracted should be 35.4 and extended 137.8
With the inner mid extended it should read 61.0
With the inner mid and the center mid extended it should read 86.6
Check the voltage on terminal #6, #7 and #9 on the main board for .495 to .500 volts with the boom fully
retracted. If off, reset per the calibration papers inside the box.
Ch. #3 - Force transducer not used
Ch. #4 - Rod transducer - Do not touch
Ch. #5 - Piston transducer-Do not touch
Ch. #6 - Total Overall Length - (top reel)
Ch. #7 - Center mid / Inner mid - (middle reel)
Ch. #8 - Angle transducer - Do not touch
Ch. #9 - Inner mid - Bottom reel
Appendix 1
TMS / TTS 870 BOOM CONTROL SYSTEM ( M4XT V2.3 C )

A. Testing boom length calibration and boom percentage.
Caution: Elevate the boom to a permissible load chart radius.
Switch to Manual mode and retract all sections with the boom stop pulled.
Boom percentage indication on console shall read 0% - 0% - 0%.
Select Manual mode and IM and extend IM fully. Indication 100% (+ / - 1 %) - 0% - 0%.
Select Manual mode and CM and extend CM fully.
Indication 100% (+ / - 1 %) -100% (+ / - 1 %) - 0%.
Select Manual mode and OM / Fly and extend OM / Fly fully.
Indication 100 % (+ / - 1 %) - 100 % (+ / - 1 %) - 100 % (+ / - 1 %)
Should indication differ ensure that boom stop was pulled, when fully retracted and all sections are
mechanically extended.
If still not correct go to step B.
B. Correcting boom length and % indication.

Caution: Elevate the boom to a permissible load chart radius.
Switch to Manual mode and use the section selector switches in the cab for the duration of the following
procedure.
Retract the boom fully with the boom stop pulled.
Reset carefully the potentiometer inside the length and length angle sensors counter clockwise until stop.
Repeat test A.
If still not corrected proceed below.
On the horizontal line of the graphic console press the two outer keys simultaneous to obtain the length
indication for IM and CM in a test picture.
With the boom stop disengaged calibrate the total length to retracted 35.4 and extended 137.8. Read the
boom length on the graphic console.
With the boom stop disengaged calibrate the IM length to retracted 35.4 and extended 61.0. Read the
boom length on the graphic console in the test picture.
With the boom stop disengaged calibrate the IM + CM length to retracted 35.4 and .extended 86.6. Read
the boom length on the graphic console.
Transfer data into Eprom and check out length indication as described above.
Repeat test A.
If still not corrected proceed with test C.
Appendix 2
C. Testing the retract and boom % reset switches
Switch to Manual mode.

With the boom stop engaged retract boom fully.
Lower the retracted boom in order to reach the switches.
Switch the engine of but leave the electrical power on.
The Red LED on the proximity switch shall be switched on for the OM / Fly, CM, IM + CM retract and
IM % reset switch. If not adjust the targets to the correct position. If still not check the power supply to
each switch using the wiring diagram.
If all LEDs are switched on check the signal voltage returning to the central unit terminal. The voltage
shall not be lower than 20 Volts with reference to crane GND ( Xl - 36 ) for
OM / Fly retract
CM retract
IM + CM retract
IM % reset
A104 X 1 / 76
A l 14 X 1 / 9
A 104 X 1 / 78
A 104 X1 / 80
Once identified which circuit is not powered use the wiring diagram to locate the wiring problem.
Note: With the boom stop engaged and the IM reset switch signal on the system is programmed to
indicate 1 % extension for the IM section. To read 0 % you must pull the boom stop down and pass the
target.
The IM reset target must be adjusted with the boom stop engaged and the boom fully retracted onto the
boom stop. The IM + CM retract switch has two targets providing the boom is equipped with boom stop
retracted against boom stop and another target for retracted against base section. Do not attempt to adjust
targets if the two positions are not met. Incorrect adjustment could cause cylinder damage.
D. Boom does not extend or retract while Auto mode is selected.
Switch to manual mode and retract the boom.
When fully retracted select a legal operating mode on graphic console.
Switch to auto mode and to mode A or B.
Ensure that no other LMI error, A2B or overload exists.
Have the operator start the engine and push the extend control.
Measure extend pressure switch signal on terminal A 104 Xl / 38 in the CU ( approx. 24 Volt reference
crane GND ).
Appendix 3
If not use the electrical diagram to identify the cause. Measure signal of pressure switch
located on the right, inside the valve bank compartment. Disconnect wire 387 from the switch and
measure voltage on switch output terminal.
Have the operator start the engine and push the retract control.
Measure retract pressure switch signal on terminal A l 04 Xl / 40 in the CU
( approx. 24 Volt reference crane GND ).
If not, use the electrical diagram to identify the cause. Measure signal of pressure switch located on the
control valve. Disconnect wire 388 from switch and measure voltage on switch output terminal.
Replace switch or rectify the wiring problem.
If signals are correct and problem is not resolved go to E.
E. Testing the boom control signals

Retract the boom.
Switch to Manual mode.
Switch to IM and measure on Al 04 -Xl / 54, 66, 69 in CU. No voltage.
Measure at the cathode of the diodes which are connected to terminal 54, 66, 69 or at the cathode terminal
of the diode matrix board. Should measure, crane voltage ( 24 Volt on cathode of diode connected to 66,
69 and no voltage on the cathode of the diode connected to 54.
Switch to CM and measure on Al 04 -Xl / 54, 66, 69 in CU. No voltage.
Measure at the cathode of the diodes which are connected to - terminal 54, 66, 69 or at the cathode
terminal of the diode matrix board. - Should measure crane voltage ( 24 Volt on cathode of diode
connected to 54, 69 and no voltage on the cathode of the diode connected to 66.
Switch to OM / Fly and measure on Al 04 - X l / 54, 66, 69 in CU. No voltage.
Measure at the cathode of the diodes which are connected to terminal 54, 66, 69 or at the cathode terminal
of the diode matrix board. Should measure crane voltage 24 Volt on cathode of diode connected to 54,
66 and no voltage on the cathode of the diode connected to 69.
If any of the above Xl terminals has crane voltage replace diode or diode matrix board. If the voltage
sequence is incorrect on the cathode of the diodes refer to the Grove electrical documentation and check
wiring.
Switch to Auto mode and measure crane voltage an terminal Al 04 -Xl / 42.
No voltage should be measured on the terminals 54, 66, 69 or on the cathode of the diodes.
Appendix 4
Switch to mode A and measure crane voltage 24 Volt on terminal Al 14 -Xl / 3 ( DI extension board ) .
Switch to mode B and measure no crane voltage on terminal Al 14 - Xl / 3 ( DI extension board ).
Start the engine and have the operator slowly push the tele out controls. Carry out the following test.
Be sure: boom is fully retracted and B mode selected.
A 104 X1 / 54 = NO VOLTAGE
A 104 X1 / 66 = 24 VOLT
A 104 X1 / 69 = 24 VOLT
When the IM has reached 50% the system switches to extend the CM.
Measure:
A104 Xl / 54 = 24 Volt
A104 Xl / 66 = NO VOLTAGE
A104 Xl / 69 = 24 Volt
When the IM and the CM have reached 100 % the system switches to extend the OM / Fly, Measure:
A104 X1 / 54 = 24 Volt
A104 X1 / 66 = 24 Volt
A104 X1 / 69 = NO VOLTAGE
If one of above measurements is incorrect check the fuses F3, F7, F8 for relay contacts K2, K6, K7
on the terminal board.
Check relay K2, K6, K7.
Connect an Amp meter in series with wire 20 and terminal Al 04 Xl / 63. When extending the boom in
Auto mode the ramping value should climb up to a 800 mA with fully open solenoid valve.
Connect an Amp meter in series with wire 21 and terminal Al 04 Xl / 64. When retracting the boom in
Auto mode the ramping value should climb up to a 800 mA with fully open solenoid valve.
If one of above fails check fuse F6 and relay K5 on the terminal board inside CU.
Connect an Amp meter in series with the black wire removed from terminal A111 X1 / 6 and
terminal A111 X1 / 6. When extending or retracting ( depends on the direction controlled by the
operator) the boom in Auto mode the ramping value should climb up to a 800 mA with fully open
solenoid valve.
Should the measurement fail check for complete solenoid circuit - Check solenoid coil resistance for
continuity. Check for good analog ground from A111 board to solenoid. Connect Ohm meter to the
removed wire ends of terminal A111 Xl / 5 and 6 and test closed circuit. Note that you will not measure
any electrical current when the circuit is interrupted.
Rectify wiring or solenoid coil failure and test again.
Appendix 5
Changes in the boom control circuit

Obsolete the 3- way valves for IM, CM & OM in the boom.
A pair of 2 - way valves for each cylinder. De-energize the pair to allow operation of the particular
telescope cylinder. Energize the other 2 pairs to prevent movement of the other telescope cylinder.
Instead of 3 separate proportional valves for each section - now use two proportional valves ( retract and
extend ). Signal extend from NO contact of K5. Signal retract from NC contact of K5. The current to
open the valve fully is now 800 mA.
A CM retract switch is added to monitor CM fully retracted. The signal is used to monitor CM fully
retracted and CM % reset to 0.
The OM / Fly retract switch is additionally used as OM / Fly % reset switch.
An additional rod drain valve is added. See below.
All relays controlling the 2 way valves are de-energized in manual mode. The two way valves are
controlled manually by switches in the cab.
All relays controlling the 2 way valves are de-energized in neutral.
Appendix 6
Test Procedure
PAT DS350 Boom Control System
RT865BXL, TMS / TTS870 With 5 Section Boom
A. Purpose:
This procedure is designed to be an aid in verifying the operation and defining the proper test methods for
the wiring and control circuitry of the PAT DS350 Boom Control System.
B. Personnel required to perform these tests:
2
C. Equipment and Tools required to perform these tests:
a. Digital multimeter
b. Central unit key
c. Medium flat blade screwdriver
d. Medium philips screwdriver
e. 10mm socket or nut driver
f. Small flat blade screwdriver
D. Sub Assembly Description:
Reference Number
a. A104
b. A111
c. A114
Part Number ( PAT )

024 - 350 - 300 - 092
024 - 350 - 300 - 135 ( B )
024 - 350 - 300 - 301
Description
Extension Board
Analog Control Board
Digital Extension Board
E. System description ( basic ):

The PAT DS350 Boom Control System ( designated as System Under Test or SUT ) it is a
microprocessor controlled system that optimizes the boom configuration during lift operations. To
understand the basic theory of the system, one must think in terms of action - reaction, i.e. for every action
there is a controlled reaction.
The following description assumes that the boom is fully retracted, the boom extension stop block is dis engaged, Auto Mode is selected, and that an extend operation is to be performed. The reverse of this
discussion is true for retract operations. The sequence of events that must occur for the boom to start
moving is as follows:
1. The SUT detects whether the operator has selected Automatic mode or Manual mode, and in Auto
mode, whether Mode A or Mode B is selected. The Auto / Manual switch toggles a digital input on
A104 - X1 - P42. If Auto is selected, this signal will be high ( from here on out, all signal levels will be
specified as either high or low. A high signal being crane voltage, 24 V, and low being near ground
level ), if Manual is selected, the signal is low. Mode A or B operations are controlled with a switch
located in the cab. This switch controls the A114 - X1 - P3 input. A high signal indicates Mode A, a low
indicates Mode B. If the Auto mode is selected, the status of Mode A / B switch can be readily seen on
the A114 board by looking at the H2 LED. If the LED is illuminated, Mode A is selected, if it is not then
Mode B is selected.
Appendix 7
2. The SUT senses that the foot pedal has been depressed by the output of a pressure switch. There are two
( 2 ) pressure switchs built into the foot pedal circuitry, one is for boom extend and the other is for boom
retract operations. The output of these switches are piped into the SUT as digital inputs. These switches
are normally open and switch crane voltage ( 24V ) on or off. Assuming that an extend operation is being
performed, A104 - X1 - P38 ( DI - 1 ) will go high and A104 - X1 - P39 ( DI - 2 ) will be low.
3. Once DI - 1 is detected, the A104 relay K - 5 is energized applying a veritable voltage signal onto
X1 - P63. This analog control is generated from the A114 board, A114 - X1 - P6, and is a variable voltage
output that is determined by a digital code supplied by the microprocessor. This code is determined by the
position of each section of the boom and the mode of operation.
4. There are three ( 3 ) control signals that are supplied by the SUT that determine which section of the
boom will be selected. The logic of these signals are such that to select a section the signal level to that
sections control valves must go low. Each section has two ( 2 ) control valves, for a total of six ( 6 ) that
must be de - energized in tandem. One valve is pilot pressure and the other is the main flow valve. The
SUT supplies control from the following terminals:
Inner Mid ( IM )
Center Mid ( CM )
Outer Mid / Fly ( OM/F
A104 - X1 - P54 to boom base junction box P - 19 and P - 24

If no boom operations are selected, all of these signals will be low, but whenever an extend / retract
operation is selected, these signals become active and control the flow of hydraulic oil. The logic table for
these valves is as follows:
A104 - X1 - P54
A104 - X1 - P66
A104 - X1 - P69
IM
CM
OM /F
0
1
1
1
0
1
1
1
0
( NOTE : 1 = high, 0 = low )

5. Flow control of hydraulic oil for the IM is as follows:
a. A104 - X1 - P54 stays low as A104 - X1 - P66 and A104 - X1 - P69 go high. This initializes
both the IM 2 - way valves for hydraulic flow.
b. The analog board, A111 - X1 - P6, generates the control voltage for voltage for the
proportional valves. This signal is directed to either the extend or retract sections of the
proportional valve by the action relay K5 located on the A104 board, A104 - X1 - P63 for extend,
A104 - X1 - P64 for retract. The proportional valve, located in the superstructure, will control the
pressure of fluid to the cylinder depending on the current output from the A111 board, 800mA
yields full flow, 0mA yields full restriction of fluid.
c. An extend signal is generated from the SUT, A104 - X1 - P63, that energizes the piston side of
the cylinder. This will allow fluid to enter the piston side to extend.
6. The sequencing of the sections are determined by the mode selected and are detailed on the attached
sheet. The IM will extend at full speed until the cross over point is reached, 50% in mode B. At this point
the speed of the section will ramp down and then stop, then the CM will start to extend under the same
conditions as the IM.
Appendix 8
TMS /TTS870 Boom Sequence, Auto Mode A and B

Mode ( A / B )
A
A
A
A
B
B
B
B
B
B
B
B
IM %
0
0
0
100
0
50
50
75
75
100
100
100
CM %
0
100
100
100
0
0
50
50
75
75
100
100
OM / Fly %
0
0
100
100
0
0
0
0
0
0
0
100
7. During the retract sequence, the operation is the same with the exception of the presence of the
proximity switches. These switches are used to detect when the applicable boom section is fully retracted.
If the OM / Fly section is being retracted, the OM / Fly switch must turn on or an E - 83 error will appear.
This will not lock out the system but will make the telescope out of sequence light to illuminate. If the
CM is being retracted, the CM switch must turn on when fully retracted before the IM will start to retract.
If this fails to happen, the IM will not retract and the telescope out of sequence light will illuminate.
Testing of these switches will be detailed in the test section.
F. Preliminary Adjustments
1. Using the 10 mm nutdriver, remove the lids from each of the cable reels.
2. Verify that all boom sections are fully retracted and that the stop block is disengaged.
3. Preset each of the length sensors to the minimum by turning the slot in the gear wheel fully
counter clockwise until it comes to a soft stop.
G. Testing the SUT:
1. Start the crane.
2. Program the PAT console to the correct operating mode.
3. Place the Auto / Manual switch in the Manual position.
OK_______ 1. Verify that the maximum load on the console is approximately 2000 lb.
OK_______ 2. Place the boom select switch into the IM position, verify that the IM lamp illuminates.
OK_______ 3. Extend the IM about 2 ft. to verify that the IM does extend, then completely retract the IM.
OK_______ 4. Place the boom select switch into the CM position, verify that the CM lamp illuminates.
OK_______ 5. Extend the CM about 2 ft. to verify that the CM does extend, then completely retract the
CM.
Appendix 9
OK_______ 6. Place the boom select switch into the OM / Fly position, verify that the OM / Fly lamp
illuminates.
OK_______ 7. Extend the OM / Fly about 2 ft. to verify that the OM / Fly does extend, then completely
retract the OM / Fly.
4. Open the central unit and the boom base junction box.
OK_______ 8. Verify that wires 11 and 12 from the 19 pin cannon plug are wired to pins L and M.
OK_______ 9. Using the meter, monitor the Manual / Auto input signal on A104 - X1 - P42, using the
chassie as ground. Verify that the signal level in Manual mode is low and high in Auto
mode.
OK_______ 10. Using the meter, monitor the telescope extend pressure switch input, A104 - X1 - P38.
Extend the boom to verify that the signal goes high.
OK_______ 11. Using the meter, monitor the telescope retract pressure switch input, A104 - X1 - P39.
Retract the boom with the stop block engaged to verify the signal goes high.
OK_______ 12. Select Auto mode and monitor the input at A114 - X1 - P3 to verify that the signal goes
high when in the A code, and low in the B code.
OK_______ 13. Select Auto mode A, and monitor the extend analog voltage control signal,
A104 - X1 - P63, Extend the boom to verify that the signal goes to a higher level, around
25 volts. Retract the boom with the stop block engaged.
Record Voltage ____________

OK_______ 14. Disconnect wire 20 from A104 - X1 - P63 on the extension board. Set the meter to
measure current, 10 amp setting. Connect the black lead to A104 - X1 - P63 and the red
lead to wire 20. Extend the boom to verify that the current is between 750 mA and 850
mA. Reconnect wire 20.
Record Current ____________
OK_______ 15. Select Auto mode A, using the meter monitor the retract analog voltage control signal,
A104 - X1 - P64. Extend the boom about 10 ft., then retract the boom to verify that the
signal goes to a higher voltage level, around 25 volts.
OK_______ 16. Disconnect wire 21 from A104 - X1 - P64 on the extension board. Set the meter to
measure current, 10 amp setting. Connect the black lead to A104 - X1 - P64 and the red
lead to wire 21. Extend the boom about 10 ft., then retract the boom to verify that the
current measurement is between 750 mA and 850 mA.
Appendix 10
OK_______17. Select Manual mode, and ensure the boom is fully retracted with the stop block
disengaged. Verify that the boom is fully retracted onto the base section.
OK_______ 18. Using the meter, monitor the signal from proximity switch 1, OM / Fly retract signal on
A104 - X1 - P76 and verify a high signal.
OK_______ 19. Using the meter, monitor the signal from proximity switch 2, CM / IM retract signal on
A104 - X1 - P78 and verify a high signal.
OK_______ 20. Using the meter, monitor the signal from proximity switch 3, length reset signal on
A104 - X1 - P80 and verify a low signal.
OK_______ 21. Using the meter, monitor the signal from proximity switch 4, CM retract signal on
A114 - X1 - P9 and verify a high signal and H5 LED is illuminated.
5. Extend all boom sections about 5 ft.
OK_______ 22. Using the meter, monitor each proximity switch signal, each should be low.
OK_______ 23. Using the meter, monitor the OM / Fly proximity retract switch input signal on
A104 - X1 - P76. While retracting the OM / Fly verify the signal changes from low to
high, until the sections bottoms out.
OK_______ 24. Using the meter, monitor the CM proximity retract switch input signal on
A114 - X1 - P3. While retracting the CM verify the signal changes from low to high,
until the section bottoms out.
OK_______ 25. Using the meter, monitor the CM / IM proximity retract switch input signal on
A104 - X1 - P78. While retracting the CM - IM verify the signal changes from low to
high, until section bottoms out.
OK_______ 26. Using the meter, monitor the length reset proximity switch signal on A104 - X1 - P80 to
verify the signal is high.
OK_______ 27. Fully retract all boom sections and switch to Auto mode. Using the meter, monitor the
telescope out of sequence signal on A104 - X1 - P61 to verify the signal is low.
OK_______ 28. Telescope the boom out approximately 5 ft. in mode B. Switch to Manual mode and
telescope the CM out about 5 ft. Switch to Auto mode and verify the signal level on
A104 - X1 - P81 is high and the telescope out of sequence light is illuminated.
OK_______ 29. Using the meter, monitor the front outrigger overload signal on A111 - X1 - P6. During
normal operation, this should stay high. Disconnect wire17 from from this terminal.
Install a jumper wire from ground, A111 - X1 - P4, to the front outrigger overload input
signal, A111 - X1 - P6. Verify that the console displays E - 18 error code. Remove the
jumper wire and install wire 17 to A111 - X1 - P6.
Appendix 11
OK_______ 30. Fully retract all boom sections and select Auto mode. Using the meter, monitor the
telescope rod drain signal on A104 - X1 - P57 and verify the signal is low.
OK_______ 31. While telescoping out, monitor the signal on A104 - X1 - P57 to verify the signal stays
low.
OK______ 32. While monitoring the telescope rod drain signal on A104 - X1 - P57, stop extending the
boom at about 5 ft., when the extend operation stops and boom comes to a rest, verify
that the signal goes high.
NOTE:
Ensure that all safety precautions are performed
before performing the following steps. Ensure that the
outriggers are fully extended and jacks are down, and
properly set.
OK_______ 33. Fully retract all boom sections with the boom stop block engaged. Select Auto mode A
and raise the boom to approximately 60 degrees.
OK_______ 34. Fully extend the boom and verify that each section sequence as listed on the attached
sheet.
OK_______ 35. Retract the boom and verify the sequence is the inverse of extend.
OK_______ 36. Fully retract all boom sections with the boom stop block engaged. Select Auto mode B
and raise the boom to approximately 60 degrees.
OK_______ 37. Retract the boom and verify the sequence is the inverse of extend.
G. Final
If all these tests pass, the system is operational and ready for calibration. Provide the crane model number,
serial number, the PAT CPU part number, serial number, sign and date this page and return to Product
Support Service Department.
Crane Model Number: ___________________
S /N:_______________
PAT CPU Part Number:__________________
S / N_______________
Signature:____________________
Date:_______________
Appendix 12
TMS870,TTS870 & RT865B 5 Section Boom Drift Test

PURPOSE:
To determine the cause of the telescope cylinder drift.
TEST DESCRIPTION:
The boom shall be loaded with each section extended approximately 1- 1/2 to 2 to
determine the cause of suspected leakage in the telescope cylinder or hold valve. The boom
is only partially extended to reduce the effects of thermal contraction of the oil in the
cylinders.
TEST PREPARATION:
1
Reeve the machine with a minimum of two parts line.
Fully retract boom and extend each section (in manual mode) from 18 to 24 and mark off
1 increments for 6 on the Inner, center and outer mid sections.
Select a load (including hook block) between 20,000 to 25,000 pounds and position it at a
25 to 30 radius.
TEST PROCEDURE:
Switch boom control system to automatic mode. (Note: Boom will be out of sequence.)
Hoist load approximately 2 off of the ground with the boom nose positioned over the load.
Keep the engine running or the ignition switch on during the test.
Observe the marks on the boom sections for 30 minutes to determine which section(s) are
retracting. A slight compression of the oil is normal when the load is picked.
Approximately 1 per section would be expected. The sections should extend back to the
original position when the load is lowered to the ground.
Hoist the load to the ground, observe and record the movement of the marks on the boom
sections.
Determine which section(s) are retracting and reposition the boom sections to there original
positions.
Switch boom control system to manual mode and select a section that is not retracting. This
Will help to determine if the hold valve is leaking or if the cylinder has an internal leak.
Appendix 13
TMS870,TMS870 & RT865B Hold Valve Drift Test continued
Repeat steps 2 through 5. If the section(s) do not retract in the manual mode, the hold
valve is most likely leaking. If the section retracts, the cylinder may have an internal leak
or both the hold valve and the two way valve on the piston side are leaking.
NOTE: The piston side two way valves located inside the boom are N.O. valves connected in-line
with the hold valves. When in the Automatic Mode with the telescope controller in the neutral
position and the power on, the piston side two way valves are not powered shut. This permits any
leakage past the hold valve to drain through the piston side drain valve and the .078 in line orifice.
When in the Manual Mode under the same conditions, the two way valves are powered shut on the
sections not selected. This should block any leakage from the hold valve and prevent the cylinder
from retracting. Prior to assuming that the cylinder has a leak, the two way valve should be checked
to ensure that 24 volts are present at the valve with the system in manual mode with an other
section selected.
Thermal contraction will cause a cylinder to retract as the fluid in the cylinder cools. The change in
length of the cylinder is proportional to the extended length of the cylinder and the change of the
temperature of the oil in the cylinder. The coefficient of expansion for API Group 1 oil is
approximately 0.00043/ 0F. A cylinder that is extended 25 which has had the oil cool 100 F would
retract about 13 as the oil cools. A cylinder that is extended 2 which has had the oil cool 100
Degrees F will retract about 1 due to the thermal contraction. Testing the boom almost fully
refracted greatly reduces the effect of thermal contraction and ensures a proper diagnosis of the
system.
Appendix 14
P.A.T. L.M.I
MANUAL
SECTION 12
DS 350 GRAPHIC BCS

ELECTRICAL DIAGRAMS
DI 4 (PROXY 1 OM/FLY RETRACT)
DI 5 (PROXY 2 CM/IM RETRACT)
DI 6 (PROXY 3 LENGTH RESET)
A2B SIGNAL
PROXY (+)
GND
7 8 10 11 9 35 34 24 73 43 36 80 78 76
A2B GND
LENGTH (IM)
LENGTH (CM)
IS
AGND
LENGTH (O.A. BOOM)
30 31 32 33 44 46
-5V
ANGLE
+24V
TXD
RXD
GND
LMI BYPASS
A2B BYPASS
PRESS. PISTON SIG.
AGND
-5V
+5V
PRESS. ROD SIG.
IS
AGND
-5V
+5V
IS
A 104
12 13 14 15 16 17 18 19 20 21 28 29
X1
1 4 3
1 2 3 4 IS 1 2 3 4
2 56 7 8 9
13
11
+24V
IS
GN/YL
To page 12.2
IS 1 2 3 4 5 6
7 8
9 10 11 12 13 14
14
12
12.1
A
14 SOCKET PLUG
A BCD
A BCD
PRES. TRANS.
(ROD)
1 2 3 4
A BCD
A BCD
PRES. TRANS.
(PISTON)
1 2 3 4 5 6 7 8 9 10 11 12 13 14
A BC DE FG H I
L M N
A BC DE FG H I
L M N
1 2 3 4
To Boom Base
Junction Box
5 6 7 8 9 10 11 12 13 14
14 PIN PLUG
1 2 3 4 5 6 7
8 9 10 11 12 13 14
X1 1 2 3 4 5 6 7 8
+24V
GND
TXD
RXD
COM.
A2B
LMI
DI
1 2 3 4
X7 1 2 3 4
+24V
GND
X8
1
2
CONSOLE
TMS/TTS 870
WIRING CONNECTIONS
IS
A111
1
X1
2 3
13 14 15 20 21
23 - SOCKET RECEPT
S/S HARNESS (REF)
TMS/TTS 870
INTERFACE
TELE EXT PROP SOL
10 11 12
56 57 1 2 3 4 48 38 40 42 36 37 39 41 75 77 79 59 61 49 62 63 64
TELE ROD DRAIN SOL
8 719
240
147
238
1083
255
257
6 9
FRONT O/R OVERLOAD
HIGH SIGNAL = AUTO MODE A

NO SIGNAL = AUTO MODE B
To Boom Base
Junction Box
4
323
B
3
TELE OUT OF SEQ.
CM TELE
2 3 5 7 11 12 13 14 1
IM TELE
8 10
OM/FLY TELE
HIGH=AUTO / NONE=MANUAL
LMI UNLOCK SOLS
12.2
1
7 8
4 5 6
68 69
GND
A113
X1
71
51
73
387
388
239
242
243
244
K6 (COM) +24V
65 66
+24V
K2 (COM) +24V
53 54
4 5 6
18

23 - PIN PLUG
1 2 3 4 5 6 7 8 9 101112 13 14 15 1617 1819 20 2122 23 24 25

16
5
6 9 10
DI E5 GND
DI E5 (+24V=CM RET)
A114
3 4
X1
DI E3 (+24V)
[ +24=MODE A
0V=MODE B
DI E2 GND
DI E2
A1 (PROP)
AGND
GND
GND
+24V
+24V
K5 (COM)
K4 (COM) +24V
DI 6 GND
DI 4 GND
DI 5 GND
DI 2 GND
DI 3 GND
DI 1 GND
DI GND


+24V
+24V
GND
GND
K3 (COM) +24V
K7 (COM) +24V
+24V
IS

22 47
DI EXTENSION BOARD
24 350 300 301
9 10 11 12
7
12
9
8
17 22 23 24 25
14 SOCKET PLUG
1 14
8 9
10
IS
11 12 13
3 4
5 6
10
11 12 13 14
IS
H J
L M N
D E F G H
L M N P R S T U V
H J
L M N
D E F G H
L M N P R S T U V
8 9
10
11 12 13 14
3 4 5 6 7 8
10
11 12
14
7 8
2
13
1 7
19 20 21 22 23 24 25 26 27 28
10 11 12 13 14 15 16 17 18
4
12
5 9 6 7
4
13
10 11
7 5 8
29
30
14
9 10 11 12
31
12
14
TMS/TTS870
WIRING
CONNECTIONS
5 6
12.3
123 6 7
10 11
12 4 9 10
3
2
1
AGND
SIG.
-5V
10 11
1 2 3 4 5 6 7 8 9 10 11 12
GRA
0 0
VIO
RED
PNK
YEL
BLU
WHT
BRN
GRN
CRE
BLK
1 2 3 4 5 6 7 8 9 10 11 12
4.7K
SHD
VV
4.7K
WHT/
BLK
BRN
RED
ORG
YEL
GRN
BLU
VIO
GRA
WHT
BLK
VV
A B
A B
1 2 3 4 5 6 7 8 9
BRN
RED
ORG
YEL
GRN
BLU
VIO
GRA
WHT
BRN
RED
ORG
YEL
GRN
BLU
VIO
GRA
WHT
1234
12
LENGTH
TRANS.
BRN
RED
ORG
YEL
GRN
BLU
VIO
GRA
WHT
BLK
BRN
RED
3=RED
2=BRN
1=BLK
BLK
WHT/BLK
SHEILD
LG208 (TO NOSE)
CORE
10 11
SHD
AGND
SIG.
-5V
1 2 3 4 5 6 7 8 9
LENGTH/ANGLE LG221 (TO IM)
ANGLE
TRANS.
LENGTH/ANGLELWG221 (TOCM)
LENGTH
TRANS.
LENGTH
TRANSDUCER
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
VIO
AGND
SIG.
-5V
SIG.
AGND
-5V
56
1
3
4
2
11
2 4
1234
5 8
RED
PNK
YEL
BLU
9 14 12 7 5
CRE
BLK
8 6 4
WHT
BRN
GRN
1 2 3 13
BLK
WHT/BLK
WHT/
BLK
GRA
1
1
5 6
VIO
YEL
PNK
RED
BLK
GRA
BLU
CRE
SHD
WHT
BRN
GRN
JUNCTION
BOX (CM)
RED
1
1
RED
2
3 BLK 1
BLK
4
5 GRN 1
RED 1 = CM CYL (+)

RED = CM PILOT (+)
BLK 1 = OM CYL (+)
BLK = OM PILOT (+)
GRN 1 = CM CYL (-)
GRN = CM PILOT (-)
WHT 1= OM CYL (-)
WHT = OM PILOT (-)
TIE WRAP
USED TO IDENTIFY CABLE
GRN
6
WHT
1
7
WHT
8
9
3
10
4
11
1
PROXY SW 3 (TOP)
(LENGTH RESET)
1
1 (+)
4
4 NO
2
2 NC
3
3 (-)
PROXY SW 1
(OM/FLY RETR)
1
4
2
IS
(+)
4 NO
2 NC
12.4
RED
YEL
BLU
VIO
GRA
BLK
CRE
PNK
1
2
3
4
(-)
SHD
WHT
BRN
GRN
5
6
7
RED
BLK
GRN
WHT
RED = IM CYL (+)

BLK = IM PILOT (+)
GRN = IM CYL (-)
WHT = IM PILOT (-)
PROXY SW 4
(CM RETR)
3
4
1
1
4
2
IS
IS
(+)
4 NO
2 NC
(-)
IS
IS
JUNCTION
BOX (IM)
4
2
1
6
5
4
3
2
1
2
3
4
4
1
1
2
JUNCTION BOX
BOOM BASE
PROXY SW 2 (BOTTOM)
(CM/IM RETR. 2-POSITIONS)
1
1 (+)
4
O O
4 NO
2
2 NC
O O
3
3 (-)
IS
TMS/TTS 870
WIRING CONNECTIONS
30 31 32 33 44 46
DI 4 (PROXY 1 OM/FLY RETRACT)
DI 5 (PROXY 2 CM/IM RETRACT)
DI 6 (PROXY 3 LENGTH RESET)
PROXY (+)
GND
A2B SIGNAL
A2B GND
LENGTH (IM)
LENGTH (CM)
-5V
ANGLE
IS
AGND
LENGTH (O.A. BOOM)
+24V
TXD
RXD
GND
LMI BYPASS
A2B BYPASS
PRESS. PISTON SIG.
AGND
-5V
+5V
PRESS. ROD SIG.
IS
AGND
-5V
+5V
IS
A 104
12 13 14 15 16 17 18 19 20 21 28 29
X1
7 8 10 11 9 35 34 24 73 43 36 80 78 76
1 2 3 4
IS 1 2 3 4
1 4 3
2 56 7 8 9
13
11
+24V
IS
GN/YL
To page 12.6
IS 1 2 3 4 5 6
7 8 9 10 11 12 13 14
14
12
12.5
A
14 SOCKET PLUG
A BCD
A BCD
PRES. TRANS.
(ROD)
1 2 3 4
A BCD
A BCD
PRES. TRANS.
(PISTON)
1 2 3 4 5 6 7 8 9 10 11 12 13 14
A BC DE FG H I
L M N
A BC DE FG H I
L M N
To Boom Base
Junction Box
1 2 3 4 5 6 7 8 9 10 11 12 13 14
RT865BXL
WIRING CONNECTIONS
14 PIN PLUG
1 2 3 4 5 6 7
8 9 10 11 12 13 14
X1 1 2 3 4 5 6 7 8
+24V
GND
TXD
RXD
COM.
A2B
LMI
DI
1 2 3 4
X7 1 2 3 4
+24V
GND
X8
1
2
CONSOLE
2 3
13 14 16 20 21 17 22 23 24 25
4 5 6
18
7
8 9 10
12o
1 2 3 4 5 6 7 8 9 101112 13 14 15 1617 18 19 20 2122 23 24 25
1 2 3 4
A B C D E
A B C D E
NO
COM
CRANE 12o AREA

DEFINITION SWITCH IN
ELECTRICAL SWIVEL
348o NC
DI E5 GND
DI E5 (+24V=CM RET)
DI E1 GND
DI E1 (+24V HOUSE PIN ENGAGED)
A1 (PROP)
AGND
GND
GND
+24V
+24V
K5 (COM)
K4 (COM) +24V
DI 6 GND
DI 4 GND
DI 5 GND
DI 2 GND
DI 3 GND
DI 1 GND
DI GND


+24V
+24V
GND
GND
K3 (COM) +24V
DI E4 (+24V AREA DEF.)
A114
1 2
X1
AREA DEF.
INTERFACE
5 SOCKET PLUG
A111
1
X1
SWIVEL HARNESS
5 PIN RECEPTACLE
IS
TELE EXT PROP SOL
TELE ROD DRAIN SOL
238
1083
255
257
56 57 1 2 3 4 48 38 40 42 36 37 39 41 75 77 79 59 61 49 62 63 64
23 - SOCKET RECEPT
S/S HARNESS (REF)
RT865BXL
INTERFACE
8 7 19 10 11 12
6 9
HOUSE LOCK PIN SWITCH
323
74
744
To Boom Base
Junction Box
4
LMI L/O ALARM
B
3
TELE OUT OF SEQ.
CM TELE
8 10 2 3 5 7 11 12 13 14 1
IM TELE
OM/FLY TELE
7 8
HIGH=AUTO MODE/NONE=MANUAL MODE
12.6
1
5 6
K7 (COM) +24V
68 69
LMI UNLOCK SOLS
A113
4
X1
71
51
73
387
388
239
242
243
244
K6 (COM) +24V
65 66
GND
K2 (COM) +24V
53 54
+24V
+24V
47
IS

22
DI EXTENSION BOARD
24 350 300 301
9 10 11 12
7
12
9
8
15

23 - PIN PLUG
1 2 3 4
14 SOCKET PLUG
1 14
8 9
10
11 12 13
IS
5 6
10
11 12 13 14
IS
H J
L M N
D E F G H
L M N P R S T U V
H J
L M N
D E F G H
L M N P R S T U V
5 6
8 9
10
10
11 12
3 4 5 6 7 8
14
3
4
7 8
2
13
1 7
2 3
19 20 21 22 23 24 25 26 27 28
10 11 12 13 14 15 16 17 18
4
12
5 9 6 7
4
13 8
6
10 11
7 5
29
30
14
9 10 11 12
31
12
14
RT865BXL
WIRING
CONNECTIONS
5 6
12.7
123 6 7
10 11
12
3
2
1
AGND
SIG.
-5V
10 11
1 2 3 4 5 6 7 8 9 10 11 12
GRA
0 0
VIO
RED
PNK
YEL
BLU
WHT
BRN
GRN
CRE
BLK
1 2 3 4 5 6 7 8 9 10 11 12
4.7K
SHD
VV
4.7K
WHT/
BLK
BRN
RED
ORG
YEL
GRN
BLU
VIO
GRA
WHT
BLK
VV
A B
A B
1 2 3 4 5 6 7 8 9
BRN
RED
ORG
YEL
GRN
BLU
VIO
GRA
WHT
BRN
RED
ORG
YEL
GRN
BLU
VIO
GRA
WHT
1234
12
LENGTH
TRANS.
BRN
RED
ORG
YEL
GRN
BLU
VIO
GRA
WHT
BLK
BRN
RED
3=RED
2=BRN
1=BLK
BLK
WHT/BLK
SHEILD
LG208 (TO NOSE)
CORE
10 11
SHD
AGND
SIG.
-5V
1 2 3 4 5 6 7 8 9
LENGTH/ANGLE LG221 (TO IM)
LENGTH
TRANSDUCER
ANGLE
TRANS.
LENGTH/ANGLELWG221 (TOCM)
LENGTH
TRANS.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1
3
4
2
11
VIO
AGND
SIG.
-5V
SIG.
AGND
-5V
56
5 8
2 4
123 4
4 9 10
RED
PNK
YEL
BLU
9 14 12 7 5
CRE
BLK
8 6 4
WHT
BRN
GRN
1 2 3 13
BLK
WHT/BLK
WHT/
BLK
GRA
1
1
11 12 13 14
VIO
YEL
PNK
RED
BLK
GRA
BLU
CRE
SHD
WHT
BRN
GRN
JUNCTION
BOX (CM)
RED
1
1
RED
2
3 BLK 1
BLK
4
5 GRN 1
RED 1 = CM CYL (+)

RED = CM PILOT (+)
BLK 1 = OM CYL (+)
BLK = OM PILOT (+)
GRN 1 = CM CYL (-)
GRN = CM PILOT (-)
WHT 1= OM CYL (-)
WHT = OM PILOT (-)
TIE WRAP
GRN
6
WHT
1
7
WHT
8
9
3
10
4
11
1
PROXY SW 3 (TOP)
(LENGTH RESET)
1
1 (+)
4
4 NO
2
2 NC
3
3 (-)
PROXY SW 1
(OM/FLY RETR)
1
4
2
IS
(+)
4 NO
2 NC
12.8
RED
YEL
BLU
VIO
GRA
BLK
CRE
PNK
1
2
3
4
(-)
SHD
WHT
BRN
GRN
5
6
7
RED
BLK
GRN
WHT
RED = IM CYL (+)

BLK = IM PILOT (+)
GRN = IM CYL (-)
WHT = IM PILOT (-)
PROXY SW 4
(CM RETR)
3
4
1
1
4
2
IS
IS
(+)
4 NO
2 NC
(-)
IS
IS
JUNCTION
BOX (IM)
4
2
1
6
5
4
3
2
1
2
3
4
4
1
1
2
JUNCTION BOX
BOOM BASE
PROXY SW 2 (BOTTOM)
(CM/IM RETR. 2-POSITIONS)
1
1 (+)
4
O O
4 NO
2
2 NC
O O
3
3 (-)
IS
RT865BXL
WIRING CONNECTIONS
P.A.T. L.M.I
MANUAL
SECTION 13
DS 350 GRAPHIC BCS

SERVICE BULLETINS &
MISCELLANEOUS
INFORMATION
P.A.T. GRAPHIC CONSOLE

JUMPER CONNECTION
The jumpers J1 and J2 must be inserted according to the type
of central unit to which this console is connected
or an Error code 91 occurs.
X1
L1
J2
1
J1
Central Unit with DS350 modular

or DS150 mainboard or compatible
interface like 24 350 30 0128
( J1 = closed / J2 = 1 -2)
L1
J1
Central Unit with DS350G mainboard or

compatible interface like 24 350 30 0127
( J1 = open / J2 = 2-3)
J2
1
X1
13.1
P.A.T. L.M.I
MANUAL
SECTION 14
DS 350 Graphic Modular

CONSOLE CONNECTIONS
& WIRING DIAGRAM
14.1
VIEW OF BACKSIDE
OF GRAPHIC CONSOLE
J1
J2
1 2 3 4 5 6 7 8
X1
MP 1
+UB
MP 0
GND
MP 7
MP 6
MP 2
+7V
MP 5
+5V
J4
J5
X5 1 2 3 4
J3
MP 4
-24V
MP 3
-24V
+UB
GND
RXD
TXD
A2B BYPASS
A2B BYPASS
LMI BYPASS
+UB
ELECTRICAL WIRING FROM

CENTRAL UNIT TO CONSOLE
+UB
GND
CENTRAL UNIT
MAIN BOARD
51 52 3 4 5 6 7 8 9 10
8
2 3
5 6 7
6 7
10
10
11 12 13 14
CONSOLE (1318)
A B C D
1 2 3 4
LOAD
DI
A2B
8 X1
GND
A2B
X7 1 2 3 4
LIGHTBAR
4 5 6
RXD
4 5
TXD
SIG -
+UB
GND
+UB
SIG +
14.2
X8
+UB 1
GND 2
9 11 12 13 14
P.A.T. L.M.I
MANUAL
SECTION 15

CENTRAL UNIT,
P.C. BOARD LAYOUT
& CONNECTIONS
PAT DS350 Graphic Modular

CENTRAL UNIT TERMINAL BOARD CONNECTIONS
X1 TERM.
DESCRIPTION
X1 TERM.
DESCRIPTION
1,3
+12V Battery - Input
27
Length Signal
2,4
GND ( ) Battery-Input
28
GND
29
Angle Signal
30
Force Signal
31
A2B Signal
32
A2B Ground
Data Received from Console
Data Transmit to Console
A2B Bypass
A2B Bypass
33,34,35,36
9
LMI Bypass
10
+ 12V (ub)
11
+UBR
12
LMI Lockout Solenoid
13
Ext. Hor. # 1
14
Not Used
51
+UB
52
GND
53
Fuse (4 AMP)
54
Fuse (4 AMP)
57
Not Used
58
Not Used
60
+UBS
+UBS
15
GND
16
Digital Input # 1
61
Fuse (10AMP)
17
Digital Input # 2
62
Fuse (10 AMP)
18
Digital Input # 3
64
UB
65
GND
19
Digital Input # 4
20
+UB Piston Pressure Transducer
21
Piston Pressure Signal
22
23
+UB Rod Pressure Transducer
24
Rod Pressure Signal
25
26
+UB Length Transducer
66,67,68,69
15.1
Not Used
76
+UB
77
GND
+UBS
+
CONSOLE 4
K8
DIN
DIN
F2- 10A
REL
DAV 1
DAV 2
LWG 1
LG 2
HES
DHG
S1
SI-UB
24 352 31 0001
ADDITIONAL TERMS
LOAD
KEY
SWITCH
SI-REL
DE 5,6
+UBS
76
77
+ +UBS
0V
15.2
A107
MEMORY
EXTENTION
12V
A101 MAIN BOARD DS350

MODULAR/CURRENT IN
S2
A106 ANALOGG INPUT
DE 1-4
K10B
X3
+UBS
11 REL -M
12
REL -A
13
REL -R
14
+ +UBS
15
DE 1
16
17
DE 2
18
DE 3
19
DE 4
20
+ +UBS
I
21
DAV1
U
0V
22
23
+ +UBS
I
24
DAV2
U
0V
25
26
+ +UBS
I
27
LG 1
U
0V
28
I
29
WG 1
U
I
30
LG
1
U
31
0V
32
33
+ +UBS
I
34
S1 DHG 1
U
0V
35
I
36
S2 DHG 2
U
51
+ +UB
0V
52
F1 - 4A
53
SI - OUT
54
SI - IN
57
A2B-0
58
A2B-I
LOAD-I
59
60
+ +UBS
F2-10A
61
SI-REL
62
SI-REL
64
+ +UBS
65
0V
66
DE 5
67
68
DE 6
69
X12
+ +UBS
A105 SERIAL
EXTENSION
A2B-O
A2B-I
LOAD-I
K9
A102
X11
CPUMODULE
0V
RXD
TXD
10
K10A
+ +UBS
STOP
LOAD
SWITCH
5
6
7
8
9
+ +12V
0V
X3
2
3
A103
DATENMODULE
12V
A104 DIGITAL
OUTPUT
+UB
F1
1 3
2 3
4 1
2 3
V V V
6 PIN PLUG
+UBE
SIG+
SIGGND
+UB
GND
TXD
RXD
A2B
A2B
LOAD
D1
GN/YL
73
(LMI UNLOCK SOL.)
A
A
B C
B C
V V
V V
71 (+UB)
51 (GND)
1 2 3 4 5 6 7
V V
LIGHTBAR
V V V
1 2 3 4
A B C
A B C
A BC D
V V V V
1 2 3 4
V V
NO
C
1 2 3 4
V V V V
1 2 3 4
V V VV V V
X7 1 2 3 4
X8
+UBE 1
GND 2
A BCD E
A BCD E
V V V V V
1 2 3 4 5 6 7 8 X1
1 2 3 4 5 6
TO MAIN BOOM
CONNECTOR
NC
over front
on rubber
DS350
GRAPHIC MODULAR
CENTRAL UNIT
OUTER SHIELD GROUNDED AT STRAIN

RELIEF CONNECTOR.
INNER SHIELD CUT AND INSULATED
CRANE SYSTEM AREA

DEF. SWITCH ELEC. SWIVEL
10 AMP
FUSE
NOTES:
NO
NC
on outriggers
FUSE (10 amp)
FUSE (10 amp)
+UBS
LMI BYPASS
FUSE (4 amp)
FUSE (4 amp)
4
LMI BYPASS
KEY SWITCH
5 PIN
DEUTSCH
1 2 3 4
PLUG
V V V V V
15.3
V
V
61 62
4 AMP
FUSE
10 8 9 11 12 13 14
1 2 3 4 5 6 7
59 60
26 27 28 29 30 31 32 33 34 35 36 53 54
CONSOLE (1318)
1 2 3
NOT USED
NOT USED
NOT USED
NOT USED
A2B GROUND
A2B SIGNAL
ANGLE
FORCE
GND
LENGTH
+UB
GND
ROD
+UB
GND
PISTON
+UB
DI4
DI3
DI1
DI2
GND
EXT. HOR. *1
23 24 25
IN
1 2 3 4 5 6 7 10 11 12 13 14
20 21 22
OUT
13 14 15 16 17 18 19
OUT
+UBS
GND
+UB
GND
RXD
TXD
A2B BYPASS
A2B BYPASS
LMI BYPASS
+UB
51 52 3 4 5 6 7 8 9 10
IN
GN/YL
1 2 3
+UB
+UBR
LMI UNLOCK S.
+UB
GND
X1 1 2 12 11
pres. trans.
(piston)
pres. trans.
(rod)
INSULATE OUTER SHIELD AND

CONNECT TO CHASIS GND.
*1) OPTIONAL FOR EXTERNAL HORN
(EEC UNITS ONLY)
P.A.T. DS350 Graphic Modular

MAIN BOARD
A
G1
MP42
KGND
MP 26
KGND
MP 4
+5V
MP 9
+6V
X15
GND
GND
AGND
KGND
+BATT
MP24
MP23
VBAT
+UB1
PWM DC
MP 8
+9V
GND
5
+UB1 +UB
DI 6
KGND
X12
MP41 MP40
V10 H11 V11
H1 H2 H3 H4 H5 H6
DI 1
MP21
PFAIL+UB1
DI 1- DI 6 =>
X17
power o.k.
X14
J11
X11
SP5
X13
H12
TXD
AGND
H10
K8
MP29
10
LEVER
LOCKOUT
K10
A2B
+UB
2
1
MAIN
ON/OFF
KGND
J10
3
4
LMI
KGND
10
LOAD
+5V/RS232
AGND
F1
69 68 67 66 65 64
62 61
60 59 58 57
55 54
52 51
12
KGND
3
1
77 76
F2
H9
A2B
KGND
J4
J3
J2
J1
KGND
X1
12
11
KGND
K9
11
X1
13
X16
KGND
MP
1 +UB
36
35 34 33
32
31
30 29 28 27 26
25 24 23
22 21 20
19 18 17 16 15
14
13 12 11
10 9
MP25
LOCATIONS :
LEDS
MP 1 - zone M13 = KGND.

MP 25 - zone M13 = +UBS CONSOLE, SENSORS, DIs
MP 8 - zone M2 = +9V
MP 41 - zone M4 = POWER FAIL
MP 42 - zone G1 = +5V
MP 26 - zone M1 = GND.
MP 21 - zone E5 = +5V
MP 23 - zone A2 = VBATT
MP 29 - zone D10 = +5V
MP 24 - zone D2 = +BATT
H1-H6 - zone I5 = DI 1-6
MP 40 - zone M4 = +UB
H 8 - zone M3 - LOAD
H 9 - zone E11 - A2B
H 10 - zone G9 - MAIN IN/OUT
H 11 - zone M3 - POWER
H 12 - zone I11 - TXD
15.4
13

EXTENSION BOARDS
MP7
J1
J13
J12
J2
D3
D1
MP4
D2
X1
D14
X2
D13
P1
SYSTEM
D10
J8
D6
J9 MP3 J6
D17
J10
D15
D7
D21
D9
D12
J15
J11
J14
D18
J7
D11
D19
D20
X3
BR6
MP6MP5
EJECT
BR5
MP2
A102 CPU
J1
J2
DATA
D1
J5
J3
TLK
D3
J6
BR
4
3
2
1
X1
A103 DATEN
Ensure the notch is in the correct direction ( to the right )

The EPROMS must be installed completely to the left,
leaving blank holes to the right.
15.5
DS350 Graphic Module

Analog Input Module
P7
MP12
1
2
40
AGND
AGND
-
P6
MP13
J2
20
P5
16
P4
P3
MP9
J1
MP11
X16
P2
MP10
P1
1 1
2
X1
MP17
BR1
MP0
MP8
VREFA
P8
7
6
5
MP16 16
MP7 - MP1->
X17
1
2
MP14
3
2
1
40
1
2
AGND
AGND
BOARD P/N 9-333-103290

X1:1-7
X1:8
X1:9
X1:10
X1:11
X1:12-15
X1:16
X1:17
X1:18
X1:19
X1:20
ADC INPUT 0.5 V 4.5 V, Note: If channel adjustments are made through
the software and graphic console, DO NOT adjust offset with P1 - P7
= TEMP (0.5V + 10mV/oC)
MP 1 = AGND
= VREFA = 5.000V reference
MP 8 = + 5V
= AGND (reference GND)
MP 1 - 7 = Input channels 1 - 7 - 0.5V/ 4mA
= VREF+ = 5.0V power ADC
2.5V/20mA
= CH01-04, DIN 1-4 / 10
MP
14
=
+
13V
REF 02
= CH05, +UBS / 10
MP
16
=
HESIN
input voltage
= CH06, HESIN(A2B) *4
MP
17
=
app
5.4V
clamp for inputs
= CH07, +9V *4
= CH08, VREFA / 2 = 2.500V
= UKLEMM, app. VREFA, limits ADC input to 5.0V
15.6
MODEL:
S/N:
PAT DS35O Graphic Modular

BASIC ADJUSTMENTS AND VOLTAGE CHECKS
1. Crane Supply Voltage @ Xl -1 ( + ) & Xl -4(GND) =
VDC
2. Main Board Power Supply ( Reference Voltages +/- 50 MV) :

(For MP Locations Refer To Page 15.4 )
+12/+24V @ MP 25=
+ 9V @ MP 8=
+5V @ MP 4=
+6V @ MP 9=
+5V @ MP 42=
+5V @ MP 29=
+12/+24V @ MP 40=
3.
4.
5.
6.
VDC MP 1 Ground
VDC MP 1 Ground
VDC MP 1 Ground
VDC MP 1 Ground
VDC MP 1 Ground
VDC MP 1 Ground
VDC MP 1 Ground
Boom Length:
Fully Retracted
Ft.
Fully Extended
Ft.
Fully Retracted
Ft.
Fully Extended
Ft.
+12/+24V Volt Reference Voltage
mA @ X1-27
mA @ X1-27
VDC @ MP X1-3(A106), MP 0 (GND)
VDC @ MP X1-3(A106), MP 0 (GND)
VDC @ X1-26 (X1-28 GND)
Boom Angle:
Minimum Angle
Degs.
Maximum Angle
Degs.
Minimum Angle
Degs.
Maximum Angle
Degs.
+12/+24V Volt Reference Voltage
mA @ X1-29
mA @ X1-29
VDC @ MP X1-4(A106), MP 0 (GND)
VDC @ MP X1-4(A106), MP 0 (GND)
VDC @ X1-26 (X1-28 GND)
Pressure Transducers:
Piston Zero Point
mA @ X1-21 /
Rod Zero Point
mA @ X1-24 /
Piston +12/+24 Volt Reference Voltage
Rod +12/+24 Volt Reference Voltage
Analog Input Module (A106):
+5V @ MP8 =
+5V @ MP17=
+5V @ MP16=
VDC MP 0 Ground
VDC MP 0 Ground
VDC MP 0 Ground
15.7
VDC @ X1-1(A106), MP0 (GND)

VDC @ X1-2(A106), MP0 (GND)
VDC @ X1-20 (X1-22 GND)
VDC @ X1-23 (X1-25 GND)
P.A.T. L.M.I
MANUAL
SECTION 16

BOOM LENGTH CONNECTIONS
& WIRING DIAGRAMS
P1
AGND
MP14
.0V
ERROR
CODE
J1
E11
.500v MIN.
MP7 - MP1->
1
2
MP16
16
1
2
AGND
BR1
20
40
X1
AGND
X1 26 27 28
WORKING
RANGE
- +
MP11
MP10
J2
VOLTAGES
X1 3 ANALOG INPUT MODULE
+ 500MV (.500V) = MIN. SIGNAL (RETRACTED BOOM)
+ 4.50V = MAX. SIGNAL (10 TURNS ON POT)
ALL VOTAGES ARE MEASURED WITH
REFERENCE TO GND (TERMINAL X1 - 28) ON MAIN BOARD.
* THESE MEASUREMENTS ARE MADE IN PARALLEL
4.50v MAX.
ERROR
CODE
(GND)
P2
LENGTH
P3
MP9
VREFA
P4
+UB
MP12
P5
Channel # 1
OPERATING WINDOW
MP17
P6
MP13
MP0
MP8
- +
AGND
P7
P8
E21
5.0V
16.1
Current Based Amplifier

All sensing devices used for Analog Inputs now have a
current output. (min. signal 4mA, max. signal 20mA)
This circuit is measured in series.
2 3
E11 / E21
1
6 Pin
GND
Measure Voltage - Length transducer at X1 2(+) & 3 (-)

Range 1V to 5.6V
7 8
X2
Measure Amps - Length transducer at X1 2(+) &

(-) WIRE 2. Range 4 mA to 20 mA
DS350 GRAPHIC MODULAR

CHANNEL # 1
5 3 1
GND
5 3 1
5 3 1
X4
+UB

Range 10V to 30V
1 OUT
CORE
+UB
SHIELD
1 OUT
(measurements in cable reel)
5 3 1
X3
Plug
1 2 3 4 5 6 7
1 2 3 4 5 6
1 2 3 4 5 6 7
S 8 7 6 5 4 3 2 1 X1
6 Pin
6 5
7
4 3 2 1
Connector

Boom Length Signal
16.2
NO. OF TURNS
ON CABLE
REEL
NO. OF TURNS
ON LENGTH
POT
SIGNAL AT X1 TERM.
PIN #27 ON C.P.U.
TERMINAL
SIGNAL ON ANALOG
MODULE AT X1-3
(X1-28 GND.)
4 mA
.5 V
5.5 mA
.9 V
7.2 mA
1.3 V
8.7 mA
1.7 V
12
10.4 mA
2.1 V
15
12.0 mA
2.5 V
18
13.6 mA
2.9 V
21
15.2 mA
3.3 V
24
16.8 mA
3.7 V
27
18.4 mA
4.1 V
30
10
20 mA
4.5 V
CHANNEL # 1
( 3 TURNS OF CABLE REEL = 1 TURN OF LENGTH POT.)

CHART SHOWS TYPICAL MILLI-AMP AND VOLTAGE SIGNALS. THESE VOLTAGES ARE TO BE USED AS A
REFERENCE ONLY, THE ACTUAL SIGNAL MAY VARY SLIGHTLY.
MEASURE VOLTAGE IN LENGTH TRANSDUCER

AT X1 - 1 (+) & X1 - 3 (-) RANGE = 10V - 30V.
24.0
XA2
1 2 3 4 5 6 7 8
16.3
1
2
3
4
5
6
7
8
S
X2
1 X3
1
2
3
3
5
L
XB2
X2
1 X4
1
2
3
3
5
A
X2
X1
9333103309
7 (9)
8 (10)
MEASURE VOLTAGE IN LENGTH TRANSDUCER

AT X1 - 2 (+) & X1 - 3 (-) RANGE = 1V - 5.6V.
1.0
XA2
1 2 3 4 5 6 7 8
16.4
1
2
3
4
5
6
7
8
S
X2
1 X3
1
2
3
3
5
L
XB2
X2
1 X4
1
2
3
3
5
A
X2
X1
9333103309
7 (9)
8 (10)
MEASURE AMPERAGE IN LENGTH TRANSDUCER

AT X1 - 2 (+) & WIRE #2 (-) RANGE = 4mA - 20mA.
4.00
XA2
1 2 3 4 5 6 7 8
16.5
1
2
3
4
5
6
7
8
S
X2
1 X3
1
2
3
3
5
L
XB2
X2
1 X4
1
2
3
3
5
A
X2
X1
9333103309
7 (9)
8 (10)
P.A.T. L.M.I
MANUAL
SECTION 17

PISTON, ROD
CONNECTIONS &
WIRING DIAGRAMS
GRAPHIC CONSOLE
SPECIAL FUNCTION 0 - SETTING OF TRANSDUCER INPUT
0 - SETTING OF PRESSURE AND FORCE INPUTS
The 0 - setting consists of calculating an appropriate 0 - point offset, which, when added to the
transducer measurement, allows the real physical pressure of force to be calculated. To achieve
this, a procedure has been developed, allowing the 0 - setting to be performed and visualized in a
simple manner.
ACTIVATING THE 0 - SETTING FUNCTION
To activate the 0 - Setting Function, press the INFO key to activate the Info Function. Now press
the CTRL key. At this point, a five digit Authorization Number must be entered. Only authorized
personnel may adjust the 0 - point settings.
Example : 6 4 3 5 6
0 - SETTING THE TRANSDUCER INPUTS

Now, having successfully entered a valid password, the piston - side 0 - point setting function
is activated.
The display shows which transducer (piston-side, rod-side or force) is being zeroed and a horizontal
dial marks the present pressure (or force) difference in %. By pressing the + key, the input pressure
(or force) is adjusted upwards, and by pressing the - key, the input value is adjusted downwards.
When the + and - keys are pressed simultaneously, the 0 - setting occurs automatically. Manual
adjustments may be performed using + or -.
The return key toggles between the piston - side, the rod - side, and the force 0 - setting.
When the operator is finished, pressing the EXC or INFO key returns the console back to the normal
display.
17.1
AGND
MP14
.0V
ERROR
CODE
J1
E12
.500v MIN.
MP7 - MP1->
1
2
MP16
16
1
2
17.2
VOLTAGES
+ 500MV (.500V) = MIN. SIGNAL (ZERO PRESSURE)
+ 4.50V = MAX. SIGNAL (300 BAR PRESSURE)
AGND
BR1
20
40
X1
AGND
X1 20 21 22
-
WORKING
RANGE
- +
MP11
MP10
J2
4.50v MAX.
ERROR
CODE
(GND)
P1
(PISTON)
P2
OUTPUT SIGNAL
P3
MP9
VREFA
P4
+UB
MP12
P5
Channel # 2
OPERATING WINDOW
MP17
P6
MP13
MP0
MP8
- +
AGND
P7
P8
E22
5.0V
2 3

E12 / E22
(measurements at transducer)
1 2 3
Measure Voltage - (Elec) Piston transducer at A (+) & C (-)

Range 10V to 30V
Measure Voltage - (Elec) Piston transducer at B (+) & C (-)
Range 0V
A B C
A B C
Measure resistance - (Hyd) Piston transducer at B (+) & C (-)

Range 200 - 300 Ohm
PRESS. TRANS.
(PISTON)

CHANNEL # 2
AGND
MP14
.0V
ERROR
CODE
J1
E13
.500v MIN.
MP7 - MP1->
1
2
MP16
16
1
2
17.3
VOLTAGES
E13 / E23
AGND
BR1
20
40
X1
AGND
X1 23 24 25
-
WORKING
RANGE
- +
MP11
MP10
J2
4.50v MAX.
ERROR
CODE
(GND)
P1
(ROD)
P2
OUTPUT SIGNAL
P3
MP9
+UB
P4
MP17
MP12
P5
Channel # 3
OPERATING WINDOW
VREFA
P6
MP13
MP0
MP8
- +
AGND
P7
P8
E23
5.0V
2 3

1 2 3
Measure Voltage - (Elec) Rod transducer at A (+) & C (-)

Range 10V to 30V
Measure Voltage - (Elec) Rod transducer at B (+) & C (-)
Range 0V
A B C
A B C
Measure resistance - (Hyd) Rod transducer at B (+) & C (-)

Range 200 - 300 Ohm
PRESS. TRANS.
(ROD)

CHANNEL # 3

PISTON AND ROD
CONNECT DIGITAL VOLT METER NEGATIVE (-) LEAD TO TERMINAL C.
+24.0 VDC (SUPPLY VOLTAGE).
CONNECT POSITIVE (+) LEAD TO TERMINAL B, AND NEGATIVE (-) LEAD
TO TERMINAL C, VOLTAGE SHOULD BE 0 VDC. IF INCORRECT CHECK CABLE
CONNECTIONS IN CENTRAL UNIT AND CHECK CABLE FOR DEFECTS.
IF CORRECT REPLACE PRESSURE TRANSDUCER.
MEASURING RESISTANCE BETWEEN B (+) AND C (-)
RANGE 200 - 300 Ohm.
+24.0
+0.
A
B
17.4
P.A.T. L.M.I
MANUAL
SECTION 18

BOOM ANGLE
CONNECTIONS &
WIRING DIAGRAMS
P5
P4
P3
P2
MP9
AGND
MP14
Channel # 5
OPERATING WINDOW
VREFA
P6
MP13
MP0
MP8
- +
AGND
P7
P1
P8
.500v MIN.
1
2
MP16
16
1
2
18.1
VOLTAGES
+ 2.50V = 45o ANGLE
+ 4.5 V = 0o ANGLE MAX. SIGNAL
E15 / E25
X1 26 28 29
WORKING
RANGE
AGND
BR1
20
40
X1
AGND
4.50v MAX.
ERROR
CODE
(90o TO 0o)
MP10
MP7 - MP1->
- +
MP11
E15
(GND)
J1
J2
+UB
MP17
ERROR
CODE
ANGLE
.0V
MP12
E25
5.0V

SHIELD
CORE
3 4
6 Pin
Plug
7 8
X2
Measure Amps - Angle transducer at X1 4(+) &

5 3 1
X4
+UB
GND
5 3 1
1 OUT
+UB
GND
Measure Voltage - Angle transducer at X1 2(+) & 3 (-)

Range 1V to 5.6V
1 OUT
5 3 1

Range 10V to 30V
5 3 1
X3
1 2 3 4 5 6 7
1 2 3 4 5 6
1 2 3 4 5 6 7
S 8 7 6 5 4 3 2 1 X1
6 Pin

CHANNEL # 5
6 5
7
4 3 2 1
Connector

Boom Angle Signal
18.2
ACTUAL
BOOM ANGLE
IN DEGS.
90o
SIGNAL AT X1 TERM.
PIN #29 ON C.P.U.
TERMINAL
4.0 mA
SIGNAL ON ANALOG
MODULE AT X1-4
(X1-28 GND.)
0.48
85o
4.9 mA
+ .70
80o
5.7 mA
+ .92
75o
6.6 mA
+ 1.15
70o
7.4 mA
+ 1.37
65o
8.3 mA
+ 1.60
60o
9.2 mA
+ 1.80
55o
10.2 mA
+ 2.04
50o
11.2 mA
+ 2.26
45o
12.1 mA
+ 2.48
40o
12.9 mA
+ 2.70
35o
13.7 mA
+ 2.92
30o
14.7 mA
+ 3.15
25
15.6 mA
+ 3.38
20o
16.5 mA
+ 3.60
15o
17.3 mA
+ 3.82
10o
18.0 mA
+ 4.04
5o
19.2 mA
+ 4.27
0o
20 mA
+ 4.49
CHANNEL #5
CHART SHOWS TYPICAL MILLI-AMP AND VOLTAGE SIGNALS.

THESE VALUES ARE TO BE USED AS A REFERENCE ONLY, THE ACTUAL SIGNAL MAY VARY
SLIGHTLY.
24.0
1
2
3
4
5
6
7
8
S
18.3
9333103309
X1
X2
X2
XB2
X2
XA2
7 (9)
8 (10)
1 X4
1
2
3
3
5
1 X3
1
2
3
3
5
MEASURE VOLTAGE IN ANGLE TRANSDUCER

AT X1 - 1 (+) & X1 - 3 (-) RANGE = 10V - 30V.
1 2 3 4 5 6 7 8
1.0
1
2
3
4
5
6
7
8
S
18.4
9333103309
X1
X2
X2
XB2
X2
XA2
7 (9)
8 (10)
1 X4
1
2
3
3
5
1 X3
1
2
3
3
5
MEASURE VOLTAGE IN ANGLE TRANSDUCER

AT X1 - 2 (+) & X1 - 3 (-) RANGE = 1V - 5.6V.
1 2 3 4 5 6 7 8
20.0
1
2
3
4
5
6
7
8
S
18.5
9333103309
X1
X2
X2
XB2
X2
XA2
7 (9)
8 (10)
1 X4
1
2
3
3
5
1 X3
1
2
3
3
5
MEASURE AMPERAGE IN ANGLE TRANSDUCER

AT X1 - 4 (+) & WIRE #4 (-) RANGE = 4mA - 20mA.
1 2 3 4 5 6 7 8
D S350
Graphic
Modular
Slewing Angle
18-6
1 2 3
4 1 2 3
1 2 3
6 2
+UBE
SIG+
SIGGND
1 2 3 4
X7 1 2 3 4
1 2 3 4
1 2 3 4
1 2 3 4 5 6 7
A B C
A B C
A B C
A B C
1 2 34 5 6
TO MAIN BOOM
CONNECTOR
pres. trans.
(piston)
pres. trans.
(rod)
GN/YL
FUSE (10 amp)
FUSE (10 amp)
+UBS
LMI BYPASS
FUSE (4 amp)
4
10 AMP
FUSE
LMI BYPASS
KEY SWITCH
6 PIN PLUG
+UB
GND
TXD
RXD
A2B
A2B
LOAD
D1
Rear Axle Oscil. Relay
X8
+UBE 1
GND 2
V V V
LMI Lockout Alarm
1 2 3 4 5 6 7 8 X1
V V V
V V
V V
V
V
(LMI UNLOCK SOL.)
10 8 9 11 12 13 14
1 2 3 4 5 6 7
FUSE (4 amp)
4 AMP
FUSE
V V V
V
V
71 (+UB)
51 (GND)
73
GND
V V V
V V VV V V
V
V
18-7
V
V
CONSOLE (1318)
1 2 3
SLEW 2
+ 12 V
A2B GROUND
SLEW 1
A2B SIGNAL
ANGLE
GND
+UB
LENGTH
ROD
GND
+UB
GND
+UB
PISTON
DI4
DI2
DI3
DI1
+UBS
9 1 2 3 4 5 6 7 10 11 12 13 14
IN
61 62
OUT
59 60
26 27 28 29 31 32 30 33 34 35 53 54
OUT
23 24 25
IN
1 2 3
51 52 3 4 5 6 7 8 9 10 14 15 16 17 18 19 20 21 22
GN/YL
1 2 12 11 13
DI GND
+UB
X2/1 1 2 3
GND
+UB
GND
RXD
TXD
A2B BYPASS
A2B BYPASS
LMI BYPASS
+UB
GND
K10 NC
EXT. HOR. *1
LMI UNLOCK S.
+UBR K10 COM
+UB
GND
X1
D.O.Module
V V V V
NOTES:
1

RELIEF CONNECTOR.

A BC D
V V V V
1 2 3 4
LIGHTBAR

(EEC UNITS ONLY)
DS350
GRAPHIC MODULAR
with SLEWING
POTINTIOMETER
P2
P1
1
2
MP7 - MP1->
MP16
16
MP14
VOLTAGES
+ 500MV (.500V) = MIN. SIGNAL BOOM OVER FRONT
+ 4.50V = MAX. SIGNAL BOOM OVER REAR
REFERENCE TO GND (MP 0) ON ANALOG BOARD.
MP11
P3
MP9
J1
P4
DS350
GRAPHIC MODULAR
SLEW ANGLE
#1
J2
P5
- +
MP0
MP8
BR1
P8
VREFA
AGND
AGND
20
40
P6
MP13
MP10
P7
MP17
X1
MP12
- +
4 mA
.500V (A106)
18-8
AGND
1
2
E2A
WORKING
RANGE
E1A
5.0V
4.50v MAX.
.500v MIN.
AGND
12 mA
2.5V (A106)
12 mA
2.5V (A106)
OPEN
4.5V (A106)

ERROR
CODE
ERROR
CODE
OPERATING WINDOW
.0V
(GND)
SLEW ANGLE 1
+UB
2
2
W
1
R
5
Y
3
B
2 4 3
X1 33 30 35
SLEW ANGLE 2
P2
P1
1
2
MP7 - MP1->
MP16
16
MP14
VOLTAGES
+ 500MV (.500V) = MIN. SIGNAL BOOM OVER FRONT
+ 4.50V = MAX. SIGNAL BOOM OVER REAR
REFERENCE TO GND (MP 0) ON ANALOG BOARD.
MP11
P3
MP9
J1
P4
DS350
GRAPHIC MODULAR
SLEW ANGLE
#2
J2
P5
- +
MP0
MP8
BR1
P8
VREFA
AGND
AGND
20
40
P6
MP13
MP10
P7
MP17
X1
MP12
- +
12 mA
2.5V (A106)
18-9
AGND
1
2
E2B
WORKING
RANGE
E1B
5.0V
4.50v MAX.
.500v MIN.
AGND
4 mA
.500V (A106)
OPEN
4.5V (A106)
12mA
2.5V (A106)

ERROR
CODE
ERROR
CODE
OPERATING WINDOW
.0V
(GND)
SLEW ANGLE 2
+UB
2
2
W
1
R
5
Y
3
B
3 4 2
X1 33 34 35
SLEW ANGLE 1

Slewing Potentiometer Components
Electrical Slip ring Assembly

Slewing Potentiometer
Printed Circuit Slewing Board
18-10
Slew Potentiometer Installation &

Adjustment Procedure
These instructions are applicable for
installing direct drive parts (if required)
to the slew potentiometer mounted in the
top of the slip ring assembly.
Collar set fastened to shaft

by two (2) set screws.
Printed Circuit Slewing Board
(showing X1 Terminal Board)
Potentiometer
18-11
Collar
Slotted Clutch Plate
Plug to the Slip ring

Circuit Board
Slotted Clutch Plate

Potentiometer
Collar
18-12
Note: These four (4) washers

must be installed before
proceeding to the next step.
Plastic Shield installed

on top of four washers .
18-13
Clutch plate installed on

top of slip ring
assembly.
18-14
Position the collar so

there is
between 1/32 to 1/16
clearance
to the bottom of the
potentiometer.
Tighten set screws.
Install the aluminum plate

with
potentiometer over
mounting posts.
Turn shaft in the center of
potentiometer with
screwdriver until
drive pin seats in the slot
in the clutch
plate.
Collar with drive pin seated

in the slot in clutch plate.
18-15
Use a torpedo level to assure plate is level.
18-16
These instructions are applicable to cranes using a top mounted

slew potentiometer inside the slip ring assembly.
1. Position the superstructure over the front and engage the house lock pin.
2. Set the Console to read Slewing Angle:
A. Complete the LMI console setup according to the cranes current
operating configuration.
B. Press limits LMI.
C. Press 4 for Slew Angle/virtual wall limits.
D. Press 1 for Slew Angle.
E. Press 2 or 3 to display Slewing Angle.
NOTE: Refer to the P.A.T. Load Moment Indicator Operators Handbook
for detailed instructions.
18-17
3. Remove the Slip Ring cover.
4. Loosen the three screws that

secure the potentiometer.
DO NOT ATTEMPT TO ROTATE THIS

SLOTTED SHAFT.
18-18
5. Disengage the house lock pin and swing approximately 10 deg. to the right
(clockwise). Slowly swing back to the left and engage the house lock pin*.
Rotate the body of the slew potentiometer until the slew angle indicates 0.6 deg.
(+/- 0.1 deg.). NOTE: This value may not be obtainable due to limited wire
length on the slew potentiometer, or the electrical terminals interferance with
one of the mounting screws, if this occurs,reposition the collar set screwed to
the potentiometer shaft and repeat step 5.
6. Disengage the house lock pin and swing approximately 10 deg. to the left
(counterclockwise). Slowly swing back to the right and engage the house lock
pin*. If the angle indicated on the console does not exceed +/- 1.0 deg.,
proceed to step 7. If the indicated angle exceeds +/- 1.0 deg. Return to step 5.
7. Tighten the three screws that secure the slew potentiometer to the mounting
plate. Install the slip ring cover.
8. Disengage the house lock pin and swing approximately 10 deg. to the right
(clockwise). Slowly swing back to the left and engage the house lock pin*. If
the angle indicated on the console does not exceed +/- 1.0 deg., proceed to step
9. If it does exceed +/- 1.0 return to step 4.
9. Disengage the house lock pin and swing approximately 10 deg. to the left
(counterclockwise). Slowly swing back to the right and engage the house lock
pin*. Verify the angle indicated on the console does not exceed +/- 1.0 deg. If
the angle exceeds +/- 1.0 deg., Return to step 4.
* IF THE SUPERSTRUCTURE SWINGS PAST THE HOUSE LOCK PIN
ENGAGED POSITION, THE PROCEDURE MUST BE REPEATED.
18-19
P.A.T. L.M.I
MANUAL
SECTION 19

ANTI - TWO - BLOCK
CONNECTIONS &
WIRING DIAGRAMS
ANTI - TWO - BLOCK

WIRING DIAGRAM
6 Pin
GND
19.1
2
1
7 8
X2
5 3 1
X4
1 2 3 4 5 6
5 3 1
X3
1 2 3 4 5 6 7
2
S 8 7 6 5 4 3 2 1 X1
6 Pin
6 5
1
1 2
4 3 2 1
ANTI - TWO BLOCK SWITCH
NOTES:
OUTER SHIELD GROUNDED AT
1
STRAIN RELIEF CONNECTOR
2
CUT AND INSULATE INNER SHIELD
SWITCH PREWIRED AND POTTED
IMPORTANT CHANGE
Plug
1 2 3 4 5 6 7
5 3 1
+UB
5 3 1
GND
1 OUT
CORE
+UB
SHIELD
6 PIN
SHIELD
To Central Unit
1 OUT
1
2
3
4
5
6
CORE
6 PIN DUMMY PLUG
CONNECTOR
4.7K
RESISTOR
Connector
ANTI - TWO - BLOCK

WIRING DIAGRAM
4.7K
RESISTOR
To Central Unit
1
2
SHIELD
3 4
2
5 3 1
19.2
1
2
7 8 5 3 1
X2
X4
A
B
1 2 3 4 5 6
5 3 1
X3
1 2 3 4 5 6 7
2
S 8 7 6 5 4 3 2 1 X1
1 2
1 2
6 5
1 2
Plug
1 2 3 4 5 6 7
5 3 1
+UB
1 2
3
6 Pin
GND
GND
CORE
CORE
1 OUT
SHIELD
6 PIN DUMMY PLUG
+UB
A
B
1 OUT
6 Pin
4 3 21
Connector
NO.
1
1 2
AUX. BOOM NOSE

PART NO.
QTY
1
2
3
4
5
9-333-102764
9-333-102717
9-333-102666
9-333-102663
9-333-102230
1
1
1
4
1
9-333-102765
DESCRIP.
COMP. ASSEM.
2-POLE JUMPER BAR
TAGS, TERMINAL STRIP
BLOCK, TERMINAL STRIP
SWITCH A2B, WITH RETAINER
CRIMP
COMP. ASSEM., DUMMY PLUG
NOTES:
1
2
IMPORTANT CHANGE
Auxiliary Boom Nose
3 4
NO.
PART NO.
QTY
1
2
9-333-102238
9-333-102235
1
1
3+
4
9-333-102767
9-333-102687
1
2
19.3
DESCRIPTION
SWITCH, A2B W/O CRIMP
CONDUIT 10 FEET
(MUST CUT TO LENGTH)
JUNCTION BOX ASSEM.
SCREW
Auxiliary Boom Nose

JUNCTION BOX ASSEMBLY
1(BLACK)
1
2(BROWN)
A2B CABLE
3(RED)
2
3
Complete Assembly # 9-333-102767

NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
PART NO.
QTY
9-333-102758
9-333-102793
9-333-101984
9-333-102759
9-333-102663
9-333-102664
9-333-102665
9-333-102666
9-333-102760
9-333-102482
9-333-102612
9-333-102669
9-333-102266
9-333-102480
1
1
1
1
3
1
2
1
1
1
1
4
4
4
DESCRIPTION
Junction Box
Strain Relief (90o)
Locknut
Mounting rail, terminal strip
Block, terminal strip
End plate, terminal strip
End bracket, terminal strip
Tags, terminal strip
Connector, cannon 2-pin male recp.
Gasket
Cover, dust
Screw #4
Lockwasher #4
Nut #4
19.4
19.5
PART NO.
9-333-102238
7-110-151205
9-333-102235
9-333-102690
9-333-102687
NO.
1
2
3
4+
5
1
2
QTY
1
2
1
DESCRIPTION
Switch, A2B W/O Crimp
Capscrew
Conduit 10 feet
(must cut to length)
Junction box assembly
Screw
Fixed Swingaway Extension
Fixed Swingaway
1(BLACK)
1
A2B CABLE
2(BROWN)
3(RED)

NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
PART NO.
9-333-102758
9-333-102674
9-333-102759
9-333-102663
9-333-102664
9-333-102665
9-333-102666
9-333-102760
9-333-102482
9-333-102612
9-333-102669
9-333-102266
9-333-102480
QTY
DESCRIPTION
1
1
1
3
1
2
1
1
1
1
4
4
4
Junction Box
Strain Relief
Gasket
Cover, dust
Screw #4
Lockwasher #4
19.6
Nut #4
P.A.T. L.M.I
MANUAL
SECTION 20

TROUBLESHOOTING
GUIDE
PAT DS350 Graphic Modular

TROUBLESHOOTING
General Flowchart
Lever Lockout Activated
Broken Length Cable
No Display
Anti - Two - Block
Length Reading Problem
Angle Reading Problem
Load Reading Problem
Bad Data Transfer Between Console & Central Unit
Error Code Displayed
20.1
20.2
20.3
20.4
20.5
20.7
20.10
20.13
20.16
20.18
20.20
GENERAL FLOWCHART
Indicator System - P.A.T. DS350 Graphic Modular. The procedures are easy to follow and are
given in flowcharts on the following pages. Start with general flowchart below which will
guide you to one of the more detailed flowcharts shown on pages 20.3 through 20.19.
START
Whats Wrong?
Lever Lockout
Activated
Length Cable
Problem
Go to Page 20.3
Go to Page 20.4
Wrong Length
Displayed
Go to Page 20.10
Wrong Angle
Displayed
Go to Page 20.13
No Display
No Function
Anti-Two-Block
Go to Page 20.5
Go to Page 20.7
Wrong Load
Displayed
Go to Page 20.16
20.2
Bad Data
Transfer
Error Code
Displayed
Go to Page 20.18
Go to Page 20.20

PROBLEM
START

fixed?
YES
NO
Does the console indicate
NO
YES

If console displays is
in power supply,
wiring or fuses.
Fault in Anti-Two
Block system.

Light is lit, the fault
is located in LMI,
console.
Check lever lockout

system in crane
Go to page 20.5
Go to page 20.7

and go to page20.20.
20.3
BROKEN LENGTH CABLE

PROBLEM
STEP
ACTION
Open cable reel cover and disconnect wiring from terminal block. Pull 7- conductor
from Terminal X1 and X2 See drawing 1 on page 20.28.
No. X2 See drawing 1 on page 20.28.
onto the drum.
10
Set preload on cable reel by turning the drum counter-clockwise 5 to 8 turns.
11
at the boom nose.
12

20.4
NO DISPLAY
PROBLEM
START
correct?
NO
Replace fuses.
YES
Measure crane voltage on main board terminal
strip between X1-1(+12/24V) andX1-2 (ground).
This is an imput voltage from crane
Note: If crane voltage is measured below
10V system will switch off.
correct?
NO

YES
Measure crane voltage on main board

terminal strip between X1-3(+12/24V) and
X1-4 (ground). This is a output voltage to
the console.
correct?
Defect on main board.

Replace main board, see replacement
procedure.
NO
YES
NEXT PAGE
20.5
NO DISPLAY
continued
PREVIOUS PAGE
Measure voltage in the console

between X1-1 (+12/24V) and
X1-2 (ground).
Refer to Drawing 6 on page20.32 .
correct?
Check connections of the

cable between console and
central unit. Replace cable
if necessary.
NO
YES
Display is defective. Replace the console.
END
20.6
PROBLEM
START
NO
correct?
YES
Turn power off or disconnect

wire from X1-31 in central unit.
NO

correct?
YES
Measure the resistance at the boom nose
box between terminals 1 and 6 with
ohmmeter. This checks the function of the
Anti-Two-Block switch.
See drawing 2 on page 20.28.
Switch Closed = 4700 +/- 500 Ohms
Switch Open = > 1 Megaohm
NO
correct?
YES
NEXT PAGE
20.7
PREVIOUS PAGE
Measure the A2B signal in the cable reel between

X1:Brown and X2:Red wires on the slip ring with
an ohmmeter. See drawing 1 on page 20.28.
Switch closed = 4700 +/- 500 Ohms
Reconnect slip ring wires.
NO
correct?
Fault in wiring cable from junction box at

boom nose to cable reel or short circuit in
length cable. Check wiring.
YES

7 and 8 with an ohmmeter.
+ 500 Ohms.
NO
correct?
Replace slip ring.
YES
Measure the A2B signal in the boom base
box between terminal 5 and 6 with an ohmeter.
+ 500 Ohms.
NO
correct?
YES
NEXT PAGE
20.8
Fault in 7 conductor cable between

cable reel and boom base box.
PREVIOUS PAGE
Connect wire # 5 back to terminal X1-31

on themain board.
Turn system power off. Check Anti-Two-Block
signal in central unit with ohmmeter measure
between X1-31 and X1-32.
+ 500 Ohms

found check cable.
NO
correct?
YES
Disconnect X1-31 and X1-32.
temporary resistor, 4700 Ohms, between X131 and X1-32 in central unit. With resistor
connected alarm should be inactive.
NO
Defect on main board. Replace main

correct?
Reconnect wire #5 to X1-31 and wire #6 to X1-32.
END
20.9
LENGTH READING PROBLEM

PROBLEM
Length reading incorrect.
Crane is not in out of load chart condition.
START
Check mechanical adjustment of

length potentiometer in cable reel.
When main boom is fully retracted,
adjust length potentiometer counterclockwise until it stops.
Check out clutch in big gear wheel

of length transducer. Extend and
retract boom to ensure that clutch is
not slipping on potentiometer axle.
correct?
NO
Replace the gearwheel, clean potentiometer

axle. Reset length potentiometer.
YES
Check power supply to length
transducer on main board,
terminal X1-28 (ground) and
X1-26 (+12/24V).
correct?
Main board defective. Replace main

NO
YES
NEXT PAGE
20.10

PREVIOUS PAGE
Measure supply to length transducer in

cable reel at terminal between Pin 1
(ground) and Pin 3 (+12/24V).
NO
Faulty wiring between central unit

and length transducer. Check wiring.
correct?
YES
Measure signal from length transducer
in cable reel at X1-2 and wire #2, the
return signal is a current output. Measurement should be in series.
Retracted Boom =
0 Potentiometer Turns = 4mA
NO
correct?
YES
Replace length potentiometer assembly. Remove

slip ring body from shaft and remove gear wheel
from potentiometer axle. Unscrew mounting plate
and remove potentiometer assembly from mounting
plate. Remove assembly wires from terminal block.
Connect new assembly to terminal block.
Reinstall mounting plate, gear wheel and slip rings.
Reset potentiometer with fully retracted boom, turn
counterclockwise until it stops.
Measure signal from length transducer

in central unit. The return signal is a current
output and must be measured in series.
Connect meter between wire #2 and X1-27.
NO
Faulty wiring between central unit

and length transducer. Check wiring.
correct?
YES
NEXT PAGE
20.11
PREVIOUS PAGE
Measure length signal of amplified output on analog

input module between test point MP0 and X1-3.
The measurement should be between 0.5V-4.5V.
0 Potentiometer Turns = 0.5 V (500mV)

10 Potentiometer Turns = 4.5 V
Refer to Drawing 5 on page 20.31.
correct?
YES
Main board defective. Replace main board.

Reset pressure channel.
NO
Analog Input Module is

defective. Replace module.
END
20.12

PROBLEM
START

cable reel.

NO
correct?
YES
Place the boom at 0 o. Check power supply

to angle sensor on main board between X126 (+12/24V) and X1-28 (GND)
NO
correct?

reset pressure channel.
YES
NEXT PAGE
20.13
PREVIOUS PAGE

reel at terminal between X1-1 (+12/24V)
and X1-3 (GND).
NO

correct?
YES
Measure signal in series from angle sensor

in cable reel, one lead to wire #4 and the other
lead X1-4.
Boom Angle Signal :
0 Degrees
20 mA
45 Degrees
12 mA
90 Degrees
4 mA
NO
correct?
YES
NEXT PAGE
20.14

PREVIOUS PAGE
Measure signal from angle sensor in central

unit. Measurement should be taken in series
at X1-29 and wire #4.
Boom Angle Signal :
0 Degrees
20 mA
45 Degrees
12 mA
90 Degrees
4 mA
NO

correct?
YES
Measure angle signal analog input module

between test point MP0 and X1-4. The measurement should be between 0.5 - 4.5V.
Boom Angle Signal :
0 Degrees
0.5 Volt
45 Degrees
2.48 Volts
90 Degrees
4.5 Volts
NO
Faulty analog input module or CPU module in

central unit.
correct?
YES
END
20.15

PROBLEM
START
NO

correct?
YES
until it stops .
NO
correct?
YES
displayed radius.

NO
correct?
YES

Measure voltage at the cable connection between
A (+12/24V) and C (ground).
Check power supply at main board between
X1-20 (+12/24V) and X1-22 (ground) for piston
and X1-23 (+12/24V) and X1-25 (ground) for
rod side.
NO
correct?
YES
correct?
Fault in pressure transducer.

YES
Replace the main in central unit. Refer to Drawing
on page 15.3.
NO
NEXT PAGE
20.16

PREVIOUS PAGE
Measure in series piston side signal, in central

unit, remove wire #2 from X1-21. Connect one
lead to wire #2 and the other to X1-21. The
measurement should be between 4-20mA (4
mA at 0 PSI to 20mA at 4410 PSI). Rod side,
remove wire #2 from X1-24. Referto Drawing
9 &10 on pages 20.35 & 20.36.
Measurement is not within 4-20mA.

NO Fault in pressure transducer cable.
Refer to Drawing 9&10, page 20.35
& 20.36.
NO
4-20mA
correct?
YES
YES
Measurement within 4-20mA, but 4mA

does not equal 0 PSI. Adjust zero point
on pressure transducers at console. Refer
to page 17.1.
If transducer(s) are not adjustable,

replace pressure transducer(s) and
adjust zero point. Refer to page 17.1.
Measure pressure transducer signals on the analog input module between test
points, (Piston side, MP0 (GND) and X1-1) (Rod side, MP0 (GND) and X1-2).
The measurement should be between 0.5V - 4.5V at 0 PSI to 4.5V at 4410PSI.
NO
Replace the analog input module board in

central unit.
correct?
YES
END
20.17

PROBLEM
START
Check the H12 (TXD) LED on the main board ON/OFF.

On
Make sure that EPROMS are correct and plugged into
EPROM MODULE is on main board. Refer to Drawing
4 on page 20.30.
NO
correct?
Place EPROM S in correct socket.

Refer to Drawing 4 on page 20.30
YES
Measure process voltage on the main board in the
central unit between MP24 (+5V) and MP0 (GND).
NO
correct?
Off
Make sure external and internal power supply is

correct. Refer to page 20.5.
YES
Turn off system power. Check the continuity

of the receive (RXD) and transfer (TXD) wires.
Check continuity between:
X1-5 main board and X1-3 console
Refer to Drawings 3&6 on pages 20.29,20.32.
NO
correct?
YES
Check connections and replace cable from central

unit to console, if necessary. Refer to Drawing 8
on page 20.34.
NEXT PAGE
20.18
PREVIOUS PAGE
Check if additional ground link between main

bracket is in place. Refer to Drawing 3 on page
20.29.
NO
correct?
YES

Refer to connection and wiring diagrams,
NO
correct?
YES
END
20.19
PROBLEM
START
Check system out; refer to Section 8 - Bad Data
NO
correct?
YES
bracket is in place. Refer to Drawing 4, Main
Board, in Section 11.

central unit box mounting bracket. Refer to
Drawing 4, Main Board, in Section 11.
NO
correct?
YES
Refer to connections and wiring diagrams, Drawings 9A,B,C in Section 11.

Drawings 9A,9B and 9C in Section 11.
NO
correct?
YES
Refer to Drawing 7, Suppressor Diode, in Section 11.
END
20.20
ERROR CODE DISPLAY
PROBLEM
Warning lights on.
ERROR
DISPLAY
ERROR
CAUSE
ACTION
E 01*

range.

the boom too far.

chart.
E 02*

angle range.


chart.
E 03*

(no load area)

with load.

range.
E 04*

configuration.

crane.
E 05*



See page 20.33.


chart.
E 06*

20.21
ERROR CODE DISPLAY

ERROR
DISPLAY
ERROR
CAUSE
E 07
No acknowledgement signal

E 08
relay (K9).

selected.
E 11

channel "length".
E 12
E 13
E 14



ACTION

defective, not connected or water in the necessary. See page 20.33.
connectors

potentiometer. See page 20.33.

main board.


the plug.



on main board.


in the plug.


side defective.

on main board.


20.22

replace if need be.
pressure channels.
ERROR CODE DISPLAY
ERROR
DISPLAY
E 15
E 16
ERROR

E 17
CAUSE
ACTION

water inside plug.
Check cable.
See page 20.37.




inside the plug.

replace if need be.


pressure channels.
E 18

the front.

Immediately.
E 19

pressure channels.
+5 volt supply
E 1A
E 1B
E 21
Below limiting value for slewing

angle 1.
angle 2.

exceeded.
Cable from central unit to the slewing

angle sensor defective or loose.
Slewing angle pot. defective.
wiring, (external).
Electronic component in the measuring
channel defective on main board.
or loose.
defective.
on main board.
20.23

necessary.
Replace and reset slewing angle
potentiometer.
pressure channels.
necessary. See page 20.37.
ERROR CODE DISPLAY
ERROR
DISPLAY
E 22
E 23
E 24
E 25
E 26
ERROR

rod side" exceeded.



CAUSE
ACTION



side defective.


on main board.




side defective.


on main board.



replace if need be.


pressure channels.

or loose.
on main board.
See Error E 16.
Check cable.
20.24

pressure channels.
See Error E 16.
ERROR CODE DISPLAY

ERROR
DISPLAY
E 27
ERROR
Upper limit value for the measurchannel 7 exceeded.
CAUSE
Sensor of channel 7 defective
or loose.
Sensor of channel 7 defective.
measuring channel 7 defective.
E 29

voltage.
-5 volt supply
E 2A
E 2B
E 31
E 37
Above limiting value for slewing

angle 1.
angle 2.
Check cable.
pressure channels.

MP10 is more than 3.3V.
A/D converter defective.
wiring, (external).

necessary.
potentiometer.
pressure channels.
EPROM with system

program defective.

program.
pressure channels.

defective.
board defective.

EPROM.
pressure channels.

program.
program.

correct version of system or
Data EPROM.
TLK EPROM.
80C31. Replace main
channels.
(CMOS-RAM).
pressure channels.
E 38
E 39
E 41


read memory (RAM).
Internal defect in
E 42
ACTION
20.25

pressure channels.
ERROR CODE DISPLAY

ERROR
DISPLAY
ERROR
CAUSE
E 42
Error in the external

write/read memory
(RAM) part 1.
Internal defect in digital part

of CPU.
E 43

write/read memory
(RAM) part 2.

of CPU.
E 45
Error in internal
communications.
Error in A/D
conversion
Malfunction in the
memory.
E 46
E 47
component.
component.
Internal defect in
ACTION
(CMOS-RAM). Replace main
Board and reset pressure
channels.
channels.
pressure channels.
E 48

pressure channels.
E 51
E 52
Error in TLK memory.

board defective.
Eprom Module not bridge correctly.
TLK EPROM on the main
Replace Data EPROM.

board is installed.
Pressure channels.
E 56
Error in crane data EEPROM
Memory module wrongly bridged.
Bridge memory module acc. To

memory type.
Replace EPROM module and
Write data on serial crane data
EEPROM (by means of test
program or on line function),
then restart the LMI
Crane data EEPROM defective.

E 57
E 58
Error in serial crane data EEPROM
Error in the serial analog data

EEPROM
E 61
Serial communicate problem
E 63
Digital inputs on buss extension
E 69
Error in serial crane data

EEPROM
The number of the selected
EPROM base and the
identical.
Serial crane data EEPROM does not

contain valid data.
Memory module defective.
Replace EPROM module and

No valid data in the serial analog

data EEPROM.
LMI main board defective.
Same action as E 57
Replace main board.
Green cable in Buss ext. or module

itself.
Check connections
Replace module.
Replace buss extension
Memory module wrongly bridged.

to memory type.
Load chart EPROM defective.
programming values are not
Bridge memory module acc.
20.26
Replace load chart EPROM.
ERROR CODE DISPLAY

ERROR
DISPLAY
ERROR
CAUSE
E 71
Incorrect acknowledgment
of the 1 relay on the main board.
a.Anti two block relay is stuck or

defective
b. Two block relay is not being
selected due to a break on the main
board.
E 72 E 77
Analogous to E 71 for the relays.

K2K7
Analogous to E 71 for the relays

K2K7
E 80
Wipers for slewing potentiometer

out of tolerance.
E 84
Wrong rigging condition.
ACTION
Replace main board.
Analogous to E 71 for the relays

K2K7.
Replace potentiometer.
The selected rigging condition is not

contained in the data EPROM.
Select another rigging condition

Check the programming in the
data EPROM.
E 85
Error in the radius determination.
E 89
Changed of the operating code

E 91
No data transmission from the

E 92

E 93

from central unit
The computed radius is too small

( negative deflection )
The mode switch was changed
a. Supply voltage of console
interrupted.
b. Interruption or ground in the line
c. Transmitter/receiver module
defective.
a. Temporary interruption of the

data line from console electronics
to central unit.
b. Transmitter/receiver module
defective.
a. Temporary interruption of the
data line from console electronics
to central unit.
defective.
20.27
Check the programming in the

data eprom.
switch to the correct operating
configuration of the crane.
a. Check voltage at terminal X1
b. Check connection between
console and central unit.
c. If accidental ground occurs,
The transmitter module in the
damaged. Replace the
console electronics or main
board.
a. Check connection between

b. Replace console electronics
ERROR CODE DISPLAY
ERROR
DISPLAY
ERROR
E 94

E 95
CAUSE
ACTION
a. Interruption or accidental ground

in the line from console to CU.

Console electronics and central
unit. If you find an accidental
ground, the transmitter module
in the console
electronics can be damaged.
Replace the console electronics.
b. Replace console electronics
defective.
Or main board respectively.
c. Data-EPROM defective.
c. Check data EPROM.
d. CPU defective.
d. Replace CPU module.
e. Electromagnetic interference
e. Eliminate interference
(when switching contractors or
source by inverse diodes or
valves).
Varistor.

defective.
Replace data EPROM.

pressure channels.
E 96

CPU of the console.

defective.
E 97

CPU of the console.

defective.
board defective.

E 98

console.

board defective.
EAB
Short circuit in the anti - two

block switch circuit
Short circuit in the anti - two block

switch.
Short circuit in the cable to the two
block switch
Electronic component on the analog
input module defective
Replace two block switch

Replace cable to the two block
switch
Check analog input module
Replace if necessary
Note:
If an error message is displayed which is not contained in above list, please con Grove or PAT service departments.
20.28

A
G1
KGND
KGND
MP 4
+5V
MP 9
+6V
X15
GND
MP 26
GND
AGND
KGND
MP24
MP23
VBAT
+BATT
+UB1
PWM DC
MP42
MP 8
+9V
GND
5
+UB1 +UB
DI 6
KGND
X12
MP41 MP40
V10 H11 V11
H1 H2 H3 H4 H5 H6
DI 1
MP21
PFAIL+UB1
DI 1- DI 6 =>
X17
power o.k.
X14
J11
X11
SP5
X13
TXD
H12
AGND
H10
K8
MP29
10
LEVER
LOCKOUT
K10
A2B
+UB
2
1
MAIN
ON/OFF
KGND
J10
3
4
LMI
KGND
10
LOAD
+5V/RS232
AGND
K9
69 68 67
66 65 64
63 62
61 60 59 58
57 56
55 54
12
KGND
3
1
77 76
F
1
H9
A2B
KGND
KGND
J4
J3
J2
J1
X1
12
11
KGND
F
2
11
X1
13
X16
KGND
MP1
+UBS
36 35 34 33
32 31
30 29 28 27 26
25
24 23
22 21 20
19 18 17
16 15 14
13 12
LOCATIONS :
MP 25 - zone M13 = +UBS
11
10 9
13
MP 25
LEDS
MP 42 - zone G1 = +5V
MP 21 - zone E5 = +5V
MP 29 - zone D10 = +5V
H1-H6 - zone I5 = DI 1-6
20.29
H 10 - zone G9 - MAIN IN/OUT
Drawing 4 : CPU and Daten EPROM boards
MP7
J1
J13
J12
J2
D3
D1
MP4
D2
X1
D14
X2
D13
P1
SYSTEM
D10
J8
D6
J9 MP3 J6
D17
J10
D15
D7
D21
D9
D12
J15
J11
J14
D18
J7
D11
D19
D20
X3
BR6
MP6MP5
EJECT
BR5
MP2
A102 CPU
J1
J2
DATA
D1
J5
J3
TLK
D3
J6
BR
4
3
2
1
X1
A103 DATEN

The EPROMS must be installed completely to the left, leaving
blank holes to the right
20.30
Drawing 5 : Analog Input Module
P7
MP12
1
2
40
AGND
AGND
-
P6
MP13
J2
20
P5
16
P4
P3
MP9
J1
MP11
X16
P2
MP10
P1
1 1
2
X1
MP17
BR1
MP0
MP8
VREFA
P8
MP7 - MP1->
X17
1
2
MP16
16
6 5
4 3
MP14
2 1
40
1
2
AGND
AGND
BOARD P/N 9-333-103290

The analog input module converts the sensor signals on channels 1 - 7 to signals that will be
processed at the CPU and software. The incoming signal measured at the measuring points
( MP ) will be 0.5V/4mA . 2.5V/20mA. The analog input module then converts the channel
signals to 0.5V. 4.5V, which can be measured on X1:1 through X1:7. The signal voltage can
be measured at either point using ground and signal input.
20.31
20.32
J1
J2
1 2 3 4 5 6 7 8
X1
MP 1
+UB
MP 0
GND
Drawing 6 :VIEW OF BACKSIDE

OF GRAPHIC CONSOLE
MP 7
MP 6
MP 2
+7V
MP 5
+5V
J4
J5
X5 1 2 3 4
J3
MP 4
-24V
MP 3
-24V
20.33
9333103309
X1
X2
X2
XB2
X2
1
3
5
7 (9)
8 (10)
1
2
3
1 X3
1
2
3
3
5
ADJUST LENGTH POTENIOMETER WITH BOOM FULLY RETRACTED,

1
2
3
4
5
6
7
8
S
XA2

Transducer
1 2 3 4 5 6 7 8
+UB
GND
RXD
TXD
A2B BYPASS
A2B BYPASS
LMI BYPASS
+UB
Drawing 8 :ELECTRICAL WIRING FROM

CENTRAL UNIT TO CONSOLE
+UB
GND
CENTRAL UNIT
MAIN BOARD
51 52 3 4 5 6 7 8 9 10
8
1 2 3
5 6
11 12 13 14
9 11 12 13 14
4 5 6
8 X1
A B C D
1 2 3 4
DI
A2B
10
GND
X7 1 2 3 4
LIGHTBAR
LOAD
A2B
4 5
TXD
SIG -
+UB
GND
RXD
CONSOLE (1318)
+UB
SIG +
20.34
7 10
X8
+UB 1
GND 2
1 2 3
GN/YL
1 2 12 11
51 (GND)
1 2 3
X1
+UB
GND
CENTRAL UNIT
MAIN BOARD
+UBR

CENTRAL UNIT TO PRESSURE
TRANSDUCER (PISTON)
71 (+UB)
LMI UNLOCK S.
73
20.35
(LMI UNLOCK SOL.) GN/YL
PISTON
+UB
B
B
C
C
PRESS. TRANS.
(PISTON)
A
A
1 2 3 4
20 21 22
GND
1 2 3
GN/YL
1 2 12 11
51 (GND)
1 2 3
X1
+UB
GND
CENTRAL UNIT
MAIN BOARD
+UBR

CENTRAL UNIT TO PRESSURE
TRANSDUCER (ROD)
71 (+UB)
LMI UNLOCK S.
73
20.36
(LMI UNLOCK SOL.) GN/YL
ROD
+UB
B
B
C
C
PRESS. TRANS.
(ROD)
A
A
1 2 3 4
23 24 25
GND
4.7K
RESISTOR
>1>
>2>
>3>
>4>
>5>
>6>
2
+UB
LEN
(GND) 0.0V
3
CORE
SHIELD
6 PIN RECEPTACLE
1 2
ANGLE
FORCE
7
A2B SIG.
A2B GROUND
5 6
FUSE (4 AMP)
FUSE (4 AMP)
NOT USED
NOT USED
NOT USED
NOT USED
CORE
X2
SHIELD
X1
5 3 1
5 3 1
X3
X4
X2
3 2
S 8 7 6 5 4 3 2 1 X1
5 3 1
5 3 1
7 8
RED
BRN
CABLE REEL
ANGLE SIG.
3 4
GND
1 2
+UB
26 27 28 29 30 31 32 33 34 35 36 53 54
GND
CENTRAL UNIT
MAIN BOARD
+UB

CENTRAL UNIT TO CABLE REEL
/ANTI-TWO BLOCK
LENGTH SIG.
20.37
6 PIN RECEPTACLE
1 2 3 4 5 6 7
1 2 3 4 5 6
1 2 3 4 5 6 7
6 SOCKET PLUG
20-38
20-39
P.A.T. L.M.I
MANUAL
SECTION 21
DS 350 Graphic Modular (BCS)

Console Connections,
Wiring Diagrams

LMI L/O ALARM (EEC)
LEVER LOCKOUT W # 73A
SOLENOIDS
10
CONSOLE
BY - PASS
KEY
3
4
8
5
4
3
21.1
AB
A2B
3
4
DATA FROM C.U.
DATA TO C.U.
2
1
3
(GND) 2
(+24 V)
GRAPHIC CONSOLE
4A
13
14
10A
= CONNECTED
= WIRES ARE
GROUPED
TOGETHER
K10A
+ +UBS
0V
RXD
TXD
A2B-O
A2B-I
LOAD-I
+ +UBS
K9
K8
F2- 10A
11 REL -M
12
REL -A
13
REL -R
14
+ +UBS
15
DE 1
16
DE 2
17
DE 3
18
DE 4
19
20
+ +UBS
I
21
DAV1
U
0V
22
23
+ +UBS
I
24
DAV2
U
0V
25
+ +UBS
26
I
27
LG 1
U
0V
28
I
29
WG 1
U
I
30
LG 1
U
31
0V
32
33
+ +UBS
I
34
S1 DHG 1
U
0V
35
I
36
S2 DHG 2
U
51
+ +UB
0V
52
F1 - 4A
53
SI - OUT
54
SI - IN
57
A2B-0
A2B-I
58
LOAD-I
59
60
+ +UBS
F2-10A
61
SI-REL
62
SI-REL
+ +UBS
64
0V
65
66
DE 5
67
68
DE 6
69
+UBS
+
76
0V
77
K10B
X4
BRN
1
2 WHT
PNK
3 GRA
4
5 GRN
6 YEL
WHT
WHT
BRN
BRN
YEL
GRA
GRN
PNK
YEL
GRN
3-Pair
Twisted
Cable
GRA
PNK
X2
1
2
GRN
3
YEL
4
5
6
PNK
7
GRA
8
BRN
WHT
BUS EXTENSION
DS350 Graphic Modular BCS

Console to C.P.U. Connections
LMI BYPASS
KEY SWITCH
+ +24V
0V
MAIN BOARD
LMI
+UBS
W # 71K = 24 VOLTS
F1
STOP
W # 51AJ = GND
1
2
3
4
5
6
7
1
2
3
4
5
6
7
8
9
+UB
X1
1
2
FIVE SECTION BOOM SERVICE SCREEN

(RT865BXL - BCS)
PAT
DS 350
STOP
STOP
156ft
0335
TARE
90.0ft
?
Ramp Seq.
IM Hex Value
255
CM Hex Value
OM/Fly Hex Value
STOP
79.4o
LIM
SEL
255
50.8ft
MAX
02 73.5oo
38.2
38.2
38.2
38.2
100%
(lbs)
ACT
(lbs)
34.900
100%
i
CTRL
100%
STOP
F1
Length of IM
F2
F3
F4
Tot. Length
minus IM
To activate service screen press and hold F1 & F4 until screen

appears in lower left corner. The ramping value will indicate the
ramping up and ramping down of the output signal to the
solenoids.
21.2
P.A.T. L.M.I
MANUAL
SECTION 22

System Theory &
Component Location

SYSTEM THEORY
DI 1
DI 2
DI 3
DIGITAL DI 4
INPUT DI 5
DI 6
DI 7
DIGITAL INPUTS
BOOM EXTEND
BOOM RETRACT
OM / FLY RET.
IM RET.
IM % RESET
K5 NC
22.1
K6
K7
K5
RxD
TxD
AO1
IM 2 WAY SOL.
CM 2 WAY SOL.
PRESS. SW. EXTEND PILOT PRESS.

PRESS. SW. RETRACT PILOT PRESS.
AUTOMODE SWITCH IN CAB
OM 2 WAY SOL.
ON CM SECTION
ON IM SECTION
ON BASE SECTION
ON BASE SECTION
OUT OF SEQ. WARNING LIGHT IN CAB

PROP. PRESS. REDUCING VALVE EXT.
PROP. PRESS. REDUCING VALVE RET.
IM - 2 WAY SOLENOID VALVE
CABLE
REEL
DIGITAL
OUTPUT K2
CRANE
INTERFACE
CONNECTOR
PROP. EXT.
PROP. RET.
BOOM
CONTROL BUS
EXTENSION
HOUSE PIN SWITCH
PROX. SW.
PROX. SW.
PROX. SW.
PROX. SW.
CM RET. & % RESET
OUT OF SEQ. WARN.
CENTRAL
UNIT
ON RUBBER - OVER FRONT
AUTOMODE ON
K4
K5 NO
CRANE
INTERFACE
CONNECTOR
ON RUBBER OVER FRONT

HOUSE PIN ENGAGED
CM - 2 WAY SOLENOID VALVE

OM - 2 WAY SOENOID VALVE
PROP.
ANALOG
OUTPUT
AI 1
ANALOG INPUT
P1
P2
A1
L1
ANALOG
INPUT
AI 2
CENTER MID LENGTH SENSOR
INNER MID LENGTH SENSOR
MAIN BOOM LENGTH SENSOR
ANGLE SENSOR
ROD PRESS. TRANS.
PISTON PRESS. TRANS.
LMI CONSOLE
HOW DOES THE SYSTEM WORK?

HYDRAULIC
1. Pilot operated 4 way valve provides oil flow to extend and retract the 3 telescoping
cylinders. On this valve are 2 pressure reducing valves electrically operated by the PAT
system. Their function is to reduce the pilot pressure when nearing the point a section
must stop in order to slow it down smoothly, then they will increase the pilot pressure
back to normal once the next section begins to move allowing for a smooth transition.
Directional pressure switches
In each of the pilot pressure lines is a normally open pressure switch, one for extend and
one for retract. These pressure switches tell the PAT which direction has been selected
by the operator, so it will know which section is next to go out or in and when the pilot
pressure is to be reduced and returned to normal.
Third switch pressure
A third pressure switch ( normally closed ) mounted near the top of the 4 way valve
monitors joystick pressure directly on the main spool for extend. When no pressure is
evident, or the controller is in neutral, the switch is closed , and the piston side dump
valve is energized allowing piston side pressure to be released through a .078 orifice.
2. Two - way valves control the oil to each telescope cylinder. One for the pilot
pressure to the holding valve and one for the piston side oil to flow. These are operated
in pairs only. When a pair of two-way valves are de-energized, that particular telescope
cylinder will then operate. The other two pair of two way - valves must be energized to
prevent movement of the other two telescope cylinders. These valves are also switched
on and off by the PAT system when in Automatic mode. They are controlled by an
individual selector switch when in the Manual mode.
Two - way valves are normally open, so that in the event of an electrical malfunction,
the boom could always be telescoped in for repair.
Piston side dump valve

In the piston side, there is a piston side dump valve which allows piston side oil to be
released back to tank by the way of a .078 orifice. This valve is controlled by the
normally closed contacts of the third pressure switch and dumps to tank, when the
controller is in neutral and pilot pressure has decayed.
Rod side dump valve
In the rod side, there is a rod side dump valve which allows rod side oil to be released
back to tank. This valve is electrically operated by the PAT system and is switched on to
dump rod side pressure when the controller is in neutral.
22.2
Sequence valve
The sequence valve maintains pressure on the rod side to prevent the cylinders from extending
when
the trombone tubes are pressurized.
* If the boom sections drift back in momentarily after the controller is released, this is a good
indication
the sequence valve is defective.
1. Install gauge into test port between pressure reducing valve and sequence valve.
2. Select manual mode.
3. Select either inner mid or center mid section.
4. Extend the boom section and monitor pressure while boom is extending. If it does not
read 1,000 P.S.I., adjust valve accordingly.
Pressure reducing valve
The pressure reducing valve is used to flood the rod side whenever the telescope cylinders first
begin to extend.
* If the boom sections take off with a jump, this is a good indication the pressure reducing valve
is defective.
1. Always be sure to check setting of the sequence valve first.
2. Gauge should still be in test port from checking sequence valve.
3. With manual mode still selected.
4. Select either the inner mid or center mid section chosen.
5. Extend the section completely until it bottoms out.
6. Release controller or treadle valve to neutral (this allows oil to drain off).
7. Then operate controller or treadle valve to extend and note pressure reading, it should
read 800 P.S.I. if it does not, adjust pressure reducing valve accordingly.
Check valve
The purpose of the check valve, is to prevent high pressure oil from flowing back through the
800 P.S.I. pressure reducing valve when trying to retract.
22.3
HELPFUL HINTS
CHECKING THE COILS IN THE TWO WAY VALVES FOR CONTINUITY
1. Select manual mode
2. Select individual sections to operate.
3. If there is continuity in the wiring to the valve, the section lights will illuminate.
CHECKING THE BOOM LENGTH SIGNALS

Three length sensors are located on the side of the boom ,(Overall length, Inner Mid &
Center Mid) the software utilizes the signals to calculate the outer mid & fly section length.
Disengage the boom stop, retract the boom and measure all with meter in series:
Overall boom length signal 4 mA (A 101 Main X1-27)
Inner Mid length signal 4mA (A 101 Bus X1-63 )
Center Mid length signal 4 mA (A 101 Bus X1-64 )
CHECKING PROXIMITY SWITCH INPUTS

Four proximity switches are used to tell the system if all sections are fully retracted.
Inner mid retract & percentage reset switch:
Reset proximity switch provides +24V signal to A 101 Bus X1-41 when retracted
against boom stop.
Center mid retract & percentage reset switch:
Reset proximity switch provides +24V signal to A 101 Bus X1 - 37.
Outer mid / fly retract & percentage reset switch:
Reset proximity switch provides +24V signal to A 101 Bus X1-35.
Retract proximity switch provides a +24V signal to A 101 X1-39 when boom stop
is disengage.
22.4
VIEW A - A
VIEW B - B
22.5
SS CABLE TO CRANE INTERFACE
CRANE ELECTRIC
INTERFACE CONNECTION
3 - PAIR CABLE TO CENTRAL UNIT
CABLE ASSY. TO BOOM
CENTRAL UNIT
CABLE ASSY. TO BOOM
CABLE ASSY. TO PRESS. TRANSDUCER ( PISTON )
CABLE TO AREA DEFINITION
CABLE ASSY. TO PRESS. TRANSDUCER ( ROD )
CABLE TO CRANE INTERFACE
CABLE ASSY. TO CONSOLE
3 - PAIR CABLE BUS EXTENSION
CABLE ASSY. TO BOOM
FUSE ( 10A)
FUSE ( 4A )
BYPASS KEY SWITCH
P.A.T. - LMI
RT865 BXL (BCS)
TURNTABLE COMPONENTS
BOOM CONTROL
BUS EXTENSION
B PAT B
RT865BXL
CONNECTIONS FOR
TURNTABLE HARDWARE
TO BOOM HARDWARE
19 - pin plug
14 - pin plug
7 - pin plug
RT865BXL (BCS)
Central Processing Unit
A 102 CPU
MODULE
SYSTEM
E-PROM
A 105 SERIAL
EXTENSION
MODULE
SYS
A 103 E-PROM
MODULE
DATA
DATA E-PROM
TLK
A 101 MAIN
BOARD
TLK E-PROM
LMI
BYPASS
KEY SWITCH
K8
K10
K9
A 106 ANALOG
INPUT MODULE
RELAYS
X1 TERMINAL
STRIP
FERRITE
FILTER
4 AMP
10 AMP
RT865BXL (BCS)
Bus Extension
A 104 PV
EXTENSION
MODULE
A102 CPU
MODULE
4 AMP
FUSE
X1
TERMINAL
X1
TERMINAL
A 105 ANALOG
INPUT
MODULE
2 AMP
FUSE
X2
TERMINAL
A 101 BUS
EXTENSION
K1-K8
RELAYS
22.6

BUS EXTENSION BOARDS
8
MP
A 104 PV
Extension
Module
A 105 Analog
Input Module
A 102 CPU
Module
25
2
26
8
72
THIS BOARD IS NOT

USED - RT865BXL (BCS)
A 101
Bus Extension
22.7
RT865BXL
with Boom Control
Turntable Components
22.8
RT865BXL (BCS)
Relay Outputs
INPUT
K1
K2
CU
DESCRIPTION
TERMINAL
A101 BUS
NOT USED
X1/3
A101 BUS
X1/5
NOTES
NONE
2 - WAY IM SOLENOID VALVES (2)

PILOT PRESSURE
OFF = IM EXTENDS OR RETRACTS ON = IM

IS NOT ALLOWED TO M OVE
K3
A101 BUS
X1/8
TELE ROD DRAIN VALVE
OFF = BOOM IS EXTENDING OR RETRACTING

AND IS NOT FULLY RETRACTED
ON = BOOM IS IN NEUTRAL POSITION OR
FULLY RETRACTED
K4
A101 BUS
X1/12
PROVIDES SIGNAL TO GRV WARNING LIGHT
K5
A101 BUS
X1/13
ANALOG OUTPUT SIGNAL FROM

ANALOG BOARD
ANALOG OUTPUT TO PROPORTIONAL

SOLENOID VALVES, EXTEND & RETRACT,
RELAY K5 SELECTS EXTEND OR RETRACT
K5
A101 BUS
X1/14

PROPORTIONAL EXTEND
SOLENOID VALVE
M AXIM UM 800mA TO EXTEND VALVE

ONE VALVE FOR ALL SECTIONS
K5
A101 BUS
X1/15

PROPORTIONAL RETRACT
SOLENOID VALVE
M AXIM UM 800mA TO RETRACT VALVE

ONE VALVE FOR ALL SECTIONS
K6
A101 BUS
X1/17
2 - WAY CM SOLENOID VALVES (2)

OFF = CM EXTENDS OR RETRACTS
PILOT PRESSURE
ON = CM IS NOT ALLOWED TO M OVE
2 - WAY OM /FLY SOLENOID
K7
A101 MAIN
VALVES (2) PILOT PRESSURE
X1/20
OFF = OM /FLY EXTENDS OR RETRACTS

ON = OM /FLY IS NOT ALLOWED TO M OVE
K8
A101 MAIN
LM I CUT OFF INTERNAL RELAY
X1/9
CONNECT LM I BYPASS VIA DIODE ASSEM BLY

FROM GRAPHIC CONSOLE AND CU KEY
SWITCH
K9
A101 MAIN
A2B CUT OFF INTERNAL RELAY
X1/8
CONNECT A2B BYPASS FROM GRAPHIC

CONSOLE
K10
A101 MAIN
LM I UNLOCK RELAY OUTPUT
X1/12
POWERS THE LM I UNLOCK SOLENOID WHEN

NO OVERLOAD, A2B OR ERROR CONDITION
K10
A101 MAIN
EXTERNAL ALARM OUTPUT
X1/13
USED FOR EEC UNITS ONLY
22.9

Relay Diagram
BUS EXTENSION
6
7
TELE ROD DRAIN
16
8
9
10
A104
X1
1
2
3
4
11
TELE OUT OF SEQUENCE 13
ANALOG SIGNAL
12
13
TELE EXT. PROP. SOL.
17
14
TELE RET. PROP. SOL.
18
15
16
CM TELE
17
18
19
OM / FLY TELE
TELE
PROP.
ANALOG
GND.
20
21
22
23
24
26
H17
>
K2
>
K3
H19
22.10
+24V TELE ROD

DRAIN SOL.
2A - F4
>
K4
H20 TELE SEQUENCE
2A - F5
>
K5
NO PROP. EXT.
H21 NC PROP. RET.
2A - F6
>
K6
H22
+24V CM 2WAYS
2A - F7
>
K7
+24V OM 2WAYS
H23
2A - F8
>
K8
H24
+UB
10 - 35V
27
28
+24V IM 2WAYS
H18
25
K1
2A - F3
>
>
>
>
>
>
IM TELE
>
2A - F2
>
>
>
>
>
>
2A - F1
>
>
>
>
X1
KGND
RT865BXL (BCS)
DS350Graphic Modular
Automode control of two way valves
K2
0
1
1
0
0
K6
1
0
1
0
0
K7
1
1
0
0
0
DESCRIPTION
IM EXTENDING OR RETRACTING
CM EXTENDING OR RETRACTING
OM/FLY EXTENDING OR RETRACTING
OUT OF SEQUENCE
NEUTRAL POSITION
Analog Outputs
ANALOG
1
1
CU
DESCRIPTION
TERMINAL
A104 X1/2 Analog GND for proportional extend or retract solenoid valves.
A104 X1/1 Analog signal for proportional extend or retract solenoid valves.
Input / Output Logic RT865BXL (BCS)

Auto IM
Auto IM
Ext.
DI 1
1
0
Retr.
DI 2
0
1
Relay
K2
0
0
Relay
K6
1
1
Relay
K7
1
1
Relay
K5
1
0
2 way
IM
0
0
2 way
CM
1
1
2 way
OM
1
1
analog
output
1
1
Auto CM
Auto CM
Auto OM
Auto OM
1
0
1
0
0
1
0
1
1
1
1
1
0
0
1
1
1
1
0
0
1
0
1
0
1
1
1
1
0
0
1
1
1
1
0
0
1
1
1
1
1
0
1
0
0
1
0
1
Man. IM
Man. IM
Man. CM
0
1
1
0
0
0
0
0
0
0
0
0
0
1
1
0
1
1
0
0
0
1
1
0
Man. CM
Man. OM
0
1
1
0
0
0
0
0
0
0
0
0
1
1
0
1
1
0
0
0
0
1
1
0
Man. OM
Neutral
Mode
Logic 1 ON - 0 OFF
Boom sequence RT865BXL (BCS)

Mode
B - Mode
B - Mode
B - Mode
B - Mode
B - Mode
B - Mode
B - Mode
B - Mode
IM%
0
50
50
75
75
100
100
100
CM%
0
0
50
50
75
75
100
100
22.11
OM%
0
0
0
0
0
0
0
100
FLY%
0
0
0
0
0
0
0
100
Prop. val. Prop. val.

EXT.
RETR.
1
0
0
1
P.A.T. L.M.I
MANUAL
SECTION 23

Boom Length Connections
& Wiring Diagrams

RT 865BXL
5
DS350 Graphic Modular - BCS
PAT
PAT
PAT
3
5
23.1
1

AND SECURE TO BUSHING ON THE BOOM NOSE
PER DETAIL A.

AND SECURE TO BUSHING ON THE INNER - MID
PER DETAIL A.

AND SECURE TO BUSHING ON THE CENTER - MID
PER DETAIL B
REMOVE 1/4 - 20 NUTS ON BOTTOM OF CABLE GUIDE.

INSERT CABLE GUIDE SCREWS THRU EXISTING ANGLE
BRKT AND SECURE IN PLACE WITH 1/4 - 20 NUTS
REMOVED PREVIOUSLY.
CENTER LINE OF CABLE GUIDE MUST BE ALIGNED W/ CENTER

LINE OF CABLE REEL DRUM.
AFTER MACHINE IS CALIBRATED, REMOVE PROTECTIVE PAPER

CORROSION INHIBTOR AND ADHERE TO INSIDE HOUSING COVER
SURFACE OF CABLE REEL.

RT 865BXL
IM length sensor
LG321
See detail
A
See detail
C
CM length sensor
LG321
Boom length & angle sensor
LWG309
IM % reset
switch
See detail
C
23.2
PAT
PAT
PAT
See detail
C
OM retract and %
reset switch
IM retract
switch
CM retract and %
reset switch
See detail
B
PLACE (3) TIE WRAPS, 120 DEGREES

APART AROUND BUSHING. WRAP CABLE
(8-10) REVOLUTIONS OVER THE TIE WRAPS
STARTING FROM THE OUTSIDE AND
WORKING INWARD. ALLOW AMPLE CABLE
TO REACH JUNCTION BOX. SECURE CABLE
WITH (2) ADDITIONAL TIE WRAPS.

FULLY RETRACTED.
16
THIS TARGET IS ONLY INSTALLED IF THE

BOOM IS EQUIPPED WITH A BOOM
EXTENSION STOP BLOCK.
18

FULLY RETRACTED.
0.44
0.44
16
See detail
A
0.44
18
3.94
CENTER LINE OF
TARGETS &
PROXIMITY SW.
23.3
0.13
PAT
DETAIL A
1.0
DETAIL C
1.34
DETAIL B
To
wi be a
t
l
of h ce igne
c a nt e d
ble
r
ree line
ld
rum

RT 865BXL
PARTIAL TOP VIEW
19
23.4
CENTER LINE OF CABLE GUIDES
CENTER LINE OF
CABLE REEL DRUM
CABLE GUIDES ON THE BASE & INNER MID

SECTIONS ASSOCIATED WITH TOP AND
MIDDLE CABLE REEL MUST BE ALIGNED WITH
CENTER OF CABLE REEL DRUM
19
INSTALL SHIMS AS REQUIRED TO ASSURE

CENTER LINE OF CABLE REEL DRUMS ARE
PARRALLEL TO BOOM BASE SECTION AND
PLUMB WHEN CRANE IS ON A LEVEL \
SURFACE.
P1
J1
AGND
MP14
ERROR
CODE
E11
.500v MIN.
MP7 - MP1->
MP16
16
1
2
AGND
1
2
BR1
X1
AGND
20
40
23.5
VOLTAGES
+ 500MV (.500V) = MIN. SIGNAL (RETRACTED BOOM)
+ 4.50V = MAX. SIGNAL (10 TURNS ON POT)
X1 26 27 28
WORKING
RANGE
- +
MP11
MP10
J2
4.50v MAX. A
ERROR
CODE
(GND)
P2
LENGTH
P3
MP9
VREFA
P4
+UB
MP12
P5
Channel # 1
OPERATING WINDOW
.0V
MP17
P6
MP13
MP0
MP8
- +
AGND
P7
P8
E21
5.0V

2 3
E11 / E21
6 Pin

Range 10V to 30V
GND

Range 1V to 5.6V
7 8 5 3 1
X2
X4
Measure Amps - Length transducer at X1 2(+) &


CHANNEL # 1
+UB
5 3 1
5 3 1
+UB
1 OUT
CORE
GND
SHIELD
1 OUT
5 3 1
X3
S 8 7 6 5 4 3 2 1 X1
6 5
7
4 3 2 1
Plug
1 2 3 4 5 6 7
1 2 3 4 5 6
1 2 3 4 5 6 7
6 Pin
Connector
LMI L/O ALARM (EEC)

SOLENOIDS
W # 51AJ = GND
X1
1
2
1
2
3
4
5
6
7
8
9
10
IS = CUT&INSULATE
7
X2
RED
SHEILD
CORE
X1
BRN
SHIELD
A
B
CORE
1
2
X4
5
SIG. 3
+24V 1
23.6
1 2 3 4
3
2
GND
SIG.
+24V
1
2
X3
5
3
3
4
7 - PIN PLUG
X1
SIG
A 1
B 2
C 3
D 4
G 7
LG
4.7K
GND
CH #1
CH #5
IS = CUT&INSULATE
1
2
3
4
BOOM LENGTH SIGNAL

RETRACTED = 4mA
MAX RANGE = 20 mA
BOOM ANGLE SIGNAL

90o = 4mA
0o = 20 mA
OS Connected
to strain relief
insert
5
6

VARIES WITH BOOM, MAX.
SIGNAL=20mA IS FOR 10
TURNS ON POT.
7
IS = CUT
&INSULATE
4A
LMI BYPASS
KEY SWITCH
14
10A
= CONNECTED
= WIRES ARE
GROUPED
TOGETHER
+ +24V
K10A
0V
+ +UBS
0V
RXD
TXD
A2B-O
A2B-I
LOAD-I
+ +UBS
K9
K8
F2- 10A
11 REL -M
12
REL -A
13
REL -R
14
+ +UBS
15
DE 1
16
DE 2
17
DE 3
18
DE 4
19
20
+ +UBS
I
21
DAV1
U
0V
22
23
+ +UBS
I
24
DAV2
U
0V
25
+ +UBS
26
I
27
LG 1
U
0V
28
I
29
WG 1
U
I
30
LG 1
U
31
0V
32
33
+ +UBS
I
34
S1 DHG 1
U
0V
35
I
36
S2 DHG 2
U
51
+ +UB
0V
52
F1 - 4A
53
SI - OUT
54
SI - IN
57
A2B-0
A2B-I
58
LOAD-I
59
60
+ +UBS
F2-10A
61
SI-REL
62
SI-REL
+ +UBS
64
0V
65
66
DE 5
67
68
DE 6
69
+UBS
+
76
0V
77
K10B
X4
BRN
1
2 WHT
PNK
3 GRA
4
5 GRN
6 YEL
WHT
WHT
BRN
BRN
YEL
GRA
GRN
PNK
YEL
GRN
3-Pair
Twisted
Cable
GRA
PNK
X2
1
2
GRN
3
YEL
4
5
6
PNK
7
GRA
8
BRN
WHT
BUS EXTENSION

Connections
13
+UBS
MAIN BOARD
WG
GND
X2
F1
LWG309 L/A TRANSDUCER
STOP
W # 71K = 24 VOLTS
+UB
RT865BXL (BCS)
Cable Reel LWG309
PAT
PAT
PAT
23.7
Ratio = 3.75 to 1
(PRE - TENSION ON CABLE REEL = 10 REVOLUTIONS COUNTERCLOCKWISE)
XA2
1 2 3 4 5 6 7 8
1
2
3
4
5
6
7
8
S
X2
1 X3
1
2
3
3
5
L
XB2
X2
1 X4
1
2
3
3
5
ADJUST LENGTH POTENIOMETER WITH

BOOM FULLY RETRACTED, TURN THE
CENTER SCREW COUNTERCLOCKWISE
TO A SOFT STOP.
X2
X1
9333103309
7 (9)
8 (10)
Complete Assembly
Board, Terminal w/ filters
Angle Sensor WG103/0007
Length Potentiometer
Length Cable (single core, 63M - 206 ft.)
Slip Ring Assem. 2-pole
1
1
1
9-333-103394
9-333-103309
9-333-103303
9-333-103308
9-333-102382
9-333-102732

Boom Length Signal LWG 309
23.8
NO. OF TURNS NO. OF TURNS

ON CABLE
ON LENGTH
REEL
POT
0
0
3.75
1
7.5
2
11.25
3
15
4
18.75
5
22.5
6
26.25
7
30
8
33.75
9
37.5
10
SIGNAL AT X1 TERM. SIGNAL ON ANALOG

PIN #27 ON C.P.U.
MODULE AT X1-3
TERMINAL
(X1-28 GND.)
4 mA
.5 V
5.5 mA
.9 V
7.2 mA
1.3 V
8.7 mA
1.7 V
10.4 mA
2.1 V
12.0 mA
2.5 V
13.6 mA
2.9 V
15.2 mA
3.3 V
16.8 mA
3.7 V
18.4 mA
4.1 V
20 mA
4.5 V
( 3.75 TURNS OF CABLE REEL = 1 TURN OF LENGTH POT.)

CHART SHOWS TYPICAL MILLI-AMP AND VOLTAGE SIGNALS. THESE VOLTAGES ARE TO BE USED AS A
REFERENCE ONLY, THE ACTUAL SIGNAL MAY VARY SLIGHTLY.
CHANNEL # 1
RT865BXL (BCS)
Cable Reel LG321
PAT
PAT
PAT
23.9
XA2

TURN THE CENTER SCREW
COUNTERCLOCKWISE TO A
SOFT STOP.
Complete Assembly
Length Cable (eleven core, 25 M - 86 ft.)
Slip Ring Assem. 11 pole
Junction Box
Gear Wheel
1
1
9-333-103621
9-333-101777
9-333-101617
1
1
1
9-333-102490
9-333-102737
9-333-101778
9-333-103752
(CUT CABLE TO SPECIFIED LENGTH)
1
2
3
4
5
6
7
8
S
1 2 3 4 5 6 7 8
Ratio = 2 to 1
X2
1 X3
1
2
3
3
5
L
XB2
X2
1 X4
1
2
3
3
5
A
X2
7 (9)
8 (10)
X1
X1
11
12
13
11
12
13
14
15
16
17
18
19
14
15
16
9333103309
17
18
19
X1
LG 321 CABLE REEL

(TO IM)
X1
TO
JUCTION
BOX - IM
14
20
WHT/BLK
19
19
10
BLK
18
18
11
BLK
WHT
WHT
17
17
GRA
GRA
16
16
VIO
VIO
15
15
BLU
BLU
14
14
GRN
13
13
10
GRN
YEL
YEL
12
12
ORG
ORG
11
11
8
5
14
10
S
RED
BRN
BRN
X2
LG
23.10
12
X3
X1
BOOM LENGTH SIGNAL

RETRACTED = 4 mA
MAX RANGE = 20 mA
VARIES WITH BOOM, MAX SIGNAL
20 mA IS FOR 10 TURNS ON POT.
S
14 - SOCKET
PLUG
R
14
14
P
13
13
N
12
12
M
11
11
L
10
10
K
9
9
J
8
8
H
7
7
G
6
6
3
F
5
5
E
4
4
D
3
3
1
C
2
2
B
1
1
A
A104
X1
1
2
3
4
1
3
3
5
9
10
12
7
1
4
= Outer sheild connected to strain

relief insert.
= Inner sheild cut and insulate.
6
13
14
TO
JUCTION
BOX - BOOM BASE
K3 COM ( +24V )
K3 NO ( +24V TELE ROD DRAIN SOL. )
K3 NC
K4 COM
K4 NO
K4 NC ( TELE OUT OF SEQUENCE )
K5 COM
K5 NO ( PROP EXT )
K5 NC ( PROP RET )
K6 COM ( + 24V )
K6 NO ( +24V TO CM 2-WAY SOLS. )
K6 NC
K7 COM ( +24V )
K7 NO ( +24V TO OM 2-WAY SOLS. )
K7 NC
+24V
+24V
GND
GND
DI 1 ( +24V = TELE EXT. PRESS. SW. )
DI 1 GND
DI 2 ( +24V = TELE RET. PRESS. SW. )
DI 2 GND
DI 3 ( +24V = AUTO MODE )
DI 3 GND
DI 4 ( +24V = OM / FLY RET )
DI 4 GND
DI 5 ( +24V = CM RET & % RESET )
DI 5 GND
DI 6 ( +24V = IM RET )
DI 6 GND
DI 7 ( +24V = IM % RESET )
DI 7 GND
X2
1 BRN
2 WHT
GRN
3 YEL
4
ANALOG INPUT 1 (IM LEN.)
5
ANALOG INPUT 2 (CM LEN.) 6
7 PNK
8 GRA
WHT
BRN
WHT
YEL
GRN
BRN
GRA
PNK
YEL
GRA
GRN
PNK
X4
1
WHT
2
PNK
3
GRA
4
GRN
5
YEL
6
BRN
MAIN BOARD

Inner Mid Cable Reel to
Bus Extension Connections
K2 COM ( +24V )
K2 NO ( +24V TO IM 2-WAY SOLS. )
BUS EXTENSION
WHT/BLK
11
13
RED
8
11
PV EXTENSION
20
V
U
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
RT865BXL (BCS)
Cable Reel LG321
PAT
PAT
PAT
23.11
Ratio = 1 to 1
XA2
1 2 3 4 5 6 7 8
1
2
3
4
5
6
7
8
S
X2
1 X3
1
2
3
3
5
L
XB2
X2
1 X4
1
2
3
3
5
A

X2
7 (9)
8 (10)
X1
X1
11
12
13
11
12
13
14
15
16
17
18
19
14
15
16
9333103309
17
18
19
Complete Assembly
Length Cable (eleven core, 33.5 M - 110 ft.)
Slip Ring Assem. 11 pole
Junction Box
Gear Wheel
1
1
9-333-103620
9-333-101777
9-333-101617
1
1
1
9-333-102490
9-333-102737
9-333-101778
9-333-102982
(CUT CABLE TO SPECIFIED LENGTH)
P.A.T. L.M.I
MANUAL
SECTION 24

Piston & Rod Connections
& Wiring Diagrams
LMI L/O ALARM (EEC)

SOLENOIDS
W # 51AJ = GND
X1
1
2
1
2
3
4
5
6
7
8
9
PISTON TRANSDUCER
3
4
IS = CUT& INSULATE
B 2
5
1
C 3
1
2
3
1
2
3
CH #2
24.1
CH #3
ROD TRANSDUCER
DAVS 314
A 1
OS Connected
to strain relief
insert
B 2
1
C 3
4A
LMI BYPASS
KEY SWITCH
14
10A
= CONNECTED
= WIRES ARE
GROUPED
TOGETHER
+ +24V
K10A
0V
+ +UBS
0V
RXD
TXD
A2B-O
A2B-I
LOAD-I
+ +UBS
K9
K8
F2- 10A
11 REL -M
12
REL -A
13
REL -R
14
+ +UBS
15
DE 1
16
DE 2
17
DE 3
18
DE 4
19
20
+ +UBS
I
21
DAV1
U
0V
22
23
+ +UBS
I
24
DAV2
U
0V
25
+ +UBS
26
I
27
LG 1
U
0V
28
I
29
WG 1
U
I
30
LG 1
U
31
0V
32
33
+ +UBS
I
34
S1 DHG 1
U
0V
35
I
36
S2 DHG 2
U
51
+ +UB
0V
52
F1 - 4A
53
SI - OUT
54
SI - IN
57
A2B-0
A2B-I
58
LOAD-I
59
60
+ +UBS
F2-10A
61
SI-REL
62
SI-REL
+ +UBS
64
0V
65
66
DE 5
67
68
DE 6
69
+UBS
+
76
0V
77
K10B
X4
BRN
1
2 WHT
PNK
3 GRA
4
5 GRN
6 YEL
WHT
WHT
BRN
BRN
YEL
GRA
GRN
PNK
YEL
GRN
3-Pair
Twisted
Cable
GRA
PNK
X2
1
2
GRN
3
YEL
4
5
6
PNK
7
GRA
8
BRN
WHT
BUS EXTENSION

Piston & Rod Transducers
to C.P.U. Connections
13
+UBS
MAIN BOARD
DAVS 314
A 1
F1
10
STOP
W # 71K = 24 VOLTS
+UB
AGND
MP14
ERROR
CODE
J1
E12
.500v MIN.
MP7 - MP1->
MP16
16
1
2
AGND
1
2
BR1
X1
AGND
20
40
24.2
VOLTAGES
X1 20 21 22
-
WORKING
RANGE
- +
MP11
MP10
J2
4.50v MAX.
ERROR
CODE
(GND)
P1
(PISTON)
P2
+UB
P3
MP9
VREFA
P4
OUTPUT SIGNAL
MP12
P5
Channel # 2
OPERATING WINDOW
.0V
MP17
P6
MP13
MP0
MP8
- +
AGND
P7
P8
E22
5.0V
2 3 4

E12 / E22
Measure Voltage - (Elec) Piston transducer at A (+) & C (-)
Range 10V to 30V
Measure Voltage - (Elec) Piston transducer at B (+) & C (-)
Range 0V
1 2 3 4
A B C
A B C
Measure resistance - (Hyd) Piston transducer at B (+) & C (-)

Range 200 - 300 Ohm
PRESS. TRANS.
(PISTON)

CHANNEL # 2
AGND
MP14
ERROR
CODE
J1
E13
.500v MIN.
MP7 - MP1->
MP16
16
1
2
24.3
VOLTAGES
E13 / E23
4.50v MAX.
AGND
1
2
BR1
X1
AGND
20
40
X1 23 24 25
-
WORKING
RANGE
- +
MP11
MP10
J2
ERROR
CODE
(GND)
P1
(ROD)
P2
+UB
P3
MP9
VREFA
P4
OUTPUT SIGNAL
MP12
P5
Channel # 3
OPERATING WINDOW
.0V
MP17
P6
MP13
MP0
MP8
- +
AGND
P7
P8
E23
5.0V
2 3 4

Measure Voltage - (Elec) Rod transducer at A (+) & C (-)
Range 10V to 30V
Measure Voltage - (Elec) Rod transducer at B (+) & C (-)
Range 0V
1 2 3 4
A B C
A B C
Measure resistance - (Hyd) Rod transducer at B (+) & C (-)

Range 200 - 300 Ohm
PRESS. TRANS.
(ROD)

CHANNEL # 3

PISTON AND ROD
CONNECT DIGITAL VOLT METER NEGATIVE (-) LEAD TO TERMINAL C.
+24.0 VDC (SUPPLY VOLTAGE).
CONNECT POSITIVE (+) LEAD TO TERMINAL B, AND NEGATIVE (-) LEAD
VOLTAGE SHOULD BE 0 VDC. IF INCORRECT CHECK CABLE
CONNECTIONS IN CENTRAL UNIT AND CHECK CABLE FOR DEFECTS.
IF CORRECT REPLACE PRESSURE TRANSDUCER.
MEASURING RESISTANCE BETWEEN B ( + ) AND C ( - )
RANGE 200 - 300 Ohm.
+24.0
+0
A
B
24.4
GRAPHIC MODULAR CONSOLE

SPECIAL FUNCTION 0 - SETTING OF TRANSDUCER INPUT
PAT
The first step is to lower the boom all the way down
(blocking the boom), shut the engine off then disconnect
hydraulic hose from the piston or rod side pressure
transducer.
DS 350
STOP
STOP
TARE
!
LIM
ENTER YOUR
SERVICE CODE
SEL
5 5 5 5 5
STOP
>
F2
F3
STOP
F1
(1)
(2)
CTRL
F4
The 0 - setting consists of calculating an appropriate

0 - point offset, which, when added to the
transducer measurement, allows the real physical
pressure of force to be calculated. To achieve
this, a procedure has been developed, allowing the 0
- setting to be performed and visualized in a
simple manner.
To activate the 0 - Setting Function, press the INFO
key (1) to activate the Info Function. Now press
the CTRL key (2). At this point, a five digit
Authorization Number must be entered. Only
authorized personnel may adjust the 0 - point
settings.
Example : 6 4 3 5 6
Now, having successfully entered a valid

password, the piston - side 0 - point setting
function
is activated.
The display shows which transducer (piston-side,
rod-side or force) is being zeroed and a horizontal
dial marks the present pressure (or force)
difference in %. By pressing the + key, the input
pressure
(or force) is adjusted upwards, and by pressing the
- key, the input value is adjusted downwards.
When the + and - keys are pressed simultaneously,
the 0 - setting occurs automatically. Manual
adjustments may be performed using + or -.
The return key toggles between the piston - side,
the rod - side, and the force 0 - setting.
When the operator is finished, pressing the EXC
or INFO key returns the console back to the
24.5
PAT
DS 350
STOP
0
STOP
TARE
!
LIM
SEL
STOP
-4%
-2%
0%
+2%
+4%
AUTO
0
CTRL
ESC
STOP
F1
F2
F3
F4
P.A.T. L.M.I
MANUAL
SECTION 25

Boom Angle Connections
& Wiring Diagrams
LMI L/O ALARM (EEC)

SOLENOIDS
W # 51AJ = GND
X1
1
2
1
2
3
4
5
6
7
8
9
10
IS = CUT&INSULATE
7
X2
RED
SHEILD
CORE
X1
BRN
SHIELD
A
B
CORE
1
2
X4
5
SIG. 3
+24V 1
25.1
1 2 3 4
3
2
GND
SIG.
+24V
1
2
X3
5
3
3
4
7 - PIN PLUG
X1
SIG
A 1
B 2
C 3
D 4
G 7
LG
4.7K
GND
CH #1
CH #5
IS = CUT&INSULATE
1
2
3
4
BOOM LENGTH SIGNAL

RETRACTED = 4mA
MAX RANGE = 20 mA
BOOM ANGLE SIGNAL

90o = 4mA
0o = 20 mA
OS Connected
to strain relief
insert
5
6

VARIES WITH BOOM, MAX.
SIGNAL=20mA IS FOR 10
TURNS ON POT.
7
IS = CUT
&INSULATE
4A
LMI BYPASS
KEY SWITCH
14
10A
= CONNECTED
= WIRES ARE
GROUPED
TOGETHER
+ +24V
K10A
0V
+ +UBS
0V
RXD
TXD
A2B-O
A2B-I
LOAD-I
+ +UBS
K9
K8
F2- 10A
11 REL -M
12
REL -A
13
REL -R
14
+ +UBS
15
DE 1
16
DE 2
17
DE 3
18
DE 4
19
20
+ +UBS
I
21
DAV1
U
0V
22
23
+ +UBS
I
24
DAV2
U
0V
25
+ +UBS
26
I
27
LG 1
U
0V
28
I
29
WG 1
U
I
30
LG 1
U
31
0V
32
33
+ +UBS
I
34
S1 DHG 1
U
0V
35
I
36
S2 DHG 2
U
51
+ +UB
0V
52
F1 - 4A
53
SI - OUT
54
SI - IN
57
A2B-0
A2B-I
58
LOAD-I
59
60
+ +UBS
F2-10A
61
SI-REL
62
SI-REL
+ +UBS
64
0V
65
66
DE 5
67
68
DE 6
69
+UBS
+
76
0V
77
K10B
X4
BRN
1
2 WHT
PNK
3 GRA
4
5 GRN
6 YEL
WHT
WHT
BRN
BRN
YEL
GRA
GRN
PNK
YEL
GRN
3-Pair
Twisted
Cable
GRA
PNK
X2
1
2
GRN
3
YEL
4
5
6
PNK
7
GRA
8
BRN
WHT
BUS EXTENSION

Boom Angle to C.P.U.
Connections
13
+UBS
MAIN BOARD
WG
GND
X2
F1
LWG309 L/A TRANSDUCER
STOP
W # 71K = 24 VOLTS
+UB
J1
AGND
MP14
ERROR
CODE
.500v MIN.
1
2
MP16
16
1
2
25.2
VOLTAGES
+ 2.50V = 45o ANGLE
+ 4.5 V = 0o ANGLE MAX. SIGNAL
E15 / E25
X1 26 28 29
WORKING
RANGE
AGND
BR1
20
40
X1
AGND
E15
MP7 - MP1->
- +
MP11
MP10
J2
4.50v MAX.
ERROR
CODE
(90o TO 0o)
P1
ANGLE
P2
(GND)
P3
MP9
VREFA
P4
+UB
MP12
P5
Channel # 5
OPERATING WINDOW
.0V
MP17
P6
MP13
MP0
MP8
- +
AGND
P7
P8
E25
5.0V

SHIELD
CORE
3 4
6 Pin
Plug
7 8 5 3 1
X2
X4
Measure Amps - Angle transducer at X1 4(+) &

+UB
1 OUT
5 3 1
GND
+UB
GND

Range 1V to 5.6V
1 OUT
5 3 1

Range 10V to 30V
5 3 1
X3
S 8 7 6 5 4 3 2 1 X1

CHANNEL # 5
6 5
7
4 3 2 1
1 2 3 4 5 6 7
1 2 3 4 5 6
1 2 3 4 5 6 7
6 Pin
Connector

Boom Angle Signal
ACTUAL
BOOM ANGLE
IN DEGS.
90o
SIGNAL AT X1 TERM.
PIN #29 ON C.P.U.
TERMINAL
4.0 mA
SIGNAL ON ANALOG
MODULE AT X1-4
(X1-28 GND.)
0.48
85o
4.9 mA
+ .70
5.7 mA
+ .92
75o
6.6 mA
+ 1.15
70o
7.4 mA
+ 1.37
8.3 mA
+ 1.60
60o
9.2 mA
+ 1.80
80
65
25.3
55
10.2 mA
+ 2.04
50
11.2 mA
+ 2.26
45o
12.1 mA
+ 2.48
40o
12.9 mA
+ 2.70
35o
13.7 mA
+ 2.92
14.7 mA
+ 3.15
25o
15.6 mA
+ 3.38
20o
16.5 mA
+ 3.60
17.3 mA
+ 3.82
10o
18.0 mA
+ 4.04
30
15
5
19.2 mA
+ 4.27
20 mA
+ 4.49
CHANNEL #5
CHART SHOWS TYPICAL MILLI-AMP AND VOLTAGE SIGNALS.

THESE VALUES ARE TO BE USED AS A REFERENCE ONLY, THE ACTUAL SIGNAL MAY VARY
SLIGHTLY.
RT865BXL (BCS)
Cable Reel LWG309
PAT
PAT
PAT
25.4
TO SET ANGLE TRANSDUCER, ENSURE THE

CRANE IS LEVEL AND SET THE BOOM AT 0 o
(using a level on top of base as shown in the above
drawing). LOOSEN THE FOUR ALLEN HEAD
BOLTS (A) AND WITH A LEVEL ON THE TRANSDUCER
(see drawing to right) ENSURE THAT BOTH LEVELS
ARE READING THE SAME. TIGHTEN BOLTS.
COMPLETE ASSEMBLY
9-333-103303
P.A.T. L.M.I
MANUAL
SECTION 26

Anti - Two - Block Connections
& Wiring Diagrams
ANTI - TWO - BLOCK

WIRING DIAGRAM
4.7K
RESISTOR
To Central Unit
1
2
SHIELD
5 3 1
3 4
2
4
26.1
1
2
7 8 5 3 1
X2
X4
A
B
1 2 3 4 5 6
5 3 1
X3
1 2 3 4 5 6 7
2
S 8 7 6 5 4 3 2 1 X1
1 2
1 2
1 2
6 5
3
Plug
1 2 3 4 5 6 7
5 3 1
+UB
6 Pin
GND
1 2
A B
GND
CORE
CORE
1 OUT
SHIELD
6 PIN DUMMY PLUG
+UB
A
B
1 OUT
6 Pin
4 3 21
Connector
5
7
NO.
1
1 2
AUX. BOOM NOSE

PART NO.
QTY
1
2
3
4
5
9-333-102764
9-333-102717
9-333-102666
9-333-102663
9-333-102230
1
1
1
4
1
9-333-102765
DESCRIP.
COMP. ASSEM.
2-POLE JUMPER BAR
TAGS, TERMINAL STRIP
BLOCK, TERMINAL STRIP
SWITCH A2B, WITH RETAINER
CRIMP
COMP. ASSEM., DUMMY PLUG
NOTES:
1
2
IMPORTANT CHANGE

LMI L/O ALARM (EEC)
SOLENOIDS
10
CONSOLE
BY - PASS
KEY
3
4
8
5
4
3
26.2
AB
A2B
3
4
DATA FROM C.U.
DATA TO C.U.
2
1
3
(GND) 2
(+24 V)
GRAPHIC CONSOLE
4A
13
14
10A
= CONNECTED
= WIRES ARE
GROUPED
TOGETHER
K10A
+ +UBS
0V
RXD
TXD
A2B-O
A2B-I
LOAD-I
+ +UBS
K9
K8
F2- 10A
11 REL -M
12
REL -A
13
REL -R
14
+ +UBS
15
DE 1
16
DE 2
17
DE 3
18
DE 4
19
20
+ +UBS
I
21
DAV1
U
0V
22
23
+ +UBS
I
24
DAV2
U
0V
25
+ +UBS
26
I
27
LG 1
U
0V
28
I
29
WG 1
U
I
30
LG 1
U
31
0V
32
33
+ +UBS
I
34
S1 DHG 1
U
0V
35
I
36
S2 DHG 2
U
51
+ +UB
0V
52
F1 - 4A
53
SI - OUT
54
SI - IN
57
A2B-0
A2B-I
58
LOAD-I
59
60
+ +UBS
F2-10A
61
SI-REL
62
SI-REL
+ +UBS
64
0V
65
66
DE 5
67
68
DE 6
69
+UBS
+
76
0V
77
K10B
X4
BRN
1
2 WHT
PNK
3 GRA
4
5 GRN
6 YEL
WHT
WHT
BRN
BRN
YEL
GRA
GRN
PNK
YEL
GRN
3-Pair
Twisted
Cable
GRA
PNK
X2
1
2
GRN
3
YEL
4
5
6
PNK
7
GRA
8
BRN
WHT
BUS EXTENSION

Anti - Two Block Connections
LMI BYPASS
KEY SWITCH
+ +24V
0V
MAIN BOARD
LMI
+UBS
W # 71K = 24 VOLTS
F1
STOP
W # 51AJ = GND
1
2
3
4
5
6
7
1
2
3
4
5
6
7
8
9
+UB
X1
1
2
Auxiliary Boom Nose
NO.
PART NO.
QTY
1
2
9-333-102238
9-333-102956
1
1
3+
9-333-102768
26.3
DESCRIPTION
SWITCH, A2B W/O CRIMP
CONDUIT 3 FEET
(MUST CUT TO LENGTH)
JUNCTION BOX ASSEM.
Auxiliary Boom Nose

1(BLACK)
1
2(BROWN)
A2B CABLE
3(RED)
2
3

NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
PART NO.
QTY
9-333-102758
9-333-102764
9-333-101984
9-333-102759
9-333-102663
9-333-102664
9-333-102665
9-333-102666
9-333-102760
9-333-102482
9-333-102612
9-333-102669
9-333-102266
9-333-102480
1
1
1
1
3
1
2
1
1
1
1
4
4
4
DESCRIPTION
Junction Box
Strain Relief
Locknut
Gasket
Cover, dust
Screw #4
Lockwasher #4
Nut #4
26.4
Folding Extension
4
2
26.5
1
NO.
1
2
PART NO.
9-333-102230
9-333-102956
QTY
1
1
3+
4+
9-333-102996
9-333-102766
1
1
DESCRIPTION
Switch, A2B W/O Crimp
Conduit 10 feet
(must cut to length)
Folding Extension
1(BLACK)
1
A2B CABLE
2(BROWN)
3(RED)
2
3

NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
PART NO.
9-333-102758
9-333-101995
9-333-102759
9-333-102663
9-333-102664
9-333-102665
9-333-102666
9-333-102760
9-333-102482
9-333-102612
9-333-102669
9-333-102266
9-333-102480
QTY
DESCRIPTION
1
1
1
3
1
2
1
1
1
1
4
4
4
Junction Box
Strain Relief
Gasket
Cover, dust
Screw #4
Lockwasher #4
Nut #4
26.6
Folding Extension

NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
PART NO.
9-333-102758
9-333-101995
9-333-101984
9-333-102664
9-333-102663
9-333-102664
9-333-102665
9-333-103044
9-333-102792
9-333-102482
9-333-102612
9-333-102669
9-333-102266
9-333-102480
QTY
DESCRIPTION
1
1
1
1
3
1
2
1
1
1
1
4
4
4
26.7
Junction Box
Strain Relief
Locknut
Mounting Rail
Gasket
Cover, dust
Screw #4
Lockwasher #4
Nut #4
P.A.T. L.M.I
MANUAL
SECTION 27

Digital Inputs
RT865BXL (BCS)
MAIN & BUS EXTENSION
DIGITAL INPUTS
INPUT
BUS EXT.
1
2
3
5
6
7
CU
DESCRIPTION
TERMINAL
A101 BUS
TELE EXTEND (+24V)
X1/29
A101 BUS
TELE RETRACT (+24V)
X1/31
A101 BUS
AUTO MODE SELECTED (+24V)
X1/33
A101 BUS
X1/35
A101 BUS
X1/37
A101 BUS
X1/39
A101 BUS
X1/41
PROX. SWITCH OM/FLY

RETRACTED & OM/FLY % RESET
(+24V)
NOTES
GROVE SELECTOR SWITCH SIGNAL
PAT SWITCH ON CM - SIGNAL VIA CM
CABLE REEL
PROX. SWITCH CM RETRACTED

& RESET %(+24V)
PROX. SWITCH IM RETRACT
(+24V)
PROX. SWITCH IM % RESET (+24V) PAT SWITCH ON BOOM BASE
INPUT
MAIN
2
3
A101 MAIN AREA DEFINATION SWITCH

SWIVEL LIMIT SWITCH
ON RUBBER
X1/17
A101 MAIN
HOUSE LOCK PIN SWITCH SIGNAL GROVE LIMIT SWITCH
X1/18
27.1
X1

Digital Input Diagram
25
26
+UB
10 - 35V
27
KGND
28
23 pin
plug
TELE RET. PRESS. SW.
29
30
31
32
HIGH=AUTO / NONE=MANUAL MODE

19 pin
plug
PROXY SW.1 OM / FLY RET.
PROXY SW.4 CM RET & % RESET.

14 pin
plug
PROXY SW. 2 IM RET. (2 POSITIONS)
33
34
35
36
12
37
38
39
40
PROXY SW.3 IM RESET %. (TOP)
41
42
43
44
* TERMINAL # 25 IS + 24V TO PROXY

SWITCHES 1,2,3 & 4.
45
46
47
* TERMINAL # 27 IS GND. TO PROXY

SWITCHES 1,2,3 & 4.
48
49
50
51
52
53
54
55
56
57
58
59
60
27.2
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
>
DE 1
DE 2
DE 3
DE 4
DE 5
DE 6
DE 7
DE 8
DE 9
H1
+24V TELEEXT.
PRESS. SW.
H2
+24V TELERET.
PRESS. SW.
+24V AUTO MODE
H3
H4
+24V OM / FLY
RET.
H5
+24V CM RET. &

% RESET.
+24V IM RET.
H6
+24V IM % RESET.
H7
H8
H9
DE 10
H10
DE 11
H11
DE 12
H12
DE 13
H13
DE 14
H14
DE 15
H15
DE 16
H16
P.A.T. L.M.I
MANUAL
SECTION 28

Central Unit P.C. Modular
Board Layout

MAIN BOARD
A
G1
+UB1
PWM DC
MP42
KGND
MP 26
KGND
MP 4
+5V
MP 9
+6V
X15
GND
GND
AGND
KGND
MP24
MP23
VBAT
+BATT
MP 8
+9V
GND
5
+UB1 +UB
DI 6
KGND
X12
MP40
V10 H11 V11 MP41
H1 H2 H3 H4 H5 H6
DI 1
MP21
PFAIL+UB1
DI 1- DI 6 =>
X17
power o.k.
X14
J11
X11
SP5
X13
X16
TXD
H12
K8
10
LEVER
LOCKOUT
K10
A2B
+UB
MP29
K9
KGND
F
1
H9
A2B
69 68 67
66
65 64
63 62
61 60 59 58
57 56
55 54
KGND
3
1
77 76
KGND
KGND
11
J4
J3
J2
J1
X1
12
F
2
11
X1
13
AGND
H10
2
1
MAIN
ON/OFF
KGND
J10
3
4
LMI
KGND
10
LOAD
+5V/RS232
AGND
12
KGND
MP1
+UBS
36 35 34 33
32 31
30 29 28 27 26
25 24 23
22 21 20
19 18 17 16 15 14
13 12 11
10 9
MP 25
LOCATIONS :
LEDS

MP 25 - zone M13 = +UBS CONSOLE, SENSORS, DIs
MP 42 - zone G1 = +5V
MP 21 - zone E5 = +5V
MP 29 - zone D10 = +5V
H1-H6 - zone I5 = DI 1-6
H 10 - zone G9 -MAIN IN/ OUT
28.1
13

EXTENSION BOARDS
MP7
J1
J13
J12
J2
D3
D1
MP4
D2
X1
D14
X2
D13
P1
SYSTEM
D10
J8
D6
J9 MP3 J6
D17
J10
D15
D7
D21
D9
D12
J15
J11
J14
D18
J7
D11
D19
D20
X3
BR6
MP6MP5
EJECT
BR5
MP2
A102 CPU
J1
J2
DATA
D1
J5
J3
TLK
D3
J6
BR
4
3
2
1
X1
A103 DATEN

The EPROMS must be installed completely to the left, leaving
blank holes to the right.
28.2
DS350 Graphic Module

Analog Input Module
P7
MP12
1
2
40
AGND
AGND
-
P6
MP13
J2
20
P5
16
P4
P3
MP9
J1
MP11
X16
P2
MP10
P1
1 1
2
X1
MP17
BR1
MP0
MP8
VREFA
P8
MP7 - MP1->
X17
1
2
MP16
16
6 5
4 3
MP14
2 1
40
1
2
AGND
AGND
BOARD P/N 9-333-103290

X1:1-7
X1:8
X1:9
X1:10
X1:11
X1:12-15
X1:16
X1:17
X1:18
X1:19
X1:20
= ADC INPUT 0.5V 4.5 V, Note: If channel adjustments are made through
the software and graphic console, DO NOT adjust offset with P1 - P7
= TEMP (0.5V + 10mV/oC)
MP 1 = AGND
MP 8 = + 5V
MP 1 - 7 Input channels 1 - 7 - 0.5V / 4 mA
= CH01-04, DIN 1-4 / 10
2.5V / 20mA
= CH05, +UBS / 10
MP 14 = + 13V REF 02
MP 16 = HESIN input voltage
= CH07, +9V *4
MP 17 = app 5.4V clamp for inputs
= CH08, VREFA / 2 = 2.500V
28.3

A 105 Serial Extension Module
Part No. 9-333-103292
MP11
+UB1
KGND
MP1
MP10
F5 F4
2A 2A
MP15
MP4 H1 H2 MP3
X4
1 2 3 4 5 6
C30
MP0
GND
MP16
MP1
1
2
3
4
5
6
H3
A 101 Bus Extension Module

Part No. 9-333-103717
DI 16
DI 9
H9 H10 H11 H12 H13 H14 H15 H16
MP14
ADC
2 3
5 6
8 9
10 11 12
13 14 15
16 17 18
19 20 21
22 23 24
1 2 3 4 5 6 7 8
X2
2A
F25
K1
K2
K3
K4
K5
K6
K7
F1
K8
F8
F2
H17
F3
H18
F4
H19
F5
H20
F6
H21
F7
H22
H23
H24
28.4
25 26 27 28
MP4 MP5 MP6 MP7 MP10 MP11 MP12 MP13

MP 3
29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
MP 2
MP9
MP 1
61 62 63 64 65 66
MP 8
UREL
MP 0
DI 1
+ 7V
C27
KGND AGND + UB
H8 H7 H6 H5 H4 H3 H2 H1
C93
+5V +14V -14V +REF +REX -10V USIN RIPP
DI 8

A 102 CPU Module
Part No. 9-333-103718
X4
MP4
C38
J3
C37
C32
SLAVE
E - PROM
MP2
C33
H1
MP0
MP1
MP3
J1
A 105 Analog Input Module

Part No. 9-333-103719
A 104 PV Extension Module

Part No. 9-333-103720
X2
X2
P11
MP2
MP3
MP7
MP6
P12
MP0
X1
MP1
1 2 3 4
H1
MP5
28.5
MP4
RT865BXL (BCS)
BUS EXTENSION
INTERFACE
Grove wire
number
71H
51AK
Interface
connector
A
POWER SUPPLY +24V
CRANE GND
387A
388
239B
242B
243B
244B
[507]
[505]
[338]
323A
TELE EXTEND PRESSURE SWITCH (INPUT)
TELE RETRACT PRESSURE SWITCH (INPUT)
HIGH = AUTO MODE, LOW = MANUAL MODE (INPUT)
SELECT OM / FLY IN MANUAL MODE (INPUT)
SELECT CM IN MANUAL MODE (INPUT)
SELECT IM IN MANUAL MODE (INPUT)
3RD WRAP CUT OFF MAIN HOIST RT ONLY
3RD WRAP CUT OFF AUX. HOIST RT ONLY
3RD WRAP WARNING LIGHT (GND) RT ONLY
TELE OUT OF SEQUENCE SIGNAL (RELAY OUTPUT)
O
P
Q
R
238A
1083
255A
257A
PROPORTIONAL TELE - SOLENOID GND.
TELE ROD DRAIN SOLENOID VALVE SIGNAL
PROPORTIONAL TELE - SOLENOID (EXTEND)
V
W
X
PROPORTIONAL TELE - SOLENOID (RETRACT)
RT865BXL (BCS)
MAIN BOARD
INTERFACE
Grove wire
number
71K
51AJ
73A
74
744
Interface
connector
A
POWER SUPPLY +24V
CRANE GND
LMI UNLOCK SOLENOIDS
LMI LOCK OUT ALARM
F
G
H
28.6
W # 71K = 24 VOLTS
1
2
3
4
5
6
7
8
9
10
1
3
4
13
14
10A
= CONNECTED
= WIRES ARE
GROUPED
TOGETHER
+ +24V
K10A
0V
+ +UBS
0V
RXD
TXD
A2B-O
A2B-I
LOAD-I
+ +UBS
K9
K8
F2- 10A
11 REL -M
12
REL -A
13
REL -R
14
+ +UBS
15
DE 1
16
DE 2
17
DE 3
18
DE 4
19
20
+ +UBS
I
21
DAV1
U
0V
22
23
+ +UBS
I
24
DAV2
U
0V
25
+ +UBS
26
I
27
LG 1
U
0V
28
I
29
WG 1
U
I
30
LG 1
U
31
0V
32
33
+ +UBS
I
34
S1 DHG 1
U
0V
35
I
36
S2 DHG 2
U
51
+ +UB
0V
52
F1 - 4A
53
SI - OUT
54
SI - IN
57
A2B-0
A2B-I
58
LOAD-I
59
60
+ +UBS
F2-10A
61
SI-REL
62
SI-REL
+ +UBS
64
0V
65
66
DE 5
67
68
DE 6
69
+UBS
+
76
0V
77
K10B
X4
BRN
1
2 WHT
PNK
3 GRA
4
5 GRN
6 YEL
WHT
WHT
BRN
BRN
YEL
GRA
GRN
PNK
YEL
GRN
3-Pair
Twisted
Cable
GRA
PNK
X2
1
2
GRN
3
YEL
4
5
6
PNK
7
GRA
8
BRN
WHT
BUS EXTENSION

Crane Interface to Main Board
LMI BYPASS
KEY SWITCH
+UBS
MAIN BOARD
28.7
4A
F1
W # 51AJ = GND
X1
STOP
LMI L/O ALARM (EEC)

LEVER LOCKOUT
W # 73A
SOLENOIDS
1
2
+UB
X1
PV EXTENSION
16
A104
X1
1
2
3
4
13
15 17
18
8
7
+ 24V
GND
71H
51AK
387A
388
239B
242B
243B
244B
323A
TELE PROP. ANALOG GND.

TELE ROD DRAIN SOLENOID
TELE EXTEND PROP. SOLENOID
TELE RETRACT PROP. SOLENOID
S/S HARNESS
23 - SOCKET RECEPT
238A
1083
255A
257A
A
B
C
D
E
F
G
H
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
1
2
1
4
5
6
7
8
9
2
4
5
6
13
15
16
17
18
23 - PIN PLUG
= WIRES ARE
GROUPED
TOGETHER
K3 COM ( +24V )
K3 NC
K4 COM
K4 NO
K5 COM
K5 NO ( PROP EXT )
K5 NC ( PROP RET )
K6 COM ( + 24V )
K6 NC
K7 COM ( +24V )
K7 NC
+24V
+24V
GND
GND
DI 1 GND
DI 2 GND
DI 3 GND
DI 4 ( +24V = OM / FLY RET )
DI 4 GND
DI 5 GND
DI 6 ( +24V = IM RET )
DI 6 GND
DI 7 ( +24V = IM % RESET )
DI 7 GND
X2
1 BRN
2 WHT
GRN
3 YEL
4
5
ANALOG INPUT 2 (CM LEN.) 6
7 PNK
8 GRA
WHT
BRN
WHT
YEL
GRN
BRN
GRA
PNK
YEL
GRA
GRN
PNK
X4
1
WHT
2
PNK
3
GRA
4
GRN
5
YEL
6
BRN
MAIN BOARD

Crane Interface to Bus Extension
K2 COM ( +24V )
BUS EXTENSION
28.8
TELE EXTEND PRESSURE SW.

TELE RETRACT PRESSURE SW.
HIGH = AUTO MODE / NONE = MANUAL MODE
OM / FLY TELE
CM TELE
IM TELE
A
B
C
D
E
F
G
H
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
P.A.T. L.M.I
MANUAL
SECTION 29

Troubleshooting Guide
PAT DS350 Graphic Modular (BCS)

TROUBLESHOOTING
General Flowchart
Lever Lockout Activated
Broken Length Cable
No Display
Anti - Two - Block
Length Reading Problem
Angle Reading Problem
Load Reading Problem
Bad Data Transfer Between Console & Central Unit
Error Code Displayed
29.1
29.2
29.3
29.4
29.5
29.7
29.10
29.37
29.40
29.42
29.45
GENERAL FLOWCHART
Indicator System - P.A.T. DS350 Graphic Modular (BCS). The procedures are easy to follow
and are given in flowcharts on the following pages. Start with general flowchart below which
will guide you to one of the more detailed flowcharts shown on pages 35.3 through 35.45.
START
Whats Wrong?
Lever Lockout
Activated
Length Cable
Problem
No Display
Go to Page 29.3
Go to Page 29.4
Go to Page 29.5
Wrong Length
Displayed
Go to Page 29.10
Wrong Angle
Displayed
Wrong Load
Displayed
Go to Page 29.37 Go to Page 29.40
29.2
No Function
Anti-Two-Block
Go to Page 29.7
Bad Data
Transfer
Error Code
Displayed
Go to Page 29.42
Go to Page 29.45

PROBLEM
START

fixed?
YES
NO
Does the console indicate
NO
YES

If console displays is
in power supply,
wiring or fuses.
Fault in Anti-Two
Block system.

Light is lit, the fault
is located in LMI,
console.
Check lever lockout

system in crane
Go to page 29.5
Go to page 29.7

and go to page29.45.
29.3
BROKEN LENGTH CABLE

PROBLEM
STEP
ACTION
Open cable reel cover and disconnect wiring from terminal block. Pull conductor
from Terminal X1 and X2 See drawing 1 on page 29.53.
No. X2 See drawing 1 on page 29.53.
onto the drum.
10
Set preload on cable reel by turning the drum counter-clockwise.
11
at the boom nose.
12

29.4
NO DISPLAY
PROBLEM
START
correct?
NO
Replace fuses.
YES
Measure crane voltage on main board terminal
strip between X1-1(+12/24V) andX1-2 (ground).
This is an imput voltage from crane
Note: If crane voltage is measured below
10V system will switch off.
correct?
NO

YES
Measure crane voltage on main board

terminal strip between X1-3(+24V) and
X1-4 (ground). This is a output voltage to
the console.
correct?
Defect on main board.

Replace main board, see replacement
procedure.
NO
YES
NEXT PAGE
29.5
NO DISPLAY
continued
PREVIOUS PAGE
Measure voltage in the console

between X1-1 (+24V) and
X1-2 (ground).
Refer to Drawing 6 on page29.57 .
correct?
Check connections of the

cable between console and
central unit. Replace cable
if necessary.
NO
YES
Display is defective. Replace the console.
END
29.6
PROBLEM
START
NO
correct?
YES
Turn power off or disconnect

wire from X1-31 in central unit.
NO
correct?

YES
Measure the resistance at the boom nose
box between terminals 1 and 6 with
ohmmeter. This checks the function of the
Anti-Two-Block switch.
Switch Closed = 4700 +/- 500 Ohms
Switch Open = > 1 Megaohm
NO
correct?
YES
NEXT PAGE
29.7
PREVIOUS PAGE

X1:Brown and X2:Red wires on the slip ring with
an ohmmeter. See drawing 1 on page 29.53.
Switch closed = 4700 +/- 500 Ohms
Reconnect slip ring wires.
NO
correct?
Fault in wiring cable from junction box at

boom nose to cable reel or short circuit in
length cable. Check wiring.
YES

7 and 8 with an ohmmeter.
+ 500 Ohms.
NO
correct?
Replace slip ring.
YES
Measure the A2B signal in the boom base
box between terminal 5 and 6 with an ohmeter.
+ 500 Ohms.
NO
Fault in 7 conductor cable between
correct?
cable reel and boom base box.
YES
NEXT PAGE
29.8
PREVIOUS PAGE
Connect wire # 5 back to terminal X1-31
on the main board.
Turn system power off. Check Anti-Two-Block
signal in central unit with ohmmeter measure
between X1-31 and X1-32.
+ 500 Ohms

found check cable.
NO
correct?
YES
Disconnect X1-31 and X1-32.
temporary resistor, 4700 Ohms, between X131 and X1-32 in central unit. With resistor
connected alarm should be inactive.
NO
Defect on main board. Replace main

correct?
Reconnect wire #5 to X1-31 and wire #6 to X1-32.
END
29.9

PROBLEM
Length reading incorrect.
Crane is not in out of load chart condition.
A. Boom Length Percentage Problem
START
Boom length percentage problem
Switch to Manual Mode and retract the boom

completely against the stop block.
Check the Percentage indication (1%, 0 %, 0 %)
Wrong?
No
Yes
IM and/ or CM retract signal not recognized. Check
proximity switch target adjustment. Refer to Drawing
on page 23.3. If damage is visible install new switch.
Correct?
Continue to page 29.17
No
Yes
Measure the voltage supply to IM switch at terminal
1 (+24V) and 3 (GND) in the length transducer LG321.
NEXT PAGE
29.10
Adjust the target and switch

See page 23.3

A. Boom Length Percentage Problem Cont.
PREVIOUS PAGE
Correct?
No
Yes
Measure the voltage at terminal

25 (+24V) and terminal 27 (GND)
in the bus extension.
Failure in bus extension.

Check connectors, fuses and
bus extension power supply.
No
Correct?
Yes
Faulty wiring between bus

extension and LG 321. Check
wiring.
Measure voltage at terminal 1 or 2 (+24V) and 5
or 6 (GND) in the switch junction box. See page 29.5.
Correct?
No
Yes
Measure voltage at terminal 1 (+24V) and 5
(GND) in the IM junction box. Behind drum.
Correct?
Faulty wiring between length

transducer and LG 321 and switch
junction box. Check wiring.
No
transducer and LG 321 and IM
Yes
NEXT PAGE
29.11

PREVIOUS PAGE
Measure the IM reset switch signal at terminal 3

(+ 24V) and 5 (GND) in the proximity switch
junction box on base boom. See page 29.5.
Correct?
No
Yes
Measure the IM reset switch signal at wire 2
(+ 24)(fast-on connector) and terminal 3 (GND)
in the length transducer LG321. See page 29.4.
Correct?
Faulty switch wiring or defective

switch. Replace IM reset proximity
switch. Adjust switch and target.
No
Yes
Measure the IM retract switch signal at terminal 4
(+ 24) and terminal 5 (GND) in the length switch
junction box on base boom. See page 29.5.
NEXT PAGE
29.12


PREVIOUS PAGE
Correct?
No
Yes
Measure the IM reset switch signal at wire 4
(+ 24)(fast-on connector) and 3 (GND)
in the length transducer LG321. See page 29.4
Correct?
Faulty switch. Replace IM retract

proximity switch. Adjust switch
and target.
No
Yes
Measure the CM retract switch signal at
terminal 6 (+ 24) and terminal 5 (GND)
in the IM junction box. See page 29.5
Correct?

No
Yes
Measure the CM retract switch signal at
terminal 8 (+ 24) and terminal 3 (GND)
in the LG321. See page 29.4
NEXT PAGE
29.13
Defective switch. Replace CM

retract proximity switch. Adjust
switch and target

PREVIOUS PAGE
Correct?
No
Yes
Measure the IM retract switch signal at terminal 39
(+24V) and 27 (GND) in the bus extension.
See page 29.3
Correct?

transducer LG321 and switch
No
Yes
Measure the IM reset switch signal at terminal 41
(+24V) and 27 (GND) in the bus extension.
See page 29.3
Correct?

extension and length transducer
LG321 and switch junction box.
Check wiring.
No
Yes
Measure the CM retract switch signal at terminal 37
(+24V) and 27 (GND) in the bus extension. See page 29.3
Correct?

Check wiring.
No
Yes
NEXT PAGE
29.14

PREVIOUS PAGE
Measure OM retract switch power supply at terminal
X1/11 (+24V) and X1/7 (GND) in the LG 321 (CM).
See page 29.4
Correct?
No
Yes
Measure at CM junction box terminal 11 (+24V)
and 9 (GND). See page 29.5
Correct?

Check wiring.
No
Yes
Measure OM retract switch signal at CM junction
box terminal 10 (+24V) and 9 (GND). See page 29.5
Correct?
Faulty wiring between CM box

and length transducer LG321
(CM). Check wiring.
No
Yes
Measure signal at terminal X1/8 (+24V) and X1/7
(GND) in the LG 321 (CM). See page 29.4
NEXT PAGE
29.15

LG321 (CM). Check wiring.

PREVIOUS PAGE
Correct?
No
Yes
Measure signal at bus extension terminal X1/35
(+24V) and X1/27 (GND). See page 29.3
Correct?
Faulty wiring between CM box

and length transducer LG321
(CM). Check wiring.
No
Yes
Digital input defective on bus extention. Check
LEDs on bus extension. Follow replacement
procedures.
END
29.16

LG321 (CM). Check wiring.

B. Boom Out Of Sequence In Automode
START
Problem:
In Automode the boom becomes out of
sequence, the warning light is on.
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. ( 0%, 0%, 0%)
Correct?
No
Yes
Inspect the spooling of the length cable on all three drums.
Correct?
Continue with section A.
No
Yes
Remove the lid from the length transducers LWG 309
and both LG 321. Carefully reset the length transducer
potentiometer. Repeat testing the boom sequence in
automode.
NEXT PAGE
29.17
Correct the spooling manually.

CAUTION
Drum is under tension.

B. Boom Out Of Sequence In Automode Cont.
PREVIOUS PAGE
Failed?
No
Yes
In manual mode retract the boom. Disengage the boom stop block
to retract all section completely. Re-check the length potentiometer
adjustment.
Correct?
END
No
Yes
Remove lid from LG321 (IM length) and measure
supply voltage at terminal X1/1 (+24V) and X1/3
(GND). See page 29.4
Correct?
Adjust gear assembly and check

O-ring in gear wheel. Replace
O-ring if wear is visible.
Measure the voltage at terminal X1/25

(+24V) and terminal X1/27 (GND) in
bus extension.
No
Yes
Failure in bus extension.
Check connectors, fuses
and bus extension power
supply.
No
Correct?
Yes
Faulty wiring between bus extension

and LG 321 (IM). Check wiring.
NEXT PAGE
29.18

PREVIOUS PAGE
Turn the length poteniometer in the LG 321 (IM)
counter clockwise to a soft stop. Measure the voltage
at terminal X1/2 (1V) and terminal X1/3 (GND).
See page 29.4
Switch power off. Remove wire 2 from
LG 321 terminal X1/2. Switch power on.
Measure electrical current at terminal X1/2
(+ 4mA). Meter - in series.
No
Correct?
Yes
Switch power off.

Re-connect wire 2 to
terminal X1/2. Faulty
length sensor unit. Replace
length sensor unit.
No
Correct?
Yes
Switch power off. Re-connect wire 2

to terminal X1/2.
Faulty wire between length transducer LG 321

and bus extension. Check wiring.
Turn the length poteniometer in the LG 321 (IM)
clockwise to a soft stop(10 turns). Measure the voltage
at terminal X1/2 (5.6V) and terminal X1/3 (GND).
See page 29.4
NEXT PAGE
29.19

PREVIOUS PAGE
LG 321 terminal X1/2. Switch power on.
Measure electrical current at terminal X1/2
(+ 20mA). Meter - in series.
No
Correct?
Yes
Switch power off.

length sensor unit.
No
Correct?
Yes

to terminal X1/2.

and bus extension. Check wiring.
Remove lid from LG 321 (CM) and
measure supply voltage at terminal
X1/1 (+24V) and X1/3 (GND).
Correct?
No
Yes

(CM) and bus extension. Check wiring.
NEXT PAGE
29.20

PREVIOUS PAGE
Turn the length poteniometer in the LG 321 (CM)
See page 29.4
LG 321 (CM) terminal X1/2. Switch power
on. Measure electrical current at terminal
X1/2 (+ 4mA). Meter - in series
No
Correct?
Yes
Switch power off.

length sensor unit.
No
Correct?
Yes

to terminal X1/2.

Turn the length poteniometer in the LG 321 (CM)
See page 29.4
NEXT PAGE
29.21

PREVIOUS PAGE
LG 321 (CM)terminal X1/2. Switch power
X1/2 (+ 20mA). Meter - in series
No
Correct?
Yes
Switch power off.

length sensor unit.
No
Correct?
Yes

to terminal X1/2.

Remove lid from LWG 309 (OM) and
measure supply voltage at terminal
X1/1 (+24V) and X1/3 (GND).
See page 29.2
Correct?
No
Yes

NEXT PAGE
29.22

PREVIOUS PAGE
Turn the length poteniometer in the LWG 309 (OM)
LWG 309 (OM) terminal X1/2. Switch power
X1/2 (+ 4mA). Meter - in series.
No
Correct?
Yes
Switch power off.

length sensor unit.
No
Correct?
Yes

to terminal X1/2.
Faulty wire between length transducer LWG 309

(OM) and bus extension. Check wiring.
Turn the length poteniometer in the LWG 309 (OM)
NEXT PAGE
29.23

PREVIOUS PAGE
LWG 309 (OM)terminal X1/2. Switch power
X1/2 (+ 20mA). Meter - in series.
No
Correct?
Yes
Switch power off.

length sensor unit.
No
Correct?
Yes

to terminal X1/2.

(OM) and bus extension. Check wiring.
Reset all length transducer potentiometers.
Select Boom service screen on console,
compare the indicated IM length with the
actual IM length.
NEXT PAGE
29.24

PREVIOUS PAGE
Yes
Correct?
Fault is not located in the LMI circuit.

Follow the crane service instructions to
continue.
END
No
Faulty bus extension module.

Contact Technical support for
instructions
END
29.25

C. Outer Mid And Fly Section Are Not Retracted (E83)
START
Outer mid and fly sections are

not fully retracted.
Switch to manual mode and

retract the OM/Fly section fully.
E83 ?
No
Switch to auto mode and

contiue normal crane operation
Yes
Switch to auto mode and retract the boom (Caution
Reduced load chart with E83)
E83 ?
No
Defect is not located in LMI
circuit. Refer to crane service
documentation to continue.
Yes
Check the position of the OM/Fly section
NEXT PAGE
29.26

C. Outer Mid And Fly Section Are Not Retracted (E83) Cont.
PREVIOUS PAGE
Correct?
No
Yes
Switch to auto mode and retract

OM section fully.
Check the OM retract proximity switch

and target adjustment.
Defect is not located in LMI No
circuit. Refer to crane service
documentation to continue.
Correct?
Yes
Switch to auto mode and

contiue normal crane operation
Correct?
No
Adjust the switch and the target.
Yes
Measure the voltage at terminal 25
(+24V) and terminal 27 (GND) in
the bus extension. See page 29.3
NEXT PAGE
29.27

PREVIOUS PAGE
Correct?
No
Yes
Measure OM retract switch power supply at LG 321
(CM) terminal X1/11 (+24V) and X1/7 (GND)
See page 29.4
Correct?
Defective bus extension. Check

connectors, fuses and bus extension
power supply.
No
Yes
Measure OM retract switch signal at CM junction
box terminal 10 (+24V) and 9 (GND) See page 29.5
Correct?

extention and LG 321. Check
wiring.
No
Yes
Measure signal at LG 321(CM) terminal X1/8
(+24V) and X1/7 (GND). See page 29.4
NEXT PAGE
29.28

extention and LG 321. Check
wiring.

PREVIOUS PAGE
Correct?
No
Yes
Measure signal at bus extension terminal X1/35
(+24V) and X1/27 (GND) See page 29.3
Correct?
Defective wiring between CM

junction box and length transducer
LG 321(CM). Check wiring.
No
Yes
Digital input defective on bus extension. Check
LEDs on bus extension. Contact Technical
Support for replacement procedure.
END
29.29

extention and LG 321(CM).
Check wiring.

D. Error In Bus Extension (E61)
START
E61
Error in the bus extension
Check crane power, battery

voltage.
Correct?
No
Yes
Measure the power supply at the bus extension
terminal X1/26 (+24V) and 28 (GND). See page 29.3
Correct?
Refer to the crane service

documentation to correct
the power failure.
No
Yes
Faulty crane electric wiring.
Check wiring.
Check bus extention fuse FX
NEXT PAGE
29.30

D. Error In Bus Extension (E61) Cont.
PREVIOUS PAGE
Correct?
No
Yes
Check the bus extension cable wiring and
connections between bus extension and central
unit.
Correct?
Switch power off. Replace the fuse.

Switch power on and check again.
No
Yes
If damage is visible replace the cable,
otherwise rewire and tighten the
connections. CAUTION: Twisted pairs
must remain twisted.
Faulty bus extension. Contact

Technical Support for replace
procedure.
END
29.31

E. No Tele Function At All In Automode
START
Error:
No tele-function at all in
automode.
Remove load from hook. Make sure no other error or

warning is preventing you from extending or retracting
the boom. Switch to manual mode and attempt extending
and retracting the boom in manual mode.
Correct?
No
Yes
Remove lid from bus extension. Measure crane power

supply at terminal X1/26 (+24V) and X1/28 (GND).
See page 29.3
Correct?
Malfunction is not related to LMI or

boom control extension. Consult the
crane service documentation.
No
Faulty crane eletric wiring.
Yes
Switch to auto mode. Start the engine. Operate the
extend control. Measure the extend signal at bus
extension terminal X1/29 (+24V) and X1/28 (GND).
See page 29.3
NEXT PAGE
29.32

E. No Tele Function At All In Automode Cont.
PREVIOUS PAGE
Correct?
No
Yes
Operate the retract control. Measure the retract signal
at bus extension terminal X1/31 (+24V) and X1/28 (GND).
Correct?
No
Yes
Select boom service screen on console.

Operate the extend control. The ramp value
for the appropriate section should increase
in steps from 0 to 255.
Correct?
Faulty pilot pressure switch in the

tele extend pilot pressure circuit or
crane electric harness faulty. Refer
to crane documentation.
Faulty pilot pressure switch in the

tele extend pilot pressure circuit or
crane electric harness faulty. Refer
to crane documentation.
No
Yes
Select boom service screen on console.
Operate the retract control. The ramp value
for the appropriate section should increase
in steps from 0 to 255.
NEXT PAGE
29.33
Faulty digital input 1 on bus

extension. Contact Technical

PREVIOUS PAGE
Correct?
No
Yes
Select manual mode. Retract all sections. Switch power
off. Remove wire 2 from the analog output board terminal
Faulty digital input 2 on bus
A 104 X1/2 (IM). Switch power on. Operate retract and
extension. Contact Technical
extend control. Measure the electrical current (mA) between
the wire 2 (removed from terminal) and the terminal X1/2.
The signal should increase from 0 mA to approximately 800 mA.
NOTE : In the ramping area the value may be < 800 mA.
Correct?
Check the power supply to the analog

output module A 104 (IM). Measure at
terminal X1/1 (+24V) and X1/4 (GND).
No
Yes
Faulty wiring in bus
extension. Check
wiring.
No
Correct?
Yes
Operate retract or extend control.

Measure voltage at terminal A 104
X1/2 (>0V) and X1/4
NEXT PAGE
NEXT PAGE
29.34

PREVIOUS PAGE
PREVIOUS PAGE
Defective analog output board

No
A 104 (IM). Contact Technical
Support for replacement procedures.
Correct?
Yes
Refer to drawing of (K2, K6, K7

logic table) to check the two way valve
operation.
Re-connect wire 2 to terminal A 104 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).
Check fuse F5 in the bus No

extension. If blown replace
fuse. Check relay K5.
Correct?
Yes
Faulty crane wiring or defective valve coil.

Contact Technical support .
NEXT PAGE
29.35

PREVIOUS PAGE
Correct?
No
Yes
Measure the two way valve signal (>/= +20V)
at terminal 1 or 2 (IM junction box) and terminal
1 or 2 and 3 or 4 (CM junction box).
Correct?
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.
No
Yes
Faulty crane wiring or valve coil.
Refer to Crane Service Documentation.
END
29.36
Faulty wiring between bus extension and 2

way valve junction boxes on the IM and CM
section. Check wiring.

PROBLEM
START

cable reel.

NO
correct?
YES
Place the boom at 0 o. Check power supply

to angle sensor on main board between X126 (+12/24V) and X1-28 (GND)
NO
correct?
YES

reset pressure channel.
NEXT PAGE
29.37

PREVIOUS PAGE

reel at terminal between X1-1 (+12/24V)
and X1-3 (GND).
NO

correct?
YES
Measure signal in series from angle sensor

in cable reel, one lead to wire #4 and the other
lead X1-4.
Boom Angle Signal :
0 Degrees
20 mA
45 Degrees
12 mA
90 Degrees
4 mA
NO
correct?
YES
NEXT PAGE
29.38

PREVIOUS PAGE
Measure signal from angle sensor in central

unit. Measurement should be taken in series
at X1-29 and wire #4.
Boom Angle Signal :
0 Degrees
20 mA
45 Degrees
12 mA
90 Degrees
4 mA
NO

correct?
YES
Measure angle signal analog input module

between test point MP0 and X1-4. The measurement should be between 0.5 - 4.5V.
Boom Angle Signal :
0 Degrees
0.5 Volt
45 Degrees
2.48 Volts
90 Degrees
4.5 Volts
NO
Faulty analog input module or CPU module in

central unit.
correct?
YES
END
29.39

PROBLEM
START
NO

correct?
YES

until it stops .
NO
correct?
YES
displayed radius.

NO
correct?
YES

Measure voltage at the cable connection between
A (+24V) and C (ground).
Check power supply at main board between
X1-20 (+12/24V) and X1-22 (ground) for piston
and X1-23 (+12/24V) and X1-25 (ground) for
rod side.
NO
correct?
YES
correct?
Fault in pressure transducer.

YES
NO
NEXT PAGE
Replace the main in central unit.

29.40

PREVIOUS PAGE
Measure in series piston side signal, in central

unit, remove wire #2 from X1-21. Connect one
lead to wire #2 and the other to X1-21. The
measurement should be between 4-20mA (4
mA at 0 PSI to 20mA at 4410 PSI). Rod side,
remove wire #2 from X1-24.
Measurement is not within 4-20mA.
NO Fault in pressure transducer cable.
NO
4-20mA
correct?
YES
YES
Measurement within 4-20mA, but 4mA

does not equal 0 PSI. Adjust zero point
on pressure transducers at console.
If transducer(s) are not adjustable,

replace pressure transducer(s) and
adjust zero point. Refer to page 30.5.
Measure pressure transducer signals on the analog input module between test
points, (Piston side, MP0 (GND) and X1-1) (Rod side, MP0 (GND) and X1-2).
The measurement should be between 0.5V - 4.5V at 0 PSI to 4.5V at 4410PSI.
NO
Replace the analog input module board in

central unit.
correct?
YES
END
29.41

PROBLEM
START
Check the H12 (TXD) LED on the main board ON/OFF.

On
Make sure that EPROMS are correct and plugged into
EPROM MODULE is on main board.
NO
correct?
Place EPROM S in correct socket.
YES
Measure process voltage on the main board in the
central unit between MP24 (+5V) and MP0 (GND).
NO
correct?
Off
Make sure external and internal power supply is

correct.
YES
Turn off system power. Check the continuity
of the receive (RXD) and transfer (TXD) wires.
Check continuity between:
NO
correct?
Check connections and replace cable from central

unit to console, if necessary.
YES
NEXT PAGE
29.42
PREVIOUS PAGE
NO
correct?
YES

NO
correct?
YES
END
29.43
PROBLEM
START
Check system out; - Bad Data
NO
correct?
YES
NO
correct?
YES

Refer to connection and wiring diagrams
NO
correct?
YES
Refer to Drawing 8, Suppressor Diode
END
29.44
ERROR CODE DISPLAY
PROBLEM
Warning lights on.
ERROR
DISPLAY
ERROR
CAUSE
ACTION
E 01*

range.

the boom too far.

chart.
E 02*

angle range.


chart.
E 03*

(no load area)

with load.

range.
E 04*

configuration.

crane.
E 05*



See page 35.58


chart.
E 06*

29.45
ERROR CODE DISPLAY

ERROR
DISPLAY
ERROR
CAUSE
E 07

E 08
relay (K9).

selected.
E 11

channel "length".
E 12
E 13
E 14



ACTION

defective, not connected or water in the necessary. See page 35.58.
connectors


main board.


the plug.



on main board.


in the plug.


side defective.

on main board.


29.46

replace if need be.
pressure channels.
ERROR CODE DISPLAY
ERROR
DISPLAY
E 15
E 16
ERROR

CAUSE
ACTION

water inside plug.
Check cable.
See page 35.58.




inside the plug.

replace if need be.


pressure channels.
.
E 18

the front.

Immediately.
E 19

pressure channels.

angle 1.
angle 2.

wiring, (external).

necessary.
potentiometer.
pressure channels.

exceeded.

or loose.
defective.

necessary. See page 35.58.
+5 volt supply
E 1A
E 1B
E 21

on main board.
29.47

ERROR CODE DISPLAY
ERROR
DISPLAY
E 22
E 23
E 24
E 25
E 26
ERROR

rod side" exceeded.



CAUSE
ACTION



side defective.


on main board.




side defective.


on main board.



replace if need be.


pressure channels.

or loose.
on main board.
See Error E 16.
Check cable.
29.48

pressure channels.
See Error E 16.
ERROR CODE DISPLAY

ERROR
DISPLAY
E 27
ERROR
Upper limit value for the measurchannel 7 exceeded.
CAUSE
Sensor of channel 7 defective
or loose.
Sensor of channel 7 defective.
measuring channel 7 defective.
E 29

voltage.
-5 volt supply
E 2A
E 2B
E 31
E 37

angle 1.
angle 2.
ACTION
Check cable.
pressure channels.

MP10 is more than 3.3V.
A/D converter defective.
wiring, (external).

necessary.
potentiometer.
pressure channels.
EPROM with system

program defective.

program.
pressure channels.

defective.
board defective.

EPROM.
pressure channels.

program.
program.

Data EPROM.
TLK EPROM.

pressure channels.
E 38
E 39
E 41


80C31. Replace main
channels.
E 42

read memory (RAM).
Internal defect in

(CMOS-RAM).
pressure channels.
29.49
ERROR CODE DISPLAY

ERROR
DISPLAY
ERROR
CAUSE
E 42

write/read memory
(RAM) part 1.

of CPU.
E 43

write/read memory
(RAM) part 2.

of CPU.
E 45
Error in internal
communications.
Error in A/D
conversion
Malfunction in the
memory.
component.
component.
Internal defect in
E 46
E 47
ACTION
channels.
channels.
pressure channels.
E 48

pressure channels.
E 51
E 52
Error in TLK memory.

board defective.
TLK EPROM on the main
board defective.
Replace Data EPROM.

board is installed.
pressure channels.
E 71
Incorrect acknowledgment of the
A2B relay is stuck or defective.

A2B Relay on A101 Term. board.
Replace K9 relay.
A2B relay is not being selected due to

a break on the terminal board, main
board or ribbon cable.
Check terminal board, main

board and ribbon cables as well
as replace defective part, if
necessary.
E 72 E 77

K2 K7

K2 K7

K2 K7
E 89
Change of the operating code

The operating mode switch in the

console was used during lifting
a load.

operating mode switch correctly
to the code assigned to the
actual operating mode of the
crane.
29.50
ERROR CODE DISPLAY

ERROR
DISPLAY
E 91
ERROR
(See page 35.42)
CAUSE
24V supply of console
interrupted.
Check 24V at terminal Xl of

ground in the line from
console electronics to
central unit.

console electronics and
central unit. If you find an
accidental ground, the
transmitter module in the
damaged. You should,
therefore, replace the console
electronics.
console electronics and central
unit.
Transmitter / receiver module

defective.
Defective data line
from console electronics to
central unit.
module defective.
E 92

(See page 35.42)
E 93

(See page 35.42)
Defective contact in the line

module defective.

(See page 35.42)
ground in the data line from
E 94
ACTION
Check the line to the console.

5V supply for the computer

in the central unit is missing.
5V supply voltage too low.
module defective.
Check the line to the console

(in case of accidental ground
also replace console
electronics).
Check the connection to the
power supply.
Replace power supply module.
Check data EPROM.
Computer module defective.
Replace main board.
Electromagnetic interferences
(e.g. when switching
contactors or valves).
Eliminate interference source

by inverse diodes or varistors.
29.51
ERROR CODE DISPLAY
ERROR
DISPLAY
E 95
ERROR
CAUSE
defective.
ACTION
Replace data EPROM.
pressure channels.
E 96

CPU of the console.

defective.
E 97

CPU of the console.

defective.
board defective.
E 98

console.

board defective.
29.52
Drawing 1 : Slip Ring Unit
X2 : RED
X1 : BROWN
Drawing 2 : Boom Nose Junction Box
29.53

A
G1
MP42
KGND
MP 26
KGND
GND
MP 9
+6V
X15
GND
MP 4
+5V
MP 8
AGND
KGND
+BATT
MP24
MP23
VBAT
+UB1
PWM DC
+9V
GND
5
+UB1 +UB
DI 6
KGND
X12
MP40
V10 H11 V11MP41
H1 H2 H3 H4 H5 H6
DI 1
MP21
PFAIL+UB1
DI 1- DI 6 =>
X17
power o.k.
X14
J11
X11
SP5
X13
TXD
H12
AGND
H10
K8
MP29
10
LEVER
LOCKOUT
K10
A2B
+UB
2
1
MAIN
ON/OFF
KGND
J10
3
4
LMI
KGND
10
LOAD
+5V/RS232
AGND
K9
F
1
H9
A2B
69 68
67 66 65 64
63 62
61 60 59 58
57 56
55 54
12
KGND
3
1
77 76
KGND
KGND
J4
J3
J2
J1
X1
12
11
KGND
F
2
11
X1
13
X16
KGND
MP1
+UBS
36 35 34
33
32 31
30 29 28 27 26
25 24 23
22 21 20
19 18 17
16 15 14
13 12 11
LOCATIONS :
MP 25 - zone M13 = +UBS

MP 42 - zone G1 = +5V
MP 21 - zone E5 = +5V
MP 29 - zone D10 = +5V
H1-H6 - zone I5 = DI 1-6
29.54
10 9
MP 25
13
Drawing 4 : CPU and Daten EPROM boards
MP7
J1
J13
J12
J2
D3
D1
MP4
D2
X1
D14
X2
D13
P1
SYSTEM
D10
J8
D6
J9 MP3 J6
D17
J10
D15
D7
D21
D9
D12
J15
J11
J14
D18
J7
D11
D19
D20
X3
BR6
MP6MP5
EJECT
BR5
MP2
A102 CPU
J1
J2
DATA
D1
J5
J3
TLK
D3
J6
BR
4
3
2
1
X1
A103 DATEN
29.55
Drawing 5 : Analog Input Module
P7
MP12
1
2
40
AGND
AGND
-
P6
MP13
J2
20
P5
16
P4
P3
MP9
J1
MP11
X16
P2
MP10
P1
1 1
2
X1
MP17
BR1
MP0
MP8
VREFA
P8
MP7 - MP1->
X17
1
2
MP16
16
6 5
4 3
MP14
2 1
40
1
2
AGND
BOARD P/N 9-333-103290

X1:1-7
X1:8
X1:9
X1:10
X1:11
X1:12-15
X1:16
X1:17
X1:18
X1:19
X1:20
= ADC INPUT 0.5V/4mA2.5V/20mA

offset adjust with P1-P7
= TEMP (0.5V + 10mV/oC)
= CH01-04, DIN 1-4 / 10
= CH05, +UBS / 10
= CH07, +9V *4
= CH08, VREFA / 2 = 2.500V
29.56
AGND
Drawing 6 :Console Board
MP 2
+7V
MP 5
+5V
MP 0
GND
MP 3
-24V
MP 4
-24V
MP 6
MP 7
MP 1
+UB
J2
J5
J1
J4
J3
X1
X5 1 2 3 4
1 2 3 4 5 6 7 8
29.57

Transducer
PAT
PAT
XA2
1 2 3 4 5 6 7 8
1
2
3
4
5
6
7
8
S
X2
1 X3
1
2
3
3
5
L
XB2
X2
1 X4
1
2
3
3
5
A
X2
X1
7 (9)
8 (10)
9333103309
ADJUST LENGTH POTENIOMETER WITH BOOM

FULLY RETRACTED, TURN THE CENTER SCREW
COUNTERCLOCKWISE TO A SOFT STOP.
29.58
Drawing 8 : Suppressor Diode
COMPONENT
CAUSING
INTERFERENCE
+
SUPPRESSOR DIODE
29.59
CABLE ASSY. TO PRESS. TRANSDUCER ( PISTON )
CABLE TO AREA DEFINITION
CABLE TO CRANE INTERFACE
CABLE ASSY. TO CONSOLE
CABLE ASSY. TO BOOM
IN
FUSE ( 10A)
OUT
L/O
OVERRIDE
FUSE ( 4A )
NORMAL
OPERATION
3 - PAIR CABLE BUS EXTENSION
Drawing 9 : Central Unit Box
CABLE ASSY. TO PRESS. TRANSDUCER ( ROD )
CAUTION: Make sure that + and - diode connections are

made as shown to ensure proper polarity.
P.A.T. L.M.I
MANUAL
SECTION 30

Electrical Diagrams
9 1 2 3 4 5 6 7 10
4 1 2 3
1 2 3
A B C
A B C
A B CD E F
TO MAIN BOOM
CONNECTOR
NC
crane 12 o area
definition switch
in ele. swivel
CRANE SYSTEM AREA
DEF. SWITCH
ELEC. SWIVEL
GN/YL
FUSE (10 amp)
FUSE (10 amp)
+UBS
LMI BYPASS
FUSE (4 amp)
59 60
61 62
10 AMP
FUSE
LMI BYPASS
KEY SWITCH
7 PIN PLUG
+UBE
SIG+
SIGGND
744 HOUSE LOCK PIN SW.
74 (LMI L/O ALARM
+UB
GND
TXD
RXD
A2B
A2B
LOAD
D1
1 2 3 4
1 2 3 4 5 6 7
A B C
A B C
V V V
V V V V
1 2 3 4
V V V
NO
C
1 2 3 4
A BC D
V V V V
1 2 3 4
V V V
73A (LMI UNLOCK SOL.)
A BCD E
A BCD E
V V V
X7 1 2 3 4
X8
+UBE 1
GND 2
V V VV V V
1 2 3 4 5 6 7 8 X1
5 PIN
DEUTSCH
1 2 3 4 PLUG
V V VV V
71K (+UB)
51AJ (GND)
10 8 9
1 2 3 4 5 6 7
V VVV V
V V V V
V V V V
30.1
V
V
4 5
NOT USED
4 AMP
FUSE
CONSOLE (1318)
1 2 3
FUSE (4 amp)
NOT USED
NOT USED
NOT USED
A2B GROUND
A2B SIGNAL
FORCE
ANGLE
GND
LENGTH
+UB
ROD
GND
+UB
GND
PISTON
1 2 3
+UB
DI4
DI2+24V=O/F - RUB.
DI1
GND
+UBS
1
26 27 28 29 30 31 32 33 34 35 36 53 54
OUT
23 24 25
IN
5 6
20 21 22
OUT
3 4
14 15 16 17 19
IN
1 2
51 52 3 4 5 6 7 8 9 10
GN/YL
1 2 11 12 13 18
GND
+UB
GND
RXD
TXD
A2B BYPASS
A2B BYPASS
LMI BYPASS
+UB
+UB
DI 3 (+24V HOUSE
PIN ENGAGED)
K10 EXT. HOR. *1
K10 LMI UNLOCK S.
+UB
GND
K10 (COM) +24V
X1
(See Page 36.2)
NOTES:
pres. trans.
(piston)
pres. trans.
(rod)
LIGHTBAR
DS350
GRAPHIC MODULAR B.C.S.
CENTRAL UNIT

RELIEF CONNECTOR.

(EEC UNITS ONLY)
7 PIN PLUG
RT865BXL (BCS)
1 2 3 4 5 6 7
Cable Reel to Fly Section

V V VV V V
A B CD E F
A B CD E F
V V VV V V
1 2 3 4 5 6 7
30.2
LENGTH
ANGLE
TRANSDUCER TRANSDUCER
RED
X2
12345678
BRN
X1
X4
+ 24V
SIG.
GND
X3
+ 24V
SIG.
GND
5 6
LWG309 (TO NOSE)
123 4
CORE
SHEILD
SHEILD
CORE
3=RED
2=BRN
1=BLK
3
2
1
1234
12
VV
A B
A B
V V
4.7K
4.7K
1
TELE RETRACT PROP. SOLENOID
TELE EXTEND PROP. SOLENOID
TELE ROD DRAIN SOLENOID
TELE PROP. ANALOG GND.

23 - PIN PLUG
15
16
17
18
13
10 11 12 14 3
S/S HARNESS
23 - SOCKET RECEPT
238A
1083
255A
257A
323A
4
5
6
7
8
9
1
2
A
B
C
D
E
F
G
H
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
5
IM TELE
A
B
C
D
E
F
G
H
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
4
CM TELE
OM / FLY TELE
387A
388
239B
242B
243B
244B
71H
51AK
HIGH = AUTO MODE / NONE = MANUAL MODE
TELE RETRACT PRESSURE SW.
TELE EXTEND PRESSURE SW.
GND
30.3
+ 24V
1
11
16
V V V V V V V V V V VV VV VVV V V
V V V V V VVVVVVV V V
X1 26 28 29 31 33 30 32 34 36 38 40 42 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
25
13
17
4 3 2 1
18
8
13 14
7 10
12 14
RT865BXL (BCS)
BUS EXTENSION
WIRING DIAGRAM
1 4
A B C DE FG H J
GND
64 63
27
1
2
A104
X1
PV EXTENSION
K L
3 5 9 10
(See Page 36.4)
6
7
1
1
2
2
M N P
DI 4 ( +24V = OM / FLY RET )
DI 6 ( +24V = IM RET )
DI 7 ( +24V = IM % RESET )
ANALOG INPUT 2 (CM LEN.)
K7 COM ( +24V )
K6 NC
K6 COM ( + 24V )
K5 NC ( PROP RET )
K5 NO ( PROP EXT )
K5 COM
K4 NO
K4 COM
K2 COM ( +24V )
K3 COM ( +24V )
K3 NC
DI 7 GND
DI 6 GND
DI 5 GND
DI 4 GND
DI 3 GND
DI 2 GND
DI 1 GND
GND
+ 24V
+24V
K7 NC
A
101
41 39 37 35
12
13
3 5 8 9 11
7 15
= WIRES ARE
GROUPED
TOGETHER
14 - SOCKET PLUG
1 2 3 4 5 6 7 8 9 10 11 12 13 14
19 - SOCKET PLUG
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
(See Page 36.4)
NOTES:
1
RELIEF CONNECTOR.
2
14 - SOCKET PLUG
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10 11 12 13 14
RT865BXL (BCS)
19 - SOCKET PLUG
A B C DE FG H J
A B C DE FG H J
A B C DE FG H J
A B C DE FG H J
13 14
11
13 14
X2
135
18 19
4 5 6 7
8 9
10
1 2 3
86
11 12
9 14 12
13 14
5 10 11
1 2 3 4 5 6 7 8 S 11 12 13 14 15 16 17 18 19
135
7 8 11 12 13 14 15 16 17
13
18 19
AGND
SIG.
-5V
BRN
RED
ORG
YEL
GRN
BLU
VIO
GRA
WHT
BLK
SHD
BLK
WHT/BLK
GRA
VIO
WHT
BRN
GRN
CRE
BLK
RED
PNK
YEL
BLU
1 2 3 4 5 6 7 8 9 10 11 12
GRA
VIO
1 2 3 4 5 6 7 8 9 10 11 12
WHT
BRN
GRN
CRE
BLK
RED
PNK
YEL
BLU
10 11
WHT/
BLK
1 2 3 4 5 6 7 8 9
BRN
RED
ORG
YEL
GRN
BLU
VIO
GRA
WHT
LENGTH
TRANS.
WHT/
BLK
BRN
RED
ORG
YEL
GRN
BLU
VIO
GRA
WHT
BLK
BLK
WHT/BLK
10 11
LENGTH LG321 (TO CM)
1 2 3 4 5 6 7 8 9
LENGTH LG321 (TO IM)
LENGTH
TRANS.
BRN
RED
ORG
YEL
GRN
BLU
VIO
GRA
WHT
30.4
1 2 3 4 5 6 7 8 S 11 12 13 14 15 16 17 18 19
7 8 11 12 13 14 15 16 17
1 2
X2
9 10
11 12
K L M N P R S T U V
K L M N P R S T U V
X1
10
X1
6 7 12
8 9
X3
1 2 3
4 5 6 7
AGND
SIG.
-5V
4
2
3
1
K L M N P
K L M N P
X3
1 2
SHD
Cable Reels to IM & CM Section
VIO
YEL
PNK
RED
BLK
GRA
BLU
CRE
SHD
WHT
BRN
GRN
JUNCTION
BOX (CM)
1 RED 1
RED
2
BLK
1
3
BLK
4
5 GRN 1
GRN
6
WHT
1
7
WHT
8
BLU
9
BLK
10
BRN
11
WHT
RED 1 = CM CYL (+)

RED = CM PILOT (+)
BLK 1 = OM CYL (+)
BLK = OM PILOT (+)
GRN 1 = CM CYL (-)
GRN = CM PILOT (-)
WHT 1= OM CYL (-)
WHT = OM PILOT (-)
TIE WRAP
PROXY SW 3 (TOP)
(IM % RESET)
BRN
1 (+)
BLK
4 NO
WHT
2 NC
BLU
3 (-)
IS
PROXY SW 1
(OM/FLY RETR)
BRN
1 (+)
BLK
WHT
IS
BLU
4 NO
2 NC
(-)
IS
30.5
RED
YEL
BLU
VIO
GRA
BLK
CRE
PNK
JUNCTION
BOX (IM)
1
2
3
4
SHD
WHT
BRN
GRN
5
6
7
RED
BLK
GRN
WHT
RED = IM CYL (+)

BLK = IM PILOT (+)
GRN = IM CYL (-)
WHT = IM PILOT (-)
PROXY SW 4
(CM RETR)
BLU
BLK
BRN
BRN
BLK
WHT
WHT
IS
BLU
IS
1 (+)
4 NO
2 NC
(-)
4
2
1
6
5
4
3
2
1
PROXY SW 2 (BOTTOM)
(IM RETR. 2-POSITIONS)
BRN
1 (+)
BLK
O
4 NO
WHT
O
2 NC
BLU
3 (-)
IS
BLU WHT
BLU
BLK
BLK
BRN
BRN
WHT
JUNCTION BOX
BOOM BASE
RT865BXL (BCS)
Wiring to Proximity Switches
P.A.T. L.M.I
MANUAL
SECTION 31

Service Bulletins &
Miscellaneous Information
ERROR-E80-E85-E2D
E80 - Slewing pot out of range.
E85 - This code has only been seen on the Modular Boom Control System. The error pertains to the
internal calculation of radius ( not the displayed radius ). The displayed radius is calculated from
the boom length and signals received from the upper cable reel to the C.U. in the cab. The other
two length signals as well as all proximity switches inputs are received by the bus extension located
on the left turntable upright behind the cab. The bus extension has its own processor which
performs calculations and transmits data to the processor in the C.U.
1. Negative load display due to the velocity fuse in the piston side transducer port of the
lift cylinder.
A. The system sees a - 3,000 lb. load display and thinks that the boom must be
deflecting backward. This confuses the processor when performing its
internal calculation of radius.
2. Water in cannon connections located under the base boom. There are two fourteen
conductor and one seven conductor cables running to the cable reels on the left side of
the base boom section.
A. Found water in these connectors which caused length and percentage
problems.
B. Found twisted wires, pinched wires and in general poor assembly from PAT.
Some symptoms of water add poor assembly are that the bus extension may
receive low voltage such as +2 volt input for a proximity switch .when the
boom is extended. At this time you should see 0 volts and of course when any
of the proximity switches see their target you should see 24 volt to the input.
When the bus extension processor sees any voltage from these inputs when
the sections are extended, the processor gets confused and shows E85. Also
the lower two reels length signals may check okay at the reel, but through
these connectors the signal changes until the signal reaches the bus extension.
3. On other cause that was found for the E85 is a bad eprom module. There is a small serial
eprom ( located in the C.U. ) which contains some calibration factors which are used for
calibration purposes. Sometimes this serial eprom loses its memory and causes the E85. In
this case you must replace the eprom module. The Grove part number is 9-333-103289.
E2D - This is an error in the processor board located inside the bus extension box located behind
the cab (top left board ) At this time there is no troubleshooting procedure for this board. The
board must be replaced to correct this error. The Grove part number is 9-333-103718.
P.A.T. L.M.I
MANUAL
SECTION 32
iFLEX5
SERVICE INFORMATION
GENERAL INFORMATION
This service manual is designed to assist a service or maintenance person in identifying system
problem areas or malfunctions. A digital voltmeter with the capability to measure current will be
required, along with standard maintenance and service tools. NOTE: Knowledge of how to use a
voltmeter to measure both voltage and current is assumed.
REFERENCE:
For system operation, refer to the consoles operators manual 9333103876.
WARNINGS
The LMI is an operational aid that warns a crane operator of approaching overload conditions and
over hoist conditions that could cause damage to equipment and personnel.
The device is not, and shall not be, a substitute for good operator judgment, experience and use of
accepted safe crane operating procedures.
The responsibility for the 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 in this manual to ensure that he knows the operation and limitations of indicator and crane.
Proper functioning depends upon proper daily inspection and observance of the operating instructions
set forth in this manual. Refer to Section 6. Pre-Operation Inspection and Calibration Verification of the
operators manual.
The LMI can only work correctly, if all adjustments have been properly set. For correct
adjustment, the operator has to answer thoroughly and correctly all questions asked during
the setup procedure in accordance with the real rigging state of the crane. To prevent
material damage and serious or even fatal accidents, the correct adjustment of the LMI has
to be ensured before starting the crane operation.
Americas Training Grove
iFLEX 5
32-1
DESCRIPTION OF THE SYSTEM

The iFLEX5 system is a CAN bus system made up of a central microprocessor unit, operating
console, length/angle sensor, pressure transducers, and anti-two block switches. All components and
sensors are equipped with CAN bus controllers.
The PAT Load Moment Indicator system operates on the principle of reference/real comparison. The
real value, resulting from the pressure measurement is compared with the reference data, stored in
the central processor memory and evaluated in the microprocessor. When limits are reached, an
overload warning signal is generated at the operators console. At the same time, the aggravating
crane movements, such as hoist up, telescope out and boom down, will be stopped.
The fixed data regarding the crane, such as capacity charts, boom weights, centers of gravity and
dimensions are stored in memory chips in the central processor unit. This data is the reference
information used to calculate the operating conditions.
Boom length and boom angle are registered by the length/angle sensor, mounted inside the cable
reel, which is mounted on the boom. The boom length is measured by the cable reel cable, which also
serves as an electrical conductor for the anti two-block switches.
The crane load is measured by pressure transducer block attached to the piston and rod side of the
hoist cylinders.
The interactive user guidance considerably simplifies the input of operating modes as well as the
setting of geometry limit values.
iFLEX 5
32-2
DESCRIPTION OF THE SYSTEM COMPONENTS

Pressure Transducer: The pressure transducer transforms hydraulic pressure into an electric signal.
A pressure transducer block houses two transducers, CAN bus controller, and two bus connectors.
One pressure transducer is connected to the piston side of the lift cylinder and the other to the rod
side.
The Length-Angle Transducer: The length-angle sensor (LWG), often referred to as the cable reel,
is a combination of two transducers in one box, installed at the base section of the boom. It measures
the length and the angle of the boom.
A reeling drum drives a potentiometer, which is the length transducer. Part of the length transducer
circuit is the length cable on the drum, which is a two-conductor cable (screen and live). It is
connected to the anti-two-block switch at the boom head and to a slip ring body in the LWG.
The angle transducer is a potentiometer driven by a weighted pendulum that is oil damped. Both
length and angle transducer are connected to a CAN bus controller board, which is connected to the
bus.
Anti-Two-Block Switch: The anti-two-block switch monitors the load block and its relationship with
the head of the boom. In working condition the switch is closed. When the hook block strikes the
weight the circuit opens, disengaging a relay output to the lock out solenoid valves, where applicable.
To check the cable for damage, (short circuit to ground) there is a 4.7k resistor between ground and
the contact of the switch, to give a signal back to the central unit. The weight at the anti-two-block
switch keeps the switch closed until the hook block strikes it.
Console: The graphic console displays all geometrical information such as length and angle of main
boom, working radius and head height of the boom. It also displays the actual load and the maximum
load permitted by load chart. Furthermore, it has an alarm horn, a warning light for overload, and a
pre-warning light. The graphic display allows for a simple interactive configuration setup, as well as
sensor calibration (zero adjustment), and troubleshooting sensor output screen. The console has a
warning light for anti-two-block conditions and an override switch for overload or anti-block condition.
Central Unit: Inside the central unit there is a CPU and connection board. The board has a hard
mounted connector for power, ground, bus controller, and slew indication. The board has a green
LED, indicating relay energized and a communication LED that flashes through red, yellow, and green
colors.
iFLEX 5
32-3
WHATS WRONG?
So, whats wrong? Assuming you are reading these pages because of some kind of problem with the
PAT system, let us try to guide you quickly to solving the problem. In most cases, your problem will fall
under the following categories:
I HAVE AN ERROR CODE INDICATED ON THE CONSOLE

Please go to section Error Codes!
THE DISPLAYED ANGLE DOES NOT MATCH THE ACTUAL BOOM ANGLE
Start in section Angle Sensing to check the indicated angle.
THE DISPLAYED LENGTH DOES NOT MATCH THE ACTUAL BOOM LENGTH
Start in section Length Sensing to check the indicated length.
THE DISPLAYED SLEWING DOES NOT MATCH THE ACTUAL SLEWING ANGLE
Refer to section Slewing Sensing to check the slew sensor.
THE DISPLAYED LOAD DOES NOT MATCH THE ACTUAL LOAD

Please note that the indicated load is calculated by the system from the geometry information in the
computer, the operators selections, and all the sensor inputs. If the load display is off, it can therefore
be due to an error in any or several of these inputs! Refer to section Load sensing to narrow down the
source of your problem.
THE CONSOLE DISPLAY IS BLANK

If the console does not show any sign at all (no lights, no buzzer, no display), the problem is either in
the wiring between console and central unit, or the console itself. Refer to section No console display
for further troubleshooting.
I HAVE AN A2B PROBLEM

Please go to sectionA2B PROBLEM
I HAVE A CAN-BUS PROBLEM

Please go to section CAN-Bus Communication
!
I NEED TO IDENTIFY A SPARE PART

Please go to the Spare Part Listings
!
I HAVE NOTICED WATER IN SOME PART OF THE SYSTEM

Please go to section Troubleshooting Moisture
!
iFLEX 5
32-4
ANGLE SENSING
The System measures the angle of the main boom of the machine with an angle sensor. The angle
sensor is contained within the cable reel, located on the left side of the main boom.
Block Diagram
Angle
Sensor
CAN-Bus
Converter
iFLEX5
CU
Pressure Transducer
Cable Reel
The signal runs from the angle sensor to the Can-Bus converter board, both located in the cable reel.
From there, it travels as digital information on the CAN-Bus to the pressure transducer, which acts as
a T-connector to the main CAN-Bus running to the central unit.
So, what do you do when you are having a problem with your angle read-out?
Start by verifying the angle display. Refer to the section Troubleshooting A Sensor Problem Using
The Display to call up the sensor signal on your console display. The CAN-Bus is digital and as such
will either transmit the signal correctly or not at all. If your readings are off, you have to determine what
is causing the problem. Start by opening the cable reel and locate the angle sensor (right) and the
CAN-Bus converter board (left):
iFLEX 5
32-5
X14 (A2B)
X20 (length)
X21 (angle)
LED
X1 (CAN)
CAN-Bus electronics in cable reel.

The angle sensor has a potentiometer built in that is driven by a pendulum. As the angle changes, so
will the pendulum and with it the potentiometers axle. The converter board supplies a constant voltage
of 5V to the angle sensor and in return monitors the voltage of the potentiometer. The terminal used is
X21. The angle sensor is connected as follows:
Terminal X21
1
GND
2
Signal
3
+5V
Verify that the sensor is being supplied with 5V by measuring between pin 1 (GND) and Pin 3 (+) of
terminal X21. If the voltage is outside of a range of 4.75 to 5.25V, the converter board might be
defective. Unplug angle sensor and measure again. If the voltage is still off, exchange converter
board. If unplugging the angle sensor made the voltage return into the acceptable range, exchange
angle sensor. If the voltage is correct continue:
iFLEX 5
32-6
The angle sensor returns a voltage between 1.875V at 90 degrees and 3.125V at 0 degrees:
Angle Sensor Signal on
Pin 2
Angle
Voltage
90
1.875
75
2.083
60
2.292
45
2.500
30
2.708
15
2.917
0
3.125
Note: Actual voltages will vary slightly.
Measure this voltage between Pin 1 (GND) and Pin 2 of Terminal X21.
If you need to determine the angle for voltages other than the above, do so by using the following
formula:
Angle (degrees) = 90 degrees ((Voltage-1.875) * 72)
If this angle matches your actual angle, but the indicated angle varies significantly (more than 0.4
degrees), the angle sensor is fine and the error is somewhere else. If this angle varies significantly
from your actual angle, the angle sensor is bad and needs to be exchanged. Otherwise, continue:
At this point, you have verified that the angle sensor is giving you the right output to match your actual
angle, but the system is displaying the wrong angle. If you can rule out software and operator error, it
is most likely that the converter board is defective and it needs to be exchanged.
iFLEX 5
32-7
LENGTH SENSING
The system measures the length of the main boom of the machine with a length sensor. The length
sensor is contained within the cable reel, located on the left side of the main boom.
Block Diagram
Length
Sensor
CAN-Bus
Converter
iFLEX5
CU
The
signal
runs
Pressure
Transducer
from
the
length
sensor
Cable Reel
to the CAN-Bus
converter board, both located in
the cable reel. From there, it travels as digital information on the CAN-Bus to the pressure transducer,
which acts as a T-connector to the main CAN-Bus running to the central unit.
So, what do you do when you are having a problem with your length read-out?
Start by verifying the length display. Refer to the section Troubleshooting A Sensor Problem Using
The Display to call up the sensor signal on your console display. The CAN-Bus is digital and as such
will either transmit the signal correctly or not at all. If your readings are off, you have to determine what
is causing the problem. Start by checking the length cable tension, the cable reel has 5-8 turns of preloading on the reel. Opening the cable reel and locate the length sensor (right) and the CAN-Bus
converter board (left):
iFLEX 5
32-8
Fully retract the boom and turn the screw of the length potentiometer with a small screwdriver counter
clockwise to a soft stop. That should bring the sensor voltage to 0V (+/- 0.1Volt).
Measure voltage between Pin 5 (-) and Pin 3 of Terminal X20 and compare.
Potentiometer
Gear wheel with slip clutch
Go back to your indication screen and compare length indicated and actual again. If the indicated
length varies significantly from your actual length (more than 0.3 feet), the length sensor might be bad
and needs to be exchanged. Note, however, that the error could also be in the software or in the
converter board.
X14 (A2B)
X20 (length)
X21
LED
X1 (CAN)
iFLEX 5
32-9
The length sensor has a potentiometer built in that is driven by a gear drive from the cable drum. As
the length changes, the cable drum will turn and with it the potentiometers axle. The converter board
supplies a voltage of about 4.7V to the length potentiometer and in return monitors the output voltage
of the potentiometer. The terminal used is X20. The length sensor is connected as follows:
Terminal X20
1
+ (~ 4.8V)
3
Signal
5
- (~ 0.2V)
Verify that the sensor is being supplied with about 4.7V by measuring between pin 5 (-) and Pin 1 (+)
of terminal X20. If the voltage is outside of a range of 4.5 to 5 V, the converter board might be
defective. Unplug length sensor and measure again. If the voltage is still off, exchange converter
board. If unplugging the length sensor made the voltage return into the acceptable range, exchange
length sensor. If the voltage is correct continue:
The length sensor returns a voltage between 0.16V at 0 turns of the length pot (= fully retracted) and
4.84V at 10 turns. How many turns you get at full extension depends on the gear ratio, the boom
length, the length cable used and the spooling pattern, so we cannot provide a standard table for it.
What we can give you for trouble-shooting, however is the following table that shows the expected
output voltage (measured between X20-5 and X20-3 Signal) for each complete turn of the length
potentiometer. Note that this does not sync to the number of turns of the cable reel, though:
Length Sensor Signal on Pin 3
Turns
Voltage X20-5 to
X20-3
0
0.00
1
0.46
2
0.93
3
1.40
4
1.87
5
2.34
6
2.81
7
3.28
8
3.75
9
4.22
10
4.68
Voltage GND to X20-3

0.16
0.62
1.09
1.56
2.03
2.50
2.97
3.44
3.91
4.38
4.84
Note: Actual voltages will vary slightly.
For the boom control system, the length sensors are the same as described above with the exception
of cable reel internals (location of hardware, wiring, and gear wheels). Refer to the LWG520 and
LG152 spare part list for these differences.
iFLEX 5
32-10
PRESSURE SENSING
The System measures the pressure of the boom lift cylinder for both rod- and piston-side. Both
sensors are contained within one box that also contains the electronics needed for amplification and
creation of the CAN-Bus signal.
Block Diagram:
(2)
PressureMeasuring
Cells
Pressure Transducer
CAN-Bus
Converter
iFLEX5
CU
The signal runs from the pressure transducer as

digital information on the CAN-Bus to the central
unit.
So, what do you do when you are having a problem with your length read-out?
Start by checking the pressure display. Refer to the section Troubleshooting A Sensor Problem Using
The Display to call up the sensor signal on your console display.
The easiest spot to check the signal at is when there is no pressure applied to the sensor at all. The
only time this is for certain is when your pressure lines are drained and disconnected. In that case, the
readout should show about 500mV (+/- 25mV) and 0 PSI. Small variations could be adjusted; see
section Service Screen For Sensor Calibration.
The CAN-Bus is digital and as such will either transmit the signal correctly or not at all. If your readings
are off, chances are the pressure transducer is defective. Replace.
Note: After exchanging the pressure transducer block, BOTH transducer channels need to be zeroed,
see procedure Zero-Setting The Transducer Inputs.
iFLEX 5
32-11
SLEWING SENSING
The system measures the slewing (rotational position) of the cranes upper with a slewing sensor. The
slewing sensor is contained within the slip ring assembly.
Block Diagram
Slew
Potentiomet
er with (2)
outputs
Current
Converter
iFLEX5
CU
Slip Ring Assembly

The slew potentiometer has two potentiometers built in that are driven by the slip ring axle. As the
slewing angle changes, so will the axle and with it the potentiometers outputs. Use the display screen
by pressing i (info) twice to show all sensor inputs.
The table to the right show measured millivolt reading for
the slew potentiotmeter.
ANGLE
(deg)
0
30.3
60
89.9
120.1
150.1
180
-150.1
-120.1
-90
-60.1
-30
0
SL ANG 1
(mv)
717
1174
1680
2158
2641
3144
3595
3144
2642
2160
1681
1172
718
SL ANG 2
(mv)
2161
2645
3150
3595
3141
2639
2161
1681
1180
718
1168
1680
2161
Modular Slew Pot - Voltage on Service Screen
4000
MILLIVOLTS
3500
3000
2500
2000
1500
Potentiometer 1
1000
Potentiometer 2
500
0
0
Display screen 0
for sensor inputs
45
45
90
90
135
135
180
225
180
-135
SLEW ANGLE
iFLEX 5
270
-90
315
-45
360
0
32-12
The converter board is supplied with 12V from the central unit. The potentiometer and the board output
two signals between 4 and 20mA that go to the central unit. You can measure them at the 12-pin crane
interface connector. Start by making sure that the slew pot unit is supplied with crane voltage. Pin 7
must carry crane voltage and pin 2 is GND. The slew units output can be found on pins 8 and 9. In
order to measure the current, however, you have to disconnect a pin and measure in line with it
(measuring meter in between the cable from the slew unit and the central unit). The two outputs will
vary as shown in this chart:
Modular Slew Pot - Output Currents
mA 2
mA 3
24
20
mA
16
12
8
4
0
0
90
180
270
360
Degrees
(when the crane is over front, you should see about 4mA in one channel (wire #2) and 12mA in the
other channel (wire #3)).
Alternatively, you can also leave the wires connected and use your meter in Voltage-mode to measure
the output signals. In that case, you will see the 420mA signal range as a 1.1 to 5.5Volt range. In that
case, refer to the following chart:
If the voltage or currents do not fall in line with the charts and tables shown here, and no system errors
are present, the problem may be a mechanical. Open the slip ring unit and find out if the slew
potentiometer is set correctly.
LOAD SENSING
Please note that the load displayed by the LMI is not a direct measurement, but a calculated value that
is based on a lot of factors. Outside of the measured values (sensors), those include:
Operator settings such as:

o Operating mode/configuration
o Parts of Line/Reeving
Rigging parts such as:
Hookblock weight
Sling weights, etc.
Tip height (length of load line used)
Boom weights
Boom attachments such as
iFLEX 5
32-13
NO CONSOLE DISPLAY
If the console is not showing any lights, such as warning lights, backlighting, etc. it is most likely
missing power. Start with the following:
Next, check if power is being supplied by the central unit. Measure on the green connector. Pin 1 is
+Ub (12V), Pin 2 is GND. If you have no power, check wiring harness and central unit. Otherwise,
open console:
Check fuses in console: one (F6) is located the connection board (mounted to the inside of the
housing) which protects the override key switch function and the bargraph. The main fuse (F1) is
located on the console processor board. If both fuses are fine, check for power on connector X6 on
the connection board (Pin 1 = +Ub, Pin 2 = GND). If you have no power there (but you had power on
the external connector), most likely the connection board is defective and needs to be replaced. If you
have power on this connector, follow it to the console computer board, connector X1. Again, Pin 1 =
+Ub and Pin 2 = GND. If you have no power there, the connecting cable must be defective or loose. If
you still have power there, check fuse F1 again.
Next, make sure all connectors are correctly in place:
Connection board
Computer board
Pins
X6
X1
4
X10
X22
6
X7
X2
10
Especially verify that the X10-X22 connection is right, since it could be plugged into X17 by mistake
Check TxD LED is on. This LED is located in the center of the computer board and is normally blinking
when the console is communicating.
If you find voltage on all pins outlined and all connectors are in place, but you still do not get any light
to come up (during power-up especially!), either the software is defective or the console electronic
needs to be replaced.
iFLEX 5
32-14
A2B PROBLEM
First, perform the following operations:
Are the control levers locked out and is the crane in an anti-two block condition?
YES, Lower the hook block and/or headache ball to correct two-block condition. If two (2)
hoists are in use, both hooks must be lowered.
Is the anti-two block warning light on? Check Bypass plug installed, if not plug appropriate bypass plug
into socket of junction box.
Is the Bypass plug installed and the anti-two block warning light on?
Turn power off, remove the bypass plug, and measure the resistance at the boom nose box between
terminals 1 and 3 with an ohmmeter. This checks the function of the Anti-Two Block switch. Switch
closed = 0Ohms (weight installed); Switch open => 1 Megaohm (weight removed) Ohmmeter reading
are correct?
YES, Plug the bypass plug into the boom nose box and refer to system wiring to check wire
connections in boom nose box. If wiring is correct, replace Anti-Two-Block switch.
Ensure the bypass plug is plugged into the boom nose box. Measure the A2B signal in the cable reel
between X1:Brown and X2:Red wires on the slip ring with an ohmmeter. Switch closed =4700
500Ohms; Switch open => 1 Megaohm. Ohmmeter readings are correct?
NO, Check for damaged length cable and wiring. If broken length cable, refer to system wiring.
Measure the A2B signal in the cable reel between terminal 7 and 8 with an ohmmeter. Switch closed
=4700 500Ohms; Switch open => 1 Megaohm. Ohmmeter readings are correct?
NO, Replace slip ring
Problem with wiring harness, cable reel length/angle board, and/or central unit.
iFLEX 5
32-15
CAN-BUS COMMUNICATION
The System measures the length of the main boom, the angle of the main boom, the pressures of the
lift cylinder, and the A2B state of the machine via a CAN-Bus connection. Since this is a digital bus
connection, it is not possible to measure the signals on the bus with a multimeter. Instead, the LMI
provides you with error codes that give you an indication of the bus state.
The error codes are one of the following:
E61
E62
E63
E64
E65
Error in the CAN bus data transfer for all CAN units
Error in the can bus data transfer of the pressure transducer sensor unit
Error in the can bus pressure transducer sensor unit
Error in the can bus data transfer of the length/angle sensor unit
Error in the can bus length/angle sensor unit
Block Diagram
E65
CAN-Bus
Converter
E64
E61
iFLEX5
CU
E62
Pressure Transducer
Cable Reel
E63
The block diagram tries to clarify that: If the CU does not see any CAN-Bus component, it will report
an E61. If it sees only the cable reel, it will report an E62 (pressure transducer missing). If it sees only
the pressure transducer, it will report an E64 (cable reel missing). E63 means that the pressure
transducer is available, but is reporting an internal error. E65 means that the cable reel unit is
available, but is reporting an internal error.
So, what do you do when you are having a problem with one of those codes?
E61
In case of an E61, start by checking your cabling. You can verify that power is being supplied to the
sensor by testing the CAN connectors per this layout:
Connector
M12, 5 contacts
Pin Layout (CiA DR-303-1 7.2)
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Shield
+ Ub
Ground
CAN High
CAN Low
Measure between pins 3 and 2 for crane voltage. If you see voltage, check all pins for continuity.
Remember, the CU is reporting that neither cable reel nor pressure transducers are present.
iFLEX 5
32-16
E62
In case of an E62 the CU is reporting no signal from the pressure transducer. Start by checking your
cabling between CU and pressure transducer, even though it is not very likely that there is a problem
with it since the same cable carries also the signals from the cable reel and those appear to be fine.
You can verify that power is being supplied to the sensor by testing the CAN connectors per the above
pin layout. If you are sure that the sensor is being supplied, you have to replace the pressure
transducer.
E63
In case of an E63, the pressure transducer is reporting an internal problem. You cannot troubleshoot
any further, but need to replace the pressure transducer.
E64
In case of an E64, the CU is reporting no signal from the cable reel unit. Start by checking your cabling
between pressure transducer and cable reel. You can verify that power is being supplied to the sensor
by testing the CAN connectors per the above pin layout or by opening up the cable reel (remove the
lid) and making sure the red LED on the board is blinking.
X14 (A2B)
X20
X21
LE
X1 (CAN)

If it is not, most likely power is missing. Verify by measurement on connector X1:
iFLEX 5
32-17
X1 Pin
CAN
CAN_SHLD1
CAN +UB
CAN GND
CAN_H
CAN_L
Measure between pins 3 (GND) and 2 (+). Next, check all pins of the CAN bus cable for continuity and
cross-check for short circuits. E-64 means that the pressure transducer is working fine, but the cable
reel is not so we most likely have a defective connection between those two components. If this is
tested to not be the case (missing connections, short circuits measure with Ohm-meter), the board in
the cable reel might be defective (see also chapter Angle Sensing).
E65
In case of an E65, the cable reel is reporting an internal problem. In most cases, this will be an angle
sensor, length potentiometer or A2B wiring. Go to those chapters (Angle Sensing, Length Sensing,
A2B PROBLEM) to continue trouble shooting.
BRIEF DESCRIPTION OF A CAN BUS SYSTEM

CAN stands for Controller Area Network. Its intended use is as a serial bus system for a network of
controllers. Each controller connected through a CAN chip is called a "node" and is mostly used to
acquire data from a sensor. All nodes are connected to a common bus and all nodes are able to
simultaneously read the data on that bus. Also, all nodes are able to transmit data on that bus
however only one node at a given time has write access to the bus. If the message is relevant, it will
be processed; otherwise it is ignored. The unique identifier also determines the priority of the
message. The lower the numerical value of the identifier, the higher the priority.
The cable bus is a twisted pair of shielded wire. Data can be transmitted in blocks from 0-8
bytes at a maximum transfer rate of 1 Mbit/s for networks up to 40 mtrs. For longer network
distances the maximum transfer rate must be reduced to 50 Kbit/s for a 1 km network distance.
CAN will operate in extremely harsh environments and the extensive error checking
mechanisms ensure that any transmission errors are detected.
iFLEX 5
32-18
P.A.T. L.M.I
MANUAL
SECTION 33
TROUBLESHOOTING
a SENSOR PROBLEM USING
the DISPLAY
Troubleshooting A Sensor Problem Using The Display
TROUBLESHOOTING A SENSOR PROBLEM USING THE DISPLAY

To determine whether there is a problem with a sensor, the iFLEX5 system has sensor output screen
built in to make trouble-shooting easier. This is the right place to start if you are suspecting a problem
with a sensor (and you dont have an error code displayed).
To access the sensor output screen, press
the INFO button twice
10
10
.
to review software version information, press

the INFO button once
10
.
To EXIT the sensor output screen, press the

INFO button once from the software version
screen to return to the operating screen
10
.
The screen will show all sensor inputs as in the example below. For each sensor, an equivalent
voltage is shown in millivolts, along with the physical sensor value that that voltage refers to.
Pressure sensors are shown with physical values of [bar], angle sensors and slew sensors in degrees
and length sensors in feet (or meter for metric charts). At the bottom of the screen, the console
software version is shown.
Press INFO
To review
software
version
information
10
The values shown in the screen here are just examples of actual values. Refer to the table listed
below for actual value ranges.
If you suspect a sensor error or problem with a sensor, compare the indicated physical value of the
sensor on the display screen with the real value, i.e. length, angle, etc.
iFLEX 5
33-1
The voltages given are internal calculation values only; you will not be able to actually measure them
anywhere on the electronics! Typical values to be expected are:
Pressure transducers (piston and rod), 500mV @ 0 PSI; 4500mV @ maximum PSI
Length sensor, 500mV @ retracted boom length; voltage extended depends on the various
boom lengths.
Angle sensor, 4500mV at 0; 2500mV at 45; or 500mV at 90
Please refer to table below for more values.

Voltage Values
Value displayed Value
displayed [mV] +/- 10mV
Pressure Transducers
300 bar, type 314
500
1500
2500
3500
4500
Angle Sensor
500
1500
2500
3500
4500
Length Sensor
500
1500
2500
3500
4500
PSI
0
1088
2176
3263
4351
Bar
0
75
150
225
300
degrees
90
67.5
45
22.5
0
boom horizontal
feet
0
fully retracted
boom vertical
If the displayed value does differ from the actual value, please refer to the following sections to find the
cause of the problem:
If the displayed angle is incorrect, please go to section Angle Sensing.
If the displayed length is incorrect, please go to section Length Sensing
If the displayed pressures are incorrect, please go to section Pressure Sensing
iFLEX 5
33-2
Troubleshooting A Sensor Problem Using The Display
SLEW POT SIGNALS:

Sig 1 (mA)
Reference Angle 0.03mA
0
4.00
45
8.00
90
12.00
135
16.00
180
20.00
-135
16.00
-90
12.00
-45
8.00
Sig 2 (mA)
0.03mA
12.00
16.00
20.00
16.00
12.00
8.00
4.00
8.00
If the displayed angle is incorrect, please go to section Slewing Sensing
iFLEX 5
33-3
DRAWINGS
COMPONENTS OF THE LMI SYSTEM PAT IFLEX5
PAT
POWER
LOCKOUT
OTHER
1 Central-Micro-Processor Unit
2 Operating Console
3 Pressure Transducers
4 Length/Angle Sensor
5 Anti Two-Block Switch(es)
iFLEX 5
33-4
BLOCK DIAGRAM
70 pin
Connector
RS 485
Serial
Interface
Crane Power
Graphic
Console
iflex5 Central Unit

Lockout
CANBUS
Current
4..20mA
CAN-connector
Slew Sensor
CAN-connector
CAN-connector
Dual Pressure
Length/Angle Sensor
iFLEX 5
A2B
33-5
ELECTRICAL SYSTEM DIAGRAM STANDARD SYSTEM

Central Unit to Crane and Console Wiring Diagram
iFLEX 5
33-6
Cable Reel (length/angle sensor) Wiring Diagram
iFLEX 5
33-7
Boom Extension Anti-two Block Wiring Diagram
MAIN CENTRAL UNIT CONNECTOR

This is a 70 pass connector.
iFLEX 5
33-8
ELECTRICAL SYSTEM DIAGRAM BOOM CONTROL SYSTEM
1-1
Central Unit to Crane Interface Wiring Diagram
iFLEX 5
33-9
Console and Sensor Wiring Diagram
TO LWG520/0002
REFER TO CABLE REEL
(LWG520/0002) WIRING DIAGRAM
BOOM BASE CONNECTION

TO LG152/0056
REFER TO CABLE REEL
(LG152/0056) WIRING DIAGRAM
iFLEX 5
33-10
Cable Reel (LG152/0056) Wiring Diagram

TO LWG520/0002
REFER TO CABLE REEL LWG520/0002
WIRING DIAGRAM
TO BOOM BASE CONNECTOR

REFER TO CONSOLE AND SENSOR
WIRING DIAGRAM
iFLEX 5
33-11
Cable Reel (LWG520/0002) Wiring Diagram
LUFFING JIB CONNECTION

REFER TO LUFFING EXTENSION
WIRING DIAGRAM
TO PRESSURE TRANSDUCER BLOCK

REFER TO CONSOLE AND SENSOR
WIRING DIAGRAM
TO LG152/0056
REFER TO CABLE REEL
(LG152/0056) WIRING DIAGRAM
iFLEX 5
33-12
Luffer Extension Wiring Diagram
BOOM TIP CONNECTION

TO LWG520/0002
REFER TO CABLE REEL
(LWG520/0002) WIRING DIAGRAM
iFLEX 5
33-13
SPARE PART LISTINGS

CENTRAL UNIT, IFLEX5 PART NO. 9333103866
NO. PART NO.
1
9333103890
2
9333103891
3
9333102541
4* 9333103908
5* 9333101978
6* 9333103058
7
9333101591
* ITEM NOT SHOWN
QTY DESCRIPTION
1
CENTRAL UNIT ACCY, GROUNDING KIT
1
BATTERY, LITHIUM 3V
1
KEY SWITCH
1
CENTRAL UNIT COVER iFLEX
1
SCREW SET
1
SPARE KEY
42 GASKET
7
2
iFLEX 5
33-14
Spare Part Listings
GRAPHIC CONSOLE ASSY, VERTICAL PART NO. 9333103868

NO.
1
2
3
PART NO.
9333101691
9333103895
9333103892
1
1
1
4
5
6
7
8
9
10
9333103893
9333103894
9333103899
9333103900
9333103901
9333103902
9333103903
1
1
1
1
1
1
1
QTY DESCRIPTION
SPARE KEY, GRAPHIC CONSOLE
KEYSWITCH, WITH CABLE
FRONTFACE WITH DISPLAY, COMPUTER BOARDS, AND
LED BOARDS
CONNECTION BOARD WITH BUZZER
FUSE, 2 AMP AUTO
CABLE, 4 POL COMPUTER BRD X1 TO CONN BRD X6,X11
CABLE, 10 POL COMPUTER BRD X2 TO CONN BRD X7
CABLE, 6 POL COMPUTER BRD X10 TO CONN BRD X23
5 LED BOARD, LMI/A2B ALARM LITE
8 LED BOARD, LEDS BY SELECTION BUTTONS
4
9
3
3
6
7
1,2
10
iFLEX 5
33-15
CABLE REEL, LWG508 PART NO. 9333103873

NO. PART NO.
QTY DESCRIPTION
1
NSS
1
CABLE REEL ACCY, LWG508 DRUM BODY W/LENGTH CABLE
2
9333102986
139 LENGTH SENSOR CABLE
3
9333103896
1
BOARD, LENGTH AND ANGLE OUTPUT
4
9333103897
1
LENGTH POTENTIOMETER LWG508
5
9333103898
1
ANGLE SENSOR, WG143/09
6
9333103904
1
SLIP RING ASSEMBLY 2 CONDUCTOR
7*
9333103905
1
25T GEAR WHEEL
8
9333101625
1
75T GEAR WHEEL
9*
9333103906
1
CONNECTOR, 5 POLE W/WIRES
10*
9333103907
1
LID,
BLACK
11*
9333101565
1
CABLE REEL ACCY, GASKET FOR COVER
12*
9333101566
10
CABLE REEL ACCY, SCREW/CAPTIVE
* ITEM NOT SHOWN
4
5
1
7
Also see detail on next page.
iFLEX 5
33-16
Spare Part Listings
8
4
3
iFLEX 5
33-17

NO. PART NO.
QTY DESCRIPTION
1
NSS
1
CABLE REEL ACCY, LWG520 DRUM BODY W/LENGTH CABLE
2*
9333103773
176 LENGTH SENSOR CABLE 11 CORE
3*
9333103966
1
BOARD, 2 LENGTH AND ANGLE OUTPUT
4
9333103967
1
BOARD, FILTER
5
9333103897
1
LENGTH POTENTIOMETER LWG
6
9333103898
1
ANGLE SENSOR, WG143/09
7
9333102737
1
8*
9333103905
1
25T GEAR WHEEL
9
9333101780
1
90T GEAR WHEEL
10*
9333103906
1
CONNECTOR, 5 POLE W/WIRES
11*
9333103907
1
LID,
BLACK
12*
9333101565
1
CABLE REEL ACCY, GASKET FOR COVER
13*
9333101566
10
CABLE REEL ACCY, SCREW/CAPTIVE
* ITEM NOT SHOWN
9
7
5
10
1
iFLEX 5
33-18
Spare Part Listings

NO. PART NO.
QTY DESCRIPTION
1
NSS
1
CABLE REEL ACCY, LG152 DRUM BODY W/LENGTH CABLE
2*
9333103775
87
LENGTH SENSOR CABLE 3 CORE
3
9333101557
1
TERMINAL STRIP
4*
9333103967
1
BOARD, FILTER
5
9333103897
1
LENGTH POTENTIOMETER LWG
6
9333103756
1
7
9333103758
1
55T GEAR WHEEL ON POTENTIOMETER
8
9333103757
1
45T GEAR WHEEL ON CENTER SHAFT
9
9333102902
4
HARDWARE, STANDOFF 6MM X 117MM MM
10*
9333101965
1
HARDWARE,
GASKET
11*
9333103762
1
SENSOR ACCY, COVER KT152
12*
9333101964
1
SENSOR ACCY, NUTS (4) & WASHER (4) FOR KT152 COVER
13
9333103968
1
CABLE ASSEMBLY, 2.5m
* ITEM NOT SHOWN
9
6
13
7
5
iFLEX 5
33-19
PRESSURE TRANSDUCER BLOCK, DAV314/0014 PART NO. 9333103870
CABLE ASSEMBLY 11M, PART NO. 9333103872
WIRING HARNESS STANDARD, PART NO. 9333103869
iFLEX 5
33-20
Spare Part Listings
WIRING HARNESS BOOM CONTROL, PART NO. 9333103911

6 Cables for:
1. Console
2. Crane interface 7 conductors
3. Crane interface 24 conductors
4. LG152 cable reel
5. CAN bus cable
6. Optional radio wind speed receiver
CABLE ASSEMBLY, 14M PART NO. 9333103916
iFLEX 5
33-21
P.A.T. L.M.I
MANUAL
SECTION 34
SERVICE SCREEN
for SENSOR CALIBRATION
SERVICE SCREEN FOR SENSOR CALIBRATION

ACTIVATING THE SERVICE SCREEN FOR SENSOR CALIBRATION
To activate the service screen and sensor
calibration function, press the INFO key on
the console to activate the INFO Function.
10
11
Now press the CTRL key.

.
At this point, a five digit
Authorization Number must
be entered. Only authorized
personnel may adjust the
zero-point settings.
Use the > key to switch
between digits; use the +
and - keys to increase and
decrease each digit. Use
the enter key to confirm
entry.
iFLEX 5
34-1
Service Screen For Sensor Calibration
Now, having successfully

entered a valid password, the
piston-side zero-point setting
function is activated.
The ESC key will allow you to
leave the sensor calibration
function.
The return key toggles between
the piston-side, the rod-side
zero setting, and length, and
angle calibration.
This is the rod pressure

adjustment screen.
The ESC key will allow you to
leave the sensor calibration
function.
The return key toggles between
the piston-side, the rod-side
zero setting, and length, and
angle calibration.
The return key toggles between the piston-side, the rod-side zero setting, and length, and angle
calibration.
When the sensor calibration is finished, pressing the ESC or INFO key returns the console display to
normal.
iFLEX 5
34-2
ZERO-SETTING THE TRANSDUCER INPUTS

NOTE: The only thing adjustable for the pressure transducers is the zero point, which is the voltage
the transducer outputs when there is no (zero) pressure sensed.
CAUTION: Ensure there is no pressure in the hydraulic line when disconnecting the hoses from
pressure transducers.
The display shows which transducer (pistonside, rod-side or force) is being zeroed and a
horizontal dial marks the present pressure (or
force) difference in %. By pressing the + key,
the input pressure (or force) is adjusted
upwards, and by pressing the minus (-)key, the
input value is adjusted downwards. When the
plus (+) and minus (-) keys are pressed
simultaneously, the zero setting occurs
automatically. Manual adjustments may be
preformed using + or -.
iFLEX 5
34-3
LENGTH SENSOR CALIBRATION PROCEDURE

NOTE: The length sensor can be calibrated for its zero point and its full range. This means, for the
correct voltage for retracted boom and for the extended boom. With retracted boom, the potentiometer
of the length sensor has to be at its 0 position, which is all the way counter-clockwise. For extended
boom, the adjustment is done by software as described in 6 section Length Sensor Adjustment
Procedure.
The length should be calibrated to be about 0.1 feet (or 0.05m for metric) accurate for retracted and
extended lengths. Perform the following steps:
Fully retract the main boom and check if indicated length is within 0.1 of actual retracted boom length.
If it is not, adjust length potentiometer as described in 6.3.1. Afterwards always adjust retracted length
by software as described in section Length Sensor Adjustment Procedure.
Cable Reel LWG508 Adjustment Procedure
Now perform Length Sensor Adjustment Procedure as detailed in section Length Sensor Adjustment
Procedure.
iFLEX 5
34-4
Length Sensor Adjustment Procedure

See section Activating the Service Screen for Sensor Calibration on how to access the length sensor
calibration screen.
Select the length calibration by pressing OK
at the Calibrate Length screen.
The screen will change now and show the

picture to the right.
Fully retract the main boom and verify the
indicated boom length matches the retracted
boom length of your crane. If incorrect, make
sure you have adjusted the length pot in cable
reel (see section Cable Reel LWG508
Adjustment Procedure.)
Now, press the OK button to calibrate
retracted length. The indication will change to
show your correct retracted boom length.
Now extend main boom all the way out. Make

sure you are within the allowed operating
range (especially maximum radius).
iFLEX 5
34-5
Cable Reel Length Cable Replacement Procedure

Replace length cable using the following procedure:
Refer to system electrical wiring diagram and cable reel - parts list
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

Disconnect damaged length cable from junction box at the boom nose.
Open cable reel cover and disconnect bus connector.
Remove damaged length cable, which is mounted to the slip rings in the cable reel, from slip ring
terminal.
On the backside of the cable reel, open the strain relief attached to the axle in the center of the
drum. Pull existing length cable out of the cable reel.
Pull new length cable through the hole, pipe and strain relief and push it through the axle of the
reeling drum. Tighten new strain relief to ensure sealing.
Reconnect the length cable to the slip ring.
Remount cable reel to the boom.
Turn reeling drum clockwise to spool the new cable neatly onto the drum.
Set pre-load on cable reel by turning the drum counter-clockwise 5 to 8 turns.
Run the new length cable through the cable guides and wrap the length cable around the boom
tip anchor pin (4 or 5 wraps) and secure with tie wraps. Leave enough length cable to connect into
the boom tip junction box.
Connect the length cable into the boom tip junction box.
Reset length potentiometer in length angle transducer (screw is located in center of white gear);
with boom fully retracted, turn potentiometer carefully counter-clockwise until it stops. Recheck
length and angle display. Refer to section Cable Reel LWG508 Adjustment Procedure.
Connect bus connector
Follow Length Sensor Adjustment Procedure.
iFLEX 5
34-6
ANGLE SENSOR CALIBRATION PROCEDURE

Material required calibrated inclinometer.
See section Activating the Service Screen for Sensor Calibration on how to access the angle sensor
calibration screen.
Select the angle calibration by pressing OK
at the calibrate angle screen.
With fully retracted main boom, boom down to

a flat angle close to zero degrees, making sure
you stay within the allowed operating range.
Using the calibrated inclinometer placed flat on
the main boom, verify that the indicated boom
angle matches the measured boom angle
within +/- 0.2 degrees.
If not, mechanically adjust the angle sensor.
The angle should be set to be +/-0.1 of the
measured angle.
Press OK when the sensor is mechanically
set.
iFLEX 5
34-7
Boom up to the next correction angle, 45 degrees

(range is 40- 50). When the boom angle is within
the calibration range, the screen will add the
CHANGE,
SET and
OK text as shown on the left.
Measure the boom angle with the inclinometer and
when the boom is positioned in the calibration range,
compare the measured angle to the displayed angle.
If the indicated angle is within +/- 0.1 degrees of the
measured angle, confirm with OK. Otherwise, select
SET to adjust the angle.
Once you push SET , the screen is going to
change to the angle adjustment screen. Use
the + and -buttons to adjust the indicated
angle to match the measured angle.
When the display shows the correct angle,
press OK.
Repeat the above procedure to verify/set the angle at 60 (range 55- 65). and 70 (range 65- 75).
boom angles.
Press ESC to leave service screen.
iFLEX 5
34-8
ZERO-SETTING THE SLEW POTENTIOMETER

NOTE: The only thing adjustable for the slew potentiometer is the zero point, which is complete when
the boom is at the 0 position over the front of the crane.
Defining the crane zero position:
The zero setting consists of defining zero-point offset. To define the zero-point or the slew
potentiometer the super structure must be positioned so the boom is in the zero degree position over
the front and the house lock pin engaged.
Using graphic console for zero-setting of slew pot potentiometer:
Press return until the slew adjustment screen is displayed.
The display shows a scale from 10 to +10 degree, a horizontal mark shows the current position of the
slew pot wiper.
By pressing the + and - keys simultaneously, the zero setting occurs automatically. Note: The
indicator line will move to zero on the bar graph.
When the operator is finished, pressing the ESC key returns the console display to normal.
iFLEX 5
34-9
P.A.T. L.M.I
MANUAL
SECTION 35
Boom Control
IFLEX5 BOOM CONTROL SYSTEM (BCS)

RT9000E / RT800E BAS ICS
Terminology:
BCS
IM
CM
OM/Fly
DI
DO
PWM
0
1
= boom control system

= innermid boom section
= center-mid boom section
= outer-mid and fly boom section
= digital input, refer to table 3 for definitions
= digital output, refer to table 4 for definitions
= pulse width modulation
= off with regard to digital inputs and outputs
= on with regard to digital inputs and outputs
The BCS controls the boom telescoping sequence by controlling the current supplied to the
proportional solenoids on the 4-way directional control valves. These valves provide oil to the
telescoping cylinders. Here are the basic components, inputs, outputs, and logical functions to
make this happen.
Components:
iFLEX5 control system (central unit), located in the cab.

BCS relay junction box assy, located on rear exterior of cab.
Cable reel to measure overall length, located on boom base section.
Cable reel to measure inner-mid length, located on boom base section.
Proximity switch to sense inner-mid fully retracted, located on boom base section.
Proximity switch to sense center-mid fully retracted, located on boom inner-mid section.
Auto/Manual switch, located on the right hand arm rest in the cab.
Section selector switch, located on the right hand arm rest in the cab.
Boom out of sequence light, located on the front console in the cab.
Extend pressure switch, located on superstructure.
Retract pressure switch, located on superstructure.
Inner-mid pilot operated 4-way directional control valve with extend and retract proportional
solenoids, located on the superstructure.
Center-mid pilot operated 4-way directional control valve with extend and retract proportional
solenoids, located on the superstructure.
Tele two stage relief valve, located on the superstructure.
Manual / Auto Mode:
There are two modes of operation, manual or automatic mode. This is selectable by a switch in
the right hand arm rest in the cab, and is seen by the BCS as digital input 17. DI1 17=0 is manual
mode. And DI 17=1 is auto mode.
1
Refer to table 1 for digital input definitions
iFLEX 5
35-1
Manual Mode Operation:
Primarily used for boom maintenance and function the boom in an unlikely event of a BCS failure.
In manual mode the boom is controlled by the section selector switch in the right hand arm rest in
the cab. When IM selected, crane electric provides full power to the extend and retract
proportional solenoids on the IM pilot operated 4-way directional control valve. This means the
telescoping action is controlled directly by moving the joystick or foot operated treadle valve. The
BCS does not control movement. Likewise when CM is selected, crane electric provides full
power to the extend and retract proportional solenoids on the CM pilot operated 4-way
directional control valve.
Note: In the event of an LMI error, overload, or A2B condition the proportional valves will be not
be energized unless the LMI bypass is activated, either from the central unit or console.
Auto Mode Operation:
An extend or retract action is initiated by moving the joystick or foot operated treadle valve
causing hydraulic pilot pressure to activate an extend or retract pressure switch. The pressure
switch signals are seen as digital inputs to the BCS. As an example of extend from fully
retracted, the BCS realizes DI 19=1 (extend pressure switch on) and simultaneously activates
DO2 8 (IM extend) and DO 3 (PWM 2, IM proportional solenoid). DO 8 energizes a relay in the
BCS relay junction box assy to direct DO 3 to the IM pilot operated 4-way directional control
extend proportional solenoid. Figure 1 illustrates how DO 3 is directed to the solenoid valve. DO
3 is a PWM output and ramps the output according to variables in the data software. Ramp-up
output is time based. When the IM section approaches a change over point (change in
sequence), DO 3 is ramped down according to variables in the data software. Ramp-down
output is percentage based. See table 1 and table 2 for sequencing information. At the
specified change over point, the BCS turns off DO 8 (IM extend) and simultaneously turns on DO
6 (CM extend) and DO 1 (PWM 1, CM proportional solenoid). DO 6 energizes a relay in the
BCS relay junction box assy to direct DO 1 to the CM pilot operated 4-way directional control
extend proportional solenoid. DO 1 is a PWM output and ramps the output according to
variables in the data software. When the CM section approaches a change over point DO 1
ouput is ramped down according to variables in the data software. And so on. When retracting,
the BCS realizes DO 18=1 (retract pressure switch) and does not activate DO 6 or DO 8. DO 1
or DO 3 are activated based on the current boom position.
figure 1
Refer to table 2 for digital output definitions
iFLEX 5
35-2
TELE SEQUENCE:
RT9000E: Mode A - not available
RT800E: Mode A
Mode B
table1
Mode "B" Extend Sequence in Percentage
Tele 1 (IM)
Tele 2 (CM)
Tele 3 (OM/Fly)
0
0
0
75
0
0
75
75
0
100
75
0
100
100
0
100
100
100
Jib Mode (not selectable, realized by operating mode selection)

table 2
Jib Mode Extend Sequence in Percentage
Tele 1 (IM)
Tele 2 (CM)
Tele 3 (OM/Fly)
100
0
0
100
100
0
100
100
100
Note: Retract sequence is opposite of extend sequence.

IFLEX5 BCS DIGITAL INPUTS:
table 1
Digital
Input
6
7
8
9
10
11
16
17
18
19
Description
CM (Center-Mid) Retracted (boom proximity switch)
IM (Inner-Mid) Retracted (boom proximity switch)
Luffing Extension Raise (cab switch)
Luffing Extension Lower (cab switch)
Luffing Extension Raise (remote switch on ext.)
Luffing Extension Lower (remote switch on ext.)
A Mode (cab switch)
Auto Mode (cab switch)
Boom Retract (pressure switch)
Boom Extend (pressure switch)
iFLEX 5
*C.U. X2
Terminal
54
55
56
57
58
59
64
65
66
67
**MP
R89
R90
R91
R92
R93
R94
R100
R101
R102
R103
35-3
RT9000E / RT800E IFLEX5 BCS DIGITAL OUTPUTS:

table 2
Digital Output
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Description
PWM 1 CM Proportional Solenoid
+UB CAN bus
PWM 2 IM Proportional Solenoid
+UB to Slew Potentiometer Electronics
PWM 3 Luffing Extension Proportional Solenoid
CM Extend Relay K1 Coil in Junction Box
PWM 4 Luffing Extension Proportional Solenoid
IM Extend Relay K2 Coil in Junction Box
Luffing Extension Raise Solenoid
External LMI Alarm, Option on Boom
Luffing Extension Lower Solenoid
Rear Axle Oscillate Signal
Tele Rod Drain Solenoid
Boom Out of Sequence Lamp
Tele Two Stage Relief Solenoid
C.U. X2 Terminal
2
3
4
5
6
7
8
9
14
15
16
17
18
19
20
*C.U. =
Central Unit
**MP = Measuring Point; i.e. R89 designates resistor number; see sketches below for specific location; Notes:
must measure on bottom leg of the resistor.
DO 1 = PWM 1
DO 3 = PWM 2
DO 5 = PWM 3
DO 7 = PWM 4
iFLEX 5
35-4
A convenient method to monitor digital inputs (DI) and digital outputs (DO) is utilizing the iTOOL5
or iFLASH terminal function. At the flashing command prompt press and hold Ctrl and A to
enter the RTOS (an asterisk will display). Type digshow and press Enter. The result should be
the screen shown below. The inputs and outputs are counted from right to left and top to bottom
as illustrated below.
*digshow
(RTOS command to display digital inputs and outputs)
T E S T
D E R
D I G I T A L - E I N U N D
A U S G A E N G E
=======================================================================
Baugr. | Port | Modus | IN-Wert | IN-Wert | OUT-Wert | OUT-Wert | Status
| :Taste |
| (Hex) |
(Bin) | (Hex)
| (Bin)
| =NoLoad
-------|--------|--------|---------|----------|----------|----------|-------Basis | 0 : 1 | NORMAL |
00
| 00000000 |
05
| 00000101 | 0000-1
Basis | 1 : 2 | NORMAL |
00
| 00000000 |
82
| 10000010 | 0011-0
Basis | 2 : 3 | NORMAL |
98
| 10011000 |
00
|
|
Erw. | 0 : 4 | NORMAL |
00
| 00000000 |
00
| 00000000 | 1111-1
Erw. | 1 : 5 | NORMAL |
00
| 00000000 |
00
| 00000000 | 1111-1
Erw. | 2 : 6 | NORMAL |
00
| 00000000 |
00
| 00000000 | 1111-1
-------|--------|--------|---------|----------|----------|----------|-------Baugruppencodierung Basis
: 0F = 00001111
DO 1
Baugruppencodierung Erweiterung: FF = 11111111

Hubendschalter UNTB/OFFEN/OK/KURZ:
0000
DI 9
X:Exit
Blank:Redraw
S:Slow
DO 16
DI 1
F:Fast
DI 8
Other methods to determine digital input and output states is by probing the junction box mounted
on the rear of the cab, the C.U. 70-pass connector pins (X2), or specific resistors on the main
board, or terminal strip in the. See table above and sketches below. Be cautious not to short the
probe across connector pins.
Junction Box Assy located on rear exterior of cab
iFLEX 5
35-5
C.U. 70-pass
connector pins (X2)
Resistor bank to
measure digital input (DI)
state. Note: must
measure on bottom leg of
the resistor.
IFLEX5 BCS ANALOG IN PUTS AND PWM OUTPUTS:
iFLEX 5
35-6
Another useful tool to monitor analog inputs and PWM outputs is utilizing the iTOOL5 or iFLASH
terminal function. At the flashing command prompt press and hold Ctrl and A to enter the
RTOS (an asterisk will display). Type adctest and press Enter. The result should be the screen
shown below.
*adctest
T E S T
D E R
A N A L O G E I N G A E N G E
===============================================
Ch | MUX | Error | Kanal+ | Value | Value | UADC | Special
|
|
| Valid | (Hex) | (Dec) | [mV] |
---+-----+-------+--------+-------+-------+------+----------------0 |
|
ok | 0008 | 0310 | 784 | 784 | I_Kanal 1 = 4.356 mA
1 |
|
ok | 0009 | 0816 | 2070 | 2070 | I_Kanal 2 = 11.500 mA
2 |
|
ok | 000A | 0000 |
0 |
0 | I_Kanal 3 = 0.000 mA
3 |
|
ok | 000B | 0000 |
0 |
0 | I_Kanal 4 = 0.000 mA
4 |
|
ok | 000C | 0307 | 775 | 775 | Temperature = +27C
5 | 0 |
ok | 000D | 0B90 | 2960 | 2960 | I_Kanal 5 = 16.444 mA
5 | 1 |
ok | 000D | 0000 |
0 |
0 | I_Kanal 6 = 0.000 mA
5 | 2 |
ok | 000D | 0000 |
0 |
0 | I_Kanal 7 = 0.000 mA
5 | 3 |
ok | 000D | 0000 |
0 |
0 | I_Kanal 8 = 0.000 mA
5 | 4 |
ok | 000D | 0098 | 152 | 152 | I_PWM 1 =
0 mA
5 | 5 |
ok | 000D | 0014 |
20 |
20 | I_PWM 2 =
10 mA
5 | 6 |
ok | 000D | 0000 |
0 |
0 | I_PWM 3 =
0 mA
5 | 7 |
ok | 000D | 0000 |
0 |
0 | I_PWM 4 =
0 mA
OPERATINGMODE
X: Exit
Blank: Redraw
S: Slow
F: Fast P: PWM-Settings
T: Testmode
O: Operatingmode
C: ADC-Clockset E: Extensionmodule T E S T
D E R
A N A L O G E I N G A E N G E
Kanal
1
2
3
5
Description
Slew Angle 1
Slew Angle 2
Wind Speed
Luffing Extension Offset Angle
PWM
1
2
3
4
Description
Center-Mid Tele Output
Inner-Mid Tele Output
Luffing Extension Raise Output
Luffing Extension Raise Output
Note: DO 1 = PWM 1
DO 3 = PWM 2
DO 5 = PWM 3
DO 7 = PWM 4
iFLEX 5
35-7
IFLEX5 BCS TEST DISPLAY:

To view additional information on the console display, push buttons F1 and F4 simultaneously.
To return to the normal screen push button F1 or F4.
Boom Status /
Luffer Status
IM Tele Output
(0-255)
CM Tele Output
(0-255)
Luffing Ext Raise

Output
(0-255)
Luffing Offset
Angle(degrees)
Length 2 (IM)
(feet)
Status No.
1 - 11
29
31 - 41
59
61 - 67
79
81 - 85
99
100
101
102 - 108
110
112
127
200 - 202
210 - 212
Description
Mode B extend
Error Mode B extend
Mode B retract
Error Mode B retract
Mode A extend
Error Mode A extend
Mode A retract
Error Mode A retract
Manual Mode A neutral or extend
Manual Mode B neutral or extend
Manual Mode retract at overload, A2B, error condition
Mode A, Out of Sequence
Mode B, Out of Sequence
Mode A or B, neutral position
Luffing jib raise
Luffing jib lower
iFLEX 5
35-8
BOOM OUT OF SEQUENCE:

Digital Output 14 boom out of sequence is lamp, located on the front crane console, is activated
when the sections become greater than 3.5% out of sequence. Refer to sequence charts above.
Another indication for out of sequence are the flashing section percentages located at the bottom
of the console display
boom section
percentage
display
TELE ROD DRAIN VALVE:

The tele rod drain valve is a normally closed valve that when energized opens to allow oil in the rod side
of the tele cylinders a path to tank. The valve is de-energized to prevent flow to tank. The Boom Control
System energizes this valve at all times unless the boom is fully retracted, or the retract pressure
switch is activated. See the logic chart below. Digital Output 13 is on unless:
Tele Rod Drain Solenoid
(DO13)
0
0
IM retract sw.
(DI 7)
1
CM retract sw.
(DI 6)
1
Retract pressure sw.

(DI 18)
1
TELE TWO STAGE RELIEF VALVE:

The two stage tele relief valve is a normally closed valve that when energized increases the tele extend
relief pressure from 2500 psi to 3000 psi. The Boom Control System energizes this valve when the
retract pressure switch is activated, or when the OM/Fly section is greater than 4% while extending.
See the logic chart below.
Tele Two Stage Relief
Solenoid (DO15)
Retract pressure
sw. (DI 18)
Extend pressure
sw. (DI 19)
OM/Fly
Percentage
>4%
iFLEX 5
IM rertract
sw. (DI 7)
CM retract
sw. (DI 6)
35-9
P.A.T. L.M.I
MANUAL
SECTION 36
Luffing Boom Extension
HYDRAULIC LUFFING BOOM EXTENSION:

Hydraulic control of the extension consists of a four-way, three position directional control valve, a hose
reel, a proportional control valve and a double acting cylinder. The four-way, three position directional
control valve is mounted on the turntable. There are two solenoids for directing the flow for extension
or retraction of the cylinder. The hose reel is mounted on the boom and conveys the hydraulic fluid to
the cylinder on the boom extension. The proportional control valve is mounted to the cylinder on the
boom extension.
The offset angle is measured directly by a potentiometer located on the base adapter. The opposite
end of a lever arm mounted on the potentiometer shaft rests on and follows the structure which offsets.
PAT does not supply the potentiometer.
There are two ways to offset the luffing extension. The first is two switches located in the left hand
armrest. One switch is a luffing system ON/OFF switch. The other is a RAISE/LOWER switch. This
switch has momentary positions on either side, and a return to center position. It raises or lowers the
extension by controlling the raise and lower solenoids on the fourway three position directional valve.
This switch also sends an actuation signals to the LMI. DI 8=1 (raise) DI 9=1 (lower). The proportional
solenoid on the luffing cylinder is energized by DO 5 & 7 (PWM 3 & 4) if DI 8=1. The proportional valve
on the luffing cylinder is not be energized for luffer lower. Hydraulically the proportional valve is
bypassed for luffer lower.
Raise and lower can also be activated form remote switches located on the extension. Remote raise is
DI 10 and remote lower is DI 11. The raise and lower solenoids on the turntable are energized by DO 9
& 11 respectively. If DI 10=1, then DO 5, 7, & 9=1. If DI 11=1, then DO 11=1. The proportional valve
on the luffing cylinder is not be energized for luffer lower. Hydraulically the proportional valve is
bypassed for luffer lower. See sketch below.
iFLEX 5
36-1
P.A.T. L.M.I
MANUAL
SECTION 37
ERROR CODE LISTING
ERROR CODES
The following Error Code Table gives a brief description of Error Codes elimination. Refer to the noted
sections for detailed Troubleshooting information.
Error Code Error

Fallen below radius
E01
Possible Cause
Fallen below the

minimum radius or gone
past the maximum angle
specified in the respective
load chart due to luffing
up the boom too far
Radius range
Gone past the maximum
exceeded or fallen
radius or fallen below the
below angle range
minimum angle specified
in the respective load
chart due to luffing down
the boom too far
Non-permitted slewing The slewing zone with
zone (no load area)
load is not permitted
Operating mode not
An incorrect operating
acknowledged or non
mode has been selected
permitted slewing
zone
range or angle range
exceeded
E02
E03
E04
Elimination
Luff down the boom to a
radius or angle specified in
the load chart.
Luff up the boom to a radius

or angle specified in the load
chart.
Slew to permitted area

Set the correct operating
mode for the operating
configuration in question.
Refer to Operators
Handbook.
The boom is in a nonpermitted slewing zone
E05
Prohibited length
range
Slew the boom to a

permitted area. Refer to
Section 8.
Boom has been extended Extend/retract boom to the
correct length
either too far or not far
enough, e.g. if it is
prohibited to go beyond a
certain maximum boom
length or with load curves
for jibs where the main
boom has to be extended
to a certain length
Length sensor adjustment Retract boom. Check the
prestress of the cable reel
has changed, e.g. the
(cable must be taut). Open
cable slid off the length
the length sensor and
sensor reel.
carefully turn the length
sensor pot counterclockwise
until the detent by means of
a screw driver
Replace the complete clutch
Clutch between length
including drive wheel and
sensor pot and drive is
adjust length sensor pot as
defective
described above
iFLEX 5
37-1
Error Code
E11
E12
E13
E14
E15
E16
E17
Error
Possible Cause
Elimination
Fallen below lower

limit value for
measuring channel
"length main boom"
Fallen below the
lower limit value in
the measuring
channel "pressure
piston side"
Length potentiometer is
defective
Replace length
potentiometer, see
section Length Sensing
Pressure transducer is
defective.
Replace pressure
transducer, see section
Pressure Sensing
Fallen below lower

limit value in the
measuring channel
"pressure rod side"
Fallen below lower
limit value in
measuring channel
"force"
refer to E12
refer to E12
Force transducer
defective
the measuring channel is
defective.
Angle potentiometer
defective
Replace force
transducer
Replace sensor unit
the measuring channel
defective.
Angle potentiometer
defective
Replace electronic
board, see section
Angle Sensing
Refer to E-15
defective.
defective
Refer to E-15
Replace electronic
board, see section
Length Sensing
Check cable as well as

plugs, replace, if need
be.
Fallen below lower

limit value in
measuring channel
"angle main boom"
Fallen below lower

limit value in
measuring channel
"angle 2"
Fallen below lower

limit value "length
telescope I (+II)"
E18
Front outrigger
overloaded
defective
Front outrigger
overloaded
E1A
Fallen below lower

limit value in
measuring channel
"slewing angle 1".
Cable between the

central unit and the
slewing angle sensor
defective or loose.
iFLEX 5
Replace angle sensor,

see section Angle
Sensing
Replace length sensor,

see section Length
Sensing
37-2
Error Code
E1B
E21
E22
E23
E24
E25
E26
E27
E2A
E2B
E31
Error
Fallen below lower

limit value in
measuring channel
"slewing angle 2"
Upper limit value in
measuring channel
main boom length
has been exceeded.
measuring channel
pressure piston
side has been
exceeded
measuring channel
pressure rod side
has been exceeded.
measuring channel
force has been
exceeded.
measuring channel
main boom angle
has been exceeded.
measuring channel
angle 2 has been
exceeded.
measuring channel
length telescope I
(+II) has been
exceeded.
measuring channel
slewing angle 1
has been exceeded
measuring channel
slewing angle 2
has been exceeded
Error in the system
program
Possible Cause
Elimination
Slewing angle
Replace slewing angle
potentiometer is defective
sensor
Replace sensor unit
defective
refer to E1A
refer to E1A
refer to E11
refer to E11
refer to E12
refer to E12
refer to E12
refer to E12
refer to E14
refer to E14
refer to E15
refer to E15
refer to E16
refer to E16
refer to E17
refer to E17
refer to E1A
refer to E1A
refer to E1A
refer to E1A
The system program file

is defective.
Upload valid system

software
Flash-EPROM defective
Replace central unit
iFLEX 5
37-3
Error Code
E37
Error
Possible Cause
Elimination
Error in the logical

program flow
E38
System program
and crane data file
do not match.
E39
System program
and load chart file
do not match
E43
Error in the
write/read memory,
(RAM)
Error in the
monitored write/
read memory.
E47
E51
The CRC
verification of the
monitored
write/read memory
provides an
incoherent result
Error in the crane
data file
System program file is

defective
Upload valid system

software
The system program in
the LMI does not match to
the programming in the
crane data file
The system program in
the LMI and the
programming in the load
chart file do not match.
Write/read memory
(RAM) or central unit
defective.
The CRC sign of the
memory is wrong

Upload valid system
program file or the valid
crane data file
The buffer battery is

decharged (< 2V at
1kOhm).
Replace buffer battery

on the central unit.
Upload valid system

program file or the valid
load chart file
Restart the LMI

Central unit defective.
No valid data in the crane Upload valid crane data
data file.
file
No valid data in the load
chart file

Upload valid load chart
file
E52
Error in load chart

file.
E56
Error in crane data

file.
E57
Error in serial crane Calibration data file does
data file.
not contain valid data.

Upload calibration data
file
No valid data in the load
chart file

Upload valid load chart
file
Base number not

programmed
Program the correct

base number (1 for
base 1, 2 for base 2)
E60
The number of the

selected File base
and the
programmed value
are not identical
No valid data in the crane Restore or upload valid
crane data file
data file during
calibration.
iFLEX 5
37-4
Error Code
Error
Possible Cause
Elimination
Load chart file wrongly

programmed
E61
Error in the CAN
bus data transfer for

all CAN units
E62
E63
E64
E65
Error in the can bus

data transfer of the
pressure transducer
sensor unit

pressure transducer
sensor unit
length/angle sensor
unit

length/angle sensor
unit
E66
E67
Check base
programming in the load
chart file.
CAN Bus cable between Check the connection
between the central unit
the central unit and the
and the sensor units
sensor units defective or
(wiring harness). See
not connected.
section CAN-Bus
Communication
Short circuit in a CAN Bus Replace Can Bus cable
cable
Can bus port in the
Replace the central unit
central unit defective
Check the cable to the
Cable between the
sensor unit (wiring
central unit and the
harness). See section
sensor unit defective or
CAN-Bus
not connected.
Communication
Sensor unit is defective
Replace the sensor unit
The analog values of the Replace the sensor unit
sensor unit are invalid
See section CAN-Bus
Communication.
Check the cable to the
Cable between the
sensor unit. See section
pressure transducer and
CAN-Bus
cable reel defective or not
connected.
Communication
Replace the electronic
board in the cable reel,
see section CAN-Bus
Communication
Angle sensor defective
Replace the angle
sensor, see section
CAN-Bus
Communication
Length sensor defective
Replace the length
sensor, see section
CAN-Bus
Communication
Replace the electronic
board in the cable reel,
see section CAN-Bus
Communication
See E62
See E62

2nd length/angle
sensor unit
Error in the can bus See E63
of the 2nd length
/angle sensor unit
iFLEX 5
See E63
37-5
Error Code
E68
E69
E80
E84
E85
Error
Possible Cause

force sensor unit
force sensor unit
Elimination
See E62
See E63
Error in the slewing The difference between

See section Slewing
angle measurement
the average of the
Sensing
slewing angle and one of
the wipers of the slewing
potentiometer is out of the
tolerance
Wrong rigging
Select another rigging
The selected rigging
condition.
condition
condition is not contained
in the crane data file.
Check the programming
Error in the radius
Check the programming
The computed radius is
determination
too small (negative
deflection)
E89
Operating mode
switchover with
load.
E91
No data transmission form the

console to the
central unit
E92
Error in the data

transmission from
console to central
unit
E93
Error in the data

transmission from
the central unit to
the console
The operating mode on

the console has been
switched over with the
boom loaded.
Power supply of the
console is interrupted
Select operating mode

without load on the
boom
ground in the line
between console
electronics and central
unit
Check the connection

console electronics central unit. In case of
an accidental ground,
the transmitter module
of the console
electronics might be
damaged.
Exchange console
electronics or CU resp.
Transmitter/receiver
module of console is
defective
Loose connection in the
line between console
unit
module is defective
refer to E92
iFLEX 5
Check power at terminal

X1 of the console
electronics
Check the connection

between console
unit
Exchange console
refer to E92
37-6
Error Code
E94
E95
E96
E97
EAB
EAC
EAD
EC0
EC1
Error
Possible Cause
Elimination
No data transmission from the

central unit to the
console
ground in the line central
unit console
Check line to the

console (in case of
accidental ground,
replace console
electronics, too).
Exchange console
Exchange CU.
module is defective
Computer module is
defective
Electro-magnetic
interferences (e.g. when
switching contactors or
valves)
Error in the console The console File is
File
defective.
Error in the internal The CPU of the console
RAM of the console.
is defective.
The console main board
is defective.
Error in the external The external RAM of the
RAM of the console
console is defective.
Eliminate the source of

interferences by inverse
diodes or varistors.
Replace the console
software
Replace console
electronics.
Replace the external

RAM of the console.
Replace the console
electronics.
Replace A2B switch
Short circuit in the

A2B switch circuit
The console main board

is defective.
Short circuit in the A2B
switch
A2B switch circuit

disconnected
Replace cable to the

Short circuit in the cable
A2B switch
to the A2B switch
Disconnected cable in the Connect or replace
cable in the A2B switch
A2B switch
Disconnected cable to the Connect or replace

cable to the A2B switch
A2B switch
No valid A2B switch Sensor wrong function
Replace A2B switch
status
CAN bus delay
Replace cable to the
A2B switch
Prohibited area
Move boom to permitted
Boom is about to collide
area
with the engine hood,
switch off
Approaching
prohibited area
Boom is about to collide

with the engine hood,
prewarning
Move boom to permitted

area
Note:
If an error message is displayed which is not contained in above list, please contact the PAT service
department.
iFLEX 5
37-7
P.A.T. L.M.I
MANUAL
SECTION 38
TROUBLESHOOTING
MOISTURE
TROUBLESHOOTING MOISTURE
The PAT iFLEX5 LMI contains electronic components in various locations, such as central unit,
sensors, junction boxes etc. These internal components cannot be designed to withstand exposure to
moisture over a longer period of time. For this reason, the housings of the components are water
protected according to IP 65. If you find water or moisture inside any of the housings, the source for
the water ingress has to be detected and corrected to ensure proper operation.
There are two major possibilities for the occurrence of excessive moisture inside an enclosure:
1) Water ingress
2) Condensation
This outline gives instructions for detecting the cause for excessive moisture by using simple
troubleshooting methods and how to prevent the moisture ingress from happening again.
WATER INGRESS
There are 6 possibilities for water to enter an enclosure:
1) Spray Cleaning
2) Missing / Loose Screws
3) Bent Lid
4) Defective Gasket
5) Loose Strain Relieves
6) Water Entry Through External Cabling
It is possible to find out the source of water ingress by going through the following steps and ruling out
one possibility after the other until the cause is identified:
1) Spray Cleaning
The enclosures used for the PAT LMI system are water protected to IP 65. This means protection
against the environment, such as rain. However, through the use of spray cleaner at short
distances, it is possible to force water through the gasket or strain relieves. For this reason, avoid
spraying any components from short distances with spray cleaners. Convey this fact to any member
of a maintenance crew.
2) Missing / Loose Screws
All screws have to be present and to be equally tight to ensure water protection of the enclosure. If
there are screws missing, replace them. If no screw is missing, check the tightness. If any were
loose, then open all screws and then re-tighten them equally.
3) Bent Lid
An enclosure will only seal correctly if the lid is not bent. To check this, loosen all screws of the lid,
take the lid off the box and visually inspect it for deflection. If the lid is bent or damaged, it needs to
be replaced. Try to determine what has caused the lid to be bent and eliminate the reason for that.
Order a new lid through your PAT representative.
iFLEX 5
38-1
Troubleshooting Moisture
4) Defective Gasket
The gasket underneath the lid seals the unit. The gasket needs to be in good condition in order to
seal correctly. If the gasket is torn, brittle or severely bent, it needs to be replaced. Order a new
gasket through your PAT representative.
5) Loose Strain Relieves
The strain relieves allow cabling to enter the box without allowing water to enter it. The strain
relieves have to be correctly tightened in order to do this. Check the tightness by taking the external
cable into one hand and carefully trying to turn it. If the internal wires turn with the outer cable, the
strain relief is loose. Get a new grommet (insert) through your PAT representative and replace the
existing one with the new one. Tighten the strain relief correctly. Note: Whenever a strain relief is
opened, i.e. to replace a cable, a new grommet needs to be used. Never re-use any grommet or the
strain relief will not seal properly!
6) Water Entry Through External Cabling
Even with a tight strain relief, water may still enter the box through the inside of the cable. In this
case, you have to find out why and where water enters the cable. Look for damages to the cable
itself and inspect the opposite side of the cable. In example, if the cable comes from a connector
that is full of water, the water will run through the inside of the cable and fill up the central unit, too.
CONDENSATION
In a climate with high humidity and rapidly changing temperatures, condensation can happen inside
any enclosure, usually the larger the volume of the box, the more likely. In this case, water drops build
up on the inner components when humid air is trapped inside the box. With condensation, water
tightness is not a problem the box is sealed just fine, which is what prevents the trapped air from
exiting the box. There are two ways to deal with condensation:
1. If the volume is very small, a desiccant bag might be able to soak up the airs humidity.
2. If the effect is more severe, the only way to get rid of this effect is then to give the box the
ability to breath without sacrificing its water tightness. Contact your PAT representative for
breathing elements to than can be added to the box and will help to reduce the effects of
humid climates.
iFLEX 5
38-2
P.A.T. L.M.I
MANUAL
SECTION 39
SOFTWARE TRANSFER
INFORMATIONS INFORMATION
SOFTWARE TRANSFER INSTRUCTIONS FOR THE CONSOLE USING

THE FLASH MODULE
Remove the console from the dash by removing 8 mounting screws.

Remove four screws from the rear of the console housing, exposing the internal boards.
Attach the Console Flash Module to X6 and X7 simultaneously.
Power on the system.
At power-on if the software in the console does not match that in the Flash Module, an
option to update will be presented. This option will disappear after 10 seconds until power
is cycled.
Immediately after seeing the update option, press and hold the Horn button until its light
stops blinking.
Software is finished updating when the Grove logo appears.
Cycle power if the software is updated correctly the update option will not appear at
power-on.
Verify software update/version by pressing the Info button three during system operation.
REMOVE FLASH MODULE WHEN FINISHED IT IS NOT TO REMAIN IN THE CONSOLE!
Attach the housing and the four inner screws from the rear of the Console, exposing the
internal boards.
Insert the console into the dash and mount in place with the 8 screws.
iFLEX 5
39-1
SOFTWARE TRANSFER INSTRUCTIONS FOR THE IFLASH PALM AND

CENTRAL UNIT
INTRODUCTION
iFLASH allows for transfer data files between the palm and the PC and Palm and iflex system. Data
files can not be transferred with the Palm software program HotSync.
IFLASH Desktop
iFLASH desktop is the program, which takes care of the data transfer, is provided for communication
or the transfer of files between PC and the iFLASH Palm
iFLASH Palm
iFLASH Palm is the program which runs on the Palm. This program must be transferred to the Palm
using Hotsync. Please contact PAT on information on how you can obtain this software.
INSTALLING IFLASH DESKTOP

The iFLASH Desktop needs no installation. Just copy to your Desktop or any convenient folder.
INSTALLING IFLASH
The iFLASH program must be installed onto the Palm. To install iflash on the Palm, use the hotsync
program of the Palm. The file name is iFLASH*.prc. Follow the normal Hotsync procedure for
transferring the program from the PC to the Palm. Instructions for Hotsync will be in your Palm
documentation or on Palm's web site.
iFLEX 5
39-2
DATA TRANSFER FROM THE PC TO THE PALM

Palm
- Put Palm into the HotSync Cradle and turn it on.
PC
- Deactivate HotSync manager. If Hotsync manager is not deactivated, the program will
respond with an error, "unable to open specified port"
PC
- Double click on iFLASH Desktop
PC
- Select the necessary serial interface (COM1, COM2,...)
PC
PC
- Click on Add File to Store...
- Select the file which you want to transfer and click "Open"
iFLEX 5
39-3
Software Transfer Instructions for the iFLASH Palm and Central Unit
Palm
Palm
Palm
Palm
PC
PC
Palm
- Start iflash
- Select File Store.
- Select Receive.
- palm will show "waiting for connection"
- click on OK.
- When the transfer is complete the following message will appear.
- "Transfer complete" will show on the palm.
The file should now be stored in the Palm.
iFLEX 5
39-4
DATA TRANSFER FROM THE PALM TO THE PC

Palm
- Put Palm into the HotSync Cradle and turn it on.
PC
- Deactivate HotSync manager. If Hotsync manager is not deactivated, the program will
respond with an error, "unable to open specified port"
PC
- Double click on iFLASH Desktop
PC
- Select the necessary serial interface (COM1, COM2,...)
PC
- Click on Refresh File List
Palm
- Start iflash
Palm
- Select File Store.
Palm
- Select Send.
Palm
- palm will show "sending Filelist"
PC
- When the transfer is complete the window will be updated with the files from
the Palm file store.
iFLEX 5
39-5
Palm
PC
- "Sending complete" will show on the palm.

- Select the file you need and click Retrieve marked File(s)
After that you will get the following message:
Palm
PC
- select Receive.
Click OK.
Wait until Transfer completed is displayed in the status bar of the Palm.
Acknowledge the message on the PC:
The file has been successfully filed in the folder created by the iFLASH Palm Desktop.
iFLEX 5
39-6
TRANSFERRING SYSTEM, DATA OR TLK FILES FROM THE PALM TO THE

IFLEX5
Connect the Palm with the iFLEX5 via its serial cable.
Power the iFLEX system
Select iFLASH program
Select Settings. Note - The values are saved after the first time. This can be skipped later.
Set Speed to: 9600
Set Data Bits to: 8
Set Parity to: N
Set Stop Bits to: 1
Select Save.
Select Palm to iFLEX
Select the file to be transferred from the file selection box.
Select Start Transfer
Wait until all bytes have been transferred in the line Progress.
The data have been successfully transferred to the iFLEX5.
iFLEX 5
39-7
TRANSFERRING SYSTEM, DATA OR TLK FILES FROM THE IFLEX5 TO THE

PALM
Connect the Palm with the iFLEX5 via its serial cable.
Power the iFLEX system
Select iFLASH program
Select Settings.
Select Settings. Note - The values are saved after the first time. This can be skipped later.
Set Data Bits to: 8
Set Parity to: N
Set Stop Bits to: 1
Select Save.
Select iFLEX to Palm
Select the corresponding parameter data file in the displayed selection box. See parameter file
section.
Select the file to be transferred from the file selection box.
Using your Stylus, check off either save brn file or save bin file in the selection Save file as
depending on how you want the file to be stored.
Select Start Transfer
Wait until the message complete appears in the line Progress
The iFLEX has to be restarted manually.

The data has been successfully transferred and can be found in the FileStore. Quit the dialog
with Done and switch to the FileStore. The file name of the stored file gets the name of the
parameter data file except for the extension.
Example: Parameter file : 12k.ADR
12k.BIN and 12k.BRN
If this file name exists already in the Filestore, it will be counted upward by one.
Example: Parameter file :12k.ADR
12k_01.BIN and 12k_01.BRN

12k_02.BIN and 12k_02.BRN, etc.
PARAMETER FILES
There are several files required for transferring from iflex to palm. These files are called parameter
files. You should have a parameter file for each of the file types that you wish to transfer from the iflex
to the Palm. These files will have a "adr" extension on the filename. Examples are tlkprom.adr,
datprom.adr. These files must be transferred from the PC to the Palm using the file store program.
Please contact PAT for information on acquiring these files.
iFLEX 5
39-8

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LEVEL II

P.A.T. - L.M.I. LEVEL II

P.A.T. - L.M.I. LEVEL II

DS350 Graphic Modular Console Connections,

DS350 Graphic Modular Central Unit P.C. Board

DS350 Graphic Modular Boom Length

DS350 Graphic Modular Piston, Rod Connections

DS350 Graphic Modular Boom Angle Connection

DS350 Graphic Modular Anti - Two - Block

DS350 Graphic Modular Troubleshooting Guide

P.A.T. - L.M.I. LEVEL II

P.A.T. - L.M.I. LEVEL II

iFLEX5 Service Information

Troubleshooting a Sensor Problem Using the Display

Service Screen for Sensor Calibration

Luffing Boom Extension

Error Code Listing

Software Transfer Instructions Information

DS 350 GRAPHIC CONSOLE

DS 350 / 1319 GRAPHIC

P.A.T. LOAD MOMENT INDICATOR

3.2 SYSTEM FUNCTION

In case of system malfunction an error code number

After restarting the engine within 2 hours, the system

Basic system information for crane operator will be

Experienced operators who are familiar with the LMI

The system will display information and directions

The system is in the programming procedure. The operator

The system is ready for operation.

4.1 Pre-Setup cont.

THE LMI SYSTEM IS AN

CONSULT AND OPERATE

The operator is entirely responsible for safe crane operation.

4.2 Operating Console

4.3 Control Identification

The LC display visualizes graphical symbols, text and numerical values.

This button will be used for future functions:

The AUDIBLE ALARM sounds during the following

This button can be operated only if key switch is turned to

5. Daily Inspection & Observations

Machines with only a Main Hoist

Machines with Main and Auxiliary Hoists

Installation of Anti-Two-Block Retainer in Locking Position

Fig. 2 : Retainer in Locking Position

Removal and Storage of the Anti-Two-Block Retainer

Fig. 4 : Retainer in Storage Position

Pre-Operation Inspection and Calibration Verification

If the light and audible alarm do not function as described

6. Service and Maintenance

E01: FALLEN BELOW

E02: RADIUS RANGE

E06: BELOW JIB ANGLE

NOTE: Operating within the red area is not permitted.

DATA FROM C.U.

K1= NOT USED

FIVE SECTION BOOM SERVICE SCREEN

OM/Fly Hex Value

To activate service screen press and hold F1 & F4 until screen

DS 350 GRAPHIC BCS

DS350 GRAPHIC with BOOM CONTROL SYSTEM

Boom control information flow

B.C.S. checks input for

B.C.S. checks input for

B.C.S. checks the