DS350 Graphic Console Description, Connections & Wiring Diagram

LEVEL II
G
RO
VE
PA
DS350 GRAPHIC
T
(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 Description
1. DS350 Graphic Console Descriptions
Connections & Wiring Diagram,
2. DS350 Graphic (BCS) Hydraulic, Electrical
Theory & Component Location
3. DS350 Graphic (BCS) Boom Length
Connections & Wiring Diagrams
4. DS350 Graphic (BCS) Piston, Rod Connections
& Wiring Diagrams
5. DS350 Graphic (BCS) Boom Angle
6. DS350 Graphic (BCS) Anti - Two - Block
7. DS350 Graphic (BCS) Digital Inputs
8. DS350 Graphic (BCS) Central Unit P.C. Board
Layout
9. DS350 Graphic (BCS) Basic Adjustments
and Checks.
10. DS350 Graphic (BCS) Main Board and
Transducer Replacement Procedure
11. DS350 Graphic (BCS) Troubleshooting Guide
Appendix: Boom Length Troubleshooting
12. DS350 Graphic (BCS) Electrical Diagrams
13. 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 Description
21. DS350 Graphic Modular (BCS) Console

Connections, Wiring Diagrams
22. DS350 Graphic Modular (BCS) Component
Location
23. DS350 Graphic Modular (BCS) Boom Length
24. DS350 Graphic Modular (BCS) Piston, Rod
25. DS350 Graphic Modular (BCS) Boom Angle
26. DS350 Graphic Modular (BCS) Anti - Two - Block
27. DS350 Graphic Modular (BCS) Digital Inputs
28. DS350 Graphic Modular (BCS) Central Unit P.C.
Modular Board Layout
29. DS350 Graphic Modular (BCS) Troubleshooting
Guide
30. DS350 Graphic Modular (BCS) Electrical Diagrams
31. 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
0335 156ft
TARE
! 90.0ft
?
LIM
79.4 o
SEL
50.8ft
STOP
MAX
02 73.5oo
(lbs)
i
ACT (lbs)
34.900 CTRL
100% 100% 100%
STOP
F1 F2 F3 F4
DS 350 / 1319 GRAPHIC

OPERATOR’S 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 crane’s 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 crane’s 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 mi-
croprocessor unit. This key switch bypasses control lever lock-
out function of load moment indicator device. The switch may
only be used by authorized personnel during emergency situa-
tions. 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
NOTE:
If PAT System is to be used in
conjunction with a jib having an
existing Grove/Krueger Anti-Two-
1
GRO
Block system, a special connector
VE
cable is required. Consult Grove
customer services for requirement.
5 2
3
4
5
CONSOLE 4
1 ANTI-TWO-BLOCK SWITCHES
2 PRESSURE TRANSDUCERS
3 LENGTH/ANGLE SENSOR-ANTI-
TWO-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
Start automatic test of all lamps, the audible alarm and the
complete LMI system.
Self check of
LMI System
In case of system malfunction an error code number

Error? Error code
yes will be displayed on the console.
no
Within
yes 2 hours? After restarting the engine within 2 hours, the system
no will by-pass “Pre-Setup”.
Interactive Basic system information for crane operator will be

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

Interactive system can by-pass the info run.
INPUT
reevings The system will display information and directions
which the operator will follow by using the respective
function of the key.
Inputs
The system is in the programming procedure. The operator
OK? no has to set the LMI to the configuration of the crane.
yes
Ready for The system is ready for operation.
Operation
4 SYSTEM’S 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 Prior to operating, the operator shall carefully and thoroughly read and understand
MANUALS the crane load capacity charts and the information contained in the manuals for the
READ AND UNDERSTAND crane and the LMI, to ensure that the operator knows the operation and limitations
* PUSH “ INFO” of the crane and the LMI.
THE LMI SYSTEM IS AN

The load moment indicator (LMI) is a system which supports an operator in his
OPERATIONAL AID action to operate the crane.
WHICH CAN FAIL But the system cannot be 100% fail-safe and not all causes for danger can be
* PUSH “ INFO” recognized at the same time.
For the loading capacity of the crane only the load capacity charts are relevant. The
CONSULT AND OPERATE
ACCORDING TO IN CAB operator shall also observe the operating instructions in the load capacity charts.
LOAD CAPACITY CHARTS The load values in the load capacity chart shall under no circumstances be
* PUSH “ INFO” 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 He has to make sure that the crane is in good condition and that he works on a firm
YOUR LIFT OPERATIONS and level supporting surface. The operator shall fully acquaint himself with the
* PUSH “ INFO” most recent government regulations and industry standards relevant to safe craning
operations.
IF IN DOUBT CONSULT
THE OPERATOR MANUALS If there is anything unclear or if there are doubts about operating the crane or LMI,
BEFORE OPERATING THE the operator shall consult the operator manuals before operating the crane.
CRANE * PUSH “ INFO”
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 operator’s console is mounted in the crane’s cab in the operator’s 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 :
6
2 STOP
1. LC Display Area
2. Load Moment Limit Light 7 TARE
3. Load Moment Prewarning Light

4. Alarm Light “Anti - Two - Block”
3 !
5. Override Key Warning Light 8 LIM
6. Button “Alarm Stop”
4
7. Button and Control Light “TARE” 1
9 SEL
8. Button and Control Light “LIMITS”
9. Button and Control Light “SELECT
10.
OPERATION MODE”
Button and Control Light “INFO”
5 STOP
10 i
11. Button and Control Light “CONTROL”
14
12. Audible Alarm 11 CTRL
13. By-Pass Key Switch

14. Button and Control Light “By-Pass STOP 15
ANTI - TWO - BLOCK”
15. Button and Control Light “By-Pass F1 F2 F3 F4
LMI SHUT-OFF FUNCTION”
13
F1 Button “Function 1”
1.8
! STOP The LC display visualizes graphical symbols, text and numerical values.
1. 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
STOP crane reaches the crane load capacity. The audible alarm also sounds when this
2. 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).
3.
! 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.
4. 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 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
5. STOP 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.
6. 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.
After pushing the Tare Button before lifting, the display of actual load will be
7. TARE 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
This button will be used for future functions:
- Slewing Angle Limitation
8. LIM - Tip Height Limitation
- Radius Limitation
Boom AngleLimitation is used.
If, during the crane operation, you wish to change the crane
configuration, this button can be pushed for quick setting
9. SEL without having to go through the whole LMI programming
procedure again. (ie. Hoist Reeving, Hoist, Extension)
With the system being ready for operation, this function serves
10. i 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.

CTRL The last adjustment is stored and does not have to be repeated at
11. every system start.
The AUDIBLE ALARM sounds during the following

12. PAT 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 :
13. - deactivate the cut-off function of the LMI
B - deactivate the cut-off function of the
anti-two-block switch
It can be operated only by using the matching key
A 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
This button can be operated only if key switch is turned to
position B.
14. 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.
15. STOP 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-two-
block 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 it’s 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 Fig. 2 : Retainer in Locking Position

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 5
3
1
4
2
Fig. 3 : Removal of the Anti-Two- Fig. 4 : Retainer in Storage Position

Block Retainer
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 crane’s
LMI calibration.
WARNING
Any structural modifications or changes to the crane shall
require reverification of the crane’s 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 Error

E01 Fallen below the radius or above angle range
E02 Radius range exceeded or fallen below angle range
E03 Boom position is out of the permissible working area
E04 Operating mode not existing
E05 Prohibited length range
E06 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: FALLEN BELOW E01: ABOVE ANGLE

RADIUS RANGE RANGE
RADIUS = 27.4 ft ANGLE = 80.0 o
Cause: Elimination:
Fallen below the minimum radius Lower boom back to a radius or
or above the angle given in the angle given in the load capacity
load capacity chart due to raising chart.
the boom too far.
ERROR 02
E02: RADIUS RANGE E02: BELOW ANGLE

EXCEEDED RANGE
RADIUS = 75.6 ft ANGLE = 25.0 o
Cause: Elimination:
The maximum radius or minimum Raise boom back to a radius or
angle given in the load capacity angle given in the load capacity
chart was exceeded due to lower- chart.
ing the boom too far.
ERROR 03
E03: NO - LOAD AREA
Cause: Elimination:
Boom position is out of the permis- Move boom back to permis-
sible working area (over front) sible 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 Elimination:
Operating mode switch in the con- Set operating mode switch cor-
sole set incorrectly. rectly to the code assigned to the
operating mode of the crane.
Operating mode is not permissible Be sure crane is set up according
with the actual crane configuration, to proper operating configur-
boom position or area definition. ations.
ERROR 05
E05: LENGTH RANGE

NOT PERMITTED
LENGTH = 75.3 ft
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.
Length sensor adjustment changed For elimination refer to service
i.e. length sensor cable slid off the manual.
length sensor drum.
1.19
ERROR 06
E06: BELOW JIB ANGLE E06: RADIUS RANGE

RANGE EXCEEDED
JIB ANGLE = 15.0o RADIUS = 96.6 ft
Cause: Elimination:
The minimum angle or maximum Raise jib back to an angle given
radius of the luffing fly jib given in in the load capacity chart.
the load capacity chart was exceeded
due to lowering the jib too far.
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 operator’s 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. Lightbar’s brightness to the lighting conditions of the environment a DIM-
switch 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).
X4 X1 X1
1 3 5
2 4 6
1 2 3 4
F1
8 10 12 14 16 18 20 22 24 26 28 71 72 73 74
X1
7 9 11 13 15 17 19 21 23 25 27 29
H9 H8
V2 V1
A2B K9 LMI K8
SHUT SHUT
OFF OFF
X3 H7 H4 H1
V11 V8 V5
SEQUENCE
OUTER
OUT OF
MID
K7 K4 K1
X1
+24.0
R15 R16 R9 R10 R3 R4
R17
R18
H10
V3
H6 H5 H3 H2
V10 V9 V7 V6
K10
CENTER
4 - WAY
DRAIN
LEVER
INNER
MID
ROD
MID
K6 K5 K3 K2 LOCKOUT
X4
R13 R14 R11 R12 R7 R8 R5 R6 R2 R1
49 48 47
CM
OM
4W
SE
IM
RO
F8 F7 F6 F5 F4 F3 F2
Q
X1
70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50
X1 X1
80 79 78 77 76 75 43 42 41 40 39 38 37 36 35 34 33 32 31 30 46 45 44
X1 X1 X1
1.21
80
LENGTH
79 DE 6 RESET SW.
78
CM / IM
77 DE 5 RET. SW.
76
OM / FLY
75 DE 4 RET. / % SW.
74 -5V
73 -SIG
DS350 Graphic
72
71 GND 86
70 o K7 = OM / FLY
87A 30
69 o o - 2 WAY
Console to C.P.U.
85
87
68 F8 86
67 o K6 = CM 2 - WAY
66 87A o30
o 85
Connections
65 87
F7 86
64
o K5 = 4 - WAY
63 87A 30
o o 85 DIREC. VALVE
62 87
F6 86
61
o K4 = TELE OUT
60 87A 30
o o 85 OF SEQ.
59 87
F5 86
58
o K3 = ROD
57 87A 30
o o 85 DRAIN SOL.
56 87
F4 86
55
o K2 = IM 2 - WAY
54 87A o30
o 85
53 87
F3 86
52
o K1= NOT USED
51 87A 30
o o 85
50 87
F2
49
o
87A
o oK10
48 30
87
47
6 46
45
.
o o o K9 86
K10
85 0 (UB)
5 44
43
.
o o o K8 .
o
UB
LMI BY - PASS 14 7 UB
42 AUTO MODE
KEY o o DE 3 SW. ON
41
o o 40 PRESS. SW.
13 DE 2 BOOM RET.
39
38 PRESS. SW.
DE 1 BOOM EXT.
37
36 0 (UB)
35 SIG A2B
34 0-SIG
LMI BUTTON 2
COMPARATOR
33
BY - PASS 0 (UB)
3 32 RXD
4 31
DI (8) TXD
A2B BUTTON
8 1 30 UB
29 -SIG
BY - PASS LMI (7) 28 +SIG
7 27 -9V
CONSOLE A2B (6) 26
+9V
BY-PASS 6 25
-5V
KEY COMM. (5) 24 -SIG
5 23
RXD (4) 22 GND

DATA FROM C.U. 4 21 -SIG
20 -5V
TXD (3)
DATA TO C.U. 3 19
18 +5V
GND (2) 17
2 GND
16 -SIG
+24V (1) 15 -5V
1 14
13 +5V
12 GND LEN.(OA)
11 -5V
10
9 ANGLE
8
7 GND
6
5 X4
4 4
3
0(UB)
3
)
2 2
)
1
) 0 (UB) / GND
1 +UB
) +24 V
1.22
FIVE SECTION BOOM SERVICE SCREEN
(TMS/TTS 870 & RT865BXL)
PAT DS 350
! STOP
STOP
0335 156ft
TARE
! 90.0ft
?
Ramp Seq. IM Hex Value
LIM
79.4 o
1 255 SEL
CM Hex Value OM/Fly Hex Value
50.8ft
0 0
1 255
STOP
0 0
02
MAX
73.5oo
(lbs)
i
38.2 ACT (lbs)
38.2
34.900
38.2
CTRL
100% 100% 100%
38.2 STOP
F1 F2 F3 F4
Length of IM
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 operator’s 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.
Operation in manual
B.C.S. checks input for
off mode - no control
Automode.
output.
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 Console displays
switches on the boom correct length and % of each
and obtains the length section.
signals.
incorrect
B.C.S. defaults into a
continue on next page
rigging mode, console
displays error code or
dashboard warning
light indicates "out of
sequence".
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. TM9150, TM9100
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
continuation
B.C.S. senses the

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

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

B.C.S. changes relay
combination to close the flow to TM9150 & TM9100
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
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 Mode
TM 9150 B
TM 9100 A, B
TMS 870 A, B
TTS 870 A, B
RT 865 BXL B
2.5
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
OUTER MID CENTER INNER BOOM
FLY MID MID NOT BOOM
ON ON ON SYNC
TELESCOPE
SYSTEM
OUTER
MID A A
FLY U
T
O
2.7
CENTER
MID
M
A
N
U
INNER
A
MID B
L
BOOM TELE BOOM BOOM
SECTION SELECT MODE TELE MODE
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
TMS / TTS 870 & RT865BXL
with Boom Control
Turntable Components
TELE
EXTEND
2.9
SEQUENCE
VALVE
1000 PSI
P.A.T. DS350 GRAPHIC
C.P.U. BOARD LOCATION
TMS870/TTS870
(5 section boom)
THIRD WRAP
VALVE CONTROL
K11 K12 BOARD
A111
MH AH
DIGITAL INPUT DIODE

EXTENSION BOARD BOARD
A112 A113
MAIN
DECODER
X1 TERMINAL BOARD
BOARD
A110 BOARD A104 A101
2.10
TMS / TTS870 Central Processing Unit
5 - Section Boom
PRES. TRAN. CABLE ASSY (PISTON) CABLE ASSY TO CONSOLE
PRES. TRAN. CABLE ASSY (ROD) CABLE ASSY TO BOOM
CABLE ASSY TO BOOM
FUSE (10A)
CRANE INTERFACE CABLE
FUSE (2A)
2.11
KEY BYPASS SWITCH
DATA LOGGER DOWNLOAD RECEPT.

(DATA LOGGER OPTIONAL)
(BOTTOM VIEW
OF C.P.U.)
RT865BXL Central Processing Unit
PRES. TRAN. CABLE ASSY (PISTON) CABLE ASSY TO CONSOLE

PRES. TRAN. CABLE ASSY (ROD) CABLE ASSY TO BOOM
CABLE ASSY TO BOOM
FUSE (10A)
CRANE INTERFACE CABLE
FUSE (2A)
2.12
KEY BYPASS SWITCH
DATA LOGGER DOWNLOAD RECEPT.

(DATA LOGGER OPTIONAL)
AREA DEF CABLE
(BOTTOM VIEW
OF C.P.U.)
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
CENTER MID
CYLINDER
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
Boom Control components
TMS/TTS 870 and RT 865BXL
DS350 Graphic - BCS
IM length sensor CM length and angle sensor

LG221 LWG221
Boom length sensor

See detail
IM % reset
See detail LG208
“A” switch
“C” See detail
“C”
PAT
2.14
PAT
PAT
See detail IM retract

“C” switch
OM retract and % CM retract and %

reset switch reset switch
5 DS350 Graphic - BCS
7
7
8 1
PAT
PAT
PAT
3
5
2
2.15
1 PRE - TENSION (LENGTH SENSOR) SPRING 5 REMOVE 1/4 - 20 NUTS ON BOTTOM OF CABLE GUIDE.
BY ROTATING DRUM (16) REVOLUTIONS COUNTER INSERT CABLE GUIDE SCREWS THRU EXISTING ANGLE
CLOCKWISE. THEN UNSPOOL THE LENGTH CABLE BRKT AND SECURE IN PLACE WITH 1/4 - 20 NUTS
AND SECURE TO BUSHING ON THE BOOM NOSE REMOVED PREVIOUSLY.
PER DETAIL “A”.
7 CENTER LINE OF CABLE GUIDE MUST BE ALIGNED W/ CENTER
2 PRE - TENSION (LENGTH SENSOR) SPRING LINE OF CABLE REEL DRUM.
BY ROTATING DRUM (35) REVOLUTIONS COUNTER
CLOCKWISE. THEN UNSPOOL THE LENGTH CABLE 8 AFTER MACHINE IS CALIBRATED, REMOVE PROTECTIVE PAPER
AND SECURE TO BUSHING ON THE INNER - MID CORROSION INHIBTOR AND ADHERE TO INSIDE HOUSING COVER
PER DETAIL “A”. SURFACE OF CABLE REEL.
3 PRE - TENSION (LENGTH SENSOR) SPRING

CLOCKWISE. THEN UNSPOOL THE LENGTH CABLE
AND SECURE TO BUSHING ON THE CENTER - MID
PER DETAIL “B”
See detail
“B” 4 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.
0.44 6
0.44 6 INSTALL PROXIMITY SWITCH 0.44” FROM
16
TARGET WHEN BOOM SECTIONS ARE
FULLY RETRACTED.
See detail
“A”
0.44 16 THIS TARGET IS ONLY INSTALLED IF THE
BOOM IS EQUIPPED WITH A BOOM
EXTENSION STOP BLOCK.
18
CENTER LINE OF TARGET WHEN BOOM SECTIONS ARE
TARGETS &
PROXIMITY SW. FULLY RETRACTED.
0.13
PAT
2.16
DETAIL “A”
1.0
4
1.34
DETAIL “C”
DETAIL “B”
To
wi be a
t
of h c e ligne
ca n
bl e t e r l d
ree ine
ld
rum
4
DS350 Graphic - BCS
PARTIAL TOP VIEW
19
2.17
CENTER LINE OF CABLE GUIDES
CENTER LINE OF
CABLE GUIDES ON THE BASE & INNER MID
SECTIONS ASSOCIATED WITH TOP AND
CABLE REEL DRUM
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.
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
80
LENGTH
79 DE 6 RESET SW.
78
77
76
75
DE 5
DE 4
CM / IM
RET. SW.
OM / FLY
DS350 Graphic
X1 Terminal Board
RET. / % SW.
74 -5V
73 -SIG
72
71 GND 86
70 o K7 = OM / FLY
OM 2 - WAYS 69 87A
o o
30
85 - 2 WAY
87
68 F8 86
67 o K6 = CM 2 - WAY
CM 2 - WAYS 66 87A
o
o30 85
65 87
F7 86
ANALOG SIG. - RET. VALVE 64
o K5 = 4 - WAY
ANALOG SIG. - EXT. VALVE 63 87A
o o
30
85 DIREC. VALVE
SIG. ANALOG OUTPUT BOR. 62 87
F6 86
TELE OUT OF SEQ. 61
o K4 = TELE OUT
60 87A 30
o o 85 OF SEQ.
59 87
F5 86
58
o K3 = ROD
ROD SIDE DUMP 57 87A
o o
30
85 DRAIN SOL.
56 87
F4 86
55
o K2 = IM 2 - WAY
IM 2-WAYS 54 87A
o
o30 85
53 87
F3 86
52
o K1= NOT USED
51 87A 30
o o 85
50 87
F2
49
o
87A
o oK10
48 30
87
47
. 0 (UB)
F2
10 A 3 46 o o o K9 86 85
) K10
45
3
44
43
.
o o o K8 .
o
UB
o o UB
42 AUTO MODE
DE 3 SW. ON
41
2
GND 40
DE 2 PRESS. SW.
BOOM RET.
39
1 38 DE 1 PRESS. SW.
+24 V 37
BOOM EXT.
36 0 (UB)
35 SIG A2B
34 0-SIG
COMPARATOR
33
0 (UB)
32 RXD
31 TXD
30 UB
29 -SIG
28 +SIG
27 -9V
26
+9V
25
-5V
24 -SIG
23
X5
22 GND 1
21 -SIG 2
20 -5V 3
19 X4
4
INTERFACE
2X SERIAL
18 +5V
17 GND
EXTENSION
16 -SIG
MEMORY
15 -5V
14 40
X6
13 +5V COND.
12 GND LEN.(OA)
11 -5V
10
9 ANGLE
MEASURE
8 26
PINS
7 GND COND.
6
F1
2A 5 X4
2 4 4 X1
3
0(UB)
3
) 3
X7
2 2
) ( 2
1 1
) ( 1 0 (UB) / GND X9
1 +UB
) ( +24 V BR14
2.21
w
w
w
w
PILOT w
w
w
TEST PORT
PILOT w
w
800 PSI
w
ROD
DRAIN
w
TO DUAL RETURN .078 PISTON

P1 MANIFOLD DRAIN
)
SEQUENCE
)
VALVE
w
w
WITH CHECK
1000 PSI
TO CASE
P2
PRESSURE
SWITCH
EXTEND
PRESSURE
SWITCH
EXTEND ~
W W
DRAIN
MANIFOLD
RET EXT EXT RET
49.9
B A P1 D B A P1 GPM
w GP
w
w
220-
w
300
w
3650
w
)
w
)
w
w w w
3800 3000 1500

w
LS
TELE P2 D LIFT
W
OPEN OUT
PRESSURE
~ SWITCH
RETRACT
2.22
TO DRAIN MANIFOLD
800 PSI
w
K3
ROD
DRAIN
w
TO DUAL RETURN .078 PISTON
P1 MANIFOLD DRAIN
)
SEQUENCE
w
VALVE w
WITH CHECK
1000 PSI
P2
PRESSURE
SWITCH
EXTEND
PRESSURE
SWITCH
EXTEND
~
NO NC
TO CASE DI 1 W
W
DRAIN
MANIFOLD
RET EXT EXT RET
49.9
B A P1 D B A P1 GPM
w K5 GP
w
w
220-
w
300
w
w
3650
w
)
w
w
w w w
3800 3000 K5 1500

w
LS
TELE P2 D LIFT
DI 2 W NO OUT
PRESSURE
SWITCH TO DRAIN MANIFOLD
~ RETRACT
2.23
CYLINDER FULLY RETRACTED
PILOT w
w
2.24
DS350 GRAPHIC BOOM CONTROL SYSTEM “B” MODE
Ramping
value
1 8
255 2
INNER MID CENTER MID
7
50 6
40 t
3
Proportional Proportional solenoid
solenoid 5 valve 2
0 valve 1
4 sec.
Length
0 40 47 50 2 sec. [%]
RT 865BXL
TTS/TMS 870
1
Maximum Ramping value
-valve fully open- Minimum ramping
6
value CM
2 Ramping down
Time based ramping up
7
Minimum ramping i.e. 12 cycles = 6 seconds
3
value IM
Change over point 8
Maximum Ramping value
5 -valve fully open-
-Ramping value 0-
-valve closed-
2.25
DS350 GRAPHIC BOOM CONTROL SYSTEM
AUTOMATIC MODE
EXTEND EXTEND
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 OPEN OPEN

ROD
DRAIN CLOSED CLOSED
OPEN OPEN OPEN

PISTON
DRAIN CLOSED CLOSED
EXTEND
K5
RELAY
2.26
AUTOMATIC MODE
RETRACT RETRACT
PROPORTIONAL
OUTPUT
PROPORTIONAL VALVE
CLOSED
OM
2 WAYS OPEN
CLOSED
CM
2 WAYS OPEN
CLOSED
IM
2 WAYS OPEN OPEN
OPEN OPEN OPEN

ROD
DRAIN CLOSED CLOSED
PISTON
DRAIN
K5
RELAY
2.27
MANUAL MODE
EXTEND EXTEND
PROPORTIONAL VALVE
CLOSED
OM
2 WAYS OPEN
CLOSED
CM
2 WAYS OPEN
CLOSED
IM
2 WAYS OPEN OPEN
OPEN OPEN OPEN

ROD
DRAIN CLOSED CLOSED
OPEN OPEN OPEN

PISTON
DRAIN CLOSED CLOSED
K5
RELAY
2.28
MANUAL MODE
RETRACT RETRACT
PROPORTIONAL VALVE
OM
2 WAYS
CLOSED
CM
2 WAYS OPEN
CLOSED
IM
2 WAYS OPEN OPEN
OPEN OPEN OPEN

ROD
DRAIN CLOSED CLOSED
PISTON
DRAIN
K5
RELAY
2.29
DS350 GRAPHIC (BCS)
Automode control of two way valves
K2 K6 K7 DESCRIPTION
0 1 1 IM EXTENDING OR RETRACTING
1 0 1 CM EXTENDING OR RETRACTING
1 1 0 OM/FLY EXTENDING OR RETRACTING
0 0 0 OUT OF SEQUENCE
0 0 0 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 DI 2 DI 4 DI 5 K3
EXTEND SELECT RETRACT OM/FLY IM & CM ROD DRAIN
SELECT RETRACTED RETRACTED SOLENOID
0 0 0 0 1
0 0 0 1 1
0 0 1 0 1
0 0 1 1 1
0 1 0 0 0
0 1 0 1 0
0 1 1 0 0
0 1 1 1 0
1 0 0 0 0
1 0 0 1 0
1 0 1 0 0
1 0 1 1 0
Analog Outputs
ANALOG CU DESCRIPTION
TERMINAL
1 A111 X1/5 Analog GND for proportional extend or retract solenoid valves.
1 A111 X1/6 Analog signal for proportional extend or retract solenoid valves.
2.30
DS350 GRAPHIC (BCS)
Input Output Logic TMS/TTS 870 AND RT 865 BXL

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

Mode IM % CM % OM % FLY %
AUTO B 0 0 0 0
AUTO B 50 0 0 0
AUTO B 50 50 0 0
AUTO B 75 50 0 0
AUTO B 75 75 0 0
AUTO B 100 75 0 0
AUTO B 100 100 0 0
AUTO B 100 100 100 100
AUTO A 0 0 0 0
AUTO A 0 100 0 0
AUTO A 0 100 100 100
AUTO A 100 100 100 100
Boom sequence TMS/TTS 870, RT 865 BXL, TM 9100 AND TM9150 boom extensions
Mode IM % CM % OM % FLY %
AUTO 100 0 0 0
AUTO 100 100 0 0
AUTO 100 100 100 100
2.32
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 0%
Mid 0%
IM 1%
IM 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
LENGTH
79 DE 6 RESET SW.
78
CM / IM
77 DE 5 RET. SW.
76
OM / FLY
75 DE 4 RET. / % SW.
74 -5V
73 -SIG
DS350 Graphic
72
71 GND 86
70 o K7 = OM / FLY
87A 30
69 o o - 2 WAY
Boom Length to C.P.U.

85
87
68 F8 86
67 o K6 = CM 2 - WAY
66 87A o30
o 85
Connections
65 87
F7 86
64
o K5 = 4 - WAY
63 87A 30
LG 208 CABLE REEL o o 85 DIREC. VALVE
62 87
F6
(TO NOSE) 61
86
o K4 = TELE OUT
60 87A 30
o o 85 OF SEQ.
59 87
F5 86
58
o K3 = ROD
57 87A 30
17 18 o o 85 DRAIN SOL.
56 87
F4 86
55
o K2 = IM 2 - WAY
54 87A o30
R.F. o 85
FILTERS
10 53 87
F3 86
52
9 o K1= NOT USED
51 87A 30
6 o o 85
8 50 87
F2
49
7 5 o
87A
o oK10
48 30
87
6 47
SHIELD CORE 5
46
45
.
o o o K9 86
K10
85 0 (UB)
4.7K A
B
1
2 4
44
43
.
o o o K8 .
o
UB
3
UB
AUTO MODE
1 2 3 4 3 42 DE 3 SW. ON
41
3 2 2
LG
2 40 PRESS. SW.
DE 2 BOOM RET.
1 39
1 1
38 PRESS. SW.
DE 1 BOOM EXT.
PIN 1 & 5 = GND 37
PIN 3 & 6 = -5V
PIN 2 = LENGTH SIGNAL
36 0 (UB)
3 5 35 SIG A2B
1
6 34 0-SIG
COMPARATOR
2
33
BOOM LENGTH SIGNAL 0 (UB)
32 RXD
RETRACTED = -0.500V
MAX RANGE = -4.5V 31 TXD
30 UB
* NOTE - MAX LENGTH SIGNAL 29 -SIG
VARIES WITH BOOM 28 +SIG
MAX VOLTAGE - 4.5V IS 27
FOR 10 TURNS ON POT.
-9V
26
+9V
25
-5V
24 -SIG
23
22 GND
21 -SIG
Boom Base 20 -5V
Junction Box 19
18 +5V
17 GND
1 1 A 1 16 -SIG
15 -5V
2 3 B 2
14
3 4 C 3 13 +5V
12 GND LEN.(OA)
5 7 E 5 3 11 -5V
2 10
6 8 F 6 9 ANGLE
1 8
7 GND
6
5 X4
4 4
TERMINALS :
3
0(UB)
3
)
1-2 & 4-5
2 2
)
ARE JUMP 1
) 0 (UB) / GND
1 +UB
TOGETHER ) +24 V
3.1
80
LENGTH
79 DE 6 RESET SW.
78
CM / IM
77 DE 5 RET. SW.
76
OM / FLY
75 DE 4 RET. / % SW.
74 -5V
8 73 -SIG
DS350 Graphic
72
71 GND 86
70 o K7 = OM / FLY
87A 30
69 o o - 2 WAY

85
87
68 F8 86
67 o K6 = CM 2 - WAY
66 87A o30
o 85
Connections
65 87
F7 86
64
o K5 = 4 - WAY
63 87A 30
LWG 221 CABLE REEL o o 85 DIREC. VALVE
62 87
(TO CM) 61
F6 86
o K4 = TELE OUT
60 87A 30
20 o o 85 OF SEQ.
59 87
F5 86
19 58
o K3 = ROD
57 87A 30
o o 85 DRAIN SOL.
18 56 87
F4 86
55
17 o K2 = IM 2 - WAY
54 87A o30
o 85
53 87
16 F3 86
52
o K1= NOT USED
15 51 87A 30
o o
TERMINALS FOR 85
PROX. SWITCHES 50 87
SEE PG. 12.1-12.4 14 F2
49
o
13 48 87A
o oK10
30
Boom Base 47
87
12 Junction Box 46
45
.
o o o K9 86
K10
85 0 (UB)
11
10
1 2 A 1 44
43
.
o o o K8 .
o
UB
UB
2 10 H 8 42 DE 3
AUTO MODE
9 41
SW. ON
3 5 C 3 40 PRESS. SW.
8 DE 2 BOOM RET.
39
13 6 D 4
BOOM EXT.
37
6 36 0 (UB)
WG
5 35 SIG A2B
34 0-SIG
13 COMPARATOR
4 TERMINALS : 33
0 (UB)
3 32 RXD
3 1-2 & 4-5
31 TXD
2 ARE JUMP
LG
2 30 UB
TOGETHER 29 -SIG
1 1 28 +SIG
PIN 1 & 5 = GND
27 -9V
PIN 3 & 6 = -5V 26
+9V
25
PIN 4 = ANGLE SIGNAL -5V
24 -SIG
23
BOOM LENGTH SIGNAL
RETRACTED = -0.500V
22 GND
21 -SIG
MAX RANGE = -4.5V
20 -5V
ANGLE SIGNAL 19
0 DEG. = -3.125V 18 +5V
45 DEG. = -2.50V 17
90 DEG. = -1.875V
GND
16 -SIG
15 -5V
* NOTE - MAX LENGTH SIGNAL
VARIES WITH BOOM 14
MAX VOLTAGE - 4.5V IS 13 +5V
FOR 10 TURNS ON POT. 12 GND LEN.(OA)
3 11 -5V
10
4 9 ANGLE
1 8
7 GND
6
5 X4
4 4
3
0(UB)
3
)
2 2
)
1
) 0 (UB) / GND
1 +UB
) +24 V
3.2
80
LENGTH
79 DE 6 RESET SW.
78
CM / IM
77 DE 5 RET. SW.
76
OM / FLY
75 DE 4 RET. / % SW.
74 -5V
73 -SIG
DS350 Graphic
72
71 GND 86
70 o K7 = OM / FLY
87A 30
69 o o - 2 WAY

85
87
68 F8 86
67 o K6 = CM 2 - WAY
66 87A o30
o 85
Connections
65 87
F7 86
64
o K5 = 4 - WAY
63 87A 30
LG 221 CABLE REEL o o 85 DIREC. VALVE
62 87
(TO IM) 61
F6 86
o K4 = TELE OUT
60 87A 30
20 o o 85 OF SEQ.
59 87
F5 86
19 58
o K3 = ROD
57 87A 30
o o 85 DRAIN SOL.
18 56 87
F4 86
55
17 o K2 = IM 2 - WAY
54 87A o30
o 85
53 87
16 F3 86
52
o K1= NOT USED
15 51 87A 30
o o 85
50 87
14 F2
49
o
TERMINALS FOR 13 48 87A
o oK10
30
PROX. SWITCHES Boom Base 47
87
SEE PG. 12.1-12.4 12 Junction Box 46
45
.
o o o K9 86
K10
85 0 (UB)
11
10
1 2 A 1 44
43
.
o o o K8 .
o
UB
UB
2 9 G 7 42 DE 3
AUTO MODE
9 41
SW. ON
3 5 C 3 40 PRESS. SW.
8 DE 2 BOOM RET.
39
BOOM EXT.
37
6 36 0 (UB)
5 35 SIG A2B
34 0-SIG
COMPARATOR
4 TERMINALS : 33
0 (UB)
3 32 RXD
3 1-2 & 4-5
31 TXD
2 ARE JUMP
LG
2 30 UB
TOGETHER 29 -SIG
1 1 28 +SIG
PIN 1 & 5 = GND
27 -9V
PIN 3 & 6 = -5V 26
+9V
25
-5V
7 24 -SIG
23
BOOM LENGTH SIGNAL
RETRACTED = -0.500V
22 GND
21 -SIG
MAX RANGE = -4.5V
20 -5V
19
* NOTE - MAX LENGTH SIGNAL
VARIES WITH BOOM 18 +5V
MAX VOLTAGE - 4.5V IS 17 GND
FOR 10 TURNS ON POT. 16 -SIG
15 -5V
14
13 +5V
12 GND LEN.(OA)
3 11 -5V
10
9 ANGLE
1 8
7 GND
6
5 X4
4 4
3
0(UB)
3
)
2 2
)
1
) 0 (UB) / GND
1 +UB
) +24 V
3.3
PAT DS350Graphic(BCS)
MAIN BOOM LENGTH SIGNAL VOLTAGE
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
3.4
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
CHANNEL # 1
(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.
CH. #1
OPERATING
X1 WINDOW
CABLE REEL 0.0V .0V
1 8
ASS’Y
FIXED
1 (GND) ERROR
CODE { E 11
.500V MIN.
3 : 1 RATIO RESISTOR WORKING
RANGE
4.50V MAX.
ZERO ADJUSTMENT
RETRACTED BOOM - 500MV (-.500V)
ERROR
CODE{ E 21
5.0V
0 “MINIMUM SIGNAL”
1
2 (RETRACTED BOOM)
3
4 TO A/D
PRELOAD SPRING
30 REVOLUTIONS
5
6
2 2 10 AMP
CONVERTER
7
8
COUNTERCLOCKWISE 9
10 MP 6
(CENTER REEL) - 4.50V
3.5
LENGTH SENSOR TEST POINT

“MAXIMUM SIGNAL”
10 K Ω /10 TURNS (10 TURNS ON POT) MP 6 VOLTAGES
+ 500MV (.500V) = MIN. SIGNAL
(RETRACTED BOOM)
+4.50V = MAX. SIGNAL

CABLE REEL TERMINAL
(10 TURNS ON POT)
FIXED ALL VOLTAGES ARE MEASURED WITH
X1 RESISTOR REFERENCE TO GND (TERMINAL X1-8 ON “A104”OR MP 15
CENTRAL UNIT
TERMINAL BOARD ON MAIN BOARD).
# WIRE NUMBER 3 3 11 -5V

TEST POINT X1
ON MAIN BOARD
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 COUNTER-
CLOCKWISE TO A SOFT STOP.
3.7
LENGTH MEASUREMENT:
VOLTMETER SHOULD MEASURE -5.0 VOLTS BETWEEN CONNECTIONS

X1 - 8 (NEGATIVE) AND X1 - 11 (POSITIVE).
X4 X1 X1
1 3 5
2 4 6
1 2 3 4
-5.00
F1
8 10 12 14 16 18 20 22 24 26 28 71 72 73 74
X1
7 9 11 13 15 17 19 21 23 25 27 29
H9 H8
V2 V1
A2B K9 LMI K8
SHUT SHUT
OFF OFF
X3 H7 H4 H1
V11 V8 V5
SEQUENCE
OUTER
OUT OF
MID
K7 K4 K1
X1
R15 R16 R9 R10 R3 R4

R17
R18
H10
V3
H6 H5 H3 H2
V10 V9 V7 V6
K10
CENTER
4 - WAY
DRAIN
LEVER
INNER
MID
ROD
MID
K6 K5 K3 K2 LOCKOUT
X4
R13 R14 R11 R12 R7 R8 R5 R6 R2 R1
49 48 47
CM
OM
4W
SE
IM
RO
F8 F7 F6 F5 F4 F3 F2
Q
X1
70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50
X1 X1
80 79 78 77 76 75 43 42 41 40 39 38 37 36 35 34 33 32 31 30 46 45 44
X1 X1 X1
3.8
LENGTH MEASUREMENT:
WITH BOOM FULLY RETRACTED THEVOLTMETER SHOULD MEASURE

-0.50 VOLTS BETWEEN CONNECTIONS X1 - 8 (NEGATIVE)
AND X1 - 10 (POSITIVE).
X4 X1 X1
1 3 5
2 4 6
1 2 3 4
-0.50
F1
8 10 12 14 16 18 20 22 24 26 28 71 72 73 74
X1
7 9 11 13 15 17 19 21 23 25 27 29
H9 H8
V2 V1
A2B K9 LMI K8
SHUT SHUT
OFF OFF
X3 H7 H4 H1
V11 V8 V5
SEQUENCE
OUTER
OUT OF
MID
K7 K4 K1
X1
R15 R16 R9 R10 R3 R4

R17
R18
H10
V3
H6 H5 H3 H2
V10 V9 V7 V6
K10
CENTER
4 - WAY
DRAIN
LEVER
INNER
MID
ROD
MID
K6 K5 K3 K2 LOCKOUT
X4
R13 R14 R11 R12 R7 R8 R5 R6 R2 R1
49 48 47
CM
OM
4W
SE
IM
RO
F8 F7 F6 F5 F4 F3 F2
Q
X1
70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50
X1 X1
80 79 78 77 76 75 43 42 41 40 39 38 37 36 35 34 33 32 31 30 46 45 44
X1 X1 X1
3.9
P.A.T. – L.M.I
MANUAL
SECTION 4
DS 350 GRAPHIC BCS

PISTON, ROD
CONNECTIONS &
WIRING DIAGRAMS
80
LENGTH
79 DE 6 RESET SW.
78
CM / IM
77 DE 5 RET. SW.
76
OM / FLY
75 DE 4 RET. / % SW.
74 -5V
73 -SIG
DS350 Graphic
72
71 GND 86
70 o K7 = OM / FLY
87A 30
69 o o - 2 WAY
Piston Pressure
85
87
68 F8 86
67 o K6 = CM 2 - WAY
66 87A o30
o 85
Transducer to C.P.U.
65 87
F7 86
64
o K5 = 4 - WAY
63 87A 30
o o 85 DIREC. VALVE
62 87
Connections
F6 86
61
o K4 = TELE OUT
60 87A 30
o o 85 OF SEQ.
59 87
F5 86
58
o K3 = ROD
57 87A 30
o o 85 DRAIN SOL.
56 87
F4 86
55
o K2 = IM 2 - WAY
54 87A o30
o 85
53 87
F3 86
52
o K1= NOT USED
51 87A 30
o o 85
50 87
F2
49
o
87A
o oK10
48 30
87
47
46
45
.
o o o K9 86
K10
85 0 (UB)
44
43
.
o o o K8 .
o
UB
14 UB
42 AUTO MODE
o o DE 3 SW. ON
41
o o 40 PRESS. SW.
13 DE 2 BOOM RET.
39
38 PRESS. SW.
PRESSURE TRANSDUCER DE 1 BOOM EXT.
37
PISTON SIDE
36 0 (UB)
35 SIG A2B
34 0-SIG
D 4 COMPARATOR
33
0 (UB)
32 RXD
C 3
DAVS
31 TXD
30 UB
B 2 29 -SIG
28 +SIG
A 1 27 -9V
26
+9V
25
-5V
24 -SIG
23
22 GND
4 21 -SIG
3 20 -5V
2 19
1 18 +5V
17 GND
16 -SIG
15 -5V
14
13 +5V
12 GND LEN.(OA)
11 -5V
10
9 ANGLE
8
7 GND
6
5 X4
4 4
3
0(UB)
3
)
2 2
)
1
) 0 (UB) / GND
1 +UB
) +24 V
4.1
PRESSURE "INPUT" SIGNAL AT "OUTPUT" SIGNAL AT MP 4
(P.S.I.) TERM. X1-21 IN TEST POINT ON MAIN
CENTRAL UNIT BOARD IN C.U.
PAT DS350Graphic (BCS) 0 0 MV. 0.5 V.
145 -33.3 MV. 0.63 V.
PISTON PRESSURE 290 -66.6 MV. 0.77 V.
435 -99.9 MV. 0.89 V.
580 -133.3 MV. 1.03 V.
TRANSDUCER 725 -166.6 MV. 1.17 V.
870 -199.9 MV. 1.29 V.
VOLTAGE SIGNALS 1015 -233.2 MV. 1.43 V.
1160 -266.6 MV. 1.53 V.
1305 -299.9 MV. 1.69 V.
1450 -333.2 MV. 1.83 V.
1595 -366.5 MV. 1.97 V.
1740 -399.9 MV. 2.09 V.
1885 -433.2 MV. 2.23 V.
2030 -466.5 MV. 2.36 V.
4.2
2175 -499.8 MV. 2.49 V.
2320 -533.1 MV. 2.63 V.
2465 -566.5 MV. 2.76 V.
2610 -599.8 MV. 2.89 V.
2755 -633.1 MV. 3.03 V.
2900 -666.4 MV. 3.16 V.
3045 -699.7 MV. 3.29 V.
3190 -733.1 MV. 3.43 V.
3335 -766.4 MV. 3.56 V.
3480 -799.7 MV. 3.69 V.
3625 -833.1 MV. 3.83 V.
3770 -866.3 MV. 3.96 V.
CHART SHOWS TYPICAL VOLTAGE SIGNALS. 3915 -899.7 MV. 4.09 V.
THESE VOLTAGES ARE TO BE USED AS A 4060 -932.9 MV. 4.23 V.
REFERENCE ONLY, THE ACTUAL SIGNAL 4205 -966.3 MV. 4.36 V.
MAY VARY SLIGHTLY. 4350 -999.9 MV. 4.50 V.
CHANNEL # 2
CH. #2
OPERATING
WINDOW
.0V
ERROR
X1 X1 CODE E 12
CENTRAL UNIT {
TERMINAL BOARD .500V MIN.
1 18 + 5.0V
# WIRE NUMBER WORKING
RANGE
TEST POINT
ON MAIN BOARD 4.50V MAX.
ERROR
CODE
{ E 22
PRESSURE TRANSDUCER
OUTPUT SIGNAL :
ZERO PRESSURE = 0.000V 5.0V
(PISTON SIDE)
A MAX. PRESSURE = -1.0V

(+ / - 25 MV)
D TO A/D
4 21 AMP
C CONVERTER
4.3
B MP 4
P4 TEST POINT
DAVS 301 P4 ZERO POINT

ADJUSTMENT MP 4 VOLTAGES
300 BAR MAX. + 500MV (.500V) = MIN. SIGNAL
(4410 PSI) (ZERO PRESSURE)
3 20 - 5.0V
(300 BAR PRESSURE)
~ ALL VOLTAGES ARE MEASURED WITH
0.0V
PRESSURE 2 19 REFERENCE TO GND (TERMINAL X1-19 “A104” OR MP 15
(GND) ON MAIN BOARD.)
FROM PISTON SIDE
X1
OF LIFT CYLINDERS

PISTON PRESSURE MEASURING CHANNEL
CHANNEL # 2
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)
+5.00 X1 X1
1 3 5
2 4 6
F1
-5.00
8 10 12 14 16 18 20 22 24 26 28 71 72 73 74
X1
7 9 11 13 15 17 19 21 23 25 27 29
H9 H8
V2 V1
A2B K9 LMI K8
SHUT SHUT
OFF OFF
H4 H1
V8 V5
SEQUENCE
OUT OF
X1
R17
R18
H10 V3
K10
LEVER
LOCKOUT
4.4
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.
X1 X1
1 3 5
2 4 6
.000
F1
8 10 12 14 16 18 20 22 24 26 28 71 72 73 74
X1 X1
7 9 11 13 15 17 19 21 23 25 27 29
H9 H8
V2 V1
A2B K9 LMI K8
SHUT SHUT
OFF OFF
H4 H1
V8 V5
SEQUENCE
OUT OF
PISTON PRESSURE TRANSDUCER

OUTPUT SIGNAL = .000 VOLT
+/- .025V AT ZERO HYDRAULIC X1
PRESSURE.
R17
R18
H10 V3
H5 H3 H2
V9 V7 V6
K10
4 - WAY
LEVER
DRAIN
INNER
ROD
MID
LOCKOUT
R2 R1
4.6
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.
X1 X1
1 3 5
2 4 6
F1
8 10 12 14 16 18 20 22 24 26 28 71 72 73 74
X1 X1
7 9 11 13 15 17 19 21 23 25 27 29
H9 H8
JUMPER
V2 V1
WIRE
A2B K9 LMI K8
SHUT SHUT
OFF OFF
H4 H1
V8 V5
SEQUENCE
OUT OF
DISCONNECT X1
FROM X1 - 21
R17
R18
H10 V3
H5 H3 H2
V9 V7 V6
K10
4 - WAY
LEVER
DRAIN
INNER
ROD
MID
LOCKOUT
R2 R1
4.8
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
LENGTH
79 DE 6 RESET SW.
78
CM / IM
77 DE 5 RET. SW.
76
OM / FLY
75 DE 4 RET. / % SW.
74 -5V
73 -SIG
DS350 Graphic
72
71 GND 86
70 o K7 = OM / FLY
87A 30
69 o o - 2 WAY
Rod Pressure
85
87
68 F8 86
67 o K6 = CM 2 - WAY
66 87A o30
o 85
Transducer to C.P.U.
65 87
F7 86
64
o K5 = 4 - WAY
63 87A 30
o o 85 DIREC. VALVE
62 87
Connections
F6 86
61
o K4 = TELE OUT
60 87A 30
o o 85 OF SEQ.
59 87
F5 86
58
o K3 = ROD
57 87A 30
o o 85 DRAIN SOL.
56 87
F4 86
55
o K2 = IM 2 - WAY
54 87A o30
o 85
53 87
F3 86
52
o K1= NOT USED
51 87A 30
o o 85
50 87
F2
49
o
87A
o oK10
48 30
87
47
46
45
.
o o o K9 86
K10
85 0 (UB)
44
43
.
o o o K8 .
o
UB
14 UB
42 AUTO MODE
o o DE 3 SW. ON
41
o o 40 PRESS. SW.
13 DE 2 BOOM RET.
39
38 PRESS. SW.
DE 1 BOOM EXT.
37
36 0 (UB)
35 SIG A2B
34 0-SIG
COMPARATOR
PRESSURE TRANSDUCER 33
0 (UB)
32 RXD
ROD SIDE
31 TXD
30 UB
29 -SIG
D 4
28 +SIG
27 -9V
C 3
DAVS
26
+9V
25
B 2 -5V
24 -SIG
23
A 1
22 GND
21 -SIG
20 -5V
19
18 +5V
17 GND
4 16 -SIG
3 15 -5V
2 14
1 13 +5V
12 GND LEN.(OA)
11 -5V
10
9 ANGLE
8
7 GND
6
5 X4
4 4
3
0(UB)
3
)
2 2
)
1
) 0 (UB) / GND
1 +UB
) +24 V
4.10
PRESSURE "INPUT" SIGNAL AT "OUTPUT" SIGNAL AT MP 5
(P.S.I.) TERM. X1-16 IN TEST POINT ON MAIN
CENTRAL UNIT BOARD IN C.U.
0 0 MV. 0.5 V.
PAT DS350Graphic (BCS)
145 -33.3 MV. 0.63 V.
290 -66.6 MV. 0.77 V. ROD PRESSURE
435 -99.9 MV. 0.89 V.
580 -133.3 MV. 1.03 V. TRANSDUCER
725 -166.6 MV. 1.17 V.
870 -199.9 MV. 1.29 V. VOLTAGE SIGNALS
1015 -233.2 MV. 1.43 V.
1160 -266.6 MV. 1.53 V.
1305 -299.9 MV. 1.69 V.
1450 -333.2 MV. 1.83 V.
1595 -366.5 MV. 1.97 V.
1740 -399.9 MV. 2.09 V.
1885 -433.2 MV. 2.23 V.
2030 -466.5 MV. 2.36 V.
4.11
2175 -499.8 MV. 2.49 V.
2320 -533.1 MV. 2.63 V.
2465 -566.5 MV. 2.76 V.
2610 -599.8 MV. 2.89 V.
2755 -633.1 MV. 3.03 V.
2900 -666.4 MV. 3.16 V.
3045 -699.7 MV. 3.29 V.
3190 -733.1 MV. 3.43 V.
3335 -766.4 MV. 3.56 V.
3480 -799.7 MV. 3.69 V.
3625 -833.1 MV. 3.83 V.
3770 -866.3 MV. 3.96 V.
3915 -899.7 MV. 4.09 V. CHART SHOWS TYPICAL VOLTAGE SIGNALS.
4060 -932.9 MV. 4.23 V. THESE VOLTAGES ARE TO BE USED AS A
4205 -966.3 MV. 4.36 V. REFERENCE ONLY, THE ACTUAL SIGNAL
4350 -999.9 MV. 4.50 V. MAY VARY SLIGHTLY.
CHANNEL # 3
CH. #3
OPERATING
WINDOW
.0V
ERROR
X1 X1 CODE E 13
CENTRAL UNIT {
TERMINAL BOARD .500V MIN.
1 13 + 5.0V
# WIRE NUMBER WORKING
RANGE
TEST POINT
ON MAIN BOARD 4.50V MAX.
ERROR
CODE
{ E 23
PRESSURE TRANSDUCER
OUTPUT SIGNAL :
ZERO PRESSURE = 0.000V 5.0V
(ROD SIDE)
A MAX. PRESSURE = -1.0V

(+ / - 25 MV)
D TO A/D
4 16 AMP
C CONVERTER
4.12
B MP 5
P5 TEST POINT
DAVS 301 P5 ZERO POINT

ADJUSTMENT MP 5 VOLTAGES
300 BAR MAX.
(4410 PSI) + 500MV (.500V) = MIN. SIGNAL
(ZERO PRESSURE)
3 15 - 5.0V
(300 BAR PRESSURE)
~ 0.0V ALL VOLTAGES ARE MEASURED WITH
PRESSURE 2 14 REFERENCE TO GND (TERMINAL X1-14 “A104” OR MP 15)
(GND)
FROM ROD SIDE ON MAIN BOARD.
X1
OF LIFT CYLINDERS

ROD PRESSURE MEASURING CHANNEL
CHANNEL #3
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
+5.00 X1 X1
1 3 5
2 4 6
F1
8 10 12 14 16 18 20 22 24 26 28 71 72 73 74
X1
7 9 11 13 15 17 19 21 23 25 27 29
H9 H8
V2 V1
A2B K9 LMI K8
SHUT SHUT
OFF OFF
H4 H1
V8 V5
SEQUENCE
OUT OF
X1
R17
R18
H10 V3
K10
LEVER
LOCKOUT
4.13
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.
X1 X1
1 3 5
2 4 6
ROD PRESSURE TRANSDUCER
F1 OUTPUT SIGNAL = .000 VOLT
8 10 12 14 16 18 20 22 24 26 28 71 72 73 74
X1
X1 HYDRAULIC
+/- .025V AT ZERO
7 9 11 13 15 17 19 21 23 25 27 29
PRESSURE.
H9 H8
V2 V1
.000
A2B K9 LMI K8
SHUT SHUT
OFF OFF
H4 H1
V8 V5
SEQUENCE
OUT OF
X1
R17
R18
H10 V3
H5 H3 H2
V9 V7 V6
K10
4 - WAY
LEVER
DRAIN
INNER
ROD
MID
LOCKOUT
R2 R1
4.15
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.
X1 X1
1 3 5
2 4 6
F1 DISCONNECT
8 10 12 14 16 18 20 22 24 26 28 71 72 73 74
X1 X1
7 9 11 13 15 17 19 21 23 25 27 29
H9 H8
FROM X1 - 16
V2 V1
A2B K9 LMI K8
SHUT SHUT
OFF OFF
H4 H1
V8 V5
SEQUENCE
OUT OF
JUMPER
WIRE X1
R17
R18
H10 V3
H5 H3 H2
V9 V7 V6
K10
4 - WAY
LEVER
DRAIN
INNER
ROD
MID
LOCKOUT
R2 R1
4.17
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
LENGTH
79 DE 6 RESET SW.
78
CM / IM
77 DE 5 RET. SW.
76
OM / FLY
75 DE 4 RET. / % SW.
74 -5V
73 -SIG
DS350 Graphic
72
71 GND 86
70 o K7 = OM / FLY
87A 30
69 o o - 2 WAY
Boom Angle to C.P.U.

85
87
68 F8 86
67 o K6 = CM 2 - WAY
66 87A o30
o 85
Connections
65 87
F7 86
64
o K5 = 4 - WAY
63 87A 30
o o 85 DIREC. VALVE
62 87
F6 86
61
o K4 = TELE OUT
60 87A 30
o o 85 OF SEQ.
59 87
F5 86
58
o K3 = ROD
57 87A 30
o o 85 DRAIN SOL.
56 87
F4 86
55
o K2 = IM 2 - WAY
54 87A o30
o 85
53 87
F3 86
52
o K1= NOT USED
51 87A 30
o o 85
50 87
F2
49
o
87A
o oK10
48 30
87
47
46
45
.
o o o K9 86
K10
85 0 (UB)
44
43
.
o o o K8 .
o
UB
14 UB
42 AUTO MODE
o o DE 3 SW. ON
41
o o 40 PRESS. SW.
13 DE 2 BOOM RET.
39
CABLE REEL 38 PRESS. SW.
DE 1 BOOM EXT.
37
36 0 (UB)
35 SIG A2B
17 18
34 0-SIG
COMPARATOR
33
0 (UB)
32 RXD
R.F. 31 TXD
FILTERS
10
30 UB
9 29 -SIG
28 +SIG
8 27 -9V
26
7 +9V
25
-5V
6 24 -SIG
23
WG
SHIELD CORE 5
4.7K A 1 22 GND
B 4 21 -SIG
2
20 -5V
1 2 3 4 3 19
3 2 18 +5V
LG
2
17 GND
1 1 16 -SIG
15 -5V
PIN 1 & 5 = GND
PIN 3 & 6 = -5V 14
3
PIN 4 = ANGLE SIGNAL
13 +5V
1 12 GND LEN.(OA)
2 3 11 -5V
BOOM LENGTH SIGNAL 2 10
RETRACTED = -0.500V 4 9 ANGLE
MAX RANGE = -4.5V 1 8
ANGLE SIGNAL
7 GND
6
0 DEG. = -3.125V
5 X4
45 DEG. = -2.50V
4 4
90 DEG. = -1.875V
3
0(UB)
3
)
* NOTE - MAX LENGTH SIGNAL 2 2
)
VARIES WITH BOOM 1
) 0 (UB) / GND
1 +UB
MAX VOLTAGE - 4.5V IS ) +24 V
FOR 10 TURNS ON POT. 5.1
PAT DS350Graphic (BCS)
BOOM ANGLE SIGNAL VOLTAGE
ACTUAL "INPUT" SIGNAL AT TERM. B "OUTPUT" SIGNAL AT MP 8
BOOM ANGLE IN CANNON PLUG AND TEST POINT ON MAIN
TERM. X1-9 IN C.U. BOARD IN C.U.
90 DEGS. -1.87 +.48
85 DEGS. -1.93 +.70
80 DEGS. -2.00 +.92
75 DEGS. -2.07 +1.15
70 DEGS. -2.14 +1.37
65 DEGS. -2.21 +1.60
60 DEGS. -2.28 +1.80
55 DEGS. -2.35 +2.04
5.2
50 DEGS. -2.42 +2.26
45 DEGS. -2.49 +2.48
40 DEGS. -2.56 +2.70
35 DEGS. -2.63 +2.92
30 DEGS. -2.70 +3.15
25 DEGS. -2.77 +3.38
20 DEGS. -2.84 +3.60
15 DEGS. -2.91 +3.82
10 DEGS. -2.98 +4.04
5 DEGS. -3.05 +4.27
0 DEGS. -3.12 +4.49
CHANNEL # 5
CHART SHOWS TYPICAL VOLTAGE SIGNALS.
THESE VOLTAGES ARE TO BE USED AS A REFERENCE ONLY, THE ACTUAL SIGNAL
MAY VARY SLIGHTLY.
CH. #5
OPERATING
X1 WINDOW
0.0V .0V
5 1 2 1 A 1 8 (GND) ERROR
BOOM ANGLE SENSOR CODE E 15
PENDULUM FIXED {
RESISTOR .500V MIN.
(PART OF THE ANGLE WORKING
90o POTENTIOMETER)
RANGE
4.50V MAX.
ERROR
CODE{ E 25
“MINIMUM SIGNAL” 5.0V
0o -1.875V = 90o ANGLE
ANGLE SENSOR AMP

TO A/D
4 13 6 4 D 4 9 CONVERTER
“MAXIMUM SIGNAL” MP 8
TEST POINT
5.3
-3.125V = 0o ANGLE
MP 8 VOLTAGES
+ 500MV (.500V) = 90o ANGLE MIN. SIGNAL
+ 2.50V = 45o ANGLE
+4.50V = 0o ANGLE MAX. SIGNAL
FIXED ALL VOLTAGES ARE MEASURED WITH
CABLE REEL TERMINAL REFERENCE TO GND (TERMINAL X1-8 “A104” OR MP 15
RESISTOR ON MAIN BOARD.)
(PART OF THE ANGLE
X1 POTENTIOMETER)
CENTRAL UNIT
TERMINAL BOARD
6 3 5 3 C 3 11 -5V
# WIRE NUMBER
X1
TEST POINT
ON MAIN BOARD
14 SOCKET PLUG JUNCTION P.A.T. DS350 Graphic (BCS)

BOX BOOM BASE
BOOM ANGLE MEASURING CHANNEL
TERMINAL STRIP
IN JUNCTION BOX CHANNEL # 5
P.A.T. – L.M.I
MANUAL
SECTION 6
DS 350 GRAPHIC BCS

ANTI - TWO - BLOCK
CONNECTIONS &
WIRING DIAGRAMS
CONSOLE LEVER LOCKOUT X1 87A
BYPASS KEY SOLENOID VALVE * 49
1 30
3 RED 73 3 48
L.M.I.
4 BLUE 87
8 7
2 47
2 F2-10A
4 VIOLET 86
7 6 6 46
3 GREY 6 V3 K10
A2B 6 K9
1 7 85
5 5 44
6 K8
1 1
LMI LMI OVERLOAD
13 7
BYPASS
45 UB
KEY 14 +24V
(CU)
CABLE REEL 1 UB
30
+24V
SHIELD
SLIP R.F. A2B
LENGTH RINGS FILTERS ELECTRONICS V2
17 +SIG K9
CABLE 9 7 5 35
OUTPUT
10 8 6 34 0- SIG
18
2
6.1
SHIELD CORE FROM 1
14 SOCKET CRANE SUPPLY
4.7K A 1 X1
PLUG +24V
B 2
1 2 3 4
3 2 X1
CENTRAL UNIT TERMINAL
1 BOARD
- # - WIRE NUMBER
3 * SOME MODELS USE MULTIPLE

1
A2B SOLENOID VALVES.
2
SWITCH
ASS’Y
PAT DS350 Graphic LMI

WEIGHT
ANTI TWO BLOCK &
ASS’Y
SHUTOFF CKT.
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
4.70
1
2
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 4.70
SHEILD
X1 BROWN
CORE 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
4.70
3
4
5
6
7
1
2
6.5
DRAWING 5:

TURN POWER OFF TO CENTRAL UNIT. MEASURE THE RESISTANCE
BETWEEN X1:34 & X1:35.
X4 X1 X1
1 3 5
2 4 6
1 2 3 4
F1
8 10 12 14 16 18 20 22 24 26 28
7 9 11 13 15 17 19 21 23 25 27 29
X1 X1
H9 H8
V2 V1
A2B K9 LMI K8
SHUT SHUT
OFF OFF
X3 H7 H4 H1
V11 V8 V5
SEQUENCE
OUTER
OUT OF
MID
K7 K4 K1
71 72 73 74
X1
R15 R16 R9 R10 R3 R4

R17
R18
H10
V3
H6 H5 H3 H2
V10 V9 V7 V6
K10
CENTER
4 - WAY
DRAIN
LEVER
INNER
MID
ROD
MID
K6 K5 K3 K2 LOCKOUT
X4
R13 R14 R11 R12 R7 R8 R5 R6 R2 R1
49 48 47
CM
OM
4W
RO
IM
SE
F8 F7 F6 F5 F4 F3 F2
Q
X1
70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50
4.70
X1 X1
80 79 78 77 76 75 43 42 41 40 39 38 37 36 35 34 33 32 31 30 46 45 44
X1 X1 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.
1 3 5
2 4 6
1 2 3 4
F1
8 10 12 14 16 18 20 22 24 26 28
7 9 11 13 15 17 19 21 23 25 27 29
A2B K9 LMI K8
SHUT SHUT
OFF OFF
X3
K7 K4 K1
71 72 73 74
R15 R16 R9 R10 R3 R4
K10
LEVER
K6 K5 K3 K2 LOCKOUT
X4
R13 R14 R11 R12 R7 R8 R5 R6 R2 R1
49 48 47
F8 F7 F6 F5 F4 F3 F2
70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50
80 79 78 77 76 75 43 42 41 40 39 38 37 36 35 34 33 32 31 30 46 45 44
4.70kΩ
6.7
P.A.T. – L.M.I
MANUAL
SECTION 7
DS 350 GRAPHIC BCS

DIGITAL INPUTS
DS350 GRAPHIC (BCS)
Digital Inputs
INPUT CU DESCRIPTION NOTES

TERMINAL
1 A104 TELE EXTEND (+24V) GROVE PRESSURE SWITCH SIGNAL
X1/38
2 A104 TELE RETRACT (+24V) GROVE PRESSURE SWITCH SIGNAL
X1/40
3 A104 AUTO MODE SELECTED (+24V) GROVE SELECTOR SWITCH SIGNAL
X1/42
4 A104 PROX. SWITCH OM/FLY RETRACTED PAT SWITCH ON CM - SIGNAL VIA CM
X1/76 & OM/FLY % RESET (+24V) CABLE REEL
5 A104 PROX. SWITCH CM/IM RETRACTED PAT SWITCH ON BOOM BASE
X1/78 (+24V)
6 A104 PROX. SWITCH IM % RESET (+24V) PAT SWITCH ON BOOM BASE
X1/80
E1 A112/A114 HOUSE LOCK PIN SWITCH SIGNAL GROVE LIMIT SWITCH (RT865BXL ONLY)
X1/1
E2 A112/A114 AUTO MODE A = ON GROVE SELECTOR SWITCH SIGNAL (NOT
X1/3 AUTO MODE B = OFF FOR RT865BXL)
E3 A112/A114 FRONT O/R OVERLOAD GROVE FRONT O/R SWITCH SIGNAL (NOT
X1/6 (GROUND SIGNAL) FOR RT865BXL)
E4 A112/A114 AREA DEFINATION SWITCH SWIVEL LIMIT SWITCH (RT865BXL ONLY)
X1/7 ON RUBBER
E5 A112/A114 PROX. SWITCH CM RETRACTED & PAT SWITCH ON IM - SIGNAL VIA IM
X1/9 CM % RESET (+24V) 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: Analog Measuring Channels / Test Points:

MP 1 = +5V E-1 Ch. 1 Boom Length - MP 6 / P6(Do Not Adjust) G-3
MP 2 = -5V E-4 Ch. 2 Piston Pressure - MP 4 / P4 G-4
MP 11 = Ground H-4 Ch. 3 Rod Pressure - MP 5 / P5 G-3
MP 12 = +5V B-7 Ch. 5 Bom Angle - MP 8 / P8(Do Not Adjust) G-2
MP 13 = Digital Ground B-7
MP 15 = Analog Ground E-1
MP 19 = -5V E-1
8.1
DS350 GRAPHIC BCS
X1 Terminals A104 Board
X1 TERM. DESCRIPTION X1 TERM. DESCRIPTION
1,2 24V Battery - Input 43 +C/M Prox. Switch
3,4 GND () Battery - Input 44 LMI Shut-off Signal
5 F1 (2 amp) GND (LMI By Pass Key)
6 F1 (2 amp) Load Side ub 45 +24V (ub) from F1 (2amp)
7 GND (Inner Shield Connection) (LMI By Pass Key)
8 GND 46 A2B Shut off Signal
9 Boom Angle Signal (A2B By Pass Key)
10 Boom Length Signal 47 +24V Battery from F2 (10 amp)
11 -5Volt Supply/Length/Angle Transducer 48 Output to Lever Lockout
49 K10 LMI Lockout Alarm
12 GND (Inner Shield Connection)
50,51,52 Not Used
13 +5Volt Supply/Piston Pressure Transducer
53 K2 +24V
14 GND
54 K2 (NO) I/M 2 way valve
15 -5Volt/Rod Pressure Transducer
55 Not Used
16 Rod Pressure Signal
56 K3 +24V
57 K3 (NO) Tele Rod Drain Sol.
18 +5Volt Supply/Piston Pressure Transducer 58 Not Used
19 GND 59 K4 +24V
20 -5Volt Supply/Piston Pressure Transducer 60 Not Used
21 Piston Pressure Signal 61 K4 (NO) Tele out of Seq. Sol.
22 GND (Inner Shield Connection) 62 K5 +24V
24 Length (I/M) Signal 63 K5 (NO) Extend
25 -5Volt Supply / Length Sensor 64 K5 (NC) Retract
26 +9 Volt Supply/Force Transducer 65 K6 +24V
27 -9 Volt Supply/Force Transducer 66 K6 (NO) C/M 2 way valve
28 + Force Signal 67 Not Used
29 - Force Signal 68 K7 +24V
30 24V (ub) 69 K7 (NO) O/M - Fly 2 way valve
31 TXD Data Transmit to Console 70,71,72 Not Used
32 RXD Data Received from Console 73 Length Signal C/M
33,36 GND (oub) 74 -5V
34 0 Signal A2B 75 Digital Input 4 GND
35 A2B Signal 76 Digital Input 4 Prox. Switch
O/M Fly Retract
37 Digital Input 1 (-)
77 Digital Input 5 GND
38 Digital Input 1 (+) Tele Ext. Press. SW.
78 Digital Input 5 Prox. Switch
CM/IM Retract
40 Digital Input 2 (+) Tele Retr. Press. SW.
79 Digital Input 6 GND
8.2 80 Digital Input 6 Prox. Switch
42 Digital Input 3 (+) Auto Mode
Length Reset
5 - Section Boom - X1 Terminal Board (A104)
X4 X1 X1
1 3 5
2 4 6
1 2 3 4
F1
8 10 12 14 16 18 20 22 24 26 28
X1
7 9 11 13 15 17 19 21 23 25 27 29
X1
H9 H8
V2 V1
A2B K9 LMI K8
SHUT SHUT
OFF OFF
X3 H7 H4 H1
V11 V8 V5
SEQUENCE
OUTER
OUT OF
MID
K7 K4 K1
71 72 73 74
X1
R15 R16 R9 R10 R3 R4

R17
R18
H10 V3
H6 H5 H3 H2
V10 V9 V7 V6
K10
CENTER
4 - WAY
DRAIN
LEVER
INNER
MID
ROD
MID
K6 K5 K3 K2 LOCKOUT
X4
R13 R14 R11 R12 R7 R8 R5 R6 R2 R1
49 48 47
OM
CM
4W
IM
SE
RO
F8 F7 F6 F5 F4 F3 F2
Q
X1
70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50
X1 X1
80 79 78 77 76 75 43 42 41 40 39 38 37 36 35 34 33 32 31 30 46 45 44
X1 X1 X1
8.3
DS350 GRAPHIC (BCS)
Relay Outputs

TERMINAL
K1 A104 NOT USED NONE
X1/52
K2 A104 2 - WAY IM SOLENOID VALVES (2) OFF = IM EXTENDS OR RETRACTS ON = IM IS
X1/54 PILOT PRESSURE NOT ALLOWED TO MOVE REFER TO TRUTH
PISTON SIDE PRESSURE TABLE 1
K3 A104 TELE ROD DRAIN VALVE OFF = BOOM IS EXTENDING OR RETRACTING

X1/57 AND IS NOT FULLY RETRACTED
ON = BOOM IS IN NEUTRAL POSITION OR FULLY
RETRACTED
K4 A104 TELE OUT OF SEQUENCE PROVIDES SIGNAL TO GRV WARNING LIGHT
X1/61
K5 A104 ANALOG OUTPUT SIGNAL FROM ANALOG OUTPUT TO PROPORTIONAL SOLENOID
X1/62 ANALOG BOARD VALVES, EXTEND & RETRACT, RELAY K5
SELECTS EXTEND OR RETRACT
K5 A104 ANALOG OUTPUT SIGNAL TO MAXIMUM 800mA TO EXTEND VALVE ONE

X1/63 PROPORTIONAL EXTEND SOLENOID VALVE FOR ALL SECTIONS
VALVE
K5 A104 ANALOG OUTPUT SIGNAL TO MAXIMUM 800mA TO RETRACT VALVE ONE

X1/64 PROPORTIONAL RETRACT SOLENOID VALVE FOR ALL SECTIONS
VALVE
K6 A104 2 - WAY CM SOLENOID VALVES (2) OFF = CM EXTENDS OR RETRACTS ON = CM IS

X1/66 PILOT PRESSURE NOT ALLOWED TO MOVE
PISTON SIDE PRESSURE
K7 A104 2 - WAY OM/FLY SOLENOID VALVES OFF = OM/FLY EXTENDS OR RETRACTS ON =

X1/69 (2) PILOT PRESSURE PISTON SIDE OM/FLY IS NOT ALLOWED TO MOVE
PRESSURE
K8 A104 LMI CUT OFF INTERNAL RELAY CONNECT LMI BYPASS VIA DIODE ASSEMBLY
X1/44 FROM GRAPHIC CONSOLE AND CU KEY SWITCH
K9 A104 A2B CUT OFF INTERNAL RELAY CONNECT A2B BYPASS FROM GRAPHIC
X1/46 CONSOLE
K10 A104 LMI UNLOCK RELAY OUTPUT POWERS THE LMI UNLOCK SOLENOID WHEN NO
X1/48 OVERLOAD, A2B OR ERROR CONDITION
K10 A104 EXTERNAL ALARM OUTPUT USED FOR EEC UNITS ONLY
X1/49
8.4
5 - Section Boom - Diode Board(A113)
24 000 35 0003
PAT BS Z:E
XD1 XC1 XB1 XA1

12 11 10 9 8 7 6 5 4 3 2 1
X1 X1

5 - Section Boom - Valve Control Board (A111)
MP11 MP4 MP5 MP6 MP7
..
1
J3
J2 3
..
1
..
X2 X3
J1
MP10
MP1
MP3MP2 MP8
X1
F1
8.5
5 - Section Boom - Digital Input
Extention Board (A112)
X2/IN X3/OUT
MP5
MP1
+5V
MP4 MP3 MP2
MP6
GND
C11 C12
MP0
H16 H15 H14 H13 H12 H11 H10 H9 H8 H7 H6 H5 H4 H3 H2 H1
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 7 8 6 4 5 1 2 3
30 25 20 15 10 5 3 2
8.6
DS350 GRAPHIC (BCS)
PAT - GROVE Interface
Grove wire Interface Description

number connector
71 A POWER SUPPLY +24V

51 B CRANE GND
73 C LMI UNLOCK SOLENOID (RELAY OUTPUT)
387 D TELE EXTEND PRESSURE SWITCH (INPUT)
388 E TELE RETRACT PRESSURE SWITCH (INPUT)
239 F HIGH = AUTO MODE, LOW = MANUAL MODE (INPUT)
242 G SELECT OM / FLY IN MANUAL MODE (INPUT)
243 H SELECT CM IN MANUAL MODE (INPUT)
244 J SELECT IM IN MANUAL MODE (INPUT)
[507] K 3RD WRAP CUT OFF MAIN HOIST RT ONLY
[505] L 3RD WRAP CUT OFF AUX. HOIST RT ONLY
[338] M 3RD WRAP WARNING LIGHT (GND) RT ONLY
323 N TELE OUT OF SEQUENCE SIGNAL (RELAY OUTPUT)
[74] O ADDITIONAL EXTERNAL ALARM (RT ONLY EEC)
[744] P HOUSE LOCK PIN SWITCH - PICK & CARRY
240 Q AUTO MODE A = HIGH, AUTO MODE B = LOW (INPUT)
147 R FRONT OUTRIGGER OVERLOAD (INPUT)
238 S PROPORTIONAL TELE - SOLENOID GND.
1083 T TELE ROD DRAIN SOLENOID VALVE SIGNAL
255 U PROPORTIONAL TELE - SOLENOID (EXTEND)
257 V PROPORTIONAL TELE - SOLENOID (RETRACT)
W
X
8.7
8.8
IS
CONTINUED FROM PAGE 12.1
X1
A113
1
IS
4
22 47
+24V
5 6
6
K2 (COM) +24V
K2 (NO) +24V TO IM 2-WAY SOLS
9
53 54
7 8
8
K6 (COM) +24V
65 66
K6 (NO) +24V TO CM 2-WAY SOLS
B
K7 (COM) +24V
9 10 11 12
Junction Box
7
To Boom Base
K7 (NO) +24V TO OM/FLY 2-WAY SOLS
68 69
K3 (COM) +24V
K3 (NO) +24V TO TELE ROD DRAIN
8 10 2 3 5 7 11 12 13 14 1
+24V
INTERFACE
TMS/TTS 870
+24V
2
GND
GND
3
K10 (NO) +24V TO LMI UNLOCK SOLS
4
DI 1 (+24V=TELE EXT PRES SW)
5
DI 2 (+24V=TELE RET PRES SW)
DI 3 (+24V=AUTO MODE
6 9
DI GND
+24V 71 8 DI 1 GND
GND 51
DI 2 GND
LMI UNLOCK SOLS 73
TELE EXT. PRESS. SW. 387 DI 3 GND
TELE RETRACT PRESS. SW. 388 DI 4 GND
HIGH=AUTO / NONE=MANUAL 239 DI 5 GND
7 19 10 11 12
OM/FLY TELE 242

CM TELE
DI 6 GND
243
IM TELE 244 K4 (COM) +24V
K4 (NC) +24V TO TELE OUT OF SEQ
K10 (NC) +24V TO LMI L/O ALARM
TELE OUT OF SEQ. 323 K5 (COM)
K5 (NO) OUTPUT TO EXT PROP
13 14 15 20 21
HIGH SIGNAL = AUTO MODE A

56 57 1 2 3 4 48 38 40 42 36 37 39 41 75 77 79 59 61 49 62 63 64
NO SIGNAL = AUTO MODE B 240 K5 (NC) OUTPUT TO RET PROP

FRONT O/R OVERLOAD 147
TELE PROP ANALOG GND 238
TELE ROD DRAIN SOL
X1
1083
A111
TELE EXT PROP SOL 255

1
TELE RETRACT PROP SOL 257 +24V

+24V
A B C D E F G H J KLM N O P Q R S T UV W X
2 3
GND
23 - PIN PLUG
GND
1 2 3 4 5 6 7 8 9 101112 13 14 15 16 17 1819 20 2122 23 24 25
18
AGND
LMI - CRANE INTERFACE
4 5 6
23 - SOCKET RECEPT A1 (PROP)

S/S HARNESS (REF)
X1
A114
16
DI E2 [ +24=MODE A
0V=MODE B
3 4
DI E2 GND
24 350 300 301
DI E3 (+24V)
DI E3 (GND=FRONT O/R OL)
12
DI EXTENSION BOARD
DI E5 (+24V=CM RET)
6 9 10
DI E5 GND
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= VDC MP 15 Ground - Force Transducer

- 9V @ MP 16= VDC MP 15 Ground - Force Transducer
+ 5V @ MP 17= VDC MP 15 Ground - Internal to Board
- 5V @ MP 19= VDC MP 15 Ground - Internal to Board
+5V @ MP 1= VDC MP 15 Ground - Internal to Board
-5V @ MP 2= VDC MP 15 Ground - Jib Angle, Length /
Angle Rod, Piston
+5V @ MP 18= VDC MP15 Ground - Piston & Rod
Pressure
+5V @ MP 12 = VDC MP 13 Ground - Internal to Board
+12V @ MP 21= VDC MP 15 Ground - Internal to Board
+ 6V @ MP 20 = VDC MP 15 Ground - Internal to Board
4. Boom Length: (MP 15 Ground for Meter)

Fully Retracted Ft. VDC @ X1-10 VDC @ MP 6
Fully Extended Ft. VDC @ X1-10 VDC @ MP 6
- 5 Volt Reference Voltage VDC @ X1-11
5. Boom Angle: (MP 15 Ground for Meter)

Minimum Angle Degs. VDC @ X1-9 VDC @ MP 8
Maximum Angle Degs. VDC @ X1-9 VDC @ MP 8
- 5 Volt Reference Voltage VDC @ X1 -11
6. 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
- 5 Volt Reference Voltage @ X1-15 & 20
9.1
5 - Section Boom - Main Board (A101)

MP 19 = -5V E-1
9.2
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
X1 X1
1 3 5
2 4 6
ROD PRESSURE TRANSDUCER
.000
F1 OUTPUT SIGNAL = .000 VOLT
8 10 12 14 16 18 20 22 24 26 28 71 72 73 74
X1
X1 HYDRAULIC
7 9 11 13 15 17 19 21 23 25 27 29
+/- .025V AT ZERO
PRESSURE.
H9 H8
V2 V1 .000
A2B K9 LMI K8
SHUT SHUT
OFF OFF
H4 H1
V8 V5
SEQUENCE
OUT OF
PISTON PRESSURE TRANSDUCER

OUTPUT SIGNAL = .000 VOLT
+/- .025V AT ZERO HYDRAULIC X1
PRESSURE.
R17
R18
H10 V3
H5 H3 H2
V9 V7 V6
K10
4 - WAY
LEVER
DRAIN
INNER
ROD
MID
LOCKOUT
R2 R1
10.2
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
What’s Wrong?
Lever Lockout Length Cable No Function

No Display Anti-Two-Block
Activated Problem
Go to Page 11.2 Go to Page 11.3 Go to Page 11.4 Go to Page 11.7
Wrong Length Wrong Angle Wrong Load Bad Data Transfer - Interface Problem
Displayed Displayed Displayed Console/CPU
Go to Page 11.10 Go to Page 11.32 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 YES
Fault in crane electric If console display is Fault in Anti-Two If Load Moment Limit
or hydraulic system. blank, fault is located Block system. Light (7) displays fault
in power supply, is located in LMI,
wiring or fuses. cables, wiring, fuses or
console.
Check lever lockout Go to Page 11.4 Go to Page 11.7 Read error code dis-
system in crane played on console
display (1) and go to
Page11.41.
11.2
BROKEN LENGTH CABLE
PROBLEM
Damaged or broken length cable.
STEP ACTION
1 Cut old cable at cable drum.
2 Open cable reel cover and disconnect wiring from terminal block. Pull 7- conductor
cable out of strain relief.
3 Remove cable reel from mounting brackets.
4 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.
5 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.
6 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.
8 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.
9 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.
NO
correct? Replace fuses.
YES
Measure crane voltage on terminal board (ter-

minal 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.
NO Check crane power supply for faulty crane

correct?
electric or if power supply is too low.
YES
Measure crane voltage on terminal board (ter-

minal block X4) between Pin 2 (+24V) and
Pin 3 (ground). Refer to Drawing 3,
“Terminal Board”, on page 11.50.
Defect on terminal board. Diode D4,

inductance L1 or capacitor C1 is faulty.
NO These items can’t be replaced, change
correct?
terminal board. Refer to Drawing 3,
YES “Terminal Board” on page 11.50.
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.
Faulty wiring or connectors

NO between terminal board and
correct? main board. Check wiring
and connections.
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.
NO Short circuit in external

correct? wiring. Check external
wiring of system for defects.
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.
Defective power supply on

NO main board. Replace main
correct? board and reset pressure
channels - see Section 10.
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.
Fault in wiring between terminal

NO block X1 and console board.
correct?
Check wiring. Refer to Drawing 5,
YES “Console Board”, on page 11.52.
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
correct? Lower hook down in safe position.
YES
Check if jumper / dummy plug is

plugged into receptacle at boom
nose.
NO
Plug appropriate plug into
correct? 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? Replace Anti-Two-Block switch.
YES
NEXT PAGE
11.7
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 Fault in wiring cable from Anti-Two-Block

correct? 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

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

With ohmmeter measure between wire discon-
nected 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,
NO using same measurements as in previous
correct? step. See cranes specific wiring diagram
for wires # 5 (+) and # 6 (-). If fault is
YES found check cable.
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

correct? main board and reset pressure channel.
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 Faulty voltage supply wiring to
at terminal 3 (24V) and 5 (GND) in the switch. Replace defective
junction box at the front of the boom base cables.
section.
Next Page 11.10

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

terminal 5 (24V) and 9 (GND) in the length Replace proximity switch.
sensor LG221.
Is the
Voltage
Correct ? No
Yes
Measure the IM reset switch signal at Faulty wiring in cable

terminal 15 (24V) and 14 (GND) in the connecting the junction box
boom base junction box. with the length sensor.
Is the
voltage
correct? No
Yes
Measure the IM reset switch signal at central unit Faulty wiring in cable connecting
terminal A104 80 (24V) and A 101 36 (GND). the length sensor LG221 and the
boom base junction box.
Is the
voltage
correct? No
Yes
Measure the CM reset switch signal at Defective CM reset switch

terminal 10 (24V) and 9 (GND) in the length Replace proximity switch.
sensor LG221.
Next Page
11.11
Previous Page
Is the
voltage
correct ? No
Yes
Measure the CM reset switch signal at Faulty wiring in cable connecting

terminal 30 (24V) and 14 (GND) in the the junction box with the length
boom base junction box. sensor.
Is the
voltage
correct ? No
Yes
Measure the CM reset switch signal at Faulty wiring in cable

central unit terminal Al14-9 (24V) and connecting the boom base
A l04-36 (GND). junction box with the LG221.
Is the
voltage
correct ? No
Yes
Measure voltage supply to OM switch at Faulty wiring in cable connecting

terminal 11 (+24V) and 9 (GND) in the center the central unit and the boom
mid junction box. base junction box.
Is the
voltage
correct ? No
Yes
Measure voltage supply to CM switch at Faulty wiring in cable

terminal 7 (+24V) and 5 (GND) in the inner connecting the central unit and
mid junction box. the boom base junction box.
Next Page 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 Faulty voltage supply wiring to switch.
10 (24V) and 9 (GND) in the center mid junction Replace defective cables.
box .
Is the
voltage
correct ? No
Yes
Measure the CM reset switch signal at Faulty wiring in cable

terminal 10 (24V) and 9 (GND) in the connecting the center mid junction
length- angle sensor LWG221. box and the LWG 221.
Is the
voltage
correct ? No
Yes
Measure the OM reset switch signal at Faulty wiring in cable connecting

terminal 17 (24V) and 14 (GND) in the the junction box with the length
boom base junction box. sensor.
Next Page
11.13
Previous Page
Is the
voltage
correct ? No
Yes
Measure the OM reset switch signal at Faulty wiring in cable

central unit terminal Al04-78 (24V) and connecting the boom base
Al04-36 (GND). junction box with the LWG 221.
Is the
voltage
correct ?
Defective digital input 4, 5 on main board or Faulty wiring in cable connecting

digital input 5 on extension board. Contact the central unit and the boom
service dealer to obtain replacement base junction box.
instructions.
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! Continue

CAUTION: To avoid length potentiometer damage. do not with *
turn the length potentiometer past the stop. on page 11.17
Is the
length cable
spooled properly on
the LG 208 No
drum ?
Yes
With all sections completely

retracted, un-spool the length
cable carefully. Let the drum
Reset the length potentiometer. rewind slowly and spool the
cable manually back on the
drum. Check the roller guides
for correct adjustment.
Has
the adjustment
corrected the boom length
indication. Yes
Continue
with *
No on page 11.17.
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 Main board component defective

central unit and cable reel. Measure with Contact authorized service dealer
the DVM at the length transducer (LG 208) for the board replacement procedure.
terminal 1(GND) and 3 (-5V)
Is the voltage
correct (-5V) ? No
Yes
Verify the length sensor signal. Faulty wiring between

Measure the voltage at the length central unit and length
transducer (LG 208) terminal 1 (GND) transducer. Check
and 2 (-500mV) with fully retracted wiring, junction boxes
boom. and connectors for faulty wiring.
Is the voltage
correct ? No
(-500mV)
Yes
Check the length signal in the central unit. Defective length potentiometer.
Measure the signal at central unit terminal Replace length potentiometer
A104 Xl/10(-5OOmV) and Al 04 Xl/8(GND) assembly. For instruction how to
with fully retracted boom. change the length potentiometer
assembly refer to Section 3.
Next Page
11.16
Previous Page
Is the voltage
correct ?
(-500mV) Yes
No
Check the wiring that connects the Main board component defective.
LG 208 with the central unit. Inspect the Contact authorized service dealer for
cable and connectors. the board replacement procedure.
Have you
found any wiring
faults ? Yes
No
Connect the voltmeter central unit Correct the wiring problem.

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 Yes
-4.5V ?
No
Check the wiring that connects the Main board component defective.
LG 208 with the central unit. Inspect the Contact authorized service dealer for
cable and connectors. the board replacement procedure.
Next Page
11.17
Previous Page
Have you
found any wiring
faults ? Yes
No
Connect the voltmeter central unit Correct the wiring problem.

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. Reset length transducer.

Replace and adjust length potentiometer. Continue with section 14.
11.18
C. Inner Mid Length Error

section completely.
Is the
inner mid boom length Yes
indicated correctly?
Continue
No
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.
Is the
length cable
No
spooled properly on
the 221
drum?
Yes retracted, un - spool the length
rewind slowly and spool the
Reset the length potentiometer.
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 No
correct (-5V)?
Yes
Possible short or wiring fault between Main board component defective.
central unit and cable reel. Measure with Contact authorized service dealer
the DVM at the length transducers (LG 221) for the board replacement
terminal 1 (GND) and 3 (-5V) procedure.
Is the voltage No
correct (-5V)?
Yes
Faulty wiring between
Verify the length sensor signal. central unit and length
Measure the voltage at the length transducer. Check
transducer (LG 221) terminal 1 (GND) wiring, junction boxes
and 2 (-500mV) with fully retracted and connectors for
boom. faulty wiring.
Is the voltage No
correct (-500mV)?
Yes
Check the length signal in the central unit.

Defective length potentiometer.
Measure the signal at central unit terminal
Replace length potentiometer
A104 X1-24 (-500mV) and A104 X1-8
assembly.
(GND) with fully retracted boom.
Next Page
11.20
Previous Page
Is the voltage Yes

correct (-500mV)?
No
Check the wiring that connects the

Main board component defective.
LG 221 with the central unit. Inspect the
See section 10 for replacement procedure.
cable and the connections.
Have you found Yes

any wiring faults?
No
Connect the voltmeter to central unit

terminal A104 X1-24 (signal) and
A104 X1-8 (GND). Correct the wiring problem.
Turn potentiometer clockwise
0 turns = -500mV, 10 turns = -4.5V.
*
Is
the voltage
Yes
decreasing from
-500mV to
- 4.5V?
No
Check the wiring between length

transducer LG 221 and central unit Main board component defective.
Inspect cable connectors and junction See section 10 for replacement procedure.
boxes.
Next Page
11.21
Previous Page
Have you found Yes

any wiring faults?
No
Connect the voltmeter to terminal 2 (signal)

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

assembly. Replace and adjust length Reset length
potentiometer. transducer. Possible main board defect.
11.22
D. Center Mid Length Error

section completely.
Is the
center mid Yes
length indicated
correctly?
Continue
with *
No on page 11.25
CAUTION: High tension on cable reel drum.
Is the CAUTION: To avoid length potentiometer damage, do not
length cable turn the length potentiometer past the stop.
spooled properly on No
the LWG 221
drum?
Yes
retracted, un-spooled the length
Reset the length potentiometer. rewind slowly and spool the cable
manually back on the drum.
Check the roller guides for
correct adjustment.
Has
the adjustment
corrected the center mid Yes
length indication?
Continue
with *
No on page 11.25

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 No
correct (-5V)?
Yes
Possible short or wiring fault between

central unit and cable reel. Measure at Main board component defective.
the length transducer, terminal 1 Follow board replacement procedure.
(GND) and 3 (-5V).
Is the voltage No
correct (-5V)?
Yes
Verify the length sensor signal. Faulty wiring between central

Measure the voltage at the length unit and length transducer.
transducer, terminal 1 (GND) Check wiring, junction boxes and
and 2 (-500mV) with fully connectors for faulty wiring.
retracted boom.
Is the voltage No
correct (-500mV)?
Yes
Measure the signal at central unit terminal Defective length potentiometer.

A 104 X1-73 (-500mV) and A 104 X1-8 Replace length potentiometer
(GND) with fully retracted boom. assembly.
Next Page
11.24
Previous Page
Is the voltage Yes

correct (-500mV)?
No

See section 10 for replacement procedure.
Have you found Yes

any wiring faults?
No
Connect the voltmeter central unit terminal

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

See section 10 for
replacement procedure.
Next Page
11.25
Previous Page
Have you found Yes

any wiring faults?
No
Connect the voltmeter to terminal 2

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

assembly. Replace and adjust length Follow main board replacement procedure.
potentiometer.
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 No
retract?
Yes
Switch to automode. Start the engine and operate the Defect in crane electric or hydraulic circuit.
extend control. Measure the voltage at central unit Reset crane fuse breaker. Check LMI fuses
terminal A 104 X1-38 (24V) and A 104 X1-37 (GND) in the central unit enclosure.
while operating the extend control.
Is the
No
voltage
correct?
Yes
Switch to automode. Start the engine and operate the Faulty wiring to extend pressure switch or
retract control. Measure the voltage at central unit defective pressure switch. Correct the
terminal A 104 X1-40 (24V) and A 104 X1-39 (GND) wiring and replace the switch if defective.
while operating the extend control.
Is the
No
voltage
correct?
Yes
Select the service screen on the console

by pressing the two outer keys (F1 & F4) Faulty wiring to retract pressure switch or
simultaneously. The ramping value for the selected defective pressure switch. Correct the wiring
section shall increase from 0 to 255. The ramping and replace the switch if defective.
value remains 0 in the neutral position.
Next Page
11.27
Previous Page
Is the
No
ramping value
increasing?
Yes
Continue to troubleshoot the wiring to

Check ribbon cable connection in
the 2 way value and the hydraulic
central unit and wiring in the central unit.
circuit.
11.28
F. Out of Sequence Warning

Boom sections are out of sequence
(Automode)
Follow instructions in
section A.
Is the
problem Yes
corrected?
End
No
section B.
Is the
problem Yes
corrected?
End
No
section C.
Is the
problem Yes
corrected?
End
No
section D.
Is the
problem Yes
corrected?
End
No
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 No
target adjusted
correctly?
Yes
Measure the switch signal

at central unit. Adjust OM retract
A 104 X1-76 (24V) and switch and target.
A 104 X1-36 (GND)
Is the
voltage Yes
correct?
No
Faulty wiring. Check the voltage at terminal Main board component defective.
17 (24V) and 13 (GND) in the boom base See main board replacement
junction box. procedure.
Have you
found a Yes
fault in
the wiring?
No Correct the wiring

between boom base
Next Page
junction box and central
unit.
11.30
Previous Page
Measure switch signal at

LWG 221 terminal 10
(24V) and 9 (GND)
Is the
voltage Yes
correct?
No
Check the signal at terminal 10 (24V) and Correct the wiring between LWG 221
9 (GND) in CM junction box. Refer to and boom base junction box. Refer to
section 9.1 and 11. section 9 and 11.
Is the
voltage No
correct?
Yes
Retract all boom section in Defective OM retract switch.

manual mode and let the system Replace proximity switch.
reset boom percentage. Refer to section 9 & 11.
Recheck.
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.
Readjust the angle sensor to the correct

position by loosening the mounting
NO screws and moving the angle sensor.
correct? Refer to Page 11.53, Angle /
Length Sensor Adjustment Procedure.
YES
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.
Main board defective. replace main board and

NO reset pressure channel. Refer to Section 10 of
correct? this Manual.
Note: Consult factory before replacing main
YES 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 Tran-
sducer on page 11.53.
NO Faulty wiring between central unit and

correct? 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
For more detailed signal voltages refer
to : Boom Angle Signal Voltage Chart
in Section 5.
Remove wire # 4 from Terminal, in thecable

reel, and recheck the boom angle signal
voltages at terminal # 4 in cable reel.
NO If the signal is correct the problem is in the
correct? wiring between the cable reel and the central
unit or the main board is defective.
YES 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).
in Section 5.

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
in Section 5.
NO reset pressure channel. Refer to Section 10 of
correct? the System Manual.
Note: Consult factory before replacing main
YES board for further troubleshooting steps.
END
11.34
LOAD READING PROBLEM
PROBLEM
Load reading incorrect.
START
Check selected operating mode(code

on operating mode switch).
NO Select operating mode switch to correct position

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

correct? boom, turn potentiometer axle counterclockwise
until it stops
YES
Measure radius and check with the

displayed radius.
NO Check if mechanical adjustment of angle transducer

correct? 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
NO point MP15 = ground and MP18 = +5V and
correct? between test point MP15 = ground and MP2 =
-5V. If incorrect, replace main board and reset
YES pressure channel.
NEXT PAGE
11.35
PREVIOUS PAGE
Check power supply to pressure transducer

(piston side). Unplug transducer cable from
transducer. Measure on terminal board at ter-
minal block X1. Measure between Pin 19
(ground) and Pin 20 (-5V). Measure between
Pin 19 (ground) and Pin 18 (+5V).
Power supply on main board defective. Check

power supply and measure between test point
NO MP 15 = ground and MP 18 = +5V and between
correct? test point MP 15 = ground and MP 2 = -5V. If
incorrect, replace main board and reset pressure
YES channels.
Check power supply at transducer plugs. Mea-

sure between B = ground and A = +5V. Meas-
ure between B = ground and C = -5V.
NO Faulty wiring. Check wiring (pressure

correct? transducer cable).
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. Dis-
connect 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 Faulty wiring. Check wiring (pressure transducer

correct? 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).
Measure voltage between test point MP 15
(ground) and test point MP 4 and reset with
P4 to 0.50V (piston side).
NO Measure voltage between test point MP 15
correct? (ground) and test point MP 5 and reset with
P5 to 0.50V (rod side).
YES 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
correct? Place EPROM in correct socket.
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.
Defective internal power supply. Replace main

NO board and reset pressure channel.
correct? or
Defect in terminal board. Replace terminal board.
YES
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

correct? unit to console. Replace cable.
YES
Ensure that wires are properly connected be-

tween terminal block X1 Pin 31 and console
terminal Pin 4 and between terminal block X1
Pin 32 and console terminal Pin 3.
NO Defective electronic components on main board

correct? 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
correct? Replace or repair part which is defective.
YES
Check if additional ground like between main
board terminal X9 and central unit box mounting
bracket is in place.
Install ground link - single cable minimum of

NO AWG14 (2.0mm2) between terminal X9/1 and
correct? central unit box mounting bracket.
YES
Ensure that cable shields are connected correctly.

Refer to connections and wiring diagrams.
NO Make correct shield connection.

correct? Refer to connection and wiring diagrams.
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 Fallen below the minimum Lower boom back to a radius
range. radius or above the angle given or angle given in the load
in the load chart due to raising chart.
the boom too far.
E 02* Beyond radius or below The maximum radius or Raise boom back to a radius
angle range. minimum angle given in the or angle given in the load
load chart was exceeded due chart.
to lowering the boom too far.
E 03* Prohibited slewing range. Slewing range prohibited Slew back into admissible
(no load area) with load. range.
E 04* Operating mode not available. Operating mode switch in the Set operating mode switch
console set incorrectly. correctly to the code assigned
Operating mode is not per- to the operating mode of the
missible with actual crane crane.
configuration.
E 05* Length range not permitted. Boom was telescoped too Telescope boom to correct
far or not far enough. length given in the load chart.
Length sensor adjustment See Section No. 3

changed; i.e. length sensor
cable slid off the cable drum.
E 06* Fallen below angle range with Fallen below the minimum jib Luff in the jib to a radius or
luffing jib operation. angle specified in the angle specified in the load
respective load chart due to chart.
luffing out the jib too far.
* This error can be corrected by the operator.
11.41
ERROR CODE DISPLAY
ERROR
E 07 No acknowledgment signal Overload relay is stuck, Replace relay.

from overload relay (K8). defective or not being selected.
E 08 No acknowledgment signal Anti-Two-Block switch relay Replace relay.

from Anti-Two-Block switch is defective or not being
relay (K9). selected.
E 11 Fallen below lower limiting Cable from central unit to length sensor Check cable. Replace if
value for the measuring defective, not connected or water in the necessary. See Section 3.
channel "length". connectors
Length potentiometer defective. Replace and reset length

potentiometer. See Section 3.
Electronic component in the Replace main board and

measuring channel defective on reset pressure channels.
main board. See Section 10.
E 12 Fallen below lower limiting Cable from central unit to Check cable as well as plug.
value for the measuring the pressure transducer Replace if necessary.
channel "pressure piston side". defective, loose or water in See Section 10.
the plug.
Pressure transducer on Replace pressure transducer

piston side defective. and reset pressure channel.
See Section 10.

measuring channel defective reset pressure channels.
on main board. See Section 10.
channel "pressure rod side". defective, loose or water in See Section 10.
in the plug.
Pressure transducer on rod Replace pressure transducer

side defective. and reset pressure channel.
See Section 10.
Electronic component in Replace main board and

the measuring channel defective reset pressure channels.
E 14 Fallen below upper limit value Cable from central unit to Check cable as well as plugs,
in measuring channel "Force". force measuring point defective replace if need be.
or water inside the plugs.
Force transducer defective. Replace force transducer.
Electronic component in the Replace main board and reset
measuring channel defective. pressure channels. Section 10
11.42
ERROR CODE DISPLAY
ERROR
E 15 Fallen below lower limiting Cable from central unit to the length/ Check cable.
value for the measuring angle sensor defective or loose or Replace if necessary.
channel "angle main boom". water inside plug. See Section 5.
Angle sensor defective. Replace angle sensor.

and reset adjustment.

measuring channel defective. reset pressure channels.
See Section 10.
E 16 Fallen below lower limit Cable from central unit Check cable as well as plug,
value for measuring channel to angle sensor defective replace if need be.
"Luffing Jib Angle". or disconnected or water
inside the plug.

measuring channel defective. pressure channels.
See Section 10.
E 18 Front Stabilizer overloaded Exceeding capacities allowed for over Achieve a safe working area
the front. Immediately.
E 19 Error in the reference voltage. Electronic component on Replace main board and reset
the main board defective. pressure channels.
+5 volt supply See Section 10.
E 20 Error in the reference voltage. Bad power supply on Check wiring, replace if
main board. need be.
-9 volt supply
Bad force transducer Check force transducer cable,
wiring, (external). replace if need be.
E 21 Upper limiting value for the Cable from central unit to the Check cable. Replace if
measuring channel "length" length/angle sensor defective necessary. See Section 3.
exceeded. or loose.
Length potentiometer Replace and reset length
defective. potentiometer.

11.43
ERROR CODE DISPLAY
ERROR
E 22 Upper limiting value for the Cable from central unit to the Check cable as well as plug.
measuring channel "pressure pressure transducer defective, Replace if necessary.
piston side” exceeded. loose or water in the plug. See Section 10.
Pressure transducer on piston Replace pressure transducer

side defective. and reset pressure channels.
See Section 10.

rod side" exceeded. loose or water in the plug. See Section 10.

See Section 10.

E 24 Upper limit value in measuring Cable between central unit and Check cable as well as plug,
channel "Force" exceeded. force measuring point defective replace if need be.
or water inside the plug.
Force sensor defective. Replace force sensor.

See Section 7.
E 25 Upper limiting value for the Cable from central unit to the Check cable.
measuring channel "angle length/angle sensor defective Replace if necessary.
main boom" exceeded. or loose. See Section 5.
Angle sensor defective. Replace angle sensor and reset
mechanical adjustment.
measuring channel defective pressure channels.
E 26 Upper limit value for See Error E 16. See Error E 16.
measuring channel "Luffing
Jib Angle" exceeded.
11.44
ERROR CODE DISPLAY
ERROR
E 29 Error in the reference Supply and Reference voltages on Check supply voltages.
voltage. MP10 is more than 3.3V
Electronic component on Replace main board and reset
-5 volt supply the main board defective. pressure channels.
See section 10.
E 31 Error in system program EPROM with system Replace EPROM with system
program defective. program.
See section 10.
E 37 Error in program run EPROM with system program Replace system program
defective. EPROM.
Electronic component on the main Replace main board and reset
board defective. pressure channels.
See section10.
E 38 Incorrect system program. CPU is equipped with an Equip main board with
incorrect version of system correct version of system
program. EPROM.
E 41 Error in the external RAM. RAM in the CPU on the Replace CPU Chip No.
main board defective. 80C31. Replace main
board and reset pressure
channels. See Section 10.
E 42 Error in the external write/ Internal defect in Exchange write/read memory

read memory (RAM). digital part of CPU. (CMOS-RAM).
Replace main board and reset
pressure channels.
See Section 10.
E 45 Error in internal Defective electronic Replace main board and

communications. component. reset pressure channels.
See Section 10.
E 47 Malfunction in the Internal defect in Replace main board and reset
monitored write/read in digital part of CPU pressure channels.
memory. See Section 10.
E 48 Malfunction in the monitored Inter defect in digital part of CPU Replace main board and reset
pressure channels.
See section 10
E 51 Error in data memory. Data EPROM on the main Replace Data EPROM.
board defective. Make sure BR3 on the main
board is installed.
See Drawing 4 on page 11.51.
11.45
ERROR CODE DISPLAY
ERROR
E 60 Error in EPROM DATA-EPROM is not plugged into Properly install DATA-EPROM

the correct socket or location is not See page 11.51
programmed correctly in the EPROM.
E 70 Error in return signal No or wrong return signal from digital Ribbon cable defective or bad
input extension module to processor. Connection. Replace cable.
Digital input circuit defective.
Replace module.
Decoder circuit defective.
Replace decoder module.
E 71 Incorrect acknowledgment of the A2B relay is stuck or defective. Replace K9 relay. See page
A2B Relay on A101 Term. board. 11.50
A2B relay is not being selected due to Check terminal board, main
a break on the terminal board, main board and ribbon cables as well
board or ribbon cable. as replace defective part, if
necessary.
E 72 – E 77 Analogous to E 71 for relays Analogous to E 71 for relays Analogous to E 71 for relays

K2 – K7 K2 – K7 K2 – K7
E 80 Error in return signal No or wrong return signal from analog Ribbon cable defective or bad
output extension module to processor. Connection. Replace cable.
(for inner mid) 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 Select manual mode, manually
fully retracted while the center mid retract the outer mid and fly
section or the inner mid section section until fully retracted.
retracts or extends. 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
E 89 Change of the operating code The operating mode switch in the Lower the load and set the
during lifting a load. console was used during lifting operating mode switch correctly
a load. to the code assigned to the
actual operating mode of the
crane.
E 91 No data transmission from 24V supply of console Check 24V at terminal Xl of

console to central unit. interrupted. console electronics.
(See page 11.38 - 11.40)
Interruption or accidental Check the connection between
ground in the line from console electronics and
console electronics to central unit. If you find an
central unit. accidental ground, the
transmitter module in the
console electronics can be
damaged. You should,
therefore, replace the console
electronics.
Transmitter / receiver module Replace console electronics
defective. or main board respectively.
E 92 Error in the data transmission Defective data line Check the connection between
from console to central unit. from console electronics to console electronics and central
(See page 11.38 - 11.40) central unit. unit.
Transmitter / receiver Replace console electronics
module defective. or main board respectively.
E 93 Error in the data transmission Defective contact in the line Check the line to the console.
from central unit to console. from central unit to console.
(See page 11.38 - 11.40) Transmitter / receiver Replace console electronics
E 94 No data transmission from Interruption or accidental Check the line to the console
central unit to console. ground in the data line from (in case of accidental ground
(See page 11.38 - 11.40) central unit to console. also replace console
electronics).
5V supply for the computer Check the connection to the
in the central unit is missing. power supply.
5V supply voltage too low. Replace power supply module.
Data EPROM defective. Check data EPROM.
Computer module defective. Replace main board.
Electromagnetic interference’s Eliminate interference source

(e.g. when switching by inverse diodes or varistors.
contactors or valves).
11.47
ERROR CODE DISPLAY
ERROR
E 95 Error in the crane data EPROM Data EPROM defective. Replace data EPROM.
Position of jumper for the selection Check the jumper position.
of the type of EPROM is wrong.
Electronic component on main board Replace main board and reset
defective. pressure channels.
E 96 Error in the internal RAM of the CPU or main board of the console Replace console main board.
CPU of the console. defective.
E 97 Error in the external RAM of the External RAM of the console Replace console main board.
Electronic component on the main Replace console main board.
board defective.
E 98 Wrong jumper position in the The jumper position BR9/BR10 in the Check the jumper position.
console. 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

1
2
3
4
11.49
Drawing 3 : Terminal Board
X4 X1 X1
1 3 5
2 4 6
1 2 3 4 F1
8 10 12 14 16 18 20 22 24 26 28
7 9 11 13 15 17 19 21 23 25 27 29
X1 X1
H9 H8
V2 V1
A2B K9 LMI K8
SHUT SHUT
OFF OFF
X3 H7 H4 H1
V11 V8 V5
SEQUENCE
OUTER
OUT OF
MID
K7 K4 K1
71 72 73 74
X1
R15 R16 R9 R10 R3 R4

R17
R18
H10
V3
H6 H5 H3 H2
V10 V9 V7 V6
K10
CENTER
4 - WAY
LEVER
DRAIN
INNER
MID
ROD
MID
K6 K5 K3 K2 LOCKOUT
X4
R13 R14 R11 R12 R7 R8 R5 R6 R2 R1
49 48 47
CM
OM
4W
RO
SE
IM
Q
F8 F7 F6 F5 F4 F3 F2
D
X1
70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50
X1 X1
80 79 78 77 76 75 43 42 41 40 39 38 37 36 35 34 33 32 31 30 46 45 44
X1 X1 X1
11.50
Drawing 4 : Main Board

MP 19 = -5V E-1 11.51
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
1 2 3 4 5 6 7 8 X5 1 2 3 4
11. 52
Drawing 6 : Length / Angle
Transducer
PAT
PAT
1
2 3 4 5 6 7 8 9 101112 131415 16
ADJUST LENGTH POTENIOMETER

TURN THE CENTER SCREW COUNTER-
CLOCKWISE TO A SOFT STOP.
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
NORMAL L/O
OPERATION OVERRIDE
(BOTTOM VIEW
OF C.P.U.) OUT IN
11.54
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 A104 X 1 / 76

CM retract A l 14 X 1 / 9
IM + CM retract A 104 X 1 / 78
IM % reset 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:
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 Part Number ( PAT ) Description

a. A104 024 - 350 - 300 - 092 Extension Board
b. A111 024 - 350 - 300 - 135 ( B ) Analog Control Board
c. A114 024 - 350 - 300 - 301 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 switch’s 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 ) A104 - X1 - P54 to boom base junction box P - 19 and P - 24

Center Mid ( CM ) A104 - X1 - P66 to boom base junction box P - 20 and P - 26
Outer Mid / Fly ( OM/F A104 - X1 - P69 to boom base junction box P - 28 and P - 29
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:
IM CM OM /F
A104 - X1 - P54 0 1 1
A104 - X1 - P66 1 0 1
A104 - X1 - P69 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 ) IM % CM % OM / Fly %
A 0 0 0
A 0 100 0
A 0 100 100
A 100 100 100
B 0 0 0
B 50 0 0
B 50 50 0
B 75 50 0
B 75 75 0
B 100 75 0
B 100 100 0
B 100 100 100
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.
2 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.
3 Select a load (including hook block) between 20,000 to 25,000 pounds and position it at a
25’ to 30’ radius.
TEST PROCEDURE:
1 Switch boom control system to automatic mode. (Note: Boom will be out of sequence.)
2 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.
3 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.
4 Hoist the load to the ground, observe and record the movement of the marks on the boom
sections.
5 Determine which section(s) are retracting and reposition the boom sections to there original
positions.
6 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
7 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)
LENGTH (O.A. BOOM)
PRESS. PISTON SIG.
PRESS. ROD SIG.
LENGTH (CM)
LENGTH (IM)
A2B BYPASS
LMI BYPASS
A2B SIGNAL
PROXY (+)
A2B GND
ANGLE
AGND
AGND
AGND
+24V
GND
RXD
TXD
GND
+5V
+5V
-5V
-5V
-5V
IS
IS
IS
A 104
12 13 14 15 16 17 18 19 20 21 28 29 30 31 32 33 44 46 7 8 10 11 9 35 34 24 73 43 36 80 78 76
X1
To page 12.2
GN/YL
1 4 3 2 56 7 8 9 IS 1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 IS 1 2 3 4
+24V
IS
13 14
11 12
A
12.1
14 SOCKET PLUG
1 2 3 4 1 2 3 4 To Boom Base
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Junction Box
A BCD A BCD
A BC DE FG H I J K L M N
A BCD A BCD
PRES. TRANS. PRES. TRANS.

(ROD) (PISTON)
1 2 3 4 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 TMS/TTS 870
X1 1 2 3 4 5 6 7 8
WIRING CONNECTIONS
COM.
+24V
GND
RXD
TXD
A2B
LMI
DI
X8
+24V 1
X7 1 2 3 4 2
GND CONSOLE
12.2
IS
X1
A113
1
IS
4
22 47
+24V
4 5 6
6
K2 (COM) +24V
9
53 54
7 8
8
K6 (COM) +24V
65 66
B
8 10
K7 (COM) +24V
9 10 11 12
Junction Box
68 69
To Boom Base
7
K3 (COM) +24V
2 3 5 7 11 12 13 14 1
+24V
INTERFACE
TMS/TTS 870
+24V
2
GND
GND
3
4
DI 1 (+24V=TELE EXT PRES SW)
5
DI 2 (+24V=TELE RET PRES SW)
6 9
DI GND
+24V 71 DI 1 GND
GND 51
DI 2 GND
8 719
LMI UNLOCK SOLS 73

TELE EXT. PRESS. SW. 387 DI 3 GND
TELE RETRACT PRESS. SW. 388 DI 4 GND
HIGH=AUTO / NONE=MANUAL 239 DI 5 GND
10 11 12
OM/FLY TELE 242

CM TELE
DI 6 GND
243
IM TELE 244 K4 (COM) +24V
TELE OUT OF SEQ. 323 K5 (COM)
K5 (NO) OUTPUT TO EXT PROP
13 14 15 20 21
HIGH SIGNAL = AUTO MODE A

56 57 1 2 3 4 48 38 40 42 36 37 39 41 75 77 79 59 61 49 62 63 64
NO SIGNAL = AUTO MODE B 240 K5 (NC) OUTPUT TO RET PROP

FRONT O/R OVERLOAD 147
TELE PROP ANALOG GND 238
TELE ROD DRAIN SOL
X1
1083
A111

1
TELE RETRACT PROP SOL 257 +24V

+24V
2 3
GND
23 - PIN PLUG
1 2 3 4 5 6 7 8 9 101112 13 14 15 1617 1819 20 2122 23 24 25
GND
18
AGND
4 5 6
23 - SOCKET RECEPT A1 (PROP)

S/S HARNESS (REF)
X1
A114
16
DI E2 [ +24=MODE A
0V=MODE B
3 4
DI E2 GND
24 350 300 301
DI E3 (+24V)
12
DI EXTENSION BOARD
DI E5 (+24V=CM RET)
6 9 10
DI E5 GND
17 22 23 24 25
A B
14 SOCKET PLUG
1 14 2 3 4 5 6 7 8 9 10 11 12 13 IS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 IS
A B C D E F G H J K L M N P A B C D E F G H J K L M N P R S T U V
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 14
1 3
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
1 3 2 4 5 9 6 7 13 8 10 11 14 12
13 3 12 4 6 7 5 8 9 10 11 12 14
TMS/TTS870
1 7 2 3 4 5 6
WIRING
12.3
CONNECTIONS
1
123 6 7 12 4 9 10 5 8 11 3
1 2 3 13 8 6 4 9 14 12 7 5 10 11 3
4
E
2
2 4
1
1234 56 7 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
AGND
SIG.
-5V
AGND
AGND
SIG.
-5V
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
SIG.
-5V
AGND
SIG.
1 2 3 4 5 6 7 8 9 10 11
-5V
LENGTH
LENGTH/ANGLE LG221 (TO IM)

LENGTH ANGLE 1 2 3 4 5 6 7 8 9 10 11 TRANS.
LENGTH/ANGLELWG221 (TOCM)
TRANS. TRANS.
BRN
LENGTH
RED
TRANSDUCER
BLK
WHT/BLK
WHT
ORG
GRN
GRA
BRN
RED
BLU
YEL
LG208 (TO NOSE)
VIO
BLK
WHT/BLK
WHT
ORG
GRN
GRA
BRN
RED
BLU
YEL
VIO
3=RED
2=BRN
SHEILD
CORE 1=BLK
3
2
1
1234
WHT/
WHT
ORG
GRN
GRA
BRN
RED
BLU
BLK
BLK
YEL
WHT/
VIO
12
WHT
ORG
GRN
GRA
BLK
BLK
BRN
RED
BLU
YEL
VIO
VV
1 2 3 4 5 6 7 8 9 10 11 12
A B 4.7K 1 2 3 4 5 6 7 8 9 10 11 12
A B
GRA
GRN
BLU
BRN
WHT
PNK
BLK
RED
YEL
CRE
VV
VIO
2
GRA
GRN
3
BLU
BRN
WHT
BLK
PNK
RED
1
YEL
CRE
VIO
0 0
4.7K
SHD
SHD
C D
JUNCTION
BOX (CM) RED 1 = CM CYL (+)
TIE WRAP
RED 1 USED TO IDENTIFY CABLE
RED = CM PILOT (+)
VIO 1 BLK 1 = OM CYL (+)
YEL 2 RED BLK = OM PILOT (+)
PNK 3 BLK 1 GRN 1 = CM CYL (-)
RED 4 BLK GRN = CM PILOT (-)
WHT 1= OM CYL (-)
BLK 5 GRN 1 PROXY SW 3 (TOP)
WHT = OM PILOT (-)
GRA 6 GRN (LENGTH RESET)
BLU 7 WHT 1 1
1 (+)
CRE 8 WHT 4
PROXY SW 1 4 NO O O
SHD 9 (OM/FLY RETR) 2
3 2 NC O O
10 4 1 3
1 (+) 3 (-)
WHT 4
11 1
C BRN 4 NO O O IS
GRN 2
2 2 NC O O
IS 3
3 (-) 3
3 2
IS 6 3
5
4 4
JUNCTION 4
RED E 2
3
4
BOX (IM)
YEL 1
12.4
2
BLU 1 1
VIO RED RED = IM CYL (+)
1
1
BLK 2
GRA 2 BLK = IM PILOT (+) JUNCTION BOX
BLK 3 GRN GRN = IM CYL (-) BOOM BASE
CRE 4 WHT WHT = IM PILOT (-)
PNK PROXY SW 2 (BOTTOM)
SHD PROXY SW 4
D (CM/IM RETR. 2-POSITIONS)
WHT 5 3 (CM RETR)
1
6 4 1 1 (+)
BRN 1 (+) 4
GRN 7 1 4 4 NO O O
4 NO O O 2
2 2 NC O O
2 2 NC O O 3
3 3 (-)
IS 3 (-)
IS
IS
TMS/TTS 870
WIRING CONNECTIONS
DI 4 (PROXY 1 OM/FLY RETRACT)
DI 5 (PROXY 2 CM/IM RETRACT)
DI 6 (PROXY 3 LENGTH RESET)
LENGTH (O.A. BOOM)
PRESS. PISTON SIG.
PRESS. ROD SIG.
LENGTH (CM)
LENGTH (IM)
A2B BYPASS
LMI BYPASS
A2B SIGNAL
PROXY (+)
A2B GND
ANGLE
AGND
AGND
AGND
+24V
GND
RXD
TXD
GND
+5V
+5V
-5V
-5V
-5V
IS
IS
IS
A 104
12 13 14 15 16 17 18 19 20 21 28 29 30 31 32 33 44 46 7 8 10 11 9 35 34 24 73 43 36 80 78 76
X1
To page 12.6
GN/YL
1 4 3 2 56 7 8 9 IS 1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 IS 1 2 3 4
+24V
IS
13 14
11 12
A
12.5
14 SOCKET PLUG
1 2 3 4 1 2 3 4 To Boom Base
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Junction Box
A BCD A BCD
A BCD A BCD
PRES. TRANS. PRES. TRANS.

(ROD) (PISTON)
1 2 3 4 5 6 7 8 9 10 11 12 13 14
14 PIN PLUG RT865BXL

WIRING CONNECTIONS
1 2 3 4 5 6 7 8 9 10 11 12 13 14
X1 1 2 3 4 5 6 7 8
COM.
+24V
GND
RXD
TXD
A2B
LMI
DI
X8
+24V 1
X7 1 2 3 4 2
GND CONSOLE
12.6
IS
X1
A113
1
22
IS
4
+24V
47
5 6
6
K2 (COM) +24V
53 54
9
7 8
8
K6 (COM) +24V
65 66
B
K7 (COM) +24V
9 10 11 12
Junction Box
68 69
To Boom Base
7
K3 (COM) +24V
8 10 2 3 5 7 11 12 13 14 1
RT865BXL
+24V
INTERFACE
+24V
2
GND
GND
3
4
+24V 71 DI 1 (+24V=TELE EXT PRES SW)
5
GND 51 DI 2 (+24V=TELE RET PRES SW)
LMI UNLOCK SOLS 73
TELE EXT. PRESS. SW. 387
6 9
TELE RETRACT PRESS. SW. 388 DI GND
HIGH=AUTO MODE/NONE=MANUAL MODE 239 DI 1 GND
OM/FLY TELE 242
CM TELE
DI 2 GND
243
IM TELE 244 DI 3 GND
DI 4 GND
DI 5 GND
8 7 19 10 11 12
TELE OUT OF SEQ. 323 DI 6 GND

LMI L/O ALARM 74 K4 (COM) +24V
HOUSE LOCK PIN SWITCH 744
TELE PROP ANALOG GND 238 K5 (COM)
TELE ROD DRAIN SOL 1083 K5 (NO) OUTPUT TO EXT PROP
56 57 1 2 3 4 48 38 40 42 36 37 39 41 75 77 79 59 61 49 62 63 64
TELE RETRACT PROP SOL 257 K5 (NC) OUTPUT TO RET PROP

23 - PIN PLUG
X1
A111
1 2 3 4 5 6 7 8 9 101112 13 14 15 1617 18 19 20 2122 23 24 25

1
+24V
13 14 16 20 21 17 22 23 24 25
+24V
23 - SOCKET RECEPT
2 3
S/S HARNESS (REF) GND

GND
18
AGND
4 5 6
A1 (PROP)
X1
A114
15
DI E1 (+24V HOUSE PIN ENGAGED)

COM
1 2
DI E1 GND
24 350 300 301
12o
1 2 3 4
7
DI E4 (+24V AREA DEF.)

CRANE 12o AREA
1 2 3 4
NO
348o NC
A B C D E
A B C D E

ELECTRICAL SWIVEL
DEFINITION SWITCH IN
12
DI EXTENSION BOARD
DI E5 (+24V=CM RET)
SWIVEL HARNESS AREA DEF.
8 9 10
5 PIN RECEPTACLE INTERFACE

DI E5 GND
5 SOCKET PLUG
A B
14 SOCKET PLUG
1 14 2 3 4 5 6 7 8 9 10 11 12 13 IS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 IS
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 14
1 3
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
1 3 2 4 5 9 6 7 13 8 10 11 14 12
13 3 12 4 6 7 5 8 9 10 11 12 14
RT865BXL
1 7 2 3 4 5 6
WIRING
12.7
CONNECTIONS
1
123 6 7 12 4 9 10 5 8 11 3
1 2 3 13 8 6 4 9 14 12 7 5 10 11 3
4
E
2
2 4
1
123 4 56 7 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
AGND
SIG.
-5V
AGND
AGND
SIG.
-5V
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
SIG.
-5V
AGND
SIG.
1 2 3 4 5 6 7 8 9 10 11
-5V
LENGTH
LENGTH/ANGLE LG221 (TO IM)

LENGTH ANGLE 1 2 3 4 5 6 7 8 9 10 11 TRANS.
LENGTH/ANGLELWG221 (TOCM)
TRANS. TRANS.
BRN
LENGTH
RED
TRANSDUCER
BLK
WHT/BLK
WHT
ORG
GRN
GRA
BRN
RED
BLU
YEL
LG208 (TO NOSE)
VIO
BLK
WHT/BLK
WHT
ORG
GRN
GRA
BRN
RED
BLU
YEL
VIO
3=RED
2=BRN
SHEILD
CORE 1=BLK
3
2
1
1234
WHT/
WHT
ORG
GRN
GRA
BLK
BLK
BRN
RED
BLU
YEL
WHT/
12
VIO
WHT
ORG
GRN
GRA
BLK
BLK
BRN
RED
BLU
YEL
VIO
VV
1 2 3 4 5 6 7 8 9 10 11 12
A B 4.7K 1 2 3 4 5 6 7 8 9 10 11 12
A B
GRA
GRN
BLU
BRN
WHT
PNK
BLK
RED
YEL
CRE
VV
VIO
2
GRA
GRN
3
BLU
BRN
WHT
BLK
PNK
RED
1
YEL
CRE
VIO
0 0
4.7K
SHD
SHD
C D
JUNCTION
BOX (CM) RED 1 = CM CYL (+)
TIE WRAP
RED 1 USED TO IDENTIFY CABLE
RED = CM PILOT (+)
VIO 1 BLK 1 = OM CYL (+)
YEL 2 RED BLK = OM PILOT (+)
PNK 3 BLK 1 GRN 1 = CM CYL (-)
RED 4 BLK GRN = CM PILOT (-)
WHT 1= OM CYL (-)
BLK 5 GRN 1 PROXY SW 3 (TOP)
WHT = OM PILOT (-)
GRA 6 GRN (LENGTH RESET)
BLU 7 WHT 1 1
1 (+)
CRE 8 WHT 4
PROXY SW 1 4 NO O O
SHD 9 3 (OM/FLY RETR) 2
2 NC O O
10 4 1 3
1 (+) 3 (-)
WHT 4
11 1
C BRN 4 NO O O IS
GRN 2
2 2 NC O O
IS 3
3 (-) 3
3 2
IS 6
3
5
4 4 4
JUNCTION E 2 4
RED BOX (IM) 3
1
12.8
YEL 2
BLU RED 1 1 1
VIO 1 RED = IM CYL (+)
BLK 2
GRA 2 BLK = IM PILOT (+) JUNCTION BOX
GRN GRN = IM CYL (-)
BLK 3 BOOM BASE
WHT WHT = IM PILOT (-)
CRE 4
PROXY SW 4
D SHD (CM/IM RETR. 2-POSITIONS)
5 3 (CM RETR)
WHT 1
6 4 1 1 (+)
BRN 1 (+) 4
GRN 7 1 4 4 NO O O
4 NO O O 2
2 2 NC O O
2 2 NC O O 3
3 3 (-)
IS 3 (-)
IS
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
Central Unit with DS350 modular

or DS150 mainboard or compatible
interface like 24 350 30 0128
J1 J2 ( J1 = closed / J2 = 1 -2)
1
X1 L1
Central Unit with DS350G mainboard or

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

CONSOLE CONNECTIONS
& WIRING DIAGRAM
VIEW OF BACKSIDE
OF GRAPHIC CONSOLE
MP 2
+7V
MP 5
+5V
MP 0
GND
MP 3
-24V
MP 4
-24V
14.1
MP 6
MP 7
MP 1
+UB
J2 J5
J1 J4
J3
X1
1 2 3 4 5 6 7 8 X5 1 2 3 4
ELECTRICAL WIRING FROM
CENTRAL UNIT TO CONSOLE
A2B BYPASS
A2B BYPASS
CENTRAL UNIT
LMI BYPASS
MAIN BOARD
GND
GND
RXD
TXD
+UB
+UB
+UB
51 52 3 4 5 6 7 8 9 10
8 9 1 2 3 4 5 6 7 10 11 12 13 14
14.2
CONSOLE (1318)
1 2 3 4 5 6 7 10 8 9 11 12 13 14
1 2 3 4 5 6 7 8 X1
GND
TXD
RXD
+UB
A2B
A2B
LOAD
DI
SIG +
SIG -
GND
X8
+UB
+UB 1
X7 1 2 3 4 GND 2
A B C D
1 2 3 4
LIGHTBAR
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
5 Data Received from Console
30 Force Signal
6 Data Transmit to Console
31 A2B Signal
7 A2B Bypass
32 A2B Ground
8 A2B Bypass
33,34,35,36 Not Used
9 LMI Bypass
51 +UB
10 + 12V (ub)
52 GND
11 +UBR
53 Fuse (4 AMP)
12 LMI Lockout Solenoid
54 Fuse (4 AMP)
13 Ext. Hor. # 1
57 Not Used
14 +UBS
58 Not Used
15 GND
60 +UBS
16 Digital Input # 1 61 Fuse (10AMP)
17 Digital Input # 2 62 Fuse (10 AMP)
64 UB
18 Digital Input # 3
65 GND
19 Digital Input # 4
66,67,68,69 Not Used

20 +UB Piston Pressure Transducer
21 Piston Pressure Signal 76 +UB
77 GND
23 +UB Rod Pressure Transducer
24 Rod Pressure Signal
26 +UB Length Transducer
15.1
+ +UB
OUTPUT
A104 DIGITAL
F1 +UBS
MODULE
DATEN-
A103
1 + +12V
12V
2 0V K10A
X3
3 + +UBS
CONSOLE 4 0V
5 RXD K9
MODULE
CPU-
A102
6 TXD
7
A2B-O
8
STOP
LOAD A2B-I K8
EXTENSION
A105 SERIAL
9
SWITCH LOAD-I
X12
X11
10 + +UBS
DIN
DIN
F2- 10A
11 REL -M
REL 12
REL -A
13 K10B
REL -R
14 + +UBS
+UBS
15
X3
16 DE 1
A106 ANALOGG INPUT

17 DE 2
DE 1-4
18 DE 3
19 DE 4
20 + +UBS
DAV 1 21 I DAV1
U
22 0V
23 + +UBS
DAV 2 24 I DAV2
U
25 0V
26 + +UBS
27 I LG 1
LWG 1 U
28 0V
29 I WG 1
U
LG 2 30 I LG 1
U
31
HES 0V
32
33 + +UBS
S1 34 I S1 DHG 1
DHG U
35 0V
MODULAR/CURRENT IN
A101 MAIN BOARD DS350
S2 36 I S2 DHG 2
U
51 + +UB
12V
EXTENTION
MEMORY
A107
52 0V
F1 - 4A
53
SI-UB SI - OUT
54
SI - IN
LOAD 57 A2B-0
ADDITIONAL TERMS
KEY 58 A2B-I
59 LOAD-I
SWITCH
60 + +UBS
F2-10A
61
SI-REL SI-REL
62
SI-REL
64 + +UBS
65 0V
66
DE 5,6 DE 5
24 352 31 0001
67
68
DE 6
69
76 + +UBS
+UBS
77 0V
15.2
A2B GROUND
LMI UNLOCK S.
FUSE (4 amp)
FUSE (4 amp)
A2B BYPASS
A2B BYPASS
EXT. HOR. *1
A2B SIGNAL
LMI BYPASS
LMI BYPASS
FUSE (10 amp)

FUSE (10 amp)
NOT USED
NOT USED
NOT USED
NOT USED
LENGTH
PISTON
ANGLE
FORCE
+UBR
+UBS
+UBS
GND
GND
GND
GND
GND
GND
GND
ROD
+UB
RXD
TXD
+UB
+UB
+UB
+UB
+UB
+UB
DI4
DI1
DI2
DI3
X1 1 2 12 11 51 52 3 4 5 6 7 8 9 10 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 53 54 59 60 61 62
GN/YL
OUT
OUT
IN
IN
1 2 3 8 9 1 2 3 4 5 6 7 10 11 12 13 14 1 3 4 2 1 2 3 4 1 2 3 4 1 2 3 4 7 5 6
4 3
1 3 2 1 2 2 2 2
1 3 1 1 1 2 1
CONSOLE (1318) 4 AMP 10 AMP

FUSE FUSE
1 2 3 4 5 6 7 10 8 9 11 12 13 14 LMI BYPASS
15.3
GN/YL
1 2 3
5 PIN KEY SWITCH
1 2 3 4 5 6 7 8 X1 DEUTSCH
V V
6 PIN PLUG
V V V 1 2 3 4 PLUG
+UB
GND
A2B
A2B
TXD
D1
RXD
LOAD
V V V V V V
A BCD E
(LMI UNLOCK SOL.)
A BCD E 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7
X8 V V V V V
DS350
+UBE
GND
SIG+
+UBE 1
SIG-
GND 2 V V V V V V V V VV V V GRAPHIC MODULAR

51 (GND)
71 (+UB)
NO A B C A B C
X7 1 2 3 4 A B C A B C
1 2 3 4 5 6 CENTRAL UNIT
C V V V V V V TO MAIN BOOM
73
1 2 3 4 CONNECTOR
NC
over front NOTES:
V V V V on rubber
A BC D NO OUTER SHIELD GROUNDED AT STRAIN
1
V V V V RELIEF CONNECTOR.
C
pres. trans. pres. trans.
(piston) (rod) 2 INNER SHIELD CUT AND INSULATED
1 2 3 4 NC
on outriggers INSULATE OUTER SHIELD AND
LIGHTBAR 3
CONNECT TO CHASIS GND.
CRANE SYSTEM AREA *1) OPTIONAL FOR EXTERNAL HORN
DEF. SWITCH ELEC. SWIVEL (EEC UNITS ONLY)
P.A.T. DS350 Graphic Modular
MAIN BOARD
A B C D E F G H I J K L M
PWM DC
+UB1
MP42
1 - G1 + KGND MP 26 1
C GND
C
KGND
MP 4
VBAT
MP23
MP24
+5V
MP 9
+BATT +6V
KGND
2 MP 8 2
AGND
+9V
X15
GND GND
V10 H11 V11

X14
3 3
power o.k.
DI 1- DI 6 =>
MP41 MP40
PFAIL+UB1
4 4
X17
DI 1
H1 H2 H3 H4 H5 H6
MP21
5 5
+UB1 +UB
DI 6
KGND
X12
6 6
X11
J11
7 SP5 7
X13
8 8
X16
TXD
H12
LOAD
ON/OFF
9 9
MAIN
AGND
H10
AGND
+5V/RS232
KGND
LMI
10 K8 10
KGND
J10
3 2
LEVER
4 1 MP29 LOCKOUT
+UB
A2B K10
K9
11 11
KGND
F2
A2B
H9
- +
F1
J4
X1
J3
12 12
KGND
J2
KGND
J1
KGND
1
3
77 76 69 68 67 66 65 64 62 61 60 59 58 57 55 54 52 51
KGND
X1
MP
13 1 +UB 13
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 MP25
LOCATIONS : LED’S
MP 1 - zone M13 = KGND. H 8 - zone M3 - LOAD

MP 25 - zone M13 = +UBS CONSOLE, SENSORS, DI’s H 9 - zone E11 - A2B
MP 8 - zone M2 = +9V H 10 - zone G9 - MAIN IN/OUT
MP 9 - zone M2 = +6V MP 41 - zone M4 = POWER FAIL
H 11 - zone M3 - POWER
MP 4 - zone M1 = +5V MP 42 - zone G1 = +5V
H 12 - zone I11 - TXD
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
15.4
EXTENSION BOARDS
MP7
J12 J2 J1
J13
D3
D1 D2
D14
MP4
X1
X2
D13
SYSTEM
D10 D6
P1
J8 J9 MP3 J6
D17
D15 D7 D21
J10
D9
D18 D12
J14
J15
J11
J7 D11
D19
D20
X3
EJECT
BR5
MP6MP5
BR6 MP2
A102 CPU J1 J2
DATA
D1
J5
J3
TLK
D3
BR J6
X1
1
4
3
2
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
AGND
AGND
MP12
- +
40
2
1
P7
MP13
J2
P6
20
P5
16
P4
X16
MP11
J1
MP9
P3
P2
MP10
P1
1 1
2 X1 MP17
BR1 MP0 - +
MP8
+ +
X17
MP7 - MP1->
2
1
VREFA
P8
+ +
MP16 16
7
6
5
MP14
4
3
2
1
40
2
1
AGND AGND
BOARD P/N 9-333-103290

X1:1-7 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
X1:8 = TEMP (0.5V + 10mV/oC)
X1:9 = VREFA = 5.000V reference MP 1 = AGND
X1:10 = AGND (reference GND) MP 8 = + 5V
X1:11 = VREF+ = 5.0V power ADC MP 1 - 7 = Input channels 1 - 7 - 0.5V/ 4mA
X1:12-15 = CH01-04, DIN 1-4 / 10 2.5V/20mA
X1:16 = CH05, +UBS / 10 MP 14 = + 13V REF 02
X1:17 = CH06, HESIN(A2B) *4 MP 16 = HESIN input voltage
X1:18 = CH07, +9V *4 MP 17 = app 5.4V clamp for inputs
X1:19 = CH08, VREFA / 2 = 2.500V
X1:20 = 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= VDC MP 1 Ground

+ 9V @ MP 8= VDC MP 1 Ground
+5V @ MP 4= VDC MP 1 Ground
+12/+24V @ MP 40= VDC MP 1 Ground
3. Boom Length:
Fully Retracted Ft. mA @ X1-27
Fully Extended Ft. mA @ X1-27
Fully Retracted Ft. VDC @ MP X1-3(A106), MP 0 (GND)
Fully Extended Ft. VDC @ MP X1-3(A106), MP 0 (GND)
+12/+24V Volt Reference Voltage VDC @ X1-26 (X1-28 GND)
4. Boom Angle:
Minimum Angle Degs. mA @ X1-29
Maximum Angle Degs. mA @ X1-29
Minimum Angle Degs. VDC @ MP X1-4(A106), MP 0 (GND)
Maximum Angle Degs. VDC @ MP X1-4(A106), MP 0 (GND)
+12/+24V Volt Reference Voltage VDC @ X1-26 (X1-28 GND)
5. Pressure Transducers:
Piston Zero Point mA @ X1-21 / VDC @ X1-1(A106), MP0 (GND)
Rod Zero Point mA @ X1-24 / VDC @ X1-2(A106), MP0 (GND)
Piston +12/+24 Volt Reference Voltage VDC @ X1-20 (X1-22 GND)
Rod +12/+24 Volt Reference Voltage VDC @ X1-23 (X1-25 GND)
6. Analog Input Module (A106):

+5V @ MP8 = VDC MP 0 Ground
+5V @ MP17= VDC MP 0 Ground
+5V @ MP16= VDC MP 0 Ground
15.7
P.A.T. – L.M.I
MANUAL
SECTION 16

BOOM LENGTH CONNECTIONS
& WIRING DIAGRAMS
AGND
P8 Channel # 1
AGND
- +
MP14
OPERATING WINDOW
VREFA
MP0
P7 P6 P5 P4 P3 P2 P1
MP8
MP13 MP9 .0V
LENGTH
ERROR
(GND)
MP12
CODE E11
MP17
+UB
J1
J2
.500v MIN.
MP10
MP7 - MP1->
MP11 X1 26 27 28
WORKING
- +
RANGE -
BR1
AGND
20
X1
1 1
AGND
40 2
MP16 16
1
2 4.50v MAX. A +
VOLTAGES ERROR
X1 3 ANALOG INPUT MODULE CODE E21
+ 500MV (.500V) = MIN. SIGNAL (RETRACTED BOOM)
+ 4.50V = MAX. SIGNAL (10 TURNS ON POT) 5.0V
ALL VOTAGES ARE MEASURED WITH
Current Based Amplifier 1 2 3
REFERENCE TO GND (TERMINAL X1 - 28) ON MAIN BOARD.
* THESE MEASUREMENTS ARE MADE IN PARALLEL All sensing devices used for Analog Inputs now have a
current output. (min. signal 4mA, max. signal 20mA)
16.1
This circuit is measured in series.
E11 / E21
SHIELD 1
(measurements in cable reel) 6 Pin Plug
CORE 2
Measure Voltage - Length transducer at X1 1(+) & 3 (-)

Range 10V to 30V 5 3 1 5 3 1 1 2 3 4 5 6 7
1 OUT
1 OUT
GND
GND
+UB
+UB
Range 1V to 5.6V
1 2 3 4 5 6
Measure Amps - Length transducer at X1 2(+) & 7 8 5 3 1 5 3 1
(-) WIRE 2. Range 4 mA to 20 mA X2 X4 X3 1 2 3 4 5 6 7
DS350 GRAPHIC MODULAR S 8 7 6 5 4 3 2 1 X1

6 Pin Connector
BOOM LENGTH MEASURING CHANNEL 6 5 4 3 2 1
CHANNEL # 1 7
Boom Length Signal
NO. OF TURNS NO. OF TURNS SIGNAL AT X1 TERM. SIGNAL ON ANALOG

ON CABLE ON LENGTH PIN #27 ON C.P.U. MODULE AT X1-3
REEL POT TERMINAL (X1-28 GND.)
0 0 4 mA .5 V
3 1 5.5 mA .9 V
6 2 7.2 mA 1.3 V
9 3 8.7 mA 1.7 V
16.2
12 4 10.4 mA 2.1 V
15 5 12.0 mA 2.5 V
18 6 13.6 mA 2.9 V
21 7 15.2 mA 3.3 V
24 8 16.8 mA 3.7 V
27 9 18.4 mA 4.1 V
30 10 20 mA 4.5 V
( 3 TURNS OF CABLE REEL = 1 TURN OF LENGTH POT.)
CHANNEL # 1
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
1 X3
XA2 1
2
3
16.3
3 5
1
1 2 3 4 5 6 7 8
X2 L
2
3 1 X4
4 XB2
2 1
5 3
3 5
6
X2
7 A
8
S X2
7 (9)
X1 8 (10)
9333103309
MEASURE VOLTAGE IN LENGTH TRANSDUCER
AT X1 - 2 (+) & X1 - 3 (-)… RANGE = 1V - 5.6V.
1.0
1 X3
XA2 1
2
3
16.4
3 5
1
1 2 3 4 5 6 7 8
X2 L
2
3 1 X4
4 XB2
2 1
5 3
3 5
6
X2
7 A
8
S X2
7 (9)
X1 8 (10)
9333103309
MEASURE AMPERAGE IN LENGTH TRANSDUCER
AT X1 - 2 (+) & WIRE #2 (-)… RANGE = 4mA - 20mA.
4.00
1 X3
XA2 1
2
3
16.5
3 5
1
1 2 3 4 5 6 7 8
X2 L
2
3 1 X4
4 XB2
2 1
5 3
3 5
6
X2
7 A
8
S X2
7 (9)
X1 8 (10)
9333103309
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
OUTPUT SIGNAL
AGND Channel # 2
AGND
P8
- +
OPERATING WINDOW
MP14
.0V
VREFA
(PISTON)
MP0
(GND)
P7 P6 P5 P4 P3 P2 P1
MP8
MP13 MP9
ERROR
+UB
CODE E12
MP12
MP17
J1
J2 .500v MIN. X1 20 21 22
MP10
MP7 - MP1->
MP11 WORKING -
RANGE
- +
A
4.50v MAX. +
BR1
AGND
AGND 20 1 X1 1 MP16 1
16
40 2 2
ERROR
VOLTAGES CODE E22
X1 1 ANALOG INPUT MODULE
+ 500MV (.500V) = MIN. SIGNAL (ZERO PRESSURE) 5.0V 1 2 3 4
+ 4.50V = MAX. SIGNAL (300 BAR PRESSURE)
* THESE MEASUREMENTS ARE MADE IN PARALLEL Current Based Amplifier
17.2
All sensing devices used for Analog Inputs now have a

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

Range 200 - 300 Ohm
PRESS. TRANS.
(PISTON)
DS350 GRAPHIC MODULAR

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

E13 / E23 This circuit is measured in series.
Measure Voltage - (Elec) Rod transducer at A (+) & C (-)
Range 10V to 30V
A B C
Measure Voltage - (Elec) Rod transducer at B (+) & C (-) A B C
Range 0V
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 C
17.4
P.A.T. – L.M.I
MANUAL
SECTION 18

BOOM ANGLE
CONNECTIONS &
WIRING DIAGRAMS
AGND
P8
AGND
- +
Channel # 5
MP14
VREFA
OPERATING WINDOW
MP0
P7 P6 P5 P4 P3 P2 P1
MP8
MP13 MP9
.0V
ANGLE
ERROR
(90o TO 0o)
MP12
MP17
J1
(GND)
CODE E15
+UB
J2
MP10
MP7 - MP1->
MP11 .500v MIN.
X1 26 28 29
- +
WORKING
RANGE -
BR1
AGND
20
X1
AGND 1 1 MP16 1
16
40 2 2
4.50v MAX. A
VOLTAGES +
X1 4 ANALOG INPUT MODULE ERROR
+ 500MV (.500V) = 90o ANGLE MIN. SIGNAL CODE E25
+ 2.50V = 45o ANGLE
+ 4.5 V = 0o ANGLE MAX. SIGNAL 5.0V
ALL VOTAGES ARE MEASURED WITH 1 3 4
* THESE MEASUREMENTS ARE MADE IN PARALLEL current output. (min. signal 4mA, max. signal 20mA)
18.1
SHIELD 1
E15 / E25 CORE 2
6 Pin Plug
(measurements in cable reel)
5 3 1 5 3 1 1 2 3 4 5 6 7
Measure Voltage - Angle transducer at X1 1(+) & 3 (-)
Range 10V to 30V
1 OUT
1 OUT
GND
GND
+UB
+UB
Measure Voltage - Angle transducer at X1 2(+) & 3 (-) 1 2 3 4 5 6
Range 1V to 5.6V 7 8 5 3 1 5 3 1
Measure Amps - Angle transducer at X1 4(+) & X2 X4 X3 1 2 3 4 5 6 7
(-) WIRE 4. Range 4 mA to 20 mA
S 8 7 6 5 4 3 2 1 X1
6 Pin Connector
6 5 4 3 2 1
7
BOOM ANGLE MEASURING CHANNEL
CHANNEL # 5
Boom Angle Signal
ACTUAL SIGNAL AT X1 TERM. SIGNAL ON ANALOG
BOOM ANGLE PIN #29 ON C.P.U. MODULE AT X1-4
IN DEGS. TERMINAL (X1-28 GND.)
90o 4.0 mA 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
18.2
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
o 15.6 mA + 3.38
25
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.
MEASURE VOLTAGE IN ANGLE TRANSDUCER
AT X1 - 1 (+) & X1 - 3 (-)… RANGE = 10V - 30V.
24.0
1 X3
XA2 1
2
3
3 5
1
X2 L
2
18.3
3 1 X4
4 XB2 1
2
5 3
3 5
6
X2
7 A
8
1 2 3 4 5 6 7 8
S X2
7 (9)
X1 8 (10)
9333103309
MEASURE VOLTAGE IN ANGLE TRANSDUCER
AT X1 - 2 (+) & X1 - 3 (-)… RANGE = 1V - 5.6V.
1.0
1 X3
XA2 1
2
3
3 5
1
X2 L
2
18.4
3 1 X4
4 XB2 1
2
5 3
3 5
6
X2
7 A
8
1 2 3 4 5 6 7 8
S X2
7 (9)
X1 8 (10)
9333103309
MEASURE AMPERAGE IN ANGLE TRANSDUCER
AT X1 - 4 (+) & WIRE #4 (-)… RANGE = 4mA - 20mA.
20.0
1 X3
XA2 1
2
3
3 5
1
X2 L
2
18.5
3 1 X4
4 XB2 1
2
5 3
3 5
6
X2
7 A
8
1 2 3 4 5 6 7 8
S X2
7 (9)
X1 8 (10)
9333103309
D S350
Graphic
Modular
Slewing Angle
18-6
D.O.Module
+UBR K10 COM
A2B GROUND
LMI UNLOCK S.
A2B BYPASS
A2B BYPASS
FUSE (4 amp)
FUSE (4 amp)
EXT. HOR. *1
LMI BYPASS
FUSE (10 amp)

FUSE (10 amp)
A2B SIGNAL
LMI BYPASS
GND
K10 NC
LENGTH
SLEW 1
SLEW 2
PISTON
ANGLE
DI GND
+ 12 V
+UBS
+UBS
GND
GND
X2/1 1 2 3
GND
RXD
GND
GND
GND
+UB
ROD
GND
+UB
TXD
+UB
+UB
+UB
+UB
+UB
DI1
DI4
DI2
DI3
X1 1 2 12 11 13 51 52 3 4 5 6 7 8 9 10 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 31 32 30 33 34 35 53 54 59 60 61 62
GN/YL
OUT
OUT
IN
IN
1 2 3 4 5 6 8 9 1 2 3 4 5 6 7 10 11 12 13 14 1 2 3 4 1 2 3 4 1 2 3 4 5 6 2 1 3 4
4 3
1 3 2 2 2 2 2
1 1 1 1 1 2 1

FUSE FUSE
1 2 3 4 5 6 7 10 8 9 11 12 13 14
18-7
1 2 3 4 5 6 LMI BYPASS
GN/YL
KEY SWITCH
1 2 3 4 5 6 7 8 X1
6 PIN PLUG
V V V V V
V V V
GND
V V
+UB
RXD
A2B
A2B
V
TXD
LOAD
D1
V
Rear Axle Oscil. Relay
LMI Lockout Alarm
2
(LMI UNLOCK SOL.)
1 2 3 4 1 2 3 4 1 2 3 4 5 6 7
X8 +UBE
SIG+
GND
SIG-
+UBE 1
V V V V V V
GND 2
V V VV V V
51 (GND)
71 (+UB)
A B C A B C 1 2 34 5 6 1 2 3 4
X7 1 2 3 4
A B C A B C TO MAIN BOOM
V V V V V V 1 2 5 3
73
1 2 3 4 CONNECTOR
V V V V
A BC D
V V V V
NOTES:
1 OUTER SHIELD GROUNDED AT STRAIN

1 2 3 4
pres. trans.
(piston)
pres. trans.
(rod) DS350
RELIEF CONNECTOR.
2
LIGHTBAR GRAPHIC MODULAR
INNER SHIELD CUT AND INSULATED
3
INSULATE OUTER SHIELD AND with SLEWING
*1) OPTIONAL FOR EXTERNAL HORN
POTINTIOMETER
(EEC UNITS ONLY)
P8
AGND
AGND
- +
OPERATING WINDOW
MP14
.0V
MP0
MP8
P7 P6 P5 P4 P3 P2 P1
VREFA
MP13 MP9 ERROR
CODE E1A
MP12
MP17
J1
.500v MIN.
+UB
(GND)
SLEW ANGLE 1
J2
MP7 - MP1->
MP10
MP11 WORKING X1 33 30 35
RANGE
- +
-
4.50v MAX.
BR1
X1
20 1 1
AGND
AGND 1 MP16 16
40 2 2
ERROR A
E2A +
VOLTAGES CODE
+ 500MV (.500V) = MIN. SIGNAL BOOM OVER FRONT
5.0V
+ 4.50V = MAX. SIGNAL BOOM OVER REAR Current Based Amplifier
SLEW ANGLE 2
ALL VOTAGES ARE MEASURED WITH All sensing devices used for Analog Inputs now have a 1 2 4 3
REFERENCE TO GND (MP 0) ON ANALOG BOARD. current output. (min. signal 4mA, max. signal 20mA)
* THESE MEASUREMENTS ARE MADE IN PARALLEL This circuit is measured in series.
12 mA
18-8
DS350
2.5V (A106)
GRAPHIC MODULAR
SLEW ANGLE 1 2 3 4
#1
1 2 5 3
R W Y B
4 mA OPEN
.500V (A106) 4.5V (A106)
12 mA
2.5V (A106)
P8
AGND
AGND
- +
OPERATING WINDOW
MP14
.0V
MP0
MP8
P7 P6 P5 P4 P3 P2 P1
VREFA
MP13 MP9 ERROR
CODE E1B
MP12
MP17
J1
.500v MIN.
+UB
(GND)
SLEW ANGLE 2
J2
MP7 - MP1->
MP10
MP11 WORKING X1 33 34 35
RANGE
- +
-
4.50v MAX.
BR1
X1
20 1 1
AGND
AGND 1 MP16 16
40 2 2
ERROR A
E2B +
VOLTAGES CODE
+ 500MV (.500V) = MIN. SIGNAL BOOM OVER FRONT
5.0V
+ 4.50V = MAX. SIGNAL BOOM OVER REAR Current Based Amplifier
SLEW ANGLE 1
ALL VOTAGES ARE MEASURED WITH All sensing devices used for Analog Inputs now have a 1 3 4 2
REFERENCE TO GND (MP 0) ON ANALOG BOARD. current output. (min. signal 4mA, max. signal 20mA)
* THESE MEASUREMENTS ARE MADE IN PARALLEL This circuit is measured in series.
OPEN
18-9
DS350
4.5V (A106)
GRAPHIC MODULAR
SLEW ANGLE 1 2 3 4
#2
1 2 5 3
R W Y B
12 mA 12mA
2.5V (A106) 2.5V (A106)
4 mA
.500V (A106)
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
Position the collar so
there is
between 1/32” to 1/16”
clearance
Clutch plate installed on to the bottom of the
top of slip ring potentiometer.
assembly.
18-14 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 crane’s 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 Operator’s 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
4.7K Ω
RESISTOR
To Central Unit
CONNECTOR
! 3
1
6 PIN DUMMY PLUG
SHIELD
2 SHIELD 1
3 6 Pin Plug
CORE 2
4
6 PIN
CORE
5
1 5 3 1 5 3 1 1 2 3 4 5 6 7
6
2
19.1
1 OUT
1 OUT
GND
GND
+UB
+UB
1 1 2 3 4 5 6
7 8 5 3 1 5 3 1
X2 X4 X3 1 2 3 4 5 6 7
2
S 8 7 6 5 4 3 2 1 X1
6 Pin Connector
6 5 4 3 2 1 1 1
1 1 2 3
ANTI - TWO BLOCK SWITCH 7 2
NOTES:
OUTER SHIELD GROUNDED AT
1
STRAIN RELIEF CONNECTOR
2 CUT AND INSULATE INNER SHIELD
1 SWITCH PREWIRED AND POTTED
IMPORTANT CHANGE
!
ANTI - TWO - BLOCK
WIRING DIAGRAM
4.7K Ω 1
6
RESISTOR
To Central Unit
! A
1
B SHIELD
2 SHIELD 1
6 Pin Plug
6 PIN DUMMY PLUG CORE 2
CORE
2 1 2 3 4 5 6 7
5 3 1 5 3 1
A B 1 2 3 4
3 2 3
1 OUT
1 OUT
GND
GND
+UB
+UB
1 1 2 3 4 5 6
4 7 8 5 3 1 5 3 1
1
A X2 X4 X3 1 2 3 4 5 6 7
1
19.2
B
2
2
S 8 7 6 5 4 3 2 1 X1
6 Pin Connector
1 1
1 2 3 6 5 4 3 21
1 1 2 3 5
1 2 3
NOTES:
NO. PART NO. QTY DESCRIP. 1 OUTER SHIELD GROUNDED AT
1 1 2 3 1 9-333-102764 1 COMP. ASSEM.
2 9-333-102717 1 2-POLE JUMPER BAR 2 CUT AND INSULATE INNER SHIELD
AUX. BOOM NOSE
ANTI - TWO BLOCK SWITCH 3 9-333-102666 1 TAGS, TERMINAL STRIP
4 9-333-102663 4 BLOCK, TERMINAL STRIP 1
SWITCH PREWIRED AND POTTED
5 9-333-102230 1 SWITCH A2B, WITH RETAINER
CRIMP !
6 9-333-102765 1 COMP. ASSEM., DUMMY PLUG
IMPORTANT CHANGE
Auxiliary Boom Nose
3 4
2 1
NO. PART NO. QTY DESCRIPTION
1 9-333-102238 1 SWITCH, A2B W/O CRIMP

2 9-333-102235 1 CONDUIT 10 FEET
(MUST CUT TO LENGTH)
3+ 9-333-102767 1 JUNCTION BOX ASSEM.
4 9-333-102687 2 SCREW
19.3
Auxiliary Boom Nose
JUNCTION BOX ASSEMBLY
1(BLACK)
1 1 A
2(BROWN)
A2B CABLE 2
3(RED) 3 2 B
Complete Assembly # 9-333-102767
1 9-333-102758 1 Junction Box

2 9-333-102793 1 Strain Relief (90o)
3 9-333-101984 1 Locknut
4 9-333-102759 1 Mounting rail, terminal strip
5 9-333-102663 3 Block, terminal strip
6 9-333-102664 1 End plate, terminal strip
7 9-333-102665 2 End bracket, terminal strip
8 9-333-102666 1 Tags, terminal strip
9 9-333-102760 1 Connector, cannon 2-pin male recp.
10 9-333-102482 1 Gasket
11 9-333-102612 1 Cover, dust
12 9-333-102669 4 Screw #4
13 9-333-102266 4 Lockwasher #4
14 9-333-102480 4 Nut #4
19.4
Fixed Swingaway Extension
19.5
1 9-333-102238 1 Switch, A2B W/O Crimp
2 7-110-151205 2 Capscrew
3 9-333-102235 1 Conduit 10 feet
(must cut to length)
4+ 9-333-102690 1 Junction box assembly
5 9-333-102687 2 Screw
Fixed Swingaway
1(BLACK)
1 1 A
2(BROWN)
A2B CABLE 2
3(RED) 3 2 B

1 9-333-102758 1 Junction Box

2 9-333-102674 1 Strain Relief
9 9-333-102482 1 Gasket
10 9-333-102612 1 Cover, dust
11 9-333-102669 4 Screw #4
12 9-333-102266 4 Lockwasher #4
13 9-333-102480 4 Nut #4 19.6
P.A.T. – L.M.I
MANUAL
SECTION 20

TROUBLESHOOTING
GUIDE
PAT DS350 Graphic Modular
TROUBLESHOOTING
General Flowchart 20.2

Lever Lockout Activated 20.3
Broken Length Cable 20.4
No Display 20.5
Anti - Two - Block 20.7
Length Reading Problem 20.10
Angle Reading Problem 20.13
Load Reading Problem 20.16
Bad Data Transfer Between Console & Central Unit 20.18
Error Code Displayed 20.20
20.1
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
What’s Wrong?

Activated Problem
Wrong Length Wrong Angle Wrong Load Bad Data Error Code
Displayed Displayed Displayed Transfer Displayed
Go to Page 20.10 Go to Page 20.13 Go to Page 20.16 Go to Page 20.18 Go to Page 20.20
20.2
PROBLEM
START

fixed?
YES
NO
Does the console indicate
NO YES
Fault in crane electric If console displays is Fault in Anti-Two If Load Moment Limit
or hydraulic system. blank, fault is located Block system. Light is lit, the fault
console.
Check lever lockout Go to page 20.5 Go to page 20.7 Read error code dis-
and go to page20.20.
20.3
BROKEN LENGTH CABLE
PROBLEM
STEP ACTION
2 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.
at the boom nose.

20.4
NO DISPLAY
PROBLEM
START
NO
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?
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.
Defect on main board.

Replace main board, see replacement
NO
correct? procedure.
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 .
Check connections of the

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

wire from X1-31 in central unit.
NO
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
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 Fault in wiring cable from junction box at

correct? 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
20.8
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

NO using same measurements as in previous
Disconnect X1-31 and X1-32.

temporary resistor, 4700 Ohms, between X1-
31 and X1-32 in central unit. With resistor
connected alarm should be inactive.
NO Defect on main board. Replace main

correct?
board and reset pressure channel.
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 counter-
clockwise 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.
NO
correct? 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).
Main board defective. Replace main

NO
correct? board and reset pressure channel.
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
correct? and length transducer. Check wiring.
YES
Measure signal from length transducer

in cable reel at X1-2 and wire #2, the
return signal is a current output. Measure-
ment should be in series. Replace length potentiometer assembly. Remove
Retracted Boom = slip ring body from shaft and remove gear wheel
0 Potentiometer Turns = 4mA from potentiometer axle. Unscrew mounting plate
10 Potentiometer Turns = 20mA and remove potentiometer assembly from mounting
plate. Remove assembly wires from terminal block.
Connect new assembly to terminal block.
NO Reinstall mounting plate, gear wheel and slip rings.
Reset potentiometer with fully retracted boom, turn
correct?
counterclockwise until it stops.
YES
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.
0 Potentiometer Turns = 4mA
10 Potentiometer Turns = 20mA
NO Faulty wiring between central unit

correct? and length transducer. Check wiring.
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.
YES Main board defective. Replace main board.

correct?
Reset pressure channel.
NO
Analog Input Module is

defective. Replace module.
END
20.12
PROBLEM
START

cable reel.

correct? See drawing 7 on page 20.33.
YES
Place the boom at 0 o. Check power supply

to angle sensor on main board between X1-
26 (+12/24V) and X1-28 (GND)

NO reset pressure channel.
correct? Note: Consult factory before replacing main
board for further troubleshooting steps.
YES
NEXT PAGE
20.13
PREVIOUS PAGE

reel at terminal between X1-1 (+12/24V)
and X1-3 (GND).

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? Replace angle sensor.
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

YES
Measure angle signal analog input module

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

correct?
central unit.
YES
END
20.15
PROBLEM
START


correct?
YES
Reset length potentiometer. With fully retracted

NO boom, turn potentiometer axle counterclockwise
correct? until it stops .
YES

displayed radius.
Check if mechanical adjustment of angle transducer

NO is correct. Angle transducer box should in line with
correct? boom and adjusted to actual boom angle.
YES

Measure voltage at the cable connection between
A (+12/24V) and C (ground).
Check power supply at main board between

NO X1-20 (+12/24V) and X1-22 (ground) for piston
correct? and X1-23 (+12/24V) and X1-25 (ground) for
rod side.
YES See drawing 3 on page 20.29.
Fault in pressure transducer.

correct?
YES
NO Replace the main in central unit. Refer to Drawing

NEXT PAGE on page 15.3.
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
NO & 20.36.
correct? 4-20mA
Measurement within 4-20mA, but 4mA
YES YES 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

correct?
central unit.
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 Place EPROM S in correct socket.

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

correct?
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 Check connections and replace cable from central

correct? unit to console, if necessary. Refer to Drawing 8
on page 20.34.
YES
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.
correct? central unit box mounting bracket.
YES


correct? Refer to connection and wiring diagrams,
YES
END
20.19
PROBLEM
START
Check system out; refer to Section 8 - Bad Data

NO
YES
bracket is in place. Refer to Drawing 4, “Main
Board”, in Section 11.
correct? central unit box mounting bracket. Refer to
Drawing 4, “Main Board”, in Section 11.
YES

Refer to connections and wiring diagrams, Draw-
ings 9A,B,C in Section 11.

Drawings 9A,9B and 9C in Section 11.
YES
Refer to Drawing 7, “Suppressor Diode”, in Sec-
tion 11.
END
20.20
ERROR CODE DISPLAY
PROBLEM
Warning lights on.
ERROR
the boom too far.
configuration.
Length sensor adjustment See page 20.33.

20.21
ERROR CODE DISPLAY
ERROR
E 07 No acknowledgement signal Overload relay is stuck,

E 08 No acknowledgement signal Anti-Two-Block switch relay

value for the measuring defective, not connected or water in the necessary. See page 20.33.

potentiometer. See page 20.33.

main board.
channel "pressure piston side". defective, loose or water in
the plug.


on main board.
channel "pressure rod side". defective, loose or water in
in the plug.


on main board.
20.22
ERROR CODE DISPLAY
ERROR
channel "angle main boom". water inside plug. See page 20.37.


inside the plug.
E 17 Angle sensor defective. Replace angle sensor.

+5 volt supply
E 1A Below limiting value for slewing Cable from central unit to the slewing Check wiring, replace if
angle 1. angle sensor defective or loose. necessary.
E 1B Below limiting value for slewing Slewing angle pot. defective. Replace and reset slewing angle
angle 2. wiring, (external). potentiometer.
Electronic component in the measuring Replace main board and reset
channel defective on main board. pressure channels.
measuring channel "length" length/angle sensor defective necessary. See page 20.37.
exceeded. or loose.
defective. potentiometer. See page 20.33.
on main board.
20.23
ERROR CODE DISPLAY
ERROR
piston side” exceeded. loose or water in the plug.


on main board.
rod side" exceeded. loose or water in the plug.


on main board.

main boom" exceeded. or loose.
on main board.
20.24
ERROR CODE DISPLAY
ERROR
E 27 Upper limit value for the measur- Cable from central unit to the Check cable.
channel 7 exceeded. Sensor of channel 7 defective Replace if necessary.
or loose.
Sensor of channel 7 defective. Replace angle sensor and reset
measuring channel 7 defective. pressure channels.
voltage. MP10 is more than 3.3V.
A/D converter defective.
E 2A Above limiting value for slewing Cable from central unit to the slewing Check wiring, replace if
E 2B Above limiting value for slewing Slewing angle pot. defective. Replace and reset slewing angle
defective. EPROM.
incorrect version of system correct version of system or
program. Data EPROM.
program. TLK EPROM.
channels.
pressure channels.
20.25
ERROR CODE DISPLAY
ERROR
E 42 Error in the external Internal defect in digital part Exchange write/read memory
write/read memory of CPU. (CMOS-RAM). Replace main
(RAM) part 1. Board and reset pressure
channels.
channels.
E 46 Error in A/D Defective electronic Replace main board and
conversion component. reset pressure channels.
memory.
pressure channels.
Eprom Module not bridge correctly. board is installed.
E 52 Error in TLK memory. TLK EPROM on the main Replace main board and reset
Pressure channels.
E 56 Error in crane data EEPROM Memory module wrongly bridged. Bridge memory module acc. To
memory type.
Crane data EEPROM defective. Replace EPROM module and
reset pressure channels.
E 57 Error in serial crane data EEPROM Serial crane data EEPROM does not Write data on serial crane data
contain valid data. EEPROM (by means of test
program or on line function),
then restart the LMI
Memory module defective. Replace EPROM module and

reset pressure channels.
E 58 Error in the serial analog data No valid data in the serial analog Same action as E 57
EEPROM data EEPROM.
LMI main board defective. Replace main board.
E 61 Serial communicate problem Green cable in Buss ext. or module Check connections
itself. Replace module.
E 63 Digital inputs on buss extension Replace buss extension
E 69 Error in serial crane data Memory module wrongly bridged. Bridge memory module acc.
EEPROM to memory type.
The number of the selected Load chart EPROM defective. Replace load chart EPROM.
EPROM base and the programming values are not
identical.
20.26
ERROR CODE DISPLAY
ERROR
E 71 Incorrect acknowledgment a.Anti two block relay is stuck or Replace main board.
of the 1 relay on the main board. defective
console to central unit. b. Two block relay is not being
selected due to a break on the main
board.
E 72 - Analogous to E 71 for the relays. Analogous to E 71 for the relays Analogous to E 71 for the relays
E 77 K2…K7 K2…K7 K2…K7.
E 80 Wipers for slewing potentiometer Replace potentiometer.

out of tolerance.
E 84 Wrong rigging condition. The selected rigging condition is not Select another rigging condition
contained in the data EPROM.
Check the programming in the
data EPROM.
E 85 Error in the radius determination. The computed radius is too small Check the programming in the
( negative deflection ) data eprom.
E 89 Changed of the operating code The mode switch was changed Lower the load and set the
during lifting a load. during lifting a load. switch to the correct operating
configuration of the crane.
E 91 No data transmission from the a. Supply voltage of console a. Check voltage at terminal X1
b. Interruption or ground in the line b. Check connection between
from console to central unit. console and central unit.
c. Transmitter/receiver module c. If accidental ground occurs,
defective. The transmitter module in the
damaged. Replace the
console electronics or main
board.
E 92 Error in the data transmission a. Temporary interruption of the a. Check connection between
from console to central unit. data line from console electronics console and central unit.
to central unit.
b. Transmitter/receiver module
defective.
E 93 Error in the data transmission a. Temporary interruption of the a. Check connection between
from central unit data line from console electronics console and central unit.
to central unit. b. Replace console electronics
b. Transmitter/receiver module or main board respectively.
defective.
20.27
ERROR CODE DISPLAY
ERROR
E 94 No data transmission from a. Interruption or accidental ground a. Check connection between
console to central unit. 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. Transmitter/receiver module 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.
board defective.
board defective.
EAB Short circuit in the anti - two Short circuit in the anti - two block Replace two block switch
block switch circuit switch.
Short circuit in the cable to the two Replace cable to the two block
block switch switch
Electronic component on the analog Check analog input module
input module defective 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
PWM DC
+UB1
MP42
1 - G1 + C
KGND
GND
MP 26
1
KGND
MP 4
VBAT
MP23
MP24
+5V
MP 9
+BATT +6V
KGND
2 MP 8 2
AGND
+9V
X15
GND GND
V10 H11 V11

X14
3 3
power o.k.
DI 1- DI 6 =>
MP41 MP40
PFAIL+UB1
4 4
X17
DI 1
H1 H2 H3 H4 H5 H6
MP21
5 5
+UB1 +UB
DI 6
KGND
X12
6 6
X11
J11
7 SP5 7
X13
8 8
X16
TXD
H12
LOAD
ON/OFF
MAIN
9 9
H10
AGND
AGND
+5V/RS232
KGND
LMI
10 K8 10
KGND
J10
3 2
LEVER
4 1 MP29 LOCKOUT
+UB
A2B K10
K9
11 11
KGND
2
F
A2B
H9
- + 1
F
J4
X1
J3
12 12
KGND
J2
KGND
J1
KGND
1
3
77 76 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54
KGND
X1
MP1
13 +UBS 13
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 MP 25
LOCATIONS : LED’S
MP 1 - zone M13 = GND. MP 41 - zone M4 = POWER FAIL
MP 25 - zone M13 = +UBS MP 42 - zone G1 = +5V H 8 - zone M3 - LOAD
MP 8 - zone M2 = +9V MP 21 - zone E5 = +5V H 9 - zone E11 - A2B
MP 9 - zone M2 = +6V MP 29 - zone D10 = +5V H 10 - zone G9 - MAIN IN/OUT
MP 4 - zone M1 = +5V H1-H6 - zone I5 = DI 1-6 H 11 - zone M3 - POWER
MP 26 - zone M1 = GND.
MP 23 - zone A2 = VBATT
H 12 - zone I11 - TXD
MP 24 - zone D2 = +BATT
20.29
Drawing 4 : CPU and Daten EPROM boards
MP7
J12 J2 J1
J13
D3
D1 D2
D14
MP4
X1
X2
D13
SYSTEM
D6
D10
P1
J8 J9 MP3 J6
D17
D15 D7 D21
J10
D9
D18 D12
J14
J15
J11
J7 D11
D19
D20
X3
EJECT
MP6MP5
BR5
BR6 MP2
A102 CPU J1 J2
DATA
D1
J5
J3
TLK
D3
BR J6
X1
1
4
2
3
A103 DATEN

The EPROMS must be installed completely to the left, leaving
blank holes to the right
20.30
Drawing 5 : Analog Input Module
AGND
AGND
MP12
- +
40
2
1
P7
MP13
J2
P6
20
P5
16
P4
X16
MP11
J1
MP9
P3
P2
MP10
P1
1 1
X1 MP17
2
BR1 MP0 - +
MP8
+ +
X17
MP7 - MP1->
2
1
VREFA
P8
+ +
MP16
7
6 5
16
4 3
MP14
2 1
40
2
1
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
Drawing 6 :VIEW OF BACKSIDE
OF GRAPHIC CONSOLE
MP 2
+7V
MP 5
+5V
MP 0
GND
MP 3
-24V
MP 4
-24V
20.32
MP 6
MP 7
MP 1
+UB
J2 J5
J1 J4
J3
X1
1 2 3 4 5 6 7 8 X5 1 2 3 4
Transducer
20.33
1 X3
XA2 1
2 3
3 5
1
X2 L
2
3 1
4 XB2 1
2 3
5 3 5
6 X2
A
7
1 2 3 4 5 6 7 8
8
S X2
7 (9)
X1 8 (10)
9333103309
ADJUST LENGTH POTENIOMETER WITH BOOM FULLY RETRACTED,

TURN THE CENTER SCREW COUNTERCLOCKWISE TO A SOFT STOP.
Drawing 8 :ELECTRICAL WIRING FROM
CENTRAL UNIT TO CONSOLE
A2B BYPASS
A2B BYPASS
LMI BYPASS
CENTRAL UNIT
MAIN BOARD
RXD
GND
GND
TXD
+UB
+UB
+UB
51 52 3 4 5 6 7 8 9 10
8 9 1 2 3 4 5 6 7 10 11 12 13 14
20.34
CONSOLE (1318)
1 2 3 4 5 6 7 10 8 9 11 12 13 14
1 2 3 4 5 6 7 8 X1
+UB
TXD
GND
RXD
A2B
A2B
DI
LOAD
SIG +
SIG -
GND
+UB
X8
+UB 1
X7 1 2 3 4 GND 2
A B C D
1 2 3 4
LIGHTBAR
CENTRAL UNIT TO PRESSURE
TRANSDUCER (PISTON)
CENTRAL UNIT
MAIN BOARD
PISTON
GND
+UB
LMI UNLOCK S.
GND
+UBR
+UB
X1 1 2 12 11 20 21 22
1 2 3 4
GN/YL
1 2 3
20.35
1 2 3
1 2 3 4
A B C
73 A B C
51 (GND)
71 (+UB)
(LMI UNLOCK SOL.) GN/YL
PRESS. TRANS.
(PISTON)
CENTRAL UNIT TO PRESSURE
TRANSDUCER (ROD)
CENTRAL UNIT
MAIN BOARD
ROD
GND
+UB
LMI UNLOCK S.
GND
+UBR
+UB
X1 1 2 12 11 23 24 25
1 2 3 4
GN/YL
1 2 3
20.36
1 2 3
1 2 3 4
A B C
73 A B C
51 (GND)
71 (+UB)
(LMI UNLOCK SOL.) GN/YL
PRESS. TRANS.
(ROD)
CENTRAL UNIT TO CABLE REEL
/ANTI-TWO BLOCK
CENTRAL UNIT
MAIN BOARD
6 SOCKET PLUG
+UB
LEN
(GND) 0.0V
ANGLE
FORCE
A2B SIG.
A2B GROUND
NOT USED
NOT USED
NOT USED
NOT USED
FUSE (4 AMP)
FUSE (4 AMP)
26 27 28 29 30 31 32 33 34 35 36 53 54 1 2 3 4 5 6 7
1 2 3 4 5 6
1 2 3 4 7 5 6
1 2 3 4 5 6 7
20.37
6 PIN RECEPTACLE
6 PIN RECEPTACLE
3
CABLE REEL
>1> SHIELD
X1 BRN
SHIELD
4.7K
>2> X2 RED
RESISTOR

>3> CORE
5 3 1 5 3 1
>4>
>5>
+UB
ANGLE SIG.
GND
GND
+UB
LENGTH SIG.
>6> 2
CORE
1 7 8 5 3 1 5 3 1
X2 X4 X3
S 8 7 6 5 4 3 2 1 X1
6 5 4 3 2 1
1 2 3
7
20-38
20-39
P.A.T. – L.M.I
MANUAL
SECTION 21
DS 350 Graphic Modular (BCS)

Console Connections,
Wiring Diagrams
+ +UB
X1 F1 +UBS
1
1 + +24V
2
2 0V K10A
E 5 1
HOUSE LOCK PIN SWITCH 3 + +UBS
2 4 0V
D 4 3
LMI L/O ALARM (EEC) 5 RXD K9
4 6 TXD
LEVER LOCKOUT W # 73A C 3 5
SOLENOIDS 7
6 A2B-O
8
STOP
B 2 7 A2B-I K8
W # 51AJ = GND 9
LOAD-I
+
A 1 10 + +UBS
W # 71K = 24 VOLTS
F2- 10A
11 REL -M
CONSOLE 3
BY - PASS 12
4 REL -A
KEY 13 K10B
REL -R
14 + +UBS
15
8 16 DE 1
17 DE 2
5
18 DE 3
MAIN BOARD
LMI 4
3 7 19 DE 4
7 20 + +UBS
6 21 I DAV1
6 U
22 0V
+
AB 23 + +UBS
I
21.1
3 24 U DAV2
A2B 4
5
5 25 0V
26 + +UBS
4 27 I LG 1
4 U
28 0V
DATA FROM C.U. 3 I
3 29 U WG 1
30 I LG 1
DATA TO C.U. (GND) 2 U
2 31
(+24 V) 1 32 0V
1
33 + +UBS
34 I S1 DHG 1
U
35 0V
GRAPHIC CONSOLE I
36 U S2 DHG 2
51 + +UB
52 0V
F1 - 4A
4A 53
SI - OUT
54 SI - IN
LMI BYPASS 57 A2B-0
KEY SWITCH 13 58 A2B-I
DS350 Graphic Modular BCS 10A

14
59
60
61
LOAD-I
+ +UBS F2-10A
X4
1
BRN WHT
WHT
BRN
BRN
WHT
X2
1
2
BUS EXTENSION
SI-REL 2 WHT BRN
Console to C.P.U. Connections

YEL GRN
62 SI-REL PNK GRA 3
+ +UBS 3 GRA GRN YEL
4
64 PNK
4 5
65 0V 5 GRN YEL
= CONNECTED 6
66 DE 5 6 YEL GRN
GRA PNK
7
67 PNK GRA
8
= WIRES ARE 3-Pair
68 DE 6
GROUPED Twisted
69 Cable
TOGETHER + +UBS
76
77 0V
FIVE SECTION BOOM SERVICE SCREEN
(RT865BXL - BCS)
PAT DS 350
! STOP
STOP
0335 156ft
TARE
! 90.0ft ?
Ramp Seq. IM Hex Value LIM
79.4o
1 255 SEL
CM Hex Value OM/Fly Hex Value
50.8ft
0 0
1 255
STOP
0 0 MAX
02 73.5oo
(lbs)
i
38.2 ACT (lbs)
38.2
34.900
38.2
CTRL
100% 100% 100%
38.2
STOP
F1 F2 F3 F4
Length of IM
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
ON RUBBER OVER FRONT
CONNECTOR
ON RUBBER - OVER FRONT
INTERFACE
HOUSE PIN ENGAGED
CRANE
HOUSE PIN SWITCH
PRESS. SW. EXTEND PILOT PRESS.
BOOM EXTEND PRESS. SW. RETRACT PILOT PRESS.
DI 1
DIGITAL INPUTS DI 2 BOOM RETRACT
AUTOMODE SWITCH IN CAB
AUTOMODE ON
DI 3
DIGITAL DI 4 OM / FLY RET.
PROX. SW. ON CM SECTION
INPUT DI 5 CM RET. & % RESET
PROX. SW. ON IM SECTION
IM RET.
DI 6 PROX. SW. ON BASE SECTION
IM % RESET
DI 7 PROX. SW. ON BASE SECTION
CONNECTOR
OUT OF SEQ. WARNING LIGHT IN CAB
INTERFACE
OUT OF SEQ. WARN.
CRANE
K4
PROP. EXT. PROP. PRESS. REDUCING VALVE EXT.
K5 NO
PROP. RET.
K5 NC PROP. PRESS. REDUCING VALVE RET.
CENTRAL BOOM DIGITAL
UNIT CONTROL BUS OUTPUT K2 IM 2 WAY SOL. IM - 2 WAY SOLENOID VALVE
CABLE
EXTENSION
REEL
CM 2 WAY SOL.
22.1
K6 CM - 2 WAY SOLENOID VALVE

OM 2 WAY SOL.
K7
K5 OM - 2 WAY SOENOID VALVE
PROP.
RxD AO1
TxD ANALOG
OUTPUT
AI 1
ANALOG INPUT ANALOG
INPUT
P1 P2 A1 L1 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
BYPASS KEY SWITCH
FUSE ( 4A )
FUSE ( 10A)
CRANE ELECTRIC
CABLE ASSY. TO BOOM
INTERFACE CONNECTION
3 - PAIR CABLE BUS EXTENSION
CENTRAL UNIT
CABLE ASSY. TO CONSOLE
CABLE TO CRANE INTERFACE
CABLE ASSY. TO PRESS. TRANSDUCER ( ROD ) A
VIEW A - A
CABLE TO AREA DEFINITION
CABLE ASSY. TO PRESS. TRANSDUCER ( PISTON )

A
22.5
B PAT B
P.A.T. - LMI
7 - pin plug
14 - pin plug
19 - pin plug
RT865 BXL (BCS)
BUS EXTENSION
BOOM CONTROL
TURNTABLE COMPONENTS
CABLE ASSY. TO BOOM
CABLE ASSY. TO BOOM
3 - PAIR CABLE TO CENTRAL UNIT
VIEW B - B
CONNECTIONS FOR
RT865BXL
TO BOOM HARDWARE
TURNTABLE HARDWARE
SS CABLE TO CRANE INTERFACE

RT865BXL (BCS)
Central Processing Unit
A 102 CPU
MODULE
A 105 SERIAL
EXTENSION
SYSTEM MODULE
E-PROM SYS
A 103 E-PROM
MODULE DATA A 101 MAIN
BOARD
DATA E-PROM TLK
TLK E-PROM A 106 ANALOG
INPUT MODULE
K8
LMI K10 RELAYS
K9
BYPASS
X1 TERMINAL
KEY SWITCH
STRIP
FERRITE
FILTER
4 AMP 10 AMP
RT865BXL (BCS)
Bus Extension
A 104 PV
EXTENSION
A102 CPU
MODULE
MODULE
4 AMP
FUSE
X1
TERMINAL
X1
A 105 ANALOG
TERMINAL INPUT
2 AMP MODULE
FUSE X2
TERMINAL
K1-K8 A 101 BUS
RELAYS EXTENSION
22.6
BUS EXTENSION BOARDS
8
MP
A 104 PV
Extension
Module
A 105 Analog
Input Module
A 102 CPU
Module
8
2 72
26
25
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

TERMINAL
A101 BUS
K1 NOT USED NONE
X1/3
2 - WAY IM SOLENOID VALVES (2)
A101 BUS OFF = IM EXTENDS OR RETRACTS ON = IM
K2 PILOT PRESSURE
X1/5 IS NOT ALLOWED TO M OVE
OFF = BOOM IS EXTENDING OR RETRACTING

A101 BUS AND IS NOT FULLY RETRACTED
K3 TELE ROD DRAIN VALVE
X1/8 ON = BOOM IS IN NEUTRAL POSITION OR
FULLY RETRACTED
A101 BUS
K4 TELE OUT OF SEQUENCE PROVIDES SIGNAL TO GRV WARNING LIGHT
X1/12
ANALOG OUTPUT TO PROPORTIONAL
A101 BUS ANALOG OUTPUT SIGNAL FROM
K5 SOLENOID VALVES, EXTEND & RETRACT,
X1/13 ANALOG BOARD
RELAY K5 SELECTS EXTEND OR RETRACT
ANALOG OUTPUT SIGNAL TO
A101 BUS M AXIM UM 800mA TO EXTEND VALVE
K5 PROPORTIONAL EXTEND
X1/14 ONE VALVE FOR ALL SECTIONS
SOLENOID VALVE
ANALOG OUTPUT SIGNAL TO
A101 BUS M AXIM UM 800mA TO RETRACT VALVE
K5 PROPORTIONAL RETRACT
X1/15 ONE VALVE FOR ALL SECTIONS
SOLENOID VALVE
2 - WAY CM SOLENOID VALVES (2)
A101 BUS OFF = CM EXTENDS OR RETRACTS
K6 PILOT PRESSURE
X1/17 ON = CM IS NOT ALLOWED TO M OVE
2 - WAY OM /FLY SOLENOID
A101 MAIN OFF = OM /FLY EXTENDS OR RETRACTS
K7 VALVES (2) PILOT PRESSURE
X1/20 ON = OM /FLY IS NOT ALLOWED TO M OVE
CONNECT LM I BYPASS VIA DIODE ASSEM BLY
A101 MAIN
K8 LM I CUT OFF INTERNAL RELAY FROM GRAPHIC CONSOLE AND CU KEY
X1/9 SWITCH
A101 MAIN CONNECT A2B BYPASS FROM GRAPHIC
K9 A2B CUT OFF INTERNAL RELAY
X1/8 CONSOLE
A101 MAIN POWERS THE LM I UNLOCK SOLENOID WHEN

K10 LM I UNLOCK RELAY OUTPUT
X1/12 NO OVERLOAD, A2B OR ERROR CONDITION
A101 MAIN
K10 EXTERNAL ALARM OUTPUT USED FOR EEC UNITS ONLY
X1/13
22.9
Relay Diagram
BUS EXTENSION
X1
2A - F1
1
> > K1
2 H17
>
3
2A - F2
IM TELE
4
> > K2 +24V IM 2WAYS
9 5
> H18
6
2A - F3
TELE ROD DRAIN

7
> > K3 +24V TELE ROD
16 8
> H19 DRAIN SOL.
9
2A - F4
10 > > K4
A104 11 > H20 TELE SEQUENCE
X1 TELE OUT OF SEQUENCE 13
12
1 2A - F5
ANALOG SIGNAL
2
3 TELE EXT. PROP. SOL.
13
> > K5 NO PROP. EXT.
4 17 14
> H21 NC PROP. RET.
TELE RET. PROP. SOL. 18 15
2A - F6
CM TELE
16
> > K6
+24V CM 2WAYS
8 17
> H22
18
2A - F7
19
> > K7 +24V OM 2WAYS
OM / FLY TELE 7 20 H23
TELE >
PROP. 21
ANALOG 2A - F8
GND. 22 > > K8
23 > H24
24
+UB
+
25
10 - 35V
26
27
KGND
28
22.10
RT865BXL (BCS)
DS350Graphic Modular
Automode control of two way valves
K2 K6 K7 DESCRIPTION
0 1 1 IM EXTENDING OR RETRACTING
1 0 1 CM EXTENDING OR RETRACTING
1 1 0 OM/FLY EXTENDING OR RETRACTING
0 0 0 OUT OF SEQUENCE
0 0 0 NEUTRAL POSITION
Analog Outputs
ANALOG CU DESCRIPTION
TERMINAL
1 A104 X1/2 Analog GND for proportional extend or retract solenoid valves.
1 A104 X1/1 Analog signal for proportional extend or retract solenoid valves.
Input / Output Logic RT865BXL (BCS)

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

Mode IM% CM% OM% FLY%
B - Mode 0 0 0 0
B - Mode 50 0 0 0
B - Mode 50 50 0 0
B - Mode 75 50 0 0
B - Mode 75 75 0 0
B - Mode 100 75 0 0
B - Mode 100 100 0 0
B - Mode 100 100 100 100
22.11
P.A.T. – L.M.I
MANUAL
SECTION 23

Boom Length Connections
& Wiring Diagrams
RT 865BXL
5
DS350 Graphic Modular - BCS
7
7
8 1
PAT
PAT
PAT
3
5
2
23.1
1 PRE - TENSION (LENGTH SENSOR) SPRING 5 REMOVE 1/4 - 20 NUTS ON BOTTOM OF CABLE GUIDE.
BY ROTATING DRUM (10) REVOLUTIONS COUNTER INSERT CABLE GUIDE SCREWS THRU EXISTING ANGLE
CLOCKWISE. THEN UNSPOOL THE LENGTH CABLE BRKT AND SECURE IN PLACE WITH 1/4 - 20 NUTS
AND SECURE TO BUSHING ON THE BOOM NOSE REMOVED PREVIOUSLY.
PER DETAIL “A”.
7 CENTER LINE OF CABLE GUIDE MUST BE ALIGNED W/ CENTER
2 PRE - TENSION (LENGTH SENSOR) SPRING LINE OF CABLE REEL DRUM.
CLOCKWISE. THEN UNSPOOL THE LENGTH CABLE 8 AFTER MACHINE IS CALIBRATED, REMOVE PROTECTIVE PAPER
AND SECURE TO BUSHING ON THE INNER - MID CORROSION INHIBTOR AND ADHERE TO INSIDE HOUSING COVER
PER DETAIL “A”. SURFACE OF CABLE REEL.
3 PRE - TENSION (LENGTH SENSOR) SPRING

CLOCKWISE. THEN UNSPOOL THE LENGTH CABLE
AND SECURE TO BUSHING ON THE CENTER - MID
PER DETAIL “B”
RT 865BXL
IM length sensor CM length sensor
LG321 LG321
Boom length & angle sensor

See detail
IM % reset
See detail LWG309
“A” switch
“C” See detail
“C”
PAT
23.2
PAT
PAT
See detail IM retract

“C” switch
OM retract and % CM retract and %

reset switch reset switch
See detail
“B” 4 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.
0.44 6
16
TARGET WHEN BOOM SECTIONS ARE
FULLY RETRACTED.
See detail
“A”
0.44 16 THIS TARGET IS ONLY INSTALLED IF THE
BOOM IS EQUIPPED WITH A BOOM
EXTENSION STOP BLOCK.
18
PAT
CENTER LINE OF TARGET WHEN BOOM SECTIONS ARE
TARGETS &
PROXIMITY SW. FULLY RETRACTED.
23.3
0.13
DETAIL “A”
1.0
4
1.34
DETAIL “C”
DETAIL “B”
To
wi be a
t l
of h ce igne
c a nt e d
ble r
ree line
ld
rum
4
RT 865BXL
PARTIAL TOP VIEW
19
23.4
CENTER LINE OF CABLE GUIDES
CENTER LINE OF
CABLE GUIDES ON THE BASE & INNER MID
SECTIONS ASSOCIATED WITH TOP AND CABLE REEL DRUM
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.
AGND
AGND
P8
Channel # 1
- +
MP14
OPERATING WINDOW
VREFA
MP0
MP8
P7 P6 P5 P4 P3 P2 P1
.0V
LENGTH
MP13 MP9
ERROR
(GND)
E11
MP17
+UB
MP12
J1 CODE
J2
.500v MIN.
MP10
MP7 - MP1->
MP11 X1 26 27 28
WORKING
- +
RANGE -
BR1
AGND
X1
20 1 1 1
AGND
40 2
MP16 16
2 4.50v MAX. A
+
VOLTAGES ERROR
X1 3 ANALOG INPUT MODULE CODE E21
+ 500MV (.500V) = MIN. SIGNAL (RETRACTED BOOM)
+ 4.50V = MAX. SIGNAL (10 TURNS ON POT) 5.0V
ALL VOTAGES ARE MEASURED WITH 1 2 3
REFERENCE TO GND (TERMINAL X1 - 28) ON MAIN BOARD. All sensing devices used for Analog Inputs now have a
* THESE MEASUREMENTS ARE MADE IN PARALLEL current output. (min. signal 4mA, max. signal 20mA)
23.5
E11 / E21
SHIELD 1
(measurements in cable reel) CORE 2
6 Pin Plug

Range 10V to 30V 5 3 1 5 3 1 1 2 3 4 5 6 7
1 OUT
1 OUT
GND
GND
+UB
+UB
Range 1V to 5.6V 1 2 3 4 5 6
7 8 5 3 1 5 3 1
Measure Amps - Length transducer at X1 2(+) &
X2 X4 X3 1 2 3 4 5 6 7
DS350 GRAPHIC MODULAR S 8 7 6 5 4 3 2 1 X1

6 Pin Connector
BOOM LENGTH MEASURING CHANNEL 6 5 4 3 2 1
CHANNEL # 1 7
+UB
E 5
+
HOUSE LOCK PIN SWITCH X1 F1 +UBS
4 1
LMI L/O ALARM (EEC) D 1 + +24V
2
2 0V K10A
LEVER LOCKOUT W # 73A C 3 3 + +UBS
SOLENOIDS 4 0V
B 2 5 RXD K9
W # 51AJ = GND
6 TXD
A 1 7
A2B-O
W # 71K = 24 VOLTS
8
STOP
A2B-I K8
9
LOAD-I
LWG309 L/A TRANSDUCER
+
10 + +UBS
IS = CUT&INSULATE
7
X2 F2- 10A
X2 11 REL -M
RED GND 7 - PIN PLUG 3
SHEILD 8 X1 12
8 6 4
13
REL -A
K10B
SIG
7 REL -R
X1 5 1 1 A 1 14 + +UBS
BRN
7
15
CORE X4 2 2 B 2 DE 1
GND 6 16
5 CH #1 17 DE 2
5 3 3 C 3 CH #5 5
WG
SIG. 3 18 DE 3
MAIN BOARD
4 4 4 D 4 19 DE 4
SHIELD CORE +24V 1
4.7K A 1 3 20 + +UBS
3 5 5 E 5 I
B 2 21 DAV1
X3 2 6 6 F 6 22 0V
U
1 2 3 4 GND 2
5 23 + +UBS
3 2 SIG. 1 1 7 7 G 7
LG
I
23.6
3 24 U DAV2
IS = CUT&INSULATE 25 0V
1 +24V 1 1 26 + +UBS
2 27 I
U LG 1
3 28 0V
BOOM LENGTH SIGNAL BOOM ANGLE SIGNAL OS Connected 4 29 I WG 1
1
3 RETRACTED = 4mA 90o = 4mA to strain relief U
insert 30 I LG 1
MAX RANGE = 20 mA 0o = 20 mA U
2 5 31
* NOTE - MAX LENGTH SIGNAL 6 0V
32
VARIES WITH BOOM, MAX.
SIGNAL=20mA IS FOR 10 33 + +UBS
7 34 I
TURNS ON POT. U S1 DHG 1
35 0V
IS = CUT 36 I S2 DHG 2
&INSULATE U
51 + +UB
52 0V
F1 - 4A
4A 53
SI - OUT
54 SI - IN
LMI BYPASS 57 A2B-0
59 LOAD-I
X2
60 X4
DS350 Graphic Modular BCS + +UBS WHT BRN
14 F2-10A BRN WHT 1
10A 61 1 BRN WHT
2
BUS EXTENSION
SI-REL 2 WHT BRN
YEL GRN
62 SI-REL PNK GRA 3
4
64 PNK
Boom Length to C.P.U. = CONNECTED

65
66
0V
DE 5
4
5 GRN
6 YEL
YEL
GRN
GRA PNK
5
6
7
67 PNK GRA
8
Connections = WIRES ARE
GROUPED
TOGETHER
68
69
76 + +UBS
DE 6
3-Pair
Twisted
Cable
77 0V
RT865BXL (BCS)
Cable Reel LWG309
PAT
PAT
PAT
Ratio = 3.75 to 1
23.7
(PRE - TENSION ON CABLE REEL = 10 REVOLUTIONS COUNTERCLOCKWISE)
1 X3
ADJUST LENGTH POTENIOMETER WITH
XA2 1
1
2
3
3
5
BOOM FULLY RETRACTED, TURN THE
1 2 3 4 5 6 7 8
X2 L
2
3 1 X4
CENTER SCREW COUNTERCLOCKWISE
4 XB2 1
5
2
3
3
5
TO A SOFT STOP.
6 X2
A
7
8
S X2
7 (9)
X1 8 (10)
Complete Assembly 9-333-103394
9333103309 Board, Terminal w/ filters 1 9-333-103309
Angle Sensor WG103/0007 1 9-333-103303
Length Potentiometer 1 9-333-103308
Length Cable -
(single core, 63M - 206 ft.) 9-333-102382
Slip Ring Assem. 2-pole 1 9-333-102732
Boom Length Signal LWG 309
NO. OF TURNS NO. OF TURNS SIGNAL AT X1 TERM. SIGNAL ON ANALOG

ON CABLE ON LENGTH PIN #27 ON C.P.U. MODULE AT X1-3
REEL POT TERMINAL (X1-28 GND.)
0 0 4 mA .5 V
3.75 1 5.5 mA .9 V
7.5 2 7.2 mA 1.3 V
11.25 3 8.7 mA 1.7 V
23.8
15 4 10.4 mA 2.1 V
18.75 5 12.0 mA 2.5 V
22.5 6 13.6 mA 2.9 V
26.25 7 15.2 mA 3.3 V
30 8 16.8 mA 3.7 V
33.75 9 18.4 mA 4.1 V
37.5 10 20 mA 4.5 V
( 3.75 TURNS OF CABLE REEL = 1 TURN OF LENGTH POT.) CHANNEL # 1
CHART SHOWS TYPICAL MILLI-AMP AND VOLTAGE SIGNALS. THESE VOLTAGES ARE TO BE USED AS A
REFERENCE ONLY, THE ACTUAL SIGNAL MAY VARY SLIGHTLY.
RT865BXL (BCS)
Cable Reel LG321
PAT
PAT
PAT
23.9
1 X3
XA2 1
2 3
Ratio = 2 to 1 1
3 5
1 2 3 4 5 6 7 8
X2 L
2
(PRE - TENSION ON CABLE REEL = 25 REVOLUTIONS COUNTERCLOCKWISE) 3 1 X4
4 XB2 1
2 3
ADJUST LENGTH POTENIOMETER 5
6 X2
3 5
A
7
WITH BOOM FULLY RETRACTED, 8
X2
S 7 (9)
TURN THE CENTER SCREW X1
X1
8 (10)
11
COUNTERCLOCKWISE TO A 11
12 12
13 13
SOFT STOP. 14 14
15 15
Complete Assembly 9-333-103621 16 16
17
Board, Terminal w/ filters 1 9-333-101777 18 17
Length Potentiometer 1 9-333-101617 19 18
Length Cable - 9333103309
19
(eleven core, 25 M - 86 ft.) 9-333-102490
Slip Ring Assem. 11 pole 1 9-333-102737
Junction Box 1 9-333-101778
Gear Wheel 1 9-333-103752
(CUT CABLE TO SPECIFIED LENGTH)
X1
LG 321 CABLE REEL 1
2
(TO IM) V 3
4 K2 COM ( +24V )
X1 U 8
5 K2 NO ( +24V TO IM 2-WAY SOLS. )
14 11 6
20 20 T 7 K3 COM ( +24V )
13 8 K3 NO ( +24V TELE ROD DRAIN SOL. )
WHT/BLK 11 WHT/BLK 19 19 S
14 - SOCKET PLUG 9 K3 NC
11 A104 10 K4 COM
18 18 R
PV EXTENSION
BLK 10 BLK X1 11 K4 NO
14 14 1 12 K4 NC ( TELE OUT OF SEQUENCE )
WHT 9 WHT 17 17 P
TO 2 13 K5 COM
8 13 13
JUCTION GRA 8 GRA 16 16 N 3 14 K5 NO ( PROP EXT )
5 12 12 4 15 K5 NC ( PROP RET )
BOX - IM 15 15 M 16 K6 COM ( + 24V )
VIO 7 VIO
14 11 11 17 K6 NO ( +24V TO CM 2-WAY SOLS. )
BLU 6 BLU 14 14 L 18 K6 NC
10 10 10 19 K7 COM ( +24V )
GRN 5 GRN 13 13 K 20 K7 NO ( +24V TO OM 2-WAY SOLS. )
9 9 9 21 K7 NC
YEL 4 YEL 12 12 J 22
3 3
4 8 8 23
ORG 3 ORG 11 11 H 24
7 7
BUS EXTENSION
1
10 G 25 +24V
4 26 +24V
6 6
S 1 1 F 3 3 27 GND
12 5 5 3 28 GND
RED 2 RED
8 8 E 5 29 DI 1 ( +24V = TELE EXT. PRESS. SW. )
4 4 30 DI 1 GND
7 7 D 9 31 DI 2 ( +24V = TELE RET. PRESS. SW. )
BRN 1 BRN
23.10
7 3 3 1 1 10 32 DI 2 GND
X2 6 C 33 DI 3 ( +24V = AUTO MODE )
6 2 2 34 DI 3 GND
5 B 35 DI 4 ( +24V = OM / FLY RET )
1 1 36 DI 4 GND
4 A 12
37 DI 5 ( +24V = CM RET & % RESET )
3
3 38 DI 5 GND
5 7
39 DI 6 ( +24V = IM RET )
2
LG
3 2 6 40 DI 6 GND
1 1 = Outer sheild connected to strain 41 DI 7 ( +24V = IM % RESET )
1 1 relief insert. 42 DI 7 GND
13 43
X3 X1 1 3 2 4 14 44
3 = Inner sheild cut and insulate. 45
46
47
BOOM LENGTH SIGNAL 48
RETRACTED = 4 mA TO 49
MAX RANGE = 20 mA 50
JUCTION
* NOTE - MAX LENGTH SIGNAL 51
VARIES WITH BOOM, MAX SIGNAL BOX - BOOM BASE 52
20 mA IS FOR 10 TURNS ON POT. 53
54
55
DS350 Graphic Modular BCS 56
57
58 X2
1 BRN
Inner Mid Cable Reel to
WHT
59 X4
MAIN BOARD
60 2 WHT BRN
WHT BRN
61 GRN YEL 1
3 YEL BRN WHT
2
62 4 GRN
GRA PNK
2 3
Bus Extension Connections 63
64
65
ANALOG INPUT 1 (IM LEN.)
ANALOG INPUT 2 (CM LEN.) 6
5
7 PNK GRA
PNK
YEL
GRN
GRA
GRN
YEL
4
5
6
66 8 GRA PNK
RT865BXL (BCS)
Cable Reel LG321
PAT
PAT
PAT
Ratio = 1 to 1
23.11
(PRE - TENSION ON CABLE REEL = 30 REVOLUTIONS COUNTERCLOCKWISE)
1 X3
XA2
2
3
1
3 ADJUST LENGTH POTENIOMETER
5
1
1 2 3 4 5 6 7 8
2
X2 L
3 1 X4
4
5
XB2
2
3
1
3 TURN THE CENTER SCREW COUNTER-
5
6
7
X2
A CLOCKWISE TO A SOFT STOP.
8
S X2
7 (9)
X1 8 (10)
X1
11 11 Complete Assembly 9-333-103620
12
12 Board, Terminal w/ filters 1 9-333-101777
13 13
Length Potentiometer 1 9-333-101617
14 14
15 Length Cable -
15
16 16 (eleven core, 33.5 M - 110 ft.) 9-333-102490
17 Slip Ring Assem. 11 pole 1 9-333-102737
18 17
19 18
Junction Box 1 9-333-101778
19 Gear Wheel 1 9-333-102982
9333103309
(CUT CABLE TO SPECIFIED LENGTH)
P.A.T. – L.M.I
MANUAL
SECTION 24

Piston & Rod Connections
& Wiring Diagrams
+UB
E 5
+
4 1
2
2 0V K10A
SOLENOIDS 4 0V
B 2 5 RXD K9
W # 51AJ = GND
6 TXD
A 1 7
A2B-O
W # 71K = 24 VOLTS
8
STOP
A2B-I K8
9
LOAD-I
+
10 + +UBS
F2- 10A
11 REL -M
3
PISTON TRANSDUCER 1 IS = CUT& INSULATE
12
4 REL -A
13 K10B
A 1 14
REL -R
+ +UBS
DAVS 314 15
16 DE 1
B 2 17 DE 2
5
18 DE 3
MAIN BOARD
1 1 19 DE 4
1
C 3 2
20 + +UBS
CH #2 3
21
22 0V
I
U DAV1
1 23 + +UBS
2
CH #3 I
24.1
24 U DAV2
3 25 0V
ROD TRANSDUCER 1 OS Connected 26 + +UBS
to strain relief 27 I
A 1 insert 28 0V
U LG 1
DAVS 314
29 I WG 1
U
30 I LG 1
B 2 31
U
32 0V
1 33 + +UBS
C 3 34
0V
I
U S1 DHG 1
35
36 I S2 DHG 2
U
51 + +UB
52 0V
F1 - 4A
4A 53
SI - OUT
54 SI - IN
LMI BYPASS 57 A2B-0
59 LOAD-I
X2
60 X4
14 F2-10A BRN WHT 1
10A 61 1 BRN WHT
2
BUS EXTENSION
SI-REL 2 WHT BRN
YEL GRN
62 SI-REL PNK GRA 3
4
64 PNK
Piston & Rod Transducers = CONNECTED

65
66
0V
DE 5
4
5 GRN
6 YEL
YEL
GRN
GRA PNK
5
6
7
67 PNK GRA
8
to C.P.U. Connections = WIRES ARE
GROUPED
TOGETHER
68
69
76 + +UBS
DE 6
3-Pair
Twisted
Cable
77 0V
OUTPUT SIGNAL
AGND Channel # 2
AGND
P8
- +
OPERATING WINDOW
MP14
VREFA
.0V
(PISTON)
(GND)
MP0
MP8
P7 P6 P5 P4 P3 P2 P1
+UB
MP13 MP9
ERROR
CODE E12
MP17
MP12
J1
J2 .500v MIN. X1 20 21 22
MP10
MP7 - MP1->
MP11 WORKING -
RANGE
- +
A
4.50v MAX. +
BR1
AGND
20 X1
AGND 1 1 MP16 1
16
40 2 2
ERROR
VOLTAGES CODE E22
24.2

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

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

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

E13 / E23 This circuit is measured in series.
Measure Voltage - (Elec) Rod transducer at A (+) & C (-)
Range 10V to 30V
A B C
Measure Voltage - (Elec) Rod transducer at B (+) & C (-) A B C
Range 0V
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 C
24.4
GRAPHIC MODULAR CONSOLE
SPECIAL FUNCTION 0 - SETTING OF TRANSDUCER INPUT
The first step is to lower the boom all the way down
PAT DS 350
(blocking the boom), shut the engine off then disconnect
! STOP
hydraulic hose from the piston or rod side pressure
transducer.
STOP
The 0 - setting consists of calculating an appropriate

TARE
!
0 - point offset, which, when added to the
LIM
transducer measurement, allows the real physical
ENTER YOUR pressure of force to be calculated. To achieve
SERVICE CODE SEL this, a procedure has been developed, allowing the 0
5 5 5 5 5 - setting to be performed and visualized in a
STOP
(1)
i simple manner.
(2) CTRL
To activate the 0 - Setting Function, press the INFO
STOP
+ > key (1) to activate the Info Function. Now press
the CTRL key (2). At this point, a five digit
F1 F2 F3 F4
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 PAT DS 350
password, the piston - side 0 - point setting

!
function STOP
is activated. 0
STOP
TARE
The display shows which transducer (piston-side,
!
rod-side or force) is being zeroed and a horizontal LIM
dial marks the present pressure (or force) 0
difference in %. By pressing the + key, the input SEL
pressure
STOP -4% -2% 0% +2% +4%
(or force) is adjusted upwards, and by pressing the AUTO i
- key, the input value is adjusted downwards. 0
CTRL
When the + and - keys are pressed simultaneously, ESC +
the 0 - setting occurs automatically. Manual STOP
adjustments may be performed using + or -.

F1 F2 F3 F4
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
P.A.T. – L.M.I
MANUAL
SECTION 25

Boom Angle Connections
& Wiring Diagrams
+UB
E 5
+
4 1
2
2 0V K10A
SOLENOIDS 4 0V
B 2 5 RXD K9
W # 51AJ = GND
6 TXD
A 1 7
A2B-O
W # 71K = 24 VOLTS
8
STOP
A2B-I K8
9
LOAD-I
LWG309 L/A TRANSDUCER
+
10 + +UBS
IS = CUT&INSULATE
7
X2 F2- 10A
X2 11 REL -M
RED GND 7 - PIN PLUG 3
SHEILD 8 X1 12
8 6 4
13
REL -A
K10B
SIG
7 REL -R
X1 5 1 1 A 1 14 + +UBS
BRN
7
15
CORE X4 2 2 B 2 DE 1
GND 6 16
5 CH #1 17 DE 2
5 3 3 C 3 CH #5 5
WG
SIG. 3 18 DE 3
MAIN BOARD
4 4 4 D 4 19 DE 4
SHIELD CORE +24V 1
4.7K A 1 3 20 + +UBS
3 5 5 E 5 I
B 2 21 DAV1
X3 2 6 6 F 6 22 0V
U
1 2 3 4 GND 2
5 23 + +UBS
3 2 SIG. 1 1 7 7 G 7
LG
I
25.1
3 24 U DAV2
IS = CUT&INSULATE 25 0V
1 +24V 1 1 26 + +UBS
2 27 I
U LG 1
3 28 0V
BOOM LENGTH SIGNAL BOOM ANGLE SIGNAL OS Connected 4 29 I WG 1
1
3 RETRACTED = 4mA 90o = 4mA to strain relief U
insert 30 I LG 1
MAX RANGE = 20 mA 0o = 20 mA U
2 5 31
* NOTE - MAX LENGTH SIGNAL 6 0V
32
VARIES WITH BOOM, MAX.
SIGNAL=20mA IS FOR 10 33 + +UBS
7 34 I
TURNS ON POT. U S1 DHG 1
35 0V
IS = CUT 36 I S2 DHG 2
&INSULATE U
51 + +UB
52 0V
F1 - 4A
4A 53
SI - OUT
54 SI - IN
LMI BYPASS 57 A2B-0
59 LOAD-I
X2
60 X4
14 F2-10A BRN WHT 1
10A 61 1 BRN WHT
2
BUS EXTENSION
SI-REL 2 WHT BRN
YEL GRN
62 SI-REL PNK GRA 3
4
64 PNK
Boom Angle to C.P.U. = CONNECTED

65
66
0V
DE 5
4
5 GRN
6 YEL
YEL
GRN
GRA PNK
5
6
7
67 PNK GRA
8
Connections = WIRES ARE
GROUPED
TOGETHER
68
69
76 + +UBS
DE 6
3-Pair
Twisted
Cable
77 0V
AGND
AGND
P8
- +
MP14
Channel # 5
VREFA
OPERATING WINDOW
MP0
MP8
P7 P6 P5 P4 P3 P2 P1
MP13 MP9
.0V
ANGLE
(90o TO 0o)
ERROR
MP17
MP12
(GND)
J1
E15
+UB
J2 CODE
MP10
MP7 - MP1->
MP11 .500v MIN.
X1 26 28 29
- +
WORKING
BR1
AGND
RANGE -
X1
AGND 20 1 1 MP16 16
1
40 2 2
4.50v MAX. A
VOLTAGES +
X1 4 ANALOG INPUT MODULE ERROR
+ 500MV (.500V) = 90o ANGLE MIN. SIGNAL CODE E25
+ 2.50V = 45o ANGLE
+ 4.5 V = 0o ANGLE MAX. SIGNAL 5.0V
ALL VOTAGES ARE MEASURED WITH Current Based Amplifier 1 3 4
REFERENCE TO GND (TERMINAL X1 - 28) ON MAIN BOARD. All sensing devices used for Analog Inputs now have a
25.2

SHIELD 1
E15 / E25 CORE 2
6 Pin Plug
(measurements in cable reel)
5 3 1 5 3 1 1 2 3 4 5 6 7
Measure Voltage - Angle transducer at X1 1(+) & 3 (-)
Range 10V to 30V
1 OUT
1 OUT
GND
GND
+UB
+UB
Measure Voltage - Angle transducer at X1 2(+) & 3 (-) 1 2 3 4 5 6
Range 1V to 5.6V 7 8 5 3 1 5 3 1
X2 X4 X3 1 2 3 4 5 6 7
Measure Amps - Angle transducer at X1 4(+) &
S 8 7 6 5 4 3 2 1 X1
6 Pin Connector
DS350 GRAPHIC MODULAR 6 5 4 3 2 1
BOOM ANGLE MEASURING CHANNEL 7
CHANNEL # 5
Boom Angle Signal
ACTUAL SIGNAL AT X1 TERM. SIGNAL ON ANALOG
BOOM ANGLE PIN #29 ON C.P.U. MODULE AT X1-4
IN DEGS. TERMINAL (X1-28 GND.)
90o 4.0 mA 0.48
85o 4.9 mA + .70
o 5.7 mA + .92
80
75o 6.6 mA + 1.15
70o 7.4 mA + 1.37
o 8.3 mA + 1.60
65
60o 9.2 mA + 1.80
o 10.2 mA + 2.04
55
25.3
o 11.2 mA + 2.26
50
45o 12.1 mA + 2.48
40o 12.9 mA + 2.70
35o 13.7 mA + 2.92
o 14.7 mA + 3.15
30
25o 15.6 mA + 3.38
20o 16.5 mA + 3.60
o 17.3 mA + 3.82
15
10o 18.0 mA + 4.04
o 19.2 mA + 4.27
5
o 20 mA + 4.49
0
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 Ω 1
RESISTOR 6
To Central Unit
! A
1
B SHIELD
2 SHIELD 1
6 Pin Plug
6 PIN DUMMY PLUG CORE 2
CORE
2 1 2 3 4 5 6 7
A B 1 2 3 4
5 3 1 5 3 1
3 2
3
1 OUT
1 OUT
GND
GND
+UB
+UB
1 1 2 3 4 5 6
4 7 8 5 3 1 5 3 1
1
1
A X2 X4 X3 1 2 3 4 5 6 7
B
26.1
2
2
S 8 7 6 5 4 3 2 1 X1
6 Pin Connector
1 1
1 2 3 6 5 4 3 21
1 1 2 3 5
1 2 3
NOTES:
NO. PART NO. QTY DESCRIP. 1
OUTER SHIELD GROUNDED AT
1 1 2 3 1 9-333-102764 1 COMP. ASSEM.
2 9-333-102717 1 2-POLE JUMPER BAR 2
AUX. BOOM NOSE 3 9-333-102666 1 TAGS, TERMINAL STRIP
CUT AND INSULATE INNER SHIELD
ANTI - TWO BLOCK SWITCH 4 9-333-102663 4 BLOCK, TERMINAL STRIP
5 9-333-102230 1 SWITCH A2B, WITH RETAINER 1 SWITCH PREWIRED AND POTTED
CRIMP
6 9-333-102765 1 COMP. ASSEM., DUMMY PLUG ! IMPORTANT CHANGE
+ +UB
X1 F1 +UBS
1
1 + +24V
2
2 0V K10A
E 5 1
HOUSE LOCK PIN SWITCH 3 + +UBS
2 4 0V
D 4 3
4 6 TXD
LEVER LOCKOUT W # 73A C 3 5
SOLENOIDS 7
6 A2B-O
8
STOP
B 2 7 A2B-I K8
W # 51AJ = GND 9
LOAD-I
+
A 1 10 + +UBS
W # 71K = 24 VOLTS
F2- 10A
11 REL -M
CONSOLE 3
BY - PASS 12
4 REL -A
KEY 13 K10B
REL -R
14 + +UBS
15
8 16 DE 1
17 DE 2
5
18 DE 3
MAIN BOARD
LMI 4
3 7 19 DE 4
7 20 + +UBS
6 21 I DAV1
6 U
22 0V
+
AB 23 + +UBS
I
26.2
3 24 U DAV2
A2B 4
5
5 25 0V
26 + +UBS
4 27 I LG 1
4 U
28 0V
DATA FROM C.U. 3 I
3 29 U WG 1
30 I LG 1
DATA TO C.U. (GND) 2 U
2 31
(+24 V) 1 32 0V
1
33 + +UBS
34 I S1 DHG 1
U
35 0V
GRAPHIC CONSOLE I
36 U S2 DHG 2
51 + +UB
52 0V
F1 - 4A
4A 53
SI - OUT
54 SI - IN
LMI BYPASS 57 A2B-0

14
59
60
61
LOAD-I
+ +UBS F2-10A
X4
1
BRN WHT
WHT
BRN
BRN
WHT
X2
1
2
BUS EXTENSION
SI-REL 2 WHT BRN
Anti - Two Block Connections

YEL GRN
62 SI-REL PNK GRA 3
4
64 PNK
4 5
65 0V 5 GRN YEL
= CONNECTED 6
66 DE 5 6 YEL GRN
GRA PNK
7
67 PNK GRA
8
= WIRES ARE 3-Pair
68 DE 6
GROUPED Twisted
69 Cable
TOGETHER + +UBS
76
77 0V
Auxiliary Boom Nose
2 1
1 9-333-102238 1 SWITCH, A2B W/O CRIMP

2 9-333-102956 1 CONDUIT 3 FEET
(MUST CUT TO LENGTH)
3+ 9-333-102768 1 JUNCTION BOX ASSEM.
26.3
Auxiliary Boom Nose
1(BLACK)
1 A
1
2(BROWN)
A2B CABLE 2
3(RED) 2 B
3
1 9-333-102758 1 Junction Box

3 9-333-101984 1 Locknut
10 9-333-102482 1 Gasket
11 9-333-102612 1 Cover, dust
12 9-333-102669 4 Screw #4
13 9-333-102266 4 Lockwasher #4
14 9-333-102480 4 Nut #4
26.4
Folding Extension
4
2 3
26.5

1 9-333-102230 1 Switch, A2B W/O Crimp
2 9-333-102956 1 Conduit 10 feet
(must cut to length)
Folding Extension
1(BLACK)
1 A
1
2(BROWN)
A2B CABLE 2
3(RED) 2 B
3

1 9-333-102758 1 Junction Box

9 9-333-102482 1 Gasket
10 9-333-102612 1 Cover, dust
11 9-333-102669 4 Screw #4
12 9-333-102266 4 Lockwasher #4
13 9-333-102480 4 Nut #4
26.6
Folding Extension

1 9-333-102758 1 Junction Box

3 9-333-101984 1 Locknut
4 9-333-102664 1 Mounting Rail
10 9-333-102482 1 Gasket
11 9-333-102612 1 Cover, dust
12 9-333-102669 4 Screw #4
13 9-333-102266 4 Lockwasher #4
14 9-333-102480 4 Nut #4
26.7
P.A.T. – L.M.I
MANUAL
SECTION 27

Digital Inputs
RT865BXL (BCS)
MAIN & BUS EXTENSION
DIGITAL INPUTS

BUS EXT. TERMINAL
A101 BUS
1 TELE EXTEND (+24V) GROVE PRESSURE SWITCH SIGNAL
X1/29
A101 BUS
2 TELE RETRACT (+24V) GROVE PRESSURE SWITCH SIGNAL
X1/31
A101 BUS
3 AUTO MODE SELECTED (+24V) GROVE SELECTOR SWITCH SIGNAL
X1/33
PROX. SWITCH OM/FLY
A101 BUS PAT SWITCH ON CM - SIGNAL VIA CM
4 RETRACTED & OM/FLY % RESET
X1/35 CABLE REEL
(+24V)
A101 BUS PROX. SWITCH CM RETRACTED
5 PAT SWITCH ON BOOM BASE
X1/37 & RESET %(+24V)
A101 BUS PROX. SWITCH IM RETRACT
6 PAT SWITCH ON BOOM BASE
X1/39 (+24V)
A101 BUS
7 PROX. SWITCH IM % RESET (+24V) PAT SWITCH ON BOOM BASE
X1/41
INPUT
MAIN
A101 MAIN AREA DEFINATION SWITCH
2 SWIVEL LIMIT SWITCH
X1/17 ON RUBBER
A101 MAIN
3 HOUSE LOCK PIN SWITCH SIGNAL GROVE LIMIT SWITCH
X1/18
27.1
DS350 Graphic Modular (BCS) X1
Digital Input Diagram +UB
+
25
10 - 35V
26
27
28 KGND
TELE EXT. PRESS. SW.
4 29 > DE 1
H1
+24V TELEEXT.
PRESS. SW.
23 pin TELE RET. PRESS. SW.

30 >
plug 5 31 > DE 2
H2
+24V TELERET.
PRESS. SW.
HIGH=AUTO / NONE=MANUAL MODE

32 >
6 33 > DE 3
H3
+24V AUTO MODE
19 pin PROXY SW.1 OM / FLY RET.

34 >
plug 6 35 > DE 4
H4
+24V OM / FLY
RET.
PROXY SW.4 CM RET & % RESET.

36 >
12 37 > DE 5
H5
+24V CM RET. &
% RESET.
14 pin
38 >
plug
PROXY SW. 2 IM RET. (2 POSITIONS)
7 39 > DE 6
H6
+24V IM RET.
PROXY SW.3 IM RESET %. (TOP)

40 >
6 41 > DE 7
H7
+24V IM % RESET.
42 >
43 > DE 8
H8
44 >
* TERMINAL # 25 IS + 24V TO PROXY 45 > DE 9
H9
SWITCHES 1,2,3 & 4. 46 >
47 > DE 10
H10
* TERMINAL # 27 IS GND. TO PROXY
48 >
SWITCHES 1,2,3 & 4.
49 > DE 11
H11
50 >
51 > DE 12
H12
52 >
53 > DE 13
H13
54 >
55 > DE 14
H14
56 >
57 > DE 15
H15
58 >
59 > DE 16
H16
27.2
60
>
P.A.T. – L.M.I
MANUAL
SECTION 28

Central Unit P.C. Modular
Board Layout
MAIN BOARD
PWM DC
+UB1
MP42
1 - G1 + C
KGND
GND
MP 26
1
KGND
MP 4
MP23
VBAT
MP24
+5V
MP 9
+BATT +6V
KGND
2 MP 8 2
AGND
+9V
X15
GND GND
V10 H11 V11 MP41

X14
3 3
power o.k.
DI 1- DI 6 =>
PFAIL+UB1
4 4
X17
MP40
DI 1
H1 H2 H3 H4 H5 H6
MP21
5 5
+UB1 +UB
DI 6
KGND
X12
6 6
X11
J11
7 SP5 7
X13
8 8
X16
TXD
H12
LOAD
ON/OFF
9 9
MAIN
H10
AGND
AGND
+5V/RS232
KGND
LMI
10 K8 10
KGND
J10
3 2
LEVER
4 1 MP29 LOCKOUT
+UB
A2B K10
K9
11 11
KGND
2
F
A2B
H9
- + 1
F
J4
X1
J3
KGND
12 J2 12
KGND
J1
KGND
1
3
77 76 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54
KGND
X1
MP1
13 +UBS 13
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 MP 25
LOCATIONS : LED’S
MP 1 - zone M13 = GND. H 8 - zone M3 - LOAD

MP 25 - zone M13 = +UBS CONSOLE, SENSORS, DI’s H 9 - zone E11 - A2B
MP 8 - zone M2 = +9V MP 41 - zone M4 = POWER FAIL H 10 - zone G9 -MAIN IN/ OUT
MP 9 - zone M2 = +6V MP 42 - zone G1 = +5V H 11 - zone M3 - POWER
MP 4 - zone M1 = +5V MP 21 - zone E5 = +5V H 12 - zone I11 - TXD
MP 26 - zone M1 = GND. MP 29 - zone D10 = +5V
MP 23 - zone A2 = VBATT H1-H6 - zone I5 = DI 1-6
28.1
EXTENSION BOARDS
MP7
J12 J2 J1
J13
D3
D1 D2
D14
MP4
X1
X2
D13
SYSTEM
D6
D10
P1
J8 J9 MP3 J6
D17
D15 D7 D21
J10
D9
D18 D12
J14
J15
J11
J7 D11
D19
D20
X3
EJECT
MP6MP5
BR5
BR6 MP2
A102 CPU J1 J2
DATA
D1
J5
J3
TLK
D3
BR J6
X1
1
4
2
3
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
AGND
AGND
MP12
- +
40
2
1
P7
MP13
J2
P6
20
P5
16
P4
X16
J1
MP11
MP9
P3
P2
MP10
P1
1 1
2 X1 MP17
BR1 MP0 - +
MP8
+ +
X17
MP7 - MP1->
2
1
VREFA
P8
+ +
MP16
7
6 5
16
4 3
MP14
2 1
40
2
1
AGND AGND
BOARD P/N 9-333-103290

X1:1-7 = 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
X1:8 = TEMP (0.5V + 10mV/oC)
X1:9 = VREFA = 5.000V reference MP 1 = AGND
X1:10 = AGND (reference GND) MP 8 = + 5V
X1:11 = VREF+ = 5.0V power ADC MP 1 - 7 Input channels 1 - 7 - 0.5V / 4 mA
X1:12-15 = CH01-04, DIN 1-4 / 10 2.5V / 20mA
X1:16 = CH05, +UBS / 10 MP 14 = + 13V REF 02
X1:17 = CH06, HESIN(A2B) *4 MP 16 = HESIN input voltage
X1:18 = CH07, +9V *4 MP 17 = app 5.4V clamp for inputs
X1:19 = CH08, VREFA / 2 = 2.500V
28.3
A 105 Serial Extension Module
Part No. 9-333-103292
MP11
KGND +UB1
MP1
MP10
F5 F4
2A 2A
MP15
MP4 H1 H2 MP3
X4
1 2 3 4 5 6
1
2
C30 3
4
GND
MP0
5
6
H3
MP16
MP1
A 101 Bus Extension Module

Part No. 9-333-103717
DI 9
DI 16
MP14
ADC
H9 H10 H11 H12 H13 H14 H15 H16
DI 8
H8 H7 H6 H5 H4 H3 H2 H1
MP4 MP5 MP6 MP7 MP10 MP11 MP12 MP13

+5V +14V -14V +REF +REX -10V USIN RIPP
C93
C27
DI 1
61 62 63 64 65 66
MP 8 MP9
MP 3
+ 7V
UREL
MP 2
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
KGND AGND + UB
MP 1
1 2 3 4 5 6 7 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
MP 0
X2
2A
F25
K1 K2 K3 K4 K5 K6 K7 K8 25 26 27 28
F1 F8
F2 F3 F4 F5 F6 F7
H17 H18 H19 H20 H21 H22 H23 H24
28.4
A 102 CPU Module
Part No. 9-333-103718
X4
MP4
J3 C38 C37
C32
SLAVE MP2
E - PROM
C33 H1
MP0 MP1 MP3
J1
A 105 Analog Input Module A 104 PV Extension Module

Part No. 9-333-103719 Part No. 9-333-103720
X2
X2
P11 MP2 MP3 MP7 MP6
P12
MP0
X1
MP1
1 2 3 4 H1
MP5 MP4
28.5
RT865BXL (BCS)
BUS EXTENSION
INTERFACE
Grove wire Interface
number connector
71H A POWER SUPPLY +24V
51AK B CRANE GND
C
387A D TELE EXTEND PRESSURE SWITCH (INPUT)
388 E TELE RETRACT PRESSURE SWITCH (INPUT)
239B F HIGH = AUTO MODE, LOW = MANUAL MODE (INPUT)
242B G SELECT OM / FLY IN MANUAL MODE (INPUT)
243B H SELECT CM IN MANUAL MODE (INPUT)
244B J SELECT IM IN MANUAL MODE (INPUT)
[507] K 3RD WRAP CUT OFF MAIN HOIST RT ONLY
[505] L 3RD WRAP CUT OFF AUX. HOIST RT ONLY
[338] M 3RD WRAP WARNING LIGHT (GND) RT ONLY
323A N TELE OUT OF SEQUENCE SIGNAL (RELAY OUTPUT)
O
P
Q
R
238A S PROPORTIONAL TELE - SOLENOID GND.
1083 T TELE ROD DRAIN SOLENOID VALVE SIGNAL
255A U PROPORTIONAL TELE - SOLENOID (EXTEND)
257A V PROPORTIONAL TELE - SOLENOID (RETRACT)
W
X
RT865BXL (BCS)
MAIN BOARD
INTERFACE
Grove wire Interface
number connector
71K A POWER SUPPLY +24V
51AJ B CRANE GND
73A C LMI UNLOCK SOLENOIDS
74 D LMI LOCK OUT ALARM
744 E HOUSE LOCK PIN SWITCH
F
G
H
28.6
+ +UB
X1 F1 +UBS
1
E 5 2
1 + +24V
HOUSE LOCK PIN SWITCH 2 0V K10A
3 + +UBS
D 4 4 0V
LEVER LOCKOUT W # 73A C 3 6 TXD
7
SOLENOIDS 8
A2B-O
STOP
A2B-I K8
9
B 2 LOAD-I
W # 51AJ = GND
+
10 + +UBS
A 1
W # 71K = 24 VOLTS F2- 10A
11 REL -M
3
12
4 REL -A
13 K10B
REL -R
14 + +UBS
15
16 DE 1
17 DE 2
5
18 DE 3
MAIN BOARD
19 DE 4
20 + +UBS
21 I DAV1
U
22 0V
23 + +UBS
I
28.7
24 U DAV2
25 0V
26 + +UBS
27 I LG 1
U
28 0V
29 I WG 1
U
30 I LG 1
U
31
32 0V
33 + +UBS
34 I S1 DHG 1
U
35 0V
36 I S2 DHG 2
U
51 + +UB
52 0V
F1 - 4A
4A 53
SI - OUT
54 SI - IN
LMI BYPASS 57 A2B-0

14
59
60
61
LOAD-I
+ +UBS F2-10A
X4
1
BRN WHT
WHT
BRN
BRN
WHT
X2
1
2
BUS EXTENSION
SI-REL 2 WHT BRN
Crane Interface to Main Board

YEL GRN
62 SI-REL PNK GRA 3
4
64 PNK
4 5
65 0V 5 GRN YEL
= CONNECTED 6
66 DE 5 6 YEL GRN
GRA PNK
7
67 PNK GRA
8
= WIRES ARE 3-Pair
68 DE 6
GROUPED Twisted
69 Cable
TOGETHER + +UBS
76
77 0V
X1
1
2
3
9 4 K2 COM ( +24V )
5 K2 NO ( +24V TO IM 2-WAY SOLS. )
6
7 K3 COM ( +24V )
16
8 K3 NO ( +24V TELE ROD DRAIN SOL. )
9 K3 NC
A104 10 K4 COM
PV EXTENSION
X1 11 K4 NO
1 13
12 K4 NC ( TELE OUT OF SEQUENCE )
2 13 K5 COM
15 17
3 14 K5 NO ( PROP EXT )
18
4 15 K5 NC ( PROP RET )
8 16 K6 COM ( + 24V )
17 K6 NO ( +24V TO CM 2-WAY SOLS. )
18 K6 NC
19 K7 COM ( +24V )
7
20 K7 NO ( +24V TO OM 2-WAY SOLS. )
21 K7 NC
+ 24V 71H 1 22
A A 23
GND 51AK 2
B B 24
BUS EXTENSION
C C 25 +24V
1
TELE EXTEND PRESSURE SW. 387A 4 26 +24V
D D 27 GND
TELE RETRACT PRESSURE SW. 388 5 2
E E 28 GND
HIGH = AUTO MODE / NONE = MANUAL MODE 239B 6 4
F F 29 DI 1 ( +24V = TELE EXT. PRESS. SW. )
OM / FLY TELE 242B 7 30 DI 1 GND
G G 5
CM TELE 243B 8 31 DI 2 ( +24V = TELE RET. PRESS. SW. )
28.8
IM TELE
H H 32 DI 2 GND
244B 9 6
J J 33 DI 3 ( +24V = AUTO MODE )
K K 34 DI 3 GND
35 DI 4 ( +24V = OM / FLY RET )
L L 36 DI 4 GND
M M 37 DI 5 ( +24V = CM RET & % RESET )
TELE OUT OF SEQUENCE 323A 13
N N 1 38 DI 5 GND
O O 39 DI 6 ( +24V = IM RET )
40 DI 6 GND
P P 41 DI 7 ( +24V = IM % RESET )
Q Q 42 DI 7 GND
R R 43
TELE PROP. ANALOG GND. 238A 15 44
S S 45
TELE ROD DRAIN SOLENOID 1083 16
T T 46
TELE EXTEND PROP. SOLENOID 255A 17
U U 47
TELE RETRACT PROP. SOLENOID 257A 18 48
V V
49
S/S HARNESS W W LMI - CRANE INTERFACE 50
23 - SOCKET RECEPT X X 23 - PIN PLUG 51
52
53
54
55
56
DS350 Graphic Modular BCS 57

58
59
X2
1 BRN WHT
X4
MAIN BOARD
60 2 WHT BRN
WHT BRN
1
Crane Interface to Bus Extension 61
62
63 ANALOG INPUT 1 (IM LEN.)
4
5
GRN
3 YEL YEL
GRN
BRN
GRA
PNK
WHT
PNK
GRA
2
3
4
= WIRES ARE 64 ANALOG INPUT 2 (CM LEN.) 6
GROUPED 65
YEL GRN
5
7 PNK GRA
GRN YEL
6
TOGETHER 66 8 GRA PNK
P.A.T. – L.M.I
MANUAL
SECTION 29

Troubleshooting Guide
PAT DS350 Graphic Modular (BCS)
TROUBLESHOOTING
General Flowchart 29.2

Lever Lockout Activated 29.3
Broken Length Cable 29.4
No Display 29.5
Anti - Two - Block 29.7
Length Reading Problem 29.10
Angle Reading Problem 29.37
Load Reading Problem 29.40
Bad Data Transfer Between Console & Central Unit 29.42
Error Code Displayed 29.45
29.1
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
What’s Wrong?

Activated Problem
Wrong Length Wrong Angle Wrong Load Bad Data Error Code
Displayed Displayed Displayed Transfer Displayed
Go to Page 29.10 Go to Page 29.37 Go to Page 29.40 Go to Page 29.42 Go to Page 29.45
29.2
PROBLEM
START

fixed?
YES
NO
Does the console indicate
NO YES
Fault in crane electric If console displays is Fault in Anti-Two If Load Moment Limit
or hydraulic system. blank, fault is located Block system. Light is lit, the fault
console.
Check lever lockout Go to page 29.5 Go to page 29.7 Read error code dis-
and go to page29.45.
29.3
BROKEN LENGTH CABLE
PROBLEM
STEP ACTION
2 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.
at the boom nose.

29.4
NO DISPLAY
PROBLEM
START
NO
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?
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.
Defect on main board.

Replace main board, see replacement
NO
correct? procedure.
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 .
Check connections of the

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

wire from X1-31 in central unit.
NO
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
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 Fault in wiring cable from junction box at

correct? 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

NO
using same measurements as in previous
Disconnect X1-31 and X1-32.
temporary resistor, 4700 Ohms, between X1-
31 and X1-32 in central unit. With resistor
connected alarm should be inactive.
NO Defect on main board. Replace main

correct?
board and reset pressure channel.
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 %)
No
Wrong?
Yes
IM and/ or CM retract signal not recognized. Check
proximity switch target adjustment. Refer to Drawing Continue to page 29.17
on page 23.3. If damage is visible install new switch.
No
Correct?
Yes
Measure the voltage supply to IM switch at terminal Adjust the target and switch
1 (+24V) and 3 (GND) in the length transducer LG321. See page 23.3
NEXT PAGE
29.10
A. Boom Length Percentage Problem Cont.
PREVIOUS PAGE
No
Correct?
Yes
Measure the voltage at terminal
25 (+24V) and terminal 27 (GND)
in the bus extension.
Failure in bus extension.

No
Check connectors, fuses and Correct?
bus extension power supply.
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.
No
Correct?
Yes
Measure voltage at terminal 1 (+24V) and 5 Faulty wiring between length
(GND) in the IM junction box. Behind drum. transducer and LG 321 and switch
junction box. Check wiring.
No
Correct?
Faulty wiring between length
Yes transducer and LG 321 and IM
NEXT PAGE junction box. Check wiring.
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.
No
Correct?
Yes
Measure the IM reset switch signal at wire 2 Faulty switch wiring or defective
(+ 24)(fast-on connector) and terminal 3 (GND) switch. Replace IM reset proximity
in the length transducer LG321. See page 29.4. switch. Adjust switch and target.
No
Correct?
Yes
Measure the IM retract switch signal at terminal 4 Faulty wiring between length
(+ 24) and terminal 5 (GND) in the length switch transducer and LG 321 and switch
junction box on base boom. See page 29.5. junction box. Check wiring.
NEXT PAGE
29.12
PREVIOUS PAGE
No
Correct?
Yes
Measure the IM reset switch signal at wire 4 Faulty switch. Replace IM retract
(+ 24)(fast-on connector) and 3 (GND) proximity switch. Adjust switch
in the length transducer LG321. See page 29.4 and target.
No
Correct?
Yes
Measure the CM retract switch signal at Faulty wiring between length

terminal 6 (+ 24) and terminal 5 (GND) transducer and LG 321 and switch
in the IM junction box. See page 29.5 junction box. Check wiring.
No
Correct?
Yes
Measure the CM retract switch signal at Defective switch. Replace CM

terminal 8 (+ 24) and terminal 3 (GND) retract proximity switch. Adjust
in the LG321. See page 29.4 switch and target
NEXT PAGE
29.13
PREVIOUS PAGE
No
Correct?
Yes
Faulty wiring between length
Measure the IM retract switch signal at terminal 39
transducer LG321 and switch
(+24V) and 27 (GND) in the bus extension.
junction box. Check wiring.
See page 29.3
No
Correct?
Yes

Measure the IM reset switch signal at terminal 41
extension and length transducer
(+24V) and 27 (GND) in the bus extension.
LG321 and switch junction box.
See page 29.3
Check wiring.
No
Correct?
Yes
Measure the CM retract switch signal at terminal 37

(+24V) and 27 (GND) in the bus extension. See page 29.3

No extension and length transducer
Correct?
LG321 and switch junction box.
Check wiring.
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
No
Correct?
Yes
Measure at CM junction box terminal 11 (+24V) extension and length transducer
and 9 (GND). See page 29.5 LG321 and switch junction box.
Check wiring.
No
Correct?
Yes
Faulty wiring between CM box
Measure OM retract switch signal at CM junction and length transducer LG321
box terminal 10 (+24V) and 9 (GND). See page 29.5 (CM). Check wiring.
No
Correct?
Yes
Measure signal at terminal X1/8 (+24V) and X1/7 Faulty wiring between bus
(GND) in the LG 321 (CM). See page 29.4 extension and length transducer
LG321 (CM). Check wiring.
NEXT PAGE
29.15
PREVIOUS PAGE
No
Correct?
Yes
Measure signal at bus extension terminal X1/35 Faulty wiring between CM box
(+24V) and X1/27 (GND). See page 29.3 and length transducer LG321
(CM). Check wiring.
No
Correct?
Yes
Digital input defective on bus extention. Check Faulty wiring between bus
LED’s on bus extension. Follow replacement extension and length transducer
procedures. LG321 (CM). Check wiring.
END
29.16
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%)
No
Correct?
Yes
Inspect the spooling of the length cable on all three drums. Continue with section A.
No
Correct?
Yes
Remove the lid from the length transducers LWG 309
Correct the spooling manually.
and both LG 321. Carefully reset the length transducer
CAUTION
potentiometer. Repeat testing the boom sequence in
Drum is under tension.
automode.
NEXT PAGE
29.17
B. Boom Out Of Sequence In Automode Cont.
PREVIOUS PAGE
No
Failed?
Yes
In manual mode retract the boom. Disengage the boom stop block
to retract all section completely. Re-check the length potentiometer END
adjustment.
No
Correct?
Yes
Remove lid from LG321 (IM length) and measure Adjust gear assembly and check
supply voltage at terminal X1/1 (+24V) and X1/3 O-ring in gear wheel. Replace
(GND). See page 29.4 O-ring if wear is visible.
Measure the voltage at terminal X1/25

No
Correct? (+24V) and terminal X1/27 (GND) in
bus extension.
Yes
Failure in bus extension.
Check connectors, fuses No
Correct?
and bus extension power
supply.
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
No LG 321 terminal X1/2. Switch power on.
Correct?
Measure electrical current at terminal X1/2
(+ 4mA). Meter - in series.
Yes
Switch power off.

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

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


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).
No
Correct?
Yes Faulty wire between length transducer LG 321

(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
No LG 321 (CM) terminal X1/2. Switch power
Correct?
on. Measure electrical current at terminal
X1/2 (+ 4mA). Meter - in series
Yes
Switch power off.


to terminal X1/2.

Turn the length poteniometer in the LG 321 (CM)

See page 29.4
NEXT PAGE
29.21
PREVIOUS PAGE

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


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
No
Correct?
Yes Faulty wire between length transducer LG 321

NEXT PAGE
29.22
PREVIOUS PAGE
Turn the length poteniometer in the LWG 309 (OM)


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


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

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


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 No
Correct?
Fault is not located in the LMI circuit. Faulty bus extension module.
Follow the crane service instructions to Contact Technical support for
continue. instructions
END 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.
No Switch to auto mode and

E83 ? contiue normal crane operation
Yes
Switch to auto mode and retract the boom (Caution

Reduced load chart with E83)
No
E83 ?
Yes Defect is not located in LMI

circuit. Refer to crane service
documentation to continue.
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
No
Correct?
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 Correct?
documentation to continue.
Yes
Switch to auto mode and

contiue normal crane operation
No
Correct?
Yes Adjust the switch and the target.
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
No
Correct?
Yes
Measure OM retract switch power supply at LG 321 Defective bus extension. Check
(CM) terminal X1/11 (+24V) and X1/7 (GND) connectors, fuses and bus extension
See page 29.4 power supply.
No
Correct?
Yes
Measure OM retract switch signal at CM junction
extention and LG 321. Check
box terminal 10 (+24V) and 9 (GND) See page 29.5
wiring.
No
Correct?
Yes

Measure signal at LG 321(CM) terminal X1/8
extention and LG 321. Check
(+24V) and X1/7 (GND). See page 29.4
wiring.
NEXT PAGE
29.28
PREVIOUS PAGE
No
Correct?
Yes
Measure signal at bus extension terminal X1/35 Defective wiring between CM

(+24V) and X1/27 (GND) See page 29.3 junction box and length transducer
LG 321(CM). Check wiring.
No
Correct?
Yes
Digital input defective on bus extension. Check Faulty wiring between bus
LED’s on bus extension. Contact Technical extention and LG 321(CM).
Support for replacement procedure. Check wiring.
END
29.29
D. Error In Bus Extension (E61)
START
E61
Error in the bus extension
Check crane power, battery

voltage.
No
Correct?
Yes
Measure the power supply at the bus extension Refer to the crane service
terminal X1/26 (+24V) and 28 (GND). See page 29.3 documentation to correct
the power failure.
No
Correct?
Yes
Faulty crane electric wiring.
Check bus extention fuse FX
Check wiring.
NEXT PAGE
29.30
D. Error In Bus Extension (E61) Cont.
PREVIOUS PAGE
No
Correct?
Yes
Check the bus extension cable wiring and
Switch power off. Replace the fuse.
connections between bus extension and central
Switch power on and check again.
unit.
No
Correct?
Yes
Faulty bus extension. Contact If damage is visible replace the cable,

Technical Support for replace otherwise rewire and tighten the
procedure. connections. CAUTION: Twisted pairs
must remain twisted.
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.
No
Correct?
Yes
Malfunction is not related to LMI or

Remove lid from bus extension. Measure crane power boom control extension. Consult the
supply at terminal X1/26 (+24V) and X1/28 (GND). crane service documentation.
See page 29.3
No
Correct?
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
No
Correct?
Yes
Faulty pilot pressure switch in the
Operate the retract control. Measure the retract signal tele extend pilot pressure circuit or
at bus extension terminal X1/31 (+24V) and X1/28 (GND). crane electric harness faulty. Refer
to crane documentation.
No
Correct?
Yes Faulty pilot pressure switch in the

tele extend pilot pressure circuit or
crane electric harness faulty. Refer
to crane documentation.
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.
No
Correct?
Yes Faulty digital input 1 on bus

extension. Contact Technical
Select boom service screen on console.
Support for replacement procedure.
Operate the retract control. The ramp value
for the appropriate section should increase
in steps from 0 to 255.
NEXT PAGE
29.33
PREVIOUS PAGE
No
Correct?
Yes
Select manual mode. Retract all sections. Switch power

off. Remove wire 2 from the analog output board terminal
A 104 X1/2 (IM). Switch power on. Operate retract and Faulty digital input 2 on bus
extend control. Measure the electrical current (mA) between extension. Contact Technical
the wire 2 (removed from terminal) and the terminal X1/2. Support for replacement procedure.
The signal should increase from 0 mA to approximately 800 mA.
NOTE : In the ramping area the value may be < 800 mA.
Check the power supply to the analog

No
Correct? output module A 104 (IM). Measure at
terminal X1/1 (+24V) and X1/4 (GND).
Yes
Faulty wiring in bus

No
extension. Check Correct?
wiring.
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 Correct?
Support for replacement procedures.
Yes
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
Refer to drawing of (K2, K6, K7 control. Measure at bus terminal X1/15 (>0V) and
logic table) to check the two way valve X1/28 (GND).
operation.
Check fuse F5 in the bus No

extension. If blown replace Correct?
fuse. Check relay K5.
Yes
Faulty crane wiring or defective valve coil.

Contact Technical support .
NEXT PAGE
29.35
PREVIOUS PAGE
No
Correct?
Yes
In the bus extension:
Measure the two way valve signal (>/= +20V) Check fuse F2 for relay K2 (IM 2 way valve).
at terminal 1 or 2 (IM junction box) and terminal Check fuse F6 for relay K6 (CM 2 way valve).
1 or 2 and 3 or 4 (CM junction box). Check fuse F7 for relay K7 (OM 2 way valve).
Replace if blown.
No
Correct?
Yes
Faulty crane wiring or valve coil. Faulty wiring between bus extension and 2
Refer to Crane Service Documentation. way valve junction boxes on the IM and CM
section. Check wiring.
END
29.36
PROBLEM
START

cable reel.

correct?
YES
Place the boom at 0 o. Check power supply

to angle sensor on main board between X1-
26 (+12/24V) and X1-28 (GND)

NO reset pressure channel.
correct? Note: Consult factory before replacing main
board for further troubleshooting steps.
YES
NEXT PAGE
29.37
PREVIOUS PAGE

reel at terminal between X1-1 (+12/24V)
and X1-3 (GND).

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? Replace angle sensor.
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

YES
Measure angle signal analog input module

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

correct?
central unit.
YES
END
29.39
PROBLEM
START


correct?
YES
Reset length potentiometer. With fully retracted

NO boom, turn potentiometer axle counterclockwise
correct? until it stops .
YES

displayed radius.
Check if mechanical adjustment of angle transducer

NO is correct. Angle transducer box should in line with
correct? boom and adjusted to actual boom angle.
YES

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

correct? YES
NO Replace the main in central unit.

NEXT PAGE
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
correct? 4-20mA
Measurement within 4-20mA, but 4mA
YES YES 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

correct?
central unit.
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 Place EPROM S in correct socket.

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

correct?
correct.
YES
Turn off system power. Check the continuity
of the receive (RXD) and transfer (TXD) wires.
Check continuity between:
NO Check connections and replace cable from central

correct? unit to console, if necessary.
YES
NEXT PAGE
29.42
PREVIOUS PAGE


correct?
central unit box mounting bracket.
YES


YES
END
29.43
PROBLEM
START
Check system out; - Bad Data

NO
YES

correct?
central unit box mounting bracket.
YES


correct? Refer to connection and wiring diagrams
YES
Refer to Drawing 8, “Suppressor Diode”
END
29.44
ERROR CODE DISPLAY
PROBLEM
Warning lights on.
ERROR
the boom too far.
configuration.
Length sensor adjustment See page 35.58

29.45
ERROR CODE DISPLAY
ERROR
E 07 No acknowledgement signal Overload relay is stuck,

E 08 No acknowledgement signal Anti-Two-Block switch relay

value for the measuring defective, not connected or water in the necessary. See page 35.58.

potentiometer. See page 35.58.

main board.
channel "pressure piston side". defective, loose or water in
the plug.


on main board.
channel "pressure rod side". defective, loose or water in
in the plug.


on main board.
29.46
ERROR CODE DISPLAY
ERROR
channel "angle main boom". water inside plug. See page 35.58.


inside the plug.

.
+5 volt supply
E 1A Below limiting value for slewing Cable from central unit to the slewing Check wiring, replace if
E 1B Below limiting value for slewing Slewing angle pot. defective. Replace and reset slewing angle
measuring channel "length" length/angle sensor defective necessary. See page 35.58.
exceeded. or loose.
defective. potentiometer. See page 35.58.

on main board.
29.47
ERROR CODE DISPLAY
ERROR
piston side” exceeded. loose or water in the plug.


on main board.
rod side" exceeded. loose or water in the plug.


on main board.

main boom" exceeded. or loose.
on main board.
29.48
ERROR CODE DISPLAY
ERROR
E 27 Upper limit value for the measur- Cable from central unit to the Check cable.
channel 7 exceeded. Sensor of channel 7 defective Replace if necessary.
or loose.
Sensor of channel 7 defective. Replace angle sensor and reset
measuring channel 7 defective. pressure channels.
voltage. MP10 is more than 3.3V.
A/D converter defective.
E 2A Above limiting value for slewing Cable from central unit to the slewing Check wiring, replace if
E 2B Above limiting value for slewing Slewing angle pot. defective. Replace and reset slewing angle
defective. EPROM.
program. Data EPROM.
program. TLK EPROM.
channels.

pressure channels.
29.49
ERROR CODE DISPLAY
ERROR
channels.
channels.
E 46 Error in A/D Defective electronic Replace main board and
conversion component. reset pressure channels.
memory.
pressure channels.
Eprom Module not bridge correctly. board is installed.
E 52 Error in TLK memory. TLK EPROM on the main Replace main board and reset
Eprom Module not bridge correctly.
E 71 Incorrect acknowledgment of the A2B relay is stuck or defective. Replace K9 relay.

A2B Relay on A101 Term. board.
A2B relay is not being selected due to Check terminal board, main
a break on the terminal board, main board and ribbon cables as well
board or ribbon cable. as replace defective part, if
necessary.
E 72 – E 77 Analogous to E 71 for relays Analogous to E 71 for relays Analogous to E 71 for relays

K2 – K7 K2 – K7 K2 – K7
E 89 Change of the operating code The operating mode switch in the Lower the load and set the
during lifting a load. console was used during lifting operating mode switch correctly
a load. to the code assigned to the
actual operating mode of the
crane.
29.50
ERROR CODE DISPLAY
ERROR
E 91 No data transmission from 24V supply of console Check 24V at terminal Xl of

(See page 35.42)
Interruption or accidental Check the connection between
ground in the line from console electronics and
console electronics to central unit. If you find an
central unit. accidental ground, the
transmitter module in the
damaged. You should,
therefore, replace the console
electronics.
Transmitter / receiver module Replace console electronics
defective. or main board respectively.
E 92 Error in the data transmission Defective data line Check the connection between
from console to central unit. from console electronics to console electronics and central
(See page 35.42) central unit. unit.
E 93 Error in the data transmission Defective contact in the line Check the line to the console.
from central unit to console. from central unit to console.
(See page 35.42) Transmitter / receiver Replace console electronics
E 94 No data transmission from Interruption or accidental Check the line to the console
central unit to console. ground in the data line from (in case of accidental ground
(See page 35.42) central unit to console. also replace console
electronics).
5V supply for the computer Check the connection to the
in the central unit is missing. power supply.
5V supply voltage too low. Replace power supply module.
Data EPROM defective. Check data EPROM.
Computer module defective. Replace main board.
Electromagnetic interferences Eliminate interference source

(e.g. when switching by inverse diodes or varistors.
contactors or valves).
29.51
ERROR CODE DISPLAY
ERROR
board defective.
board defective.
29.52
Drawing 1 : Slip Ring Unit
X2 : RED
X1 : BROWN
Drawing 2 : Boom Nose Junction Box

1
2
3
4
29.53
PWM DC
+UB1
MP42
1 - G1 + C
KGND
GND
MP 26 1
KGND
MP 4
VBAT
MP23
MP24
+5V
MP 9
+BATT +6V
KGND
2 MP 8 2
AGND
+9V
X15
GND GND
V10 H11 V11MP41

X14
3 3
power o.k.
DI 1- DI 6 =>
PFAIL+UB1
4 4
X17
MP40
DI 1
H1 H2 H3 H4 H5 H6
MP21
5 5
+UB1 +UB
DI 6
KGND
X12
6 6
X11
J11
7 SP5 7
X13
8 8
X16
TXD
H12
LOAD
ON/OFF
9 9
MAIN
H10
AGND
AGND
+5V/RS232
KGND
LMI
10 K8 10
KGND
J10
3 2
LEVER
4 1 MP29 LOCKOUT
+UB
A2B K10
K9
11 11
KGND
2
F
A2B
H9
- + 1
F
J4
X1
J3
12 12
KGND
J2
KGND
J1
KGND
1
3
77 76 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54
KGND
X1
MP1
13 +UBS 13
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 MP 25
LOCATIONS :
MP 1 - zone M13 = GND. MP 41 - zone M4 = POWER FAIL

MP 25 - zone M13 = +UBS MP 42 - zone G1 = +5V
MP 8 - zone M2 = +9V MP 21 - zone E5 = +5V
MP 9 - zone M2 = +6V MP 29 - zone D10 = +5V
MP 4 - zone M1 = +5V H1-H6 - zone I5 = DI 1-6
MP 26 - zone M1 = GND.
MP 23 - zone A2 = VBATT
29.54
Drawing 4 : CPU and Daten EPROM boards
MP7
J12 J2 J1
J13
D3
D1 D2
D14
MP4
X1
X2
D13
SYSTEM
D6
D10
P1
J8 J9 MP3 J6
D17
D15 D7 D21
J10
D9
D18 D12
J14
J15
J11
J7 D11
D19
D20
X3
EJECT
MP6MP5
BR5
BR6 MP2
A102 CPU J1 J2
DATA
D1
J5
J3
TLK
D3
BR J6
X1
1
4
2
3
A103 DATEN
29.55
Drawing 5 : Analog Input Module
AGND
AGND
MP12
- +
40
2
1
P7
MP13
J2
P6
20
P5
16
P4
X16
J1
MP11
MP9
P3
P2
MP10
P1
1 1
X1 MP17
2
BR1 MP0 - +
MP8
+ +
X17
MP7 - MP1->
2
1
VREFA
P8
+ +
MP16
7
6 5
16
4 3
MP14
2 1
40
2
1
AGND AGND
BOARD P/N 9-333-103290

X1:1-7 = ADC INPUT 0.5V/4mA…2.5V/20mA
offset adjust with P1-P7
X1:8 = TEMP (0.5V + 10mV/oC)
X1:9 = VREFA = 5.000V reference
X1:10 = AGND (reference GND)
X1:11 = VREF+ = 5.0V power ADC
X1:12-15 = CH01-04, DIN 1-4 / 10
X1:16 = CH05, +UBS / 10
X1:17 = CH06, HESIN(A2B) *4
X1:18 = CH07, +9V *4
X1:19 = CH08, VREFA / 2 = 2.500V
29.56
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
1 2 3 4 5 6 7 8 X5 1 2 3 4
29.57
Transducer
PAT
PAT
1 X3
XA2 1
2
3
3 5
1
1 2 3 4 5 6 7 8
X2 L
2
3 1 X4
4 XB2
2 1
3
5 3 5
6
X2
7 A
8
S X2
7 (9)
X1 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
CAUTION: Make sure that + and - diode connections are

made as shown to ensure proper polarity.
CABLE ASSY. TO PRESS. TRANSDUCER ( PISTON )

Drawing 9 : Central Unit Box
CABLE ASSY. TO PRESS. TRANSDUCER ( ROD )

NORMAL L/O
3 - PAIR CABLE BUS EXTENSION
OPERATION OVERRIDE
CABLE TO CRANE INTERFACE
OUT IN
CABLE TO AREA DEFINITION
CABLE ASSY. TO CONSOLE
CABLE ASSY. TO BOOM
FUSE ( 10A)
FUSE ( 4A )
29.59
P.A.T. – L.M.I
MANUAL
SECTION 30

Electrical Diagrams
K10 LMI UNLOCK S.
DI 3 (+24V HOUSE
K10 EXT. HOR. *1
K10 (COM) +24V
DI2+24V=O/F - RUB.
PIN ENGAGED)
A2B GROUND
FUSE (4 amp)
FUSE (4 amp)
A2B BYPASS
A2B BYPASS
FUSE (10 amp)

FUSE (10 amp)
A2B SIGNAL
LMI BYPASS
LMI BYPASS
NOT USED
NOT USED
NOT USED
NOT USED
LENGTH
PISTON
ANGLE
FORCE
+UBS
+UBS
GND
GND
GND
GND
GND
GND
GND
ROD
RXD
+UB
TXD
+UB
+UB
+UB
+UB
+UB
+UB
DI1
DI4
X1 1 2 11 12 13 18 51 52 3 4 5 6 7 8 9 10 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 53 54 59 60 61 62
GN/YL
OUT
OUT
IN
IN
1 2 3 4 5 6 8 9 1 2 3 4 5 6 7 10 1 2 1 2 3 4 1 2 3 4 1 2 3 4 7 5 6
4 3
1 2 2 2 2 2
1 1 1 1 2 1

FUSE FUSE
1 2 3 4 5 6 7 10 8 9
A
30.1
LMI BYPASS
GN/YL
1 2 3 4 5
5 PIN KEY SWITCH
V V V V 1 2 3 4 5 6 7 8 X1 DEUTSCH
7 PIN PLUG
V V V V V 1 2 3 4 PLUG
GND
+UB
RXD
A2B
A2B
TXD
LOAD
D1
V V VVV V
744 HOUSE LOCK PIN SW.
A BCD E
73A (LMI UNLOCK SOL.)
A BCD E 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7
74 (LMI L/O ALARM
X8 V V VV V
+UBE
SIG+
GND
SIG-
+UBE 1
51AJ (GND)
71K (+UB)
V V V V V V
GND 2
V V VV V V
NO A B C A B C A B CD E F
X7 1 2 3 4
C A B C
V V V A B C
V V V TO MAIN BOOM
1 2 3 4 CONNECTOR
NC (See Page 36.2)
crane 12 o area
V V V V
definition switch
A BC D in ele. swivel
V V V V NOTES:
CRANE SYSTEM AREA
DEF. SWITCH pres. trans. pres. trans.
(piston) (rod) 1 OUTER SHIELD GROUNDED AT STRAIN
1 2 3 4 ELEC. SWIVEL
RELIEF CONNECTOR.
LIGHTBAR
2 INNER SHIELD CUT AND INSULATED
DS350 3
INSULATE OUTER SHIELD AND
GRAPHIC MODULAR B.C.S. *1) OPTIONAL FOR EXTERNAL HORN
CENTRAL UNIT (EEC UNITS ONLY)
7 PIN PLUG
A
RT865BXL (BCS)
DS350 Graphic Modular 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
123 4 5 6 7
LWG309 (TO NOSE)

X1
12345678
X2
7 8
X3
X4
1 3 5 1 3 5
RED
BRN
+ 24V
+ 24V
GND
GND
30.2
SIG.
SIG.
LENGTH ANGLE
TRANSDUCER TRANSDUCER CORE
SHEILD
SHEILD
3=RED
CORE 2=BRN
3
1=BLK
2
1
1234
12
VV
A B
4.7K
A B
V V
1 2 3
4.7K
30.3
A
101
+ 24V 71H 1
A A
GND 51AK 2
B B
1
C C +24V
TELE EXTEND PRESSURE SW. 387A 4
D D
2
TELE RETRACT PRESSURE SW. 388 5
E E GND
HIGH = AUTO MODE / NONE = MANUAL MODE
4
239B 6
F F
OM / FLY TELE 242B 7 DI 1 ( +24V = TELE EXT. PRESS. SW. )
G G
5
CM TELE 243B 8
H H DI 2 ( +24V = TELE RET. PRESS. SW. )
IM TELE 244B 9
6
J J
DI 3 ( +24V = AUTO MODE )
K K
L L DI 1 GND
M M
TELE OUT OF SEQUENCE 323A 13 DI 2 GND
1
N N
O O DI 3 GND
P P
Q Q DI 4 GND
R R DI 5 GND
10 11 12 14 3
TELE PROP. ANALOG GND. 238A 15
S S
TELE ROD DRAIN SOLENOID 1083 16 DI 6 GND
T T
TELE EXTEND PROP. SOLENOID 255A 17
U U DI 7 GND
TELE RETRACT PROP. SOLENOID 257A 18
V V
8
K2 COM ( +24V )
9
W W
K2 NO ( +24V TO IM 2-WAY SOLS. )
11
X X
K3 COM ( +24V )
16
S/S HARNESS LMI - CRANE INTERFACE K3 NO ( +24V TELE ROD DRAIN SOL. )
23 - SOCKET RECEPT 23 - PIN PLUG
K3 NC
K4 COM
13 14
K4 NO
13
K4 NC ( TELE OUT OF SEQUENCE )
K5 COM
4 3 2 1
17
K5 NO ( PROP EXT )
X1
A104
PV EXTENSION
18
K5 NC ( PROP RET )
K6 COM ( + 24V )
8
K6 NO ( +24V TO CM 2-WAY SOLS. )

7 10
K6 NC
K7 COM ( +24V )
BUS EXTENSION
RT865BXL (BCS)
WIRING DIAGRAM
K7 NO ( +24V TO OM 2-WAY SOLS. )
7 15
K7 NC
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
12 14
+ 24V
25
14 - SOCKET PLUG
1 4
4
A B C DE FG H J
1
(See Page 36.4)
2
1
K L
2
ANALOG INPUT 1 (IM LEN.)

2
1
2
ANALOG INPUT 2 (CM LEN.)

64 63
NOTES:
B
1 2 3 4 5 6 7 8 9 10 11 12 13 14
V V V V V VVVVVVV V V
M N P
2
1
27
GND
13
19 - SOCKET PLUG
3 5 9 10
6
DI 7 ( +24V = IM % RESET )
2
1
RELIEF CONNECTOR.
7
DI 6 ( +24V = IM RET )
12
DI 5 ( +24V = CM RET & % RESET )

2
1
DI 4 ( +24V = OM / FLY RET )

41 39 37 35
(See Page 36.4)
INNER SHIELD CUT AND INSULATED

OUTER SHIELD GROUNDED AT STRAIN
3 5 8 9 11
GROUPED
TOGETHER
= WIRES ARE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
V V V V V V V V V V VV VV VVV V V
B C
14 - SOCKET PLUG 19 - SOCKET PLUG
RT865BXL (BCS) 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
Cable Reels to IM & CM Section
V V V V V VVVVVVV V V V V V V V VVVVVVV V V
A B C DE FG H J K L M N P A B C DE FG H J K L M N P R S T U V
A B C DE FG H J K L M N P A B C DE FG H J K L M N P R S T U V
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
4 1 2 3 6 7 12 4 9 10 5 8 11 13 14 1 2 3 86 4 9 14 12 7 5 10 11 13
2
F 3
1
X1
30.4
X1
1 2 3 4 5 6 7 8 S 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 S 11 12 13 14 15 16 17 18 19
X3
X2
X3
X2
135 7 8 11 12 13 14 15 16 17 18 19 135 7 8 11 12 13 14 15 16 17 18 19
AGND
AGND
SIG.
SIG.
-5V
-5V
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11
LENGTH LG321 (TO IM)
LENGTH
LENGTH LG321 (TO CM)

LENGTH
TRANS. TRANS.
WHT
BLK
WHT/BLK
WHT
ORG
GRA
GRN
BLK
WHT/BLK
BRN
RED
ORG
GRA
BLU
GRN
BRN
YEL
RED
BLU
YEL
VIO
VIO
WHT/
WHT/
WHT
WHT
ORG
GRN
GRA
BLK
BLK
BRN
RED
BLU
ORG
GRN
GRA
BLK
BLK
YEL
BRN
RED
BLU
YEL
VIO
VIO
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
GRA
GRN
GRA
BLU
BRN
PNK
BLK
WHT
RED
GRN
BLU
YEL
PNK
BRN
BLK
WHT
RED
CRE
YEL
VIO
CRE
VIO
SHD
SHD
D E
JUNCTION
RED 1 = CM CYL (+)
BOX (CM) TIE WRAP
VIO RED = CM PILOT (+)
1 RED 1 USED TO IDENTIFY CABLE
BLK 1 = OM CYL (+)
YEL RED
2 BLK = OM PILOT (+)
PNK BLK 1
3 GRN 1 = CM CYL (-)
RED BLK GRN = CM PILOT (-)
4
BLK WHT 1= OM CYL (-)
5 GRN 1 PROXY SW 3 (TOP)
GRA GRN WHT = OM PILOT (-) (IM % RESET)
6
BLU WHT 1 BRN
7 1 (+)
CRE WHT PROXY SW 1 BLK O O
8 4 NO
SHD BLU (OM/FLY RETR) WHT
9 BRN 2 NC O O
BLK 1 (+) BLU
WHT 10 3 (-)
BRN BLK
E BRN 11 4 NO O O IS
GRN WHT O O
WHT 2 NC
IS BLU
3 (-) 3 BLU WHT
IS 6
BLU
5
4 BLK
JUNCTION 4
RED F 2
3
BLK
BOX (IM)
30.5
YEL BRN
BLU 2
RED 1 BRN
VIO 1 RED = IM CYL (+) 1
GRA BLK BLK = IM PILOT (+)
WHT
2 JUNCTION BOX
BLK GRN GRN = IM CYL (-)
3 BOOM BASE
CRE WHT WHT = IM PILOT (-)
4
SHD PROXY SW 4
D WHT BLU (CM RETR)
(IM RETR. 2-POSITIONS)
5 BRN
BRN BLK BRN 1 (+)
6 1 (+) BLK
GRN 4 NO O O
7 BRN BLK O O
4 NO WHT
2 NC O O
WHT O O
WHT 2 NC BLU
IS BLU 3 (-)
3 (-) IS
IS
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 it’s 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 it’s
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 it’s 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 operator’s 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
operator’s 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 operator’s 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.

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 it’s 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.

WHAT’S WRONG?
So, what’s 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 operator’s 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
!

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 CAN-Bus iFLEX5

Sensor Converter CU
Cable Reel
Pressure Transducer
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):

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 potentiometer’s 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:

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.

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 CAN-Bus iFLEX5

Sensor Converter CU
The
signal
runs
Cable Reel
Pressure Transducer from the length 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 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 pre-
loading on the reel. Opening the cable reel and locate the length sensor (right) and the CAN-Bus
converter board (left):

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)

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 potentiometer’s 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 Voltage GND to X20-3
X20-3
0 0.00 0.16
1 0.46 0.62
2 0.93 1.09
3 1.40 1.56
4 1.87 2.03
5 2.34 2.50
6 2.81 2.97
7 3.28 3.44
8 3.75 3.91
9 4.22 4.38
10 4.68 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.

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)
Pressure- CAN-Bus iFLEX5
Measuring Converter CU
Cells
The signal runs from the pressure transducer as

Pressure Transducer 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.

8 SLEWING SENSING
The system measures the slewing (rotational position) of the crane’s upper with a slewing sensor. The
slewing sensor is contained within the slip ring assembly.
Block Diagram
Slew
Potentiomet Current iFLEX5
er with (2) Converter CU
outputs
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 potentiometer’s outputs. Use the display screen
by pressing ‘i’ (info) twice to show all sensor inputs.
ANGLE SL ANG 1 SL ANG 2
The table to the right show measured millivolt reading for (deg) (mv) (mv)
the slew potentiotmeter. 0 717 2161
30.3 1174 2645
60 1680 3150
89.9 2158 3595
120.1 2641 3141
150.1 3144 2639
180 3595 2161
-150.1 3144 1681
-120.1 2642 1180
-90 2160 718
-60.1 1681 1168
-30 1172 1680
0 718 2161
Modular Slew Pot - Voltage on Service Screen

4000
3500
3000
MILLIVOLTS
2500
2000
1500
1000 Potentiometer 1
Potentiometer 2
500
0
0 45 90 135 180 225 270 315 360
Display screen 0 45 90 135 180 -135 -90 -45 0
for sensor inputs SLEW ANGLE

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 unit’s 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
16
mA
12
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 4…20mA 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.
9 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

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.

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.

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 Error in the CAN bus data transfer for all CAN units
E62 Error in the can bus data transfer of the pressure transducer sensor unit
E63 Error in the can bus pressure transducer sensor unit
E64 Error in the can bus data transfer of the length/angle sensor unit
E65 Error in the can bus length/angle sensor unit
Block Diagram
E65
CAN-Bus E64 E61 iFLEX5
Converter CU
E62
Cable Reel
Pressure Transducer
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 Shield

Pin 2 + Ub
Pin 3 Ground
Pin 4 CAN High
Pin 5 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.

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:

X1 Pin CAN
1 CAN_SHLD1
2 CAN +UB
3 CAN GND
4 CAN_H
5 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.

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 don’t 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 10
screen to return to the operating screen
.
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.

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 PSI Bar
500 0 0
1500 1088 75
2500 2176 150
3500 3263 225
4500 4351 300
Angle Sensor degrees

500 90 boom vertical
1500 67.5
2500 45
3500 22.5
4500 0 boom horizontal
Length Sensor feet

500 0 fully retracted
1500
2500
3500
4500
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

Troubleshooting A Sensor Problem Using The Display
SLEW POT SIGNALS:

Sig 1 (mA) Sig 2 (mA)
Reference Angle ±0.03mA ±0.03mA
0° 4.00 12.00
45° 8.00 16.00
90° 12.00 20.00
135° 16.00 16.00
180° 20.00 12.00
-135° 16.00 8.00
-90° 12.00 4.00
-45° 8.00 8.00
If the displayed angle is incorrect, please go to section Slewing Sensing

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)

BLOCK DIAGRAM
70 pin
Connector
RS 485
Serial Crane Power
Interface
Graphic iflex5 Central Unit

Console
Lockout
CAN-
BUS Current
4..20mA
CAN-connector
Slew Sensor
CAN-connector
CAN-connector
Dual Pressure Length/Angle Sensor A2B

ELECTRICAL SYSTEM DIAGRAM STANDARD SYSTEM
Central Unit to Crane and Console Wiring Diagram

Cable Reel (length/angle sensor) Wiring Diagram

Boom Extension Anti-two Block Wiring Diagram
MAIN CENTRAL UNIT CONNECTOR

This is a 70 pass connector.

ELECTRICAL SYSTEM DIAGRAM BOOM CONTROL SYSTEM
Central Unit to Crane Interface Wiring Diagram
1-1

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

Cable Reel (LG152/0056) Wiring Diagram
TO LWG520/0002 TO BOOM BASE CONNECTOR
REFER TO CABLE REEL LWG520/0002 REFER TO CONSOLE AND SENSOR
WIRING DIAGRAM WIRING DIAGRAM

Cable Reel (LWG520/0002) Wiring Diagram
TO PRESSURE TRANSDUCER BLOCK

REFER TO CONSOLE AND SENSOR
WIRING DIAGRAM
REFER TO LUFFING EXTENSION

LUFFING JIB CONNECTION
WIRING DIAGRAM
TO LG152/0056
REFER TO CABLE REEL
(LG152/0056) WIRING DIAGRAM

Luffer Extension Wiring Diagram
BOOM TIP CONNECTION

TO LWG520/0002
REFER TO CABLE REEL
(LWG520/0002) WIRING DIAGRAM

SPARE PART LISTINGS
CENTRAL UNIT, IFLEX5 PART NO. 9333103866

1 9333103890 1 CENTRAL UNIT ACCY, GROUNDING KIT
2 9333103891 1 BATTERY, LITHIUM 3V
3 9333102541 1 KEY SWITCH
4* 9333103908 1 CENTRAL UNIT COVER iFLEX
5* 9333101978 1 SCREW SET
6* 9333103058 1 SPARE KEY
7 9333101591 42” GASKET
* ITEM NOT SHOWN
1 2

Spare Part Listings
GRAPHIC CONSOLE ASSY, VERTICAL PART NO. 9333103868

1 9333101691 1 SPARE KEY, GRAPHIC CONSOLE
2 9333103895 1 KEYSWITCH, WITH CABLE
3 9333103892 1 FRONTFACE WITH DISPLAY, COMPUTER BOARDS, AND
LED BOARDS
4 9333103893 1 CONNECTION BOARD WITH BUZZER
5 9333103894 1 FUSE, 2 AMP AUTO
6 9333103899 1 CABLE, 4 POL COMPUTER BRD X1 TO CONN BRD X6,X11
7 9333103900 1 CABLE, 10 POL COMPUTER BRD X2 TO CONN BRD X7
8 9333103901 1 CABLE, 6 POL COMPUTER BRD X10 TO CONN BRD X23
9 9333103902 1 5 LED BOARD, LMI/A2B ALARM LITE
10 9333103903 1 8 LED BOARD, LED’S BY SELECTION BUTTONS
4
9
3
3
5
7
1,2
10 8

CABLE REEL, LWG508 PART NO. 9333103873

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
3
2
8 5
1
7
9
6
Also see detail on next page.

Spare Part Listings
5
6


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
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
4
6
9
7
5
10

Spare Part Listings

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
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 1
6
8
13
7

PRESSURE TRANSDUCER BLOCK, DAV314/0014 PART NO. 9333103870
CABLE ASSEMBLY 11M, PART NO. 9333103872
WIRING HARNESS STANDARD, PART NO. 9333103869

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

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.

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.

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 (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 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 -.

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.

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).

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. Cut old cable at cable drum.

2. Disconnect damaged length cable from junction box at the boom nose.
3. Open cable reel cover and disconnect bus connector.
4. Remove cable reel from mounting brackets.
5. Remove damaged length cable, which is mounted to the slip rings in the cable reel, from slip ring
terminal.
6. 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.
7. 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.
8. Reconnect the length cable to the slip ring.
9. Remount cable reel to the boom.
10. Turn reeling drum clockwise to spool the new cable neatly onto the drum.
11. Set pre-load on cable reel by turning the drum counter-clockwise 5 to 8 turns.
12. 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.
13. Connect the length cable into the boom tip junction box.
14. 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.
15. Connect bus connector
16. Follow Length Sensor Adjustment Procedure.

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.

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.

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.

P.A.T. – L.M.I
MANUAL
SECTION 35
Boom Control
IFLEX5 BOOM CONTROL SYSTEM (BCS)
RT9000E / RT800E BAS ICS
Terminology:
BCS = boom control system

IM = innermid boom section
CM = center-mid boom section
OM/Fly = outer-mid and fly boom section
DI = digital input, refer to table 3 for definitions
DO = digital output, refer to table 4 for definitions
PWM = pulse width modulation
0 = off with regard to digital inputs and outputs
1 = 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

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
2
Refer to table 2 for digital output definitions

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 Description *C.U. X2 **MP
Input Terminal
6 CM (Center-Mid) Retracted (boom proximity switch) 54 R89
7 IM (Inner-Mid) Retracted (boom proximity switch) 55 R90
8 Luffing Extension Raise (cab switch) 56 R91
9 Luffing Extension Lower (cab switch) 57 R92
10 Luffing Extension Raise (remote switch on ext.) 58 R93
11 Luffing Extension Lower (remote switch on ext.) 59 R94
16 “A” Mode (cab switch) 64 R100
17 Auto Mode (cab switch) 65 R101
18 Boom Retract (pressure switch) 66 R102
19 Boom Extend (pressure switch) 67 R103

RT9000E / RT800E IFLEX5 BCS DIGITAL OUTPUTS:
table 2
Digital Output Description C.U. X2 Terminal
1 PWM 1 CM Proportional Solenoid 2
2 +UB CAN bus 3
3 PWM 2 IM Proportional Solenoid 4
4 +UB to Slew Potentiometer Electronics 5
5 PWM 3 Luffing Extension Proportional Solenoid 6
6 CM Extend Relay K1 Coil in Junction Box 7
7 PWM 4 Luffing Extension Proportional Solenoid 8
8 IM Extend Relay K2 Coil in Junction Box 9
9 Luffing Extension Raise Solenoid 14
10 External LMI Alarm, Option on Boom 15
11 Luffing Extension Lower Solenoid 16
12 Rear Axle Oscillate Signal 17
13 Tele Rod Drain Solenoid 18
14 Boom Out of Sequence Lamp 19
15 Tele Two Stage Relief Solenoid 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

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
DO 16
DI 9
X:Exit Blank:Redraw S:Slow F:Fast DI 1
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

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:

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 = +27°C
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 Description
1 Slew Angle 1
2 Slew Angle 2
3 Wind Speed
5 Luffing Extension Offset Angle
PWM Description
1 Center-Mid Tele Output
2 Inner-Mid Tele Output
3 Luffing Extension Raise Output
4 Luffing Extension Raise Output
Note: DO 1 = PWM 1
DO 3 = PWM 2
DO 5 = PWM 3
DO 7 = PWM 4

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 / IM Tele Output

Luffer Status (0-255)
CM Tele Output Luffing Ext Raise

(0-255) Output
(0-255)
Luffing Offset
Angle(degrees)
Length 2 (IM)
(feet)
Status No. Description

1 - 11 Mode B extend
29 Error Mode B extend
31 - 41 Mode B retract
59 Error Mode B retract
61 - 67 Mode A extend
79 Error Mode A extend
81 - 85 Mode A retract
99 Error Mode A retract
100 Manual Mode A neutral or extend
101 Manual Mode B neutral or extend
102 - 108 Manual Mode retract at overload, A2B, error condition
110 Mode A, Out of Sequence
112 Mode B, Out of Sequence
127 Mode A or B, neutral position
200 - 202 Luffing jib raise
210 - 212 Luffing jib lower

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 IM retract sw. CM retract sw. Retract pressure sw.
(DO13) (DI 7) (DI 6) (DI 18)
0 1 1
0 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 Retract pressure Extend pressure OM/Fly IM rertract CM retract
Solenoid (DO15) sw. (DI 18) sw. (DI 19) Percentage sw. (DI 7) sw. (DI 6)
1 1
1 1 >4%
0 1 1

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 four–way 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.

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 Possible Cause Elimination

E01 Fallen below radius • Fallen below the • Luff down the boom to a
range or angle range minimum radius or gone radius or angle specified in
exceeded past the maximum angle the load chart.
specified in the respective
load chart due to luffing
up the boom too far
E02 Radius range • Gone past the maximum • Luff up the boom to a radius
exceeded or fallen radius or fallen below the or angle specified in the load
below angle range minimum angle specified chart.
in the respective load
chart due to luffing down
the boom too far
E03 Non-permitted slewing • The slewing zone with • Slew to permitted area
zone (no load area) load is not permitted
E04 Operating mode not • An incorrect operating • Set the correct operating
acknowledged or non mode has been selected mode for the operating
permitted slewing configuration in question.
zone Refer to Operator’s
Handbook.
• The boom is in a non- • Slew the boom to a

permitted slewing zone permitted area. Refer to
Section 8.
E05 Prohibited length • Boom has been extended • Extend/retract boom to the
range either too far or not far correct length
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
has changed, e.g. the prestress of the cable reel
cable slid off the length (cable must be taut). Open
sensor reel. the length sensor and
carefully turn the length
sensor pot counterclockwise
until the detent by means of
a screw driver
• Clutch between length • Replace the complete clutch
sensor pot and drive is including drive wheel and
defective adjust length sensor pot as
described above

E11 Fallen below lower • Length potentiometer is • Replace length
limit value for defective potentiometer, see
measuring channel section Length Sensing
"length main boom"
E12 Fallen below the • Pressure transducer is • Replace pressure
lower limit value in defective. transducer, see section
the measuring Pressure Sensing
channel "pressure
piston side"
E13 Fallen below lower • refer to E12 • refer to E12

limit value in the
measuring channel
"pressure rod side"
E14 Fallen below lower • Force transducer • Replace force
limit value in defective transducer
measuring channel • Electronic component in • Replace sensor unit
"force" the measuring channel is
defective.
E15 Fallen below lower • Angle potentiometer • Replace angle sensor,
limit value in defective see section Angle
measuring channel Sensing
"angle main boom"
• Electronic component in • Replace electronic

the measuring channel board, see section
defective. Angle Sensing
E16 Fallen below lower • Angle potentiometer • Refer to E-15
limit value in defective
measuring channel
"angle 2"
• Electronic component in • Refer to E-15

the measuring channel
defective.
E17 Fallen below lower • Length potentiometer • Replace length sensor,
limit value "length defective see section Length
telescope I (+II)" Sensing
• Electronic component in • Replace electronic

the measuring channel board, see section
defective Length Sensing
E18 Front outrigger • Front outrigger •
overloaded overloaded
E1A Fallen below lower • Cable between the • Check cable as well as
limit value in central unit and the plugs, replace, if need
measuring channel slewing angle sensor be.
"slewing angle 1". defective or loose.

• Slewing angle • Replace slewing angle
potentiometer is defective sensor
• Electronic component in • Replace sensor unit
the measuring channel
defective
E1B Fallen below lower • refer to E1A • refer to E1A
limit value in
measuring channel
"slewing angle 2"
E21 Upper limit value in • refer to E11 • refer to E11
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.
E2A Upper limit value in • refer to E1A • refer to E1A
measuring channel
“slewing angle 1”
has been exceeded
E2B Upper limit value in • refer to E1A • refer to E1A
measuring channel
“slewing angle 2”
has been exceeded
E31 Error in the system • The system program file • Upload valid system
program is defective. software
• Flash-EPROM defective Replace central unit

E37 Error in the logical • System program file is • Upload valid system
program flow defective software
• Flash-EPROM defective • Replace central unit

E38 System program • The system program in • Upload valid system
and crane data file the LMI does not match to program file or the valid
do not match. the programming in the crane data file
crane data file
E39 System program • The system program in • Upload valid system
and load chart file the LMI and the program file or the valid
do not match programming in the load load chart file
chart file do not match.
E43 Error in the • Write/read memory • Replace central unit
write/read memory, (RAM) or central unit
(RAM) defective.
E47 Error in the • The CRC sign of the • Restart the LMI
monitored write/ monitored write/read
read memory. memory is wrong
The CRC • The buffer battery is • Replace buffer battery

verification of the decharged (< 2V at on the central unit.
monitored 1kOhm).
write/read memory
provides an
incoherent result • Central unit defective. • Replace central unit
E51 Error in the crane • No valid data in the crane • Upload valid crane data
data file data file. file

E52 Error in load chart • No valid data in the load • Upload valid load chart
file. chart file file

E56 Error in crane data • No valid data in the crane • Restore or upload valid
file. data file during crane data file
calibration.

E57 Error in serial crane • Calibration data file does • Upload calibration data
data file. not contain valid data. file

E60 The number of the • No valid data in the load • Upload valid load chart
selected File base chart file file
and the
programmed value
are not identical
• Base number not • Program the correct
programmed base number (1 for
base 1, 2 for base 2)

• Load chart file wrongly • Check base
programmed programming in the load
chart file.
E61 Error in the CAN • CAN Bus cable between • Check the connection
bus data transfer for the central unit and the between the central unit
all CAN units sensor units defective or and the sensor units
not connected. (wiring harness). See
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
E62 Error in the can bus • Cable between the • Check the cable to the
data transfer of the central unit and the sensor unit (wiring
pressure transducer sensor unit defective or harness). See section
sensor unit not connected. CAN-Bus
Communication
• Sensor unit is defective • Replace the sensor unit
E63 Error in the can bus • The analog values of the • Replace the sensor unit
pressure transducer sensor unit are invalid See section CAN-Bus
sensor unit Communication.
E64 Error in the can bus • Cable between the • Check the cable to the
data transfer of the pressure transducer and sensor unit. See section
length/angle sensor cable reel defective or not CAN-Bus
unit connected. Communication
• Sensor unit is defective • Replace the electronic
board in the cable reel,
see section CAN-Bus
Communication
E65 Error in the can bus • Angle sensor defective • Replace the angle
length/angle sensor sensor, see section
unit CAN-Bus
Communication
• Length sensor defective • Replace the length
sensor, see section
CAN-Bus
Communication
• Sensor unit is defective • Replace the electronic
board in the cable reel,
see section CAN-Bus
Communication
E66 Error in the can bus • See E62 • See E62
data transfer of the
2nd length/angle
sensor unit
of the 2nd length
/angle sensor unit

data transfer of the
force sensor unit
force sensor unit
E80 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
E84 Wrong rigging • The selected rigging • Select another rigging
condition. condition is not contained condition
in the crane data file.
• Check the programming
in the crane data file.
E85 Error in the radius • The computed radius is • Check the programming
determination too small (negative in the crane data file.
deflection)
E89 Operating mode • The operating mode on • Select operating mode

switchover with the console has been without load on the
load. switched over with the boom
boom loaded.
E91 No data trans- • Power supply of the • Check power at terminal
mission form the console is interrupted X1 of the console
console to the electronics
central unit
• Interruption or accidental • Check the connection
ground in the line console electronics -
between console central unit. In case of
electronics and central an accidental ground,
unit the transmitter module
of the console
electronics might be
damaged.
• Transmitter/receiver • Exchange console
module of console is electronics or CU resp.
defective
E92 Error in the data • Loose connection in the • Check the connection
transmission from line between console between console
console to central electronics and central electronics and central
unit unit unit
module is defective electronics or CU resp.
E93 Error in the data • refer to E92 • refer to E92
transmission from
the central unit to
the console

E94 No data trans- • Interruption or accidental • Check line to the
mission from the ground in the line central console (in case of
central unit to the unit – console accidental ground,
console replace console
electronics, too).
module is defective electronics or CU resp.
• Computer module is • Exchange CU.
defective
• Electro-magnetic • Eliminate the source of
interferences (e.g. when interferences by inverse
switching contactors or diodes or varistors.
valves)
E95 Error in the console • The console File is • Replace the console
File defective. software
E96 Error in the internal • The CPU of the console • Replace console
RAM of the console. is defective. electronics.
• The console main board

is defective.
E97 Error in the external • The external RAM of the • Replace the external
RAM of the console console is defective. RAM of the console.
• The console main board • Replace the console

is defective. electronics.
EAB Short circuit in the • Short circuit in the A2B • Replace A2B switch
A2B switch circuit switch
• Short circuit in the cable • Replace cable to the

to the A2B switch A2B switch
EAC A2B switch circuit • Disconnected cable in the • Connect or replace
disconnected A2B switch cable in the A2B switch
• Disconnected cable to the • Connect or replace

A2B switch cable to the A2B switch
EAD No valid A2B switch • Sensor wrong function • Replace A2B switch
status
• CAN bus delay • Replace cable to the
A2B switch
EC0 Prohibited area • Boom is about to collide • Move boom to permitted
with the engine hood, area
switch off
EC1 Approaching • Boom is about to collide • Move boom to permitted

prohibited area with the engine hood, area
prewarning
Note:
If an error message is displayed which is not contained in above list, please contact the PAT service
department.

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.

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 air’s 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.

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 it’s 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.

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.

DATA TRANSFER FROM THE PC TO THE PALM
¾ Palm - Put Palm into the HotSync Cradle and turn it on.
¾ PC - Deactivate HotSync manager. If Hotsync manager is not deactivated, the program will
respond with an error, "unable to open specified port…"
¾ PC - Double click on iFLASH Desktop
¾ PC - Select the necessary serial interface (COM1, COM2,...)
¾ PC - Click on „Add File to Store...“
¾ PC - Select the file which you want to transfer and click "Open"

Software Transfer Instructions for the iFLASH Palm and Central Unit
¾ Palm - Start iflash

¾ Palm - Select File Store.
¾ Palm - Select Receive.
¾ Palm - palm will show "waiting for connection"
¾ PC - click on OK.
¾ PC - When the transfer is complete the following message will appear.
¾ Palm - "Transfer complete" will show on the palm.
The file should now be stored in the Palm.

DATA TRANSFER FROM THE PALM TO THE PC
¾ Palm - Put Palm into the HotSync Cradle and turn it on.
¾ PC - Deactivate HotSync manager. If Hotsync manager is not deactivated, the program will
respond with an error, "unable to open specified port…"
¾ PC - Double click on iFLASH Desktop
¾ PC - Select the necessary serial interface (COM1, COM2,...)
¾ PC - Click on „Refresh File List“

¾ Palm - Start iflash
¾ Palm - Select File Store.
¾ Palm - Select Send.
¾ Palm - palm will show "sending Filelist"
¾ PC - When the transfer is complete the window will be updated with the files from
the Palm file store.

¾ Palm - "Sending complete" will show on the palm.

¾ PC - Select the file you need and click „Retrieve marked File(s)“
After that you will get the following message:
¾ Palm - select „Receive“.

¾ PC 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.

TRANSFERRING SYSTEM, DATA OR TLK FILES FROM THE PALM TO THE
IFLEX5
¾ Connect the Palm with the iFLEX5 via its serial cable.
¾ Power the iFLEX system
¾ Select iFLASH program
¾ Select Settings. Note - The values are saved after the first time. This can be skipped later.
¾ Set Speed to: 9600
¾ Set Data Bits to: 8
¾ Set Parity to: N
¾ Set Stop Bits to: 1
¾ Select Save.
¾ Select Palm to iFLEX
¾ Select the file to be transferred from the file selection box.
¾ Select Start Transfer
Wait until all bytes have been transferred in the line „Progress“.
The data have been successfully transferred to the iFLEX5.

TRANSFERRING SYSTEM, DATA OR TLK FILES FROM THE IFLEX5 TO THE

PALM “
¾ Connect the Palm with the iFLEX5 via its serial cable.
¾ Power the iFLEX system
¾ Select iFLASH program
¾ Select Settings.
¾ Select Settings. Note - The values are saved after the first time. This can be skipped later.
¾ Set Data Bits to: 8
¾ Set Parity to: N
¾ Set Stop Bits to: 1
¾ Select Save.
¾ Select iFLEX to Palm
¾ Select the corresponding parameter data file in the displayed selection box. See parameter file
section.
¾ Select the file to be transferred from the file selection box.
¾ 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.
¾ Select Start Transfer
¾ 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 Æ 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 Æ 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.

DS350 Graphic Console Description, Connections & Wiring Diagram

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LEVEL II

DS350 Graphic (BCS)

DS350 Graphic Modular

14. DS350 Graphic Modular Console Connections,

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

16. DS350 Graphic Modular Boom Length

17. DS350 Graphic Modular Piston, Rod Connections

18. DS350 Graphic Modular Boom Angle Connection

19. DS350 Graphic Modular Anti - Two - Block

20. DS350 Graphic Modular Troubleshooting Guide

DS350 Graphic Modular (BCS)

21. DS350 Graphic Modular (BCS) Console

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

The information in this manual is subject to change without notice.

DS 350 GRAPHIC CONSOLE

DS 350 / 1319 GRAPHIC

The information in this document is subject to change without notice.

NORMAL OPERATION L/O OVERRIDE

5 CENTRAL MICRO PROCESSOR UNIT

In case of system malfunction an error code number

Interactive Basic system information for crane operator will be

Experienced operators who are familiar with the LMI

THE LMI SYSTEM IS AN

The operator is entirely responsible for safe crane operation.

The console has 3 functions:

4.3 Control Identification

Fig.2: Operating Console

3. Load Moment Prewarning Light

13. By-Pass Key Switch

10. i to display the system configuration.

This function serves for the contrast adjustment of the LC display.

The AUDIBLE ALARM sounds during the following

- The by-pass function shall be used with discretion, as unwarranted use

Machines with only a Main Hoist

Machines with Main and Auxiliary Hoists

Installation of Anti-Two-Block Retainer in Locking Position

Procedure (see Fig. 1 and 2):

Fig. 1 : Setting of Anti-Two-Block Fig. 2 : Retainer in Locking Position

Removal and Storage of the Anti-Two-Block Retainer

Procedure (see Fig. 3 and 4):

Fig. 3 : Removal of the Anti-Two- Fig. 4 : Retainer in Storage Position

Pre-Operation Inspection and Calibration Verification

2. Check the anti-two-block-switches and weights for free movement.

4. Check mechanical installation and electrical connection of the force transducer(s) on

If the light and audible alarm do not function as described

6. Service and Maintenance

Daily maintenance of the load moment indicator consists of inspecting:

Error Code Error

E01: FALLEN BELOW E01: ABOVE ANGLE

E02: RADIUS RANGE E02: BELOW ANGLE

E03: NO - LOAD AREA

E04: OPERATING MODE

E05: LENGTH RANGE

E06: BELOW JIB ANGLE E06: RADIUS RANGE

The range of the bargraph is divided into three areas: