PAT America, Inc.

Rheinmetall Elektronik

DS350 MODULAR
BOOM CONTROL EXTENSION
FOR
GROVE CRANE TMS/TTS 870

TROUBLESHOOTING MANUAL

P/N 031-300-190-061 Rev. B 02/12/01

031-300-190-061 Rev. B 02/12/01 // WB //

190061_B.doc

NOTICE

The information in this document is subject

to change without notice.
PAT makes no warranty of any kind with regard
to this material, including, but not limited
to, the implied warranties of merchantability
and fitness for a particular purpose.
PAT shall not be liable for errors contained herein
or for incidental or consequential damages in
connection with the furnishing, performance
or use of this manual.
This document contains proprietary information
which is protected by copyright. All rights are
reserved. No part of this document may be
photocopied, reproduced, or translated to
another language without prior consent of PAT.

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

TABLE OF CONTENTS

GENERAL INFORMATION
REFERENCE MATERIAL
SERVICE AND MAINTENANCE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Boom Control Interface

Getting Started
Boom length percentage problem
Boom out of sequence in auto mode
E83 - Outer mid and fly section are not retracted
E61 - Error in the bus extension
No tele function in auto mode
Proximity switch location and adjustment
Boom - LMI Hardware
Length transducer- Inner mid section
Length transducer- Center mid section
Length angle transducer- Overall boom length
Length transducer adjustment
Turntable - LMI Hardware
Boom control - bus extension
Electric wiring - Central unit
Electric wiring - Bus extension
Electric wiring Turntable
Electric wiring Lower
Electric wiring Boom
Console - Boom control data display Relay output logic for the two-way-valves

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1
2
3
4
5
6
16
26
31
33
39
40
41
42
43
44
45
46
47
48
49
50
51
53
54

190061_B.doc

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

GENERAL INFORMATION
This troubleshooting manual is designed to assist a service or maintenance person in
identifying LMI (Load Moment Indicator) problem areas or malfunctions. A digital
voltmeter with the capability to also measure current will be required. Regular
maintenance and service tools will also be required.
NOTE: Knowledge of how to use a voltmeter to measure both voltage and current is
assumed.
For system operation refer to the Operators Manual for the console. This may differ from
crane manufacturer and model.
Section 2 provides the drawings and reference material that will be used in the
troubleshooting flowcharts of this manual. Use the reference drawings in conjunction
with the flowcharts to help understand the operation of the system.
The PAT LMI DS 350 Modular with Boom Control Extension has been designed to provide
the crane with the essential information required to operate the machine within the
designed parameters.
Using different sensing devices, the DS 350 LMI monitors various crane functions and
provides the operator with a continuous display of the cranes capacity. The display
continually changes as the crane moves through the motions needed to make a lift.
The DS 350 Modular LMI provides the operator with information regarding the boom
length and boom angle of the main boom, working radius rated load and the total
calculated weight being lifted by the crane.

If non-permitted conditions are approached, the DS 350 LMI will warn the operator
by sounding an audible alarm and lighting a warning light. In addition the LMI
system has the capability to provide a signal to the solenoids and thereby locking
out those functions that may aggravate the cranes condition.

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

WARNINGS
The DS 350 load moment indicator (LMI) with boom control extension is an operational
aid that warns the crane operator when approaching an overload condition, a two block
condition and an out of boom sequence condition.
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.
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.
It still remains the operators responsibility to verify the operation and to select the correct
mode during crane operations.
The DS 350 Modular with boom control extension is not, and shall not, be a substitute for
good operator judgment, experience and use of accepted safe crane operating procedure
Proper functioning depends upon proper daily inspection and observance of the operating
instructions provided with the crane and load moment indicator.
The manual mode is a rigging mode. Lifting loads in manual mode 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 continuing the lift.

REFERENCE MATERIAL
Document
Parts & Installation Manual
Operators Manual

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PAT- Part number

031-300-150-713
50\350\19_1319e.doc

Grove- Part number

9-333-103628

190061_B.doc

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

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 must be under tension to operate properly.
5. Check the pressure transducers at the hoist cylinder(s) and the connecting hoses for oil
leakage.
Other than correcting the problems identified in the Malfunctions Table and replacing
faulty mechanical parts and cables, no other repairs shall be performed by non expert
personnel.

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031-300-190-061 Rev. B 02/12/01 // WB //

P1

P2

A1

Analog input
L1

LMI Console

Analog
input

Analog
output

Digital
output

AI
1

AI
2

AO1

K5

K4

K3

K2

K5
NO
K5
NC

K4

DI 7

DI 6

DI 5

DI 4

Prop.

OM- 2way solenoids

CM- 2way solenoids

IM- 2way solenoids

Prop. retract

Prop.extend

Out of sequence warning

Inner mid % reset

Inner mid retracted

Center mid retracted & % reset

OM/Fly retracted

Automode on

Boom retract

Crane
interface
connector

RxD
TxD

Boom
Control Bus
Extension

Digital
Input

DI 3

DI 2

DI 3

Boom extend

Crane interface
connector

DS 350 Modular
Central Unit

Digital Inputs

DI 1

DI 2

House pin engaged

on rubber over front

Piston pressure transducer

Rod pressure transducer

Angle sensor

Main boom length sensor

Inner Mid length sensor

Center Mid length sensor

OM- 2way solenoid valve

CM- 2way solenoid valve

IM- 2way solenoid valve

Out of sequence warning

light in cabin
Proportional pressure
reducing valve extend
Proportional pressure
reducing valve retract

Prox.switch on base section

Prox.switch on IM section
Prox.switch on base section

Prox.switch on CM section

Automode switch in cabin

P-switch retract pilot pressure

P-switch extend pilot pressure

House pin switch

On rubber - over front switch

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

1. BOOM CONTROL INTERFACE

Cable reel

190061_B.doc

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

2. GETTING STARTED
This section explains how to handle a problem that may arise with the PAT DS 350
Modular LMI boom control extension. The procedures are given in flowchart format for the
following sections. Start with the general flowchart below that will guide you to one of
the detailed flowcharts shown in Sections 1.1 to 1.7. The drawings that are referenced in
these sections can be found in Section 2.1 to 2.13.

Start

Boom length %
problem

Boom out of sequence

in Auto mode

E83
Outer mid/ fly section is
not fully retracted or
center mid section is
not fully extended.

E61
Error in the boom
control extension

Start with section 1.3

Start with section 1.4

Start with section 1.5

Start with section 1.6

No tele function at all in

automode

Start with section 1.7

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

3. BOOM LENGTH PERCENTAGE PROBLEM

Start

Boom length percentage problem

Switch to Manual Mode and retract the boom

completely against the stop block.
Check the percentage indication (1%,0%,0%).

Wrong?

No

Yes
IM and/ or CM retract signal not recognized. Check
proximity switch target adjustment. Refer to
section 2, drawing 2.1. If damage is visible install
new switch.

Correct?

Continue with section 1.4

No

Yes
Measure the voltage supply to IM switch at terminal
1(+24V) and 3 (GND) in the length transducer
LG 321 . Refer to section 2, drawing 2.3 and 2.8 to
2.12

Adjust the target and switch.

Refer to section 2, drawing 2.1

Continue on next
page

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

No
Correct?
Measure the voltage at terminal
25(+24V) and terminal 27 (GND) in the
bus extension unit.

Yes

Failure in bus extension.

Check connectors, fuses
and bus extension power
supply. Refer to section 2,
drawing 2.7 and 2.9.

No

Correct?

Yes

Faulty wiring between bus

extension and LG 321.
Check wiring. Refer to
section 2, drawing 2.7 to
2.12.

Continue on next
page

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

Measure voltage at terminal 1or 2 (+24V) and

5 or 6 (GND) in the switch junction box. Refer to
section 2, drawing 2.2 and 2.12.

No
Correct?

Yes
Measure the voltage at terminal 1 (+24V) and 5
(GND) in the inner mid junction box.
Refer to section 2, drawing 2.2 and 2.12.

Faulty wiring between length

transducer LG 321 and switch
junction box. Check wiring.

No
Correct?

Yes

Measure the IM reset switch signal at terminal 3

(+24V) and 5 (GND) in the proximity switch junction
box. Refer to section 2, drawing 2.2 and 2.12.

Faulty wiring between length

transducer LG 321 and inner
mid junction box. Check wiring.

Continue on next
page

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

No
Correct?

Yes

Measure the IM reset switch signal at wire 2

(+24V)(fast-on connector) and terminal 3 (GND) in the
length transducer LG321. Refer to section 2, drawing
2.3 and 2.12.

Faulty switch wiring or

defective switch. Replace IM
reset proximity switch. Adjust
switch and target. Refer to
section 2, drawing 2.1.

No
Correct?

Yes

Measure the IM retract switch signal at terminal 4

(+24V) and 5 (GND) in the switch junction box.
Refer to section 2, drawing 2.2 and 2.12.

Faulty wiring between length

transducer LG 321 and switch
junction box. Check wiring.

Continue on next
page

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10

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

Correct?

No

Yes
Measure the IM retract switch signal at wire 4 (+24V)
(fast-on connector) and 3 (GND) in the length
transducer LG321. Refer to section 2,
drawing 2.3 and 2.12.

Correct?

Faulty switch. Replace IM

retract proximity switch. Adjust
switch and target. Refer to
section 2, drawing 2.1.

No

Yes

Measure the CM retract switch signal at terminal 6

(+24V) and 5 (GND) in the inner mid junction box.
Refer to section 2, drawing 2.2 and 2.12.

Faulty wiring between length

transducer LG 321 and switch
junction box. Check wiring.

No
Correct?

Yes
Measure the CM retract switch Yes
signal at terminal 8
(+24V) and 3 (GND) in the length transducer LG321.
Refer to section 2, drawing 2.2, 2.3 and 2.12 .

Defective switch. Replace CM

retract proximity switch. Adjust
switch and target. Refer to
section 2, drawing 2.1.

Continue on next
page

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

No
Correct?

Yes
Measure the IM retract switch signal at terminal 39
(+24V) and 27 (GND) in the bus extension. Refer to
section 2, drawing 2.7 and 2.9.

Faulty wiring between length

transducer LG 321 and switch
junction box.
Check wiring.

No
Correct?

Yes

Measure the IM reset switch signal at terminal 41

(+24V) and 27 (GND) in the bus extension. Refer to
section 2, drawing 2.7 and 2.9.

Faulty wiring between bus

extension and length
transducer LG 321. Check
wiring.

Continue on next
page

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

No
Correct?

Yes
Measure the CM retract switch signal at terminal 37
(+24V) and 27 (GND) in the bus extension. Refer to
section 2, drawing 2.7 and 2.9.

No
Correct?

Faulty wiring between bus

extension and length
transducer LG 321. Check
wiring.

Yes

Measure OM retract switch power supply at terminal

X1/11 (+24V) and X1/7 (GND) in the LG 321 (CM).
Refer to section 2, drawing 2.2 and 2.8 to 2.12.

Continue on next
page

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

No
Correct?

Yes

Measure at CM junction box terminal 11 (+24V) and 9

(GND) . Refer to section 2, drawing 2.2 and 2.12.

Faulty wiring between bus

extension and length
transducer LG 321(CM). Check
wiring.

No
Correct?

Yes

Measure OM retract switch signal at CM junction

box terminal 10 (+24V) and 9 (GND). Refer to
section 2, drawing 2.2 and 2.8 to 2.12.

Faulty wiring between CM

junction box and length
transducer LG 321(CM). Check
wiring.

Continue on next
page

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

No
Correct?

Yes
Measure signal at terminal X1/8 (+24V) and X1/7
(GND) in the LG 321(CM). Refer to section 2, drawing
2.2 and 2.12.

Faulty wiring between bus

extension and length
transducer LG 321(CM). Check
wiring.

No
Correct?

Yes

Measure signal at bus extension terminal X1/35

(+24V) and X1/27 (GND). Refer to section 2,
drawing 2.7 and 2.9.

Faulty wiring between CM

junction box and length
transducer LG 321(CM). Check
wiring.

Continue on next
page

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

No
Correct?

Yes

Digital input defective on bus extension. Check

LED's on bus extension. Contact authorized service
for the replacement procedure.

Faulty wiring between bus

extension and length
transducer LG 321(CM). Check
wiring.

End

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

4. BOOM OUT OF SEQUENCE IN AUTOMODE

Start

Problem:
In Auto Mode 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
(should be 0%,0%,0%).

Correct?

No

Yes

Inspect the spooling of the length cable on both drums.

Continue with section 1.3

-Boom length (%) error-

No
Correct?

Yes
Remove the lid from the length (angle) transducer
LG 321 and LWG 309. Carefully reset the length
transducer potentiometer. Refer to section 2,
drawing 2.5 for instruction. Repeat testing the boom
sequence in automode.

Correct the spooling manually.

CAUTION:
Drum is under tension.

Continue on next
page

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17

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

Failed?

No

Yes
In manual mode retract the boom. Disengage the boom stop block to
retract all section completely. Re-check the length potentiometer
adjustment. Refer to section 2, drawing 2.5.

End

No
Correct?

Yes

Remove lid from LG321(IM length) and measure

supply voltage at terminal X1/1 (+24V) and X1/3
(GND).

Adjust gear assembly and check O-ring

in gear wheel. Replace O-ring if wear is
visible.

Continue on next
page

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

No
Correct?

Measure the voltage at terminal

X1/ 25(+24V) and terminalX1/27(GND)
in the bus extension. Refer to section 2,
drawing 2.9.

Yes

Failure in bus extension.

Check connectors, fuses
and bus extension power
supply. Refer to section 2
drawing 2.7.

No

Correct?

Yes

Continue on next
page

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Faulty wiring between bus extension

and LG 321 (IM). Check wiring.
Refer to section 2, drawing 2.8 to 2.12.

190061_B.doc

19

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

Turn the length potentiometer in the LG 321 (IM)

counter clockwise to a soft stop. Refer to section 2,
drawing 2.5.
Measure the voltage at terminal X1/2(1V) and terminal
X1/3(GND). Refer to section 2, drawing 2.3.

No
Correct?

Switch power off. Remove wire 2 from

LG 321 terminal X1/2. Switch power on.
Measure electrical current at terminal
X1/2(+ 4mA ) and X1/3 (GND).

Yes

Switch power off.

Re- connect wire 2 to
terminal X1/2.
Faulty length sensor unit.
Replace length sensor unit.
Refer to section 2,
drawing 2.3.

No

Correct?

Yes

Switch power off. Re -connect wire 2

to terminal X1/2.

Continue on next
page

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Faulty wiring between length transducer

LG 321 and bus extension. Check
wiring. Refer to section 2, drawing 2.3
and 2.8 - 2.12.

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20

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

Turn the length potentiometer 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).

Correct?

No

Yes

Switch power off. Remove wire 2 from LG 321

terminal X1/2. Switch power on. Measure
electrical current at terminal
X1/2(+ 20mA ) and X1/3(GND).

Switch power off.

Re- connect wire 2 to
terminal X1/2.
Defective length sensor
unit. Replace length
potentiometer assembly.
Refer to section 2,
drawing 2.3.

Remove lid from LG321(CM length) and measure

supply voltage at terminal X1/1 (+24V) and X1/3
(GND).

No

Correct?

Yes

Switch power off. Re -connect wire 2

to terminal X1/2.

Faulty wiring between length

transducer LG 321 and bus extension.
Check wiring.
No
Correct?

Yes
Continue on next
page

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Faulty wiring between bus extension

and LG 321 (CM). Check wiring.
Refer to section 2, drawing 2.8 to 2.12.

190061_B.doc

21

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

Turn the length potentiometer in the LG 321 (CM)

counter clockwise to a soft stop. Refer to section 2,
drawing 2.5.
Measure the voltage at terminal X1/2(1V) and terminal
X1/3(GND). Refer to section 2, drawing 2.3.

No
Correct?

Switch power off. Remove wire 2 from

LG 321(CM) terminal X1/2. Switch
power on. Measure electrical current at
terminal X1/2(+ 4mA ) and X1/3 (GND).

Yes

Switch power off.

Re- connect wire 2 to
terminal X1/2.
Faulty length sensor unit.
Replace length sensor unit.
Refer to section 2,
drawing 2.3.

No

Correct?

Yes

Switch power off. Re -connect wire 2

to terminal X1/2.

Continue on next
page

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Faulty wiring between length transducer

LG 321(CM) and bus extension. Check
wiring. Refer to section 2, drawing 2.3
and 2.8 - 2.12.

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22

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

Turn the length potentiometer 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).

Correct?

No

Yes

Switch power off. Remove wire 2 from LG 321

(CM) terminal X1/2. Switch power on.
Measure electrical current at terminal
X1/2(+ 20mA ) and X1/3(GND).

Switch power off.

Re- connect wire 2 to
terminal X1/2.
Defective length sensor
unit. Replace length
potentiometer assembly.
Refer to section 2,
drawing 2.3.

Remove lid from LG309(OM length) and measure

supply voltage at terminal X1/1 (+24V) and X1/3
(GND).

No

Correct?

Yes

Switch power off. Re -connect wire 2

to terminal X1/2.

Faulty wiring between length

transducer LG 321(CM) and bus
extension. Check wiring.
No
Correct?

Yes
Continue on next
page

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Faulty wiring between bus extension

and LG 321 (CM). Check wiring.
Refer to section 2, drawing 2.8 to 2.12.

190061_B.doc

23

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

Turn the length potentiometer in the LWG 309 counter

clockwise to a soft stop.
Measure the voltage at LWG 309 terminal X1/2(1V) and
terminal X1/3(GND). Refer to section 2, drawing 2.4.

No
Correct?

Switch power off. Remove wire 2 from

LWG 309 terminal X1/2. Switch power
on. Measure electrical current at
terminal X1/2(+ 4mA ) and X1/3 (GND).

Yes

Switch power off.

Re- connect wire 2 to
terminal X1/2.
Defective length sensor
unit. Replace length sensor
unit. Refer to section 2,
drawing 2.4.

No

Correct?

Yes

Switch power off. Re-connect wire 2

to terminal X1/2.

Continue on next
page

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Faulty wiring between length transducer

LWG 309 and central unit. Check
wiring. Refer to section 2,
drawing 2.8-2.12.

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24

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

Turn the length potentiometer in the LWG 309

clockwise to a soft stop (10 turns).
Measure the voltage at LWG 309 terminal X1/2(5.6V)
and terminal X1/3(GND). Refer to section 2,
drawing 2.4.

No
Correct?

Switch power off. Remove wire 2 from

LWG 309 terminal X1/2. Switch power on.
Measure electrical current at terminal
X1/2(+ 20mA ) and X1/3(GND).

Yes
Switch power off.
Re- connect wire 2 to
terminal X1/2.
Defective length sensor
unit. Replace length sensor
unit. Refer to section 2,
drawing 2.4.
Reset all length transducer
potentiometers. Refer to section 2,
drawing 2.3, 2.4 and 2.5. Select the
boom control data display. Refer to
section 2, drawing 2.13. Compare the
indicated IM length with the actual IM
length.

No

Correct?

Yes
Switch power off. Re-connect wire 2
to terminal X1/2. Refer to section 2,
drawing 2.4.

Faulty wiring between length transducer

LWG 309 and central unit.
Check wiring.
Continue on next
page

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25

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

Yes

Correct?

No

Fault is not located in the LMI circuit.

Follow the crane service instructions to
continue.

Faulty bus extension module.

Contact PAT- Technical Support for
instruction.

End

End

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26

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

5. [E83] OUTER MID AND FLY SECTION ARE NOT RETRACTING

Start

E83
Outer mid and fly section are
not fully retracted.

Switch to manual mode and

retract the outer mid section
fully.

E83 ?

No

Yes

Switch to automode and retract the boom (Caution:

Reduced load chart with E83).

Switch to automode and

continue normal crane
operation.

No
E83 ?

Yes

Visible check the position of the outer mid and fly

section.

Defect is not located in LMI

circuit. Refer to crane service
documentation to continue.

Continue on next
page

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27

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

Correct ?

No

Yes

Switch to manual mode and retract the

outer mid section fully.
Check the OM retract proximity switch and
target adjustment. Refer to section 2,
drawing 2.1.

Defect is not located in LMI

circuit. Refer to crane service
documentation to continue.

Correct?

No

Yes

No

Yes

Measure the voltage at terminal

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

Correct?

Switch to automode and continue

normal crane operation.

Adjust the switch and the target.

Refer to section 2, drawing 2.1.

Continue on next
page

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

Correct ?

No

Yes

Measure OM retract switch power supply at LG

321 (CM) terminal X1/11 (+24V) and X1/7
(GND). Refer to section 2, drawing 2.2 and 2.8
to 2.12.

Correct?

Defective bus extension. Check

connectors, fuses and bus extension
power supply. Refer to section 2,
drawing 2.7 and 2.9.

No

Yes

Measure OM retract switch signal at

CM junction box terminal 10 (+24V) and
9 (GND). Refer to section 2, drawing
2.2 and 2.8 to 2.12.

Faulty wiring between bus extension

and LG 321. Check wiring. Refer to
section 2, drawing 2.7 to 2.12.

Continue on next
page

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

No
Correct?

Yes
Measure signal at terminal X1/8 (+24V) and X1/7
(GND) in the LG 321(CM). Refer to section 2, drawing
2.2 and 2.12.

Defective wiring between bus

extension and length
transducer LG 321(CM). Check
wiring.

No
Correct?

Yes

Measure signal at bus extension terminal X1/35

(+24V) and X1/27 (GND). Refer to section 2,
drawing 2.7 and 2.9.

Defective wiring between CM

junction box and length
transducer LG 321(CM). Check
wiring.

Continue on next
page

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30

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

Correct?

No

Yes
Digital input defective on bus
extension. Check LED's on bus
extension. Contact authorized service
for the replacement procedure.

Defective wiring between bus

extension and length
transducer LG 321(CM). Check
wiring.

End

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

6. [E61] Error in the bus extension

Start

E61
Error in the bus extension

Check crane power, battery

voltage.

No
Correct ?

Yes

Measure the power supply at the bus extension

terminal X1/26(+24V) and 28(GND).

Correct?

Refer to the crane service

documentation to correct the
power failure.

No

Yes

Check bus extension fuse FX.

Faulty crane electric wiring.

Check wiring. Refer to
section 2, drawing 2.8 - 2.12.

Continue on next
page

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

Correct ?

No

Yes

Refer to section 2, drawing 2.8 and 2.9. Check the bus

cable wiring and connections between bus extension
and central unit.

Switch power off. Replace the fuse.

Switch power on and check again.

No
Correct?

Yes

Faulty bus extension. Contact

authorized service
representative for replacement
instruction.

If damage is visible replace the cable,

otherwise rewire and tighten the
connections.
Caution: Twisted pairs must remain
twisted.

End

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

7. No tele function at all in Auto mode

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

Remove lid from bus extension enclosure. Measure

crane power supply at
terminal X1/26 (+24V) and X1/28 (GND). Refer to
section 2, drawing 2.6, 2.7 and 2.8.- 2.12.

Malfunction is not related to LMI or

boom control extension. Consult
the crane service documentation.

No
Correct ?

Yes
Continue on next
page

031-300-190-061 Rev. B 02/12/01 // WB //

Faulty crane electric wiring. Refer to

section 2. drawing 2.8 - 2.12.

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34

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

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).
Refer to section 2, drawing 2.7 and 2.8.- 2.12.

No
Correct ?

Yes
Start the engine.Operate the retract control. Measure the
retract signal at bus extension terminal X1/31 (+24V)
and X1/28 (GND). Refer to section 2, drawing 2.7 and
2.8.- 2.12.

Faulty pilot pressure switch in the tele

extend pilot pressure circuit or crane
electric harness faulty. Refer to crane
documentation.

No
Correct ?

Yes

continue on next
page

031-300-190-061 Rev. B 02/12/01 // WB //

Faulty pilot pressure switch in the tele

retract pilot pressure circuit or crane
electric harness faulty. Refer to crane
documentation.

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35

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

Refer to section 2, drawing 2.13 and select the boom

control data display. Operate the extend control. The
ramp value for the appropriate section should increase
in steps from 0 to 255.

Correct?

No

Yes

Refer to section 2, drawing 2.13 and select the

boom control data display. Operate the retract
control. The ramp value for the appropriate
section should increase in steps from 0 to 255.
Repeat test using the extend control.

Faulty digital input 1 on bus

extension. Contact authorized
service to obtain replacement
instructions.

continue on next
page

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

Correct ?

No

Yes
Select manual mode. Retract all sections. Switch power off. Remove
wire 2 from the analog output bord terminal A104 X1/2 (IM). Switch
power on. Operate retract or extend control. Measure the electrical
current (mA) between the wire 2 (removed from terminal) and the
terminal X1/2. The signal should increase from 0 mA to approximately
800 mA .
Note: In the ramping area the value may be < 800 mA.

Correct?

Faulty digital input 2 on bus

extension. Contact
authorized service to obtain
replacement instructions.

No

Check the power supply to the

analog output module A104
(IM). Measure at terminal X1/1
(+24V) and X1/4(GND).

Yes

Faulty wiring in bus

extension. Refer to
section 2, drawing 2.7
and 2.8-2.12 to check the
wiring.

No
Correct?

Yes
Operate retract or extend
control.
Measure Voltage at terminal
A104 X1/2 (>0V) and X1/4.

continue on next
page

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continue on next
page

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37

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

Continuation

Defective analog output board

A104 (IM). Contact authorized
service representative for
replacement instructions.

No
Correct ?

Yes

Refer to section 2, drawing 2.14 (K2,K6,K7

logic table) to check the two way valve
operation.

Re- connect wire 2 to terminal A104 X1/2.

Operate the extend control.
Measure at bus terminal X1/14 (>0V)) and X1/28(GND).
Operate the retract control.
Measure at bus terminal X1/15 (>0V) and X1/28(GND).

Check fuse F5 in the bus

extension. If blown replace
fuse. Check relay K5.

No
Correct?

Yes

continue on next
page

031-300-190-061 Rev. B 02/12/01 // WB //

Faulty crane wiring or defective valve coil.

Contact authorized service representative.

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38

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

Continuation

No
Correct ?

Yes

Refer to section 2, drawing 2.14 and

measure the two way valve
signal (>/= +20V) at terminal 1or 2 (IM
junction Box) and terminal 1or 2 and 3
or4 (CM junction box)

Correct?

In the bus extension:

Check fuse F2 for relay K2 (IM 2 way valve).
Check fuse F6 for relay K6 (CM 2 way valve).
Check fuse F7 for relay K7 (OM 2 way valve).
Replace if blown. Refer to section 2,
drawing 2.7.

No

Yes

Faulty crane wiring or valve coil.

Refer to crane service Documentation.

Faulty wiring between bus extension and 2

way valve junction boxes on the IM and CM
section. Refer to section 2, drawing 2.8 - 2.14.
Check wiring.

END

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

8. Proximity switch location and adjustment

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

9. Boom Hardware -LMI

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41

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

10. Length transducer - inner mid section

Slipring-assembly
Length-potentiometer
Gearwheel
Terminal X1

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42

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

11. Length transducer - Center Mid section

Slipring-assembly
Length-potentiometer
Gearwheel
Terminal X1

To19 pin connector- connecting

boom and superstructure

To center mid
junction box
Drawing 2.3.2: LG 321- Center mid section

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

12. LENGTH ANGLE TRANSDUCER- OVERALL LENGTH

Angle sensor
Slipring assembly
Length potentiometer
Terminal X1

T o 7 p in c o n n e c to r - c o n n e c tin g
b o o m w ith s u p e rs tru c tu re

T o boom nose
ju n c tio n b o x

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44

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

13.

LENGTH TRANSDUCER ADJUSTMENT

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45

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

14. TMS/TTS 870 Turntable - LMI Hardware

Pressure Transducers

Boom control
bus extension
Console

Central unit
Crane electric
interface connection

Crane electric
interface connection

031-300-190-061 Rev. B 02/12/01 // WB //

Connect the turntable

hardware with the
boom hardware

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46

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

15. Boom Control - Bus Extension

Terminal X2
Analog output module

Analog input module

CPU - Module

Bus - extension

Terminal X1

Relay output fuse

F1 - F9

Drawing 2.7: Boom control bus extension

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47

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

16. Electric Wiring - Central Unit

To bus extension

To 8 pin crane
electric connector

To area def.
switch interface

To console

To piston side
pressure transducer

To rod side pressure

transducer

To 7 pin boom
base connector

Drawing 2.8: Electrical chematic

- Central Unit DS 350 (Modular)

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

17. ELECTRIC WIRING - BUS EXTENSION

To 23 pin crane
interface connector

To 14 pin boom
base connector

To 19 pin boom
base connector

To central unit

Drawing 2.9: Electrical Schematic - Bus extension

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DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

18. Electric Wiring - Turntable

To bus extension

To central
unit

To central
unit

Drawing 2.10: Electrical Schematic - Turntable

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50

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

19. Electric Wiring - Lower

To length angle
transducer LWG 309

To central unit

Boom base connector

To central unit

To central unit

Connector for
optional lightbar

To central unit

Console

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Drawing 2.11: Electrical Schematic - Lower

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51

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

20. Electric Wiring - Boom

To bus extension

To pair of inner mid two

way valve

Drawing 2.12.1: Electrical Schematic - Boom

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52

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

To bus extension
To central unit

To pairs of
two-way-valve

Drawing 2.12.2: Electrical Schematic - Boom

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53

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

21. Console Service Display

/ /

Press the two outer keys simultaniously to view

the boom control data. Press again to hide the
data.

Drawing 2.13: Console - Boom control data display

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54

DS350 - BOOM CONTROL EXTENSION TMS/TTS 870

22. RELAY OUTPUT LOGIC FOR TWO-WAY-VALVES

Relay
No.

Designation

2
6
7

Relay K2 on bus extension

Relay K6 on bus extension
Relay K7 on bus extension

Table A
out of sequence
IM ext/ret
CM ext/ret
OM ext/ret

Tele- Section

K2
0
0
1
1

IM two-way-valves
CM two-way-valves
OM two-way-valves

K6
0
1
0
1

K7
0
1
1
0

0 = no power output
1 = +24V output
Note: The two-way-valve must be powered to stop the section from moving and is
power-free when section is allowed to move.

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190061_B.doc