Manitou 120AETJ

7/21/2019 Manitou 120AETJ

1/106

REF : 547 363 EN (05 / 04)

ACCESSPLATFORM

120 AETJREPAIRS MANUAL

BP 249 Z. I.

44 158 ANCENIS CEDEX FRANCE

TEL : +33 (0)2 40 09 10 11

YOUR CONCESSIONAIRE

R


2/106

1st EDITION 06 / 2002

ISSUE DATE COMMENTS

06/2002 1st edition

11/2003 Updated

12/2003 Variable speed drive unit parameters modification

05/2004 Updated 35-8-21-M.84

80-6-M.84

80-8-11-M.84

80-8-85-M.84


3/106

CONTENTSCONTENTS

GROUPS SECTIONS MACHINES

0 General Points

0-1-M.84 EN Technical characteristics 120 AETJ

30 Reducer

30-2-63-M.84 EN Removing the wheel reducer / brake 120 AETJ

35 Steering Axle

35-8-21-M.84 EN Free-wheeling 120 AETJ

55 Arms - Platform

55-2-21-M.84 EN Removing the wear pads 120 AETJ

70 Hydraulics

70-2-52-M.84 EN Removing the distributor elements 120 AETJ

70-2-80-M.84 EN Removing the cylinders 120 AETJ

70-5-M.84 EN Hydraulic pressure 120 AETJ

70-6-M.84 EN Hydraulic layout 120 AETJ

80 Electricity

80-2-11-M.84 EN Removing the variable speed drive unit 120 AETJ

80-2-12-M.84 EN Removing the traction batteries 120 AETJ

80-2-13-M.84 EN Removing the electrical cable looms 120 AETJ

80-6-M.84 EN Electrical layouts 120 AETJ

80-8-11-M.84 EN Checking the operation of the Sevcon 120 AETJ

variable speed drive unit

0-1-M.84

30-2-63-M.84

35-8-21-M.84

55-2-21-M.84

70-2-52-M.84

70-2-80-M.84

70-5-M.84

70-6-M.84

80-2-11-M.84

80-2-12-M.84

80-2-13-M.84

80-6-M.84

80-8-11-M.84


4/106

CONTENTSCONTENTS

GROUPS SECTIONS MACHINES

80-8-85-M.84 EN Testing the manipulator 120 AETJ

80-8-86-M.84 EN Positioning and adjusting the contactors 120 AETJ

100 Troubleshooting

100-M.84 EN Troubleshooting 120 AETJ

80-8-85-M.84

80-8-86-M.84

100-M.84


5/106

GENERALPOINTS

GROUPS 0


6/106

0-1-M.84

TECHNICAL CHARACTERISTICS

120 AETJ

0-1-M.84 EN

11 / 2003


7/106

1

0-1-M.84


8/106

2

0-1-M.84

CHARACTERISTICS

ELECTRIC PUMP

- Electrical supply 48 V

- Output 3,7 KW

- Cubic capacity 4,8 cm3- Pressure 200 bars

ELECTRIC WHEEL MOTORS

- Type T 17 - 2 KW

ELECTRICAL CIRCUIT

- Battery 48 V - 300 Ah

- Charger 50 Ah (single-phase)

BOARD FUSES

- Motherboard : 10 A

- Output 325 A

- Electric pump 100 A

- Emergency pump 100 A


9/106

3

0-1-M.84

120 AETJ

SPECIFICATIONS

- Use Indoors Outdoors

- Capacity 230 Kg 120 Kg

i.e. i.e.

2 people 1 person

+wind 45Km/h

- Control system Electro-hydraulic

- Turret rotation 350

- Operating speed 0,6 km/h

- Transport speed 6 km/h

- Operating height 11950 mm

- Floor height 9950 mm

- Max off-centring 7000 mm

- Access platform weight

Empty 6550 kg

Under nominal load 6780 kg

- No. of gears 2

- Traversable gradient 25%

- Max permissible slope 5% or 3

TYRES

Tightening torque for the front and rear wheel nuts 19 daNm

LOAD PER UNDER MAX LOAD+ OFFSUPPORT SURFACE

DIMENSIONS TYPE TYRE EMPTY CENTRING ON 1 WHEELFOR 1 WHEEL ON GROUND

STAMPING

F R F / R

600 X 190 BANDAGE 1655 KG 1620 KG 4200 KG 212 CM2 20 DAN/CM2


10/106

4

0-1-M.84

DIMENSIONS

A1 5477

A2 3740

B 1200

C 2163

D 1650

E 104

F 2228

G 1550

H 3250

I 3340J 2138

120AETJ

H

G

I

J

F

A1

A2

D

C

E

B


11/106

5

0-1-M.84

K1 2483

K2 3242

K3 6506

K4 4353L1 9950

L2 8794

L3 4773

L4 595

K1

K2

L1

L2

K3

K4

L3

L4

3

2

1

4

5

6

7

8

9

10

11

12

2 2 3 4 81 0 1 5 6 7

2 2 3 4 85 6 7

120AETJ


12/106

6

0-1-M.84

FILTER ELEMENT

LUBRICANTS

COMPONENTS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING REFERENCE

HYDRAULIC OIL RSERVOIR 12 Litres MANITOU 20 L. 582 297HYDRAULIC OIL ISO 46 55 L. 546 108

209 L. 546 109

WHEEL MOTOR (EACH ONE) 0.8 Litre SHELL 2 L. 661 998SPIRAX OIL A90 20 L. 661 950

50 L. 661 950TURRET ROTATION MOTOR 1.5 Litres

GENERAL GREASING SHELL RETINAX HD cartridge 161 589GREASE 400 Gr.

BEARING TURRET RING GREASING SHELL ALVANIA EP LF 2 1 Kg 545 836GREASE

TURRET RING TEETH LUBRICATION SHELL MALLEUS GL 205 Aerosol 545 834OIL

DESCRIPTION REFERENCE REPLACE

1 - Hydraulic return oil filter cartridge 599004 Every 900 H

1


13/106

REDUCER

GROUPS 30


14/106

30-2-63-M.84

REMOVING THE WHEEL

REDUCER/BRAKE

120 AETJ

30-2-63-M.84 EN

11 / 2003


15/106

1

30-2-63-M.84

REMOVING THE WHEEL REDUCER / BRAKE

UP TO PLATFORM NO. 505578: REDUCER598694

- Set the lower arm to maximum for optimum accessibility.

- Raise the rear of the platform and place a wedge under the chassis.

- Remove the rear wheels 1 (Fig. A) (10 bolts, No. 19 spanner).

- Open the rear cover 2 (Fig. A) (4 bolts, No. 4 hex spanner).

- Mark and remove the electric motor power cables.

- Remove the electric motors 3 (Fig. B) (8 bolts, No. 9 hex spanner).

- Remove the brake control hoses 5 (Fig. C) (No. 19 spanner).

- Place a MA8S bung in each hose to prevent any oil leaks.

- Remove the reducers 4 (Fig. B) (16 bolts, No. 10 spanner).

RE-ASSEMBLY

- Same operations as above in reverse order.

FROM PLATFORM NO. 505579: REDUCER599538

- Same procedure as for removing reducer 598694.

RE-ASSEMBLY


When fastening reducers 599538, position the CHC M12x45 bolts at

the same level as the brake controls are installed on each reducer.

A

2

B

C

1

5

3

4


16/106

120

AETJ

10D

C4

0

P.A.O

20/06/03

REDUCTEURDEROUES

RADREDUKTION

REDUCTORDERUEDA

WHEELREDUCING

2

3

4

5

6

7

8

9

10

11

12

17

18

19

20

13

14

15

16

21

22

19

23

24

25

26 1

JUSQU'ALAM

ACHINE

BISDERMASCHINE

HASTALAMAQUINA

UPTOMACHINE

N:5055

78

2

-2-63-M.84


17/106

120

AETJ

10D

C4

6

P.A.O

20/06/03

REDUCTEURDEROUES

RADREDUKTION

REDUCTORDERUEDA

WHEELREDUCING

36

2

3

4

5

6

7

8

9

10

11

20

13

12

14

15

16

17

18

19

21

22

23

3

24

25

22

2627

282930

35

312932

1

3433

APARTIRDE

LAMACHINE

ABDERMASC

HINE

APARTIRDE

LAMAQUINA

FROMMACHINE

N:5055

79

3

30-2-63-M.84


18/106

STEERINGAXLE

GROUPS 35


19/106

35-8-21-M.84

FREE-WHEELING

120 AETJ

35-8-21-M.84 EN

05 / 2004


20/106

1

35-8-21-M.84

FREE-WHEELING

The platform may only be towed a short distance and only by a

machine with significant braking performance, in order to hold it: the

two machines must be connected by a tow bar.

- To set the platform to free wheel, it must not be subject to any trans-

lation stresses from slopes. The wheels must be able to turn freely.

- If possible, raise the platform to free the drive wheels in order to faci-

litate the operation.

- Loosen bolt 1 (Fig. A) on each wheel 22 mm from the edge, up to the

resistance point, without forcing it (20 Nm).

- The machine can be towed as a trailer.

Warning: do not loosen the bolt more than 22 mm,

otherwise it may break.

RE-INSTALLATION

- Turn the wheel gently from left to right to reset the gear while retigh-

tening the screws (1) (Fig. A). Pay attention to the torque when tigh-

tening (150 Nm).

A

1


21/106

ARMSPLATFORM

GROUPS 55


22/106

55-2-21-M.84

REMOVING THE WEAR PADS

120 AETJ

55-2-21-M.84 EN

11 / 2003


23/106

1

55-2-21-M.84

A - REMOVING THE TELESCOPE CYLINDER WEAR PADS........................... P 2

B - REMOVING THE TELESCOPE ARM WEAR PADS.................................. P 2

C - REMOVING THE MOBILE TUBE WEAR PADS....................................... P 2

INDEX


24/106

C1

2

-2-21-M.84 B1

A - REMOVING THE TELESCOPE CYLINDER WEAR PADS

- Remove the telescope cylinder: see the REMOVING THE TELE-

SCOPE CYLINDERsection.

- Remove the wear pads 1 (Fig. A1) (8 bolts, No. 10 spanner).

RE-ASSEMBLY


B - REMOVING THE TELESCOPE ARM WEAR PADS

- Remove the telescope cylinder: see the REMOVING THE TELE-SCOPE CYLINDERsection.

- Lift the basket with a hoist to relieve the pads.

- Remove the top of the jib pad fasteners 2 (Fig. B1) (16 bolts, No. 6

hex spanner).

- Pay attention to the position of the adjustment plates 3 (Fig. B1).

- Remove the pads.

RE-ASSEMBLY


- If necessary, position the adjustment plates:

Plates 3 (Fig. B1): see PR catalogue for reference.

C - REMOVING THE MOBILE TUBE WEAR PADS

- Remove the telescope cylinder: see the REMOVING THE TELE-

SCOPE CYLINDERsection.

- Lift the basket with a hoist to relieve the pads.

- Remove the upper and lower top of the jib pad fasteners 4 (Fig. C1)

(8 bolts, No. 19 spanner, No. 6 hex spanner).

- Pay attention to the position of the adjustment plates 5 (Fig. C1).

- Remove the pads.

- Remove the mobile tube mobile, holding the tube with a hoist and

the basket with a forklift truck.

A1

1

3

2

4

4

5


25/106

3

55-2-21-M.84

C2- Remove the base of the jib pads 6 (Fig. C2) (hammer, chisel).

- Pay attention to the position of the adjustment plates 7 (Fig. C2).

RE-ASSEMBLY

- Same operations as above in reverse order: the base of the jib pads

must be forcibly emmancher with a hammer.

- If necessary, position the adjustment plates:

Plates 7 (Fig. C2): see PR catalogue for reference.

6

7


26/106

120

AETJ

5BA2

40

P.A.O

12/04/02

FLECHE

TELESCOPIQUE

TELESKOPAUSELEGER

AGUILON

TELESCOPICO

TELESCOPIC

JIB

4

2423

19

20

3

202

1

22

45

44

1

2

12

13

12

14

16

15

18

42

24

23

5

26

25

2862

827

17

9

10

7

8

8

3132

43

33

34

35

41

40

39

36

3738

34

11

30

29

JUSQU'ALAMACHINE

BISDER

MAS

CHINE

HASTALAMA

QUINA

UPTO

MACH

INE

N:

505421

4

-2-21-M.84


27/106

HYDRAULICS

GROUPS 70


28/106

70-2-52-M.84

REMOVING THE DISTRIBUTOR

ELEMENTS

120 AETJ

70-2-52-M.84 EN

11 / 2003


29/106

1

70-2-52-M.84

REMOVING THE DISTRIBUTOR ELEMENTS

- Switch off the electrical power supply.

- Open the right-hand cover.

- Remove the hoses (Spanners Nos. 19, 24, 27, 30).

- Mark each solenoid 1 (Fig. A) (Adhesive and marker) according to the

writing on the yellow rings on the power cable looms and then remo-

ve the loom connectors 2 (Fig. A) (flat screwdriver).

- Remove the bolts 3 (Fig. B) (4 bolts, No. 17 spanner).

- Remove the element(s) requiring to be replaced (various flat and hex

spanners).

Before removing any hose or distributor component, operate the tap-

pets on the electro-valves by pulling and then pushing them in order

to decompress the circuit (Fig. C)

A

B

C

3

3

1

2


30/106

POURRE

P:12

FURHINW

:12

PARAFIG

:12

FORITEM

:12

POURREP:6

-10-11-13

FURHINW:6

-10-11-13

PARAFIG

:6

-10-11-13

FORITEM

:6-10-11-13

A7

B8

B9

B7

A9

A8

A6 7

8

T

PRESS.

F

A1

A2

T1

B1

B2

B3

B4

B5

23

E

A4

A5

A3

B6

M1

M2

POURREP:

6-10-11-12-13

FURHINW:

6-10-11-12-13

PARAFIG:

6-10-11-12-13

FORITEM:

6-10-11-12-13

120

AETJ

10D

A

213

P.A.O

12/04/02

DISTRIBUTEUR

KOMMANDOSTEUERVEN

TIL

DITRIBUIDOR

VALVE

BLANK

9

18

19

20

8

5

4 3 2

7

6

16

14

15

14

13

11

10

1

17

15

12

2

-2-52-M.84

1

Distributor

2

Plug

3

35-BAR

reducer

4

150-BA

R

restrictor

5

Main1

80-BAR

restrictor

6

Electro

-valve

7

Plug

8

180-BA

R

balancingvalve

9

80-BAR

overloadvalve

10

Electro

-valve

11

Electro

-valve

12

Electro

-valve

13

Electro

-valve

14

Non-re

turnvalve

15

Plug

16

100-BA

R

reducer

17

2-BAR

non-returnvalve

18

Soleno

id

19

Soleno

id

20

Connectionport

PLATFORMR

OTATION

SYSTEM

H18-H19

S

TEERINGS

YSTEM

EV1-EV5

ARM1

/2RAISINGS

YSTEM

EV6-EV7

T

ELESCOPEARMR

AISING

SYSTEM

EV8-EV9

TLESCOPE

EXTENSION

SYSTEM

EV10-EV11

PENDULARAR

M

EV12-EV13

BASKETTILTINGS

YSTEM

EV14-EV15

ANTI-ROLLOVER

BARS

H20-H21

BASKETROTATIONSYSTEM

H16-H17

EV2

EV3


31/106

70-2-80-M.84

REMOVING THE CYLINDERS

120 AETJ

70-2-80-M.84 EN

11 / 2003


32/106

1

70-2-80-M.84

A - REMOVING THE STEERING CYLINDER................................................P 2

B - REMOVING THE TELESCOPE CYLINDER.............................................P 4

C - REMOVING THE ANTI-ROLLOVER BAR CYLINDERS...............................P 6

INDEX


33/106

2

-2-80-M.84

A - REMOVING THE STEERING CYLINDER

- Raise the front of the platform and place a wedge under the chas-

sis.

- Remove the front wheels 1 (Fig. A1) (12 nuts, No. 30 spanner).

- Decompress the cylinder supply hoses: see the REMOVING THEDISTRIBUTOR ELEMENTSsection.

- Mark and remove the hydraulic hoses (No. 19 spanner).

- Remove the articulation shaft 2 (Fig. A2) (1 bolt, No. 13 spanner).

- Remove the articulation shaft 3 (Fig. A3) (2 circlips, circlips clamp).

- Remove the steering cylinder 4 (Fig. A3).

RE-ASSEMBLY


Remember to install the steering latch 5 (Fig. A2) before installing the

shaft 2 (Fig. A2).

A1

1

A2

2

A3

3

4

5


34/106

120

AETJ

10C

E

34

P.A.O

12/04/02

HYDRAULIQUE(Vrinde

direction)

HYDRAULIK(Lenkungzyli

nder)

HYDRAULICO(

Cilindrode

direccin)

HYDRAULIC(Steeringcyl

inder)

POCHETTE

DE

JOINTS

DICHTUNGSATZ

JUEGOD

E

JUNTAS

SEALKIT

FEDCBA

2

G

3

4

A

B

C

D

E

F

5

7 6

G

2

5mm

Course-Hub-Carrera-Stroke:179mm

1

3

70-2-80-M.84


35/106

4

-2-80-M.84

B - REMOVING THE TELESCOPE CYLINDER

- Raise the basket to access the cylinder foot axle 6 (Fig. B1).

- In horizontal position, extend the telescope enough to access the

articulation shaft 7 (Fig. B1).

- Wedge the basket in place with lifting equipment.

- Decompress the cylinder supply hoses: see the REMOVING THE

DISTRIBUTOR ELEMENTSsection.

- Remove the protective casing 8 (Fig. B1) (2 bolts, No. 10 spanner).

- Remove the articulation shaft 7 (Fig. A3) (2 circlips, circlips clamp).

- Remove the cylinder supply hoses 9 (Fig. B2) (No. 24 spanner).

- Remove the articulation shaft 6 (Fig. A2) (1 bolt, No. 13 spanner).

- Remove the telescope cylinder by extending the arm from the front

(Fig. B3).

RE-ASSEMBLY


The cylinder's chambers contain oil under pressure. To remove the

valve block, you must equalize the pressures by progressively uns-crewing the 4 bolts 10 (Fig. B3) (No. 6 hex spanner) and letting the

oil escape.

B1

7

B2

6

B3

9

6

8

10


36/106

120

AETJ

10C

C8

2

P.A.O

12/04/02

HYDRAULIQUE(Vrinde

tlescopage)

HYDRAULIK(Zusammens

trollzylinder)

HYDRAULICO(

Cilindrode

telescopaje)

HYDRAULIC(Telescopec

ylinder)

1

3

POCHETTE

DE

JOINTS

DICHTUNGSATZ

JUEGOD

E

JUNTAS

SEALKIT

FEDCBA

2

G

4

5

6

A

B

C

B

D

E

F

E

G

7

H

H

3

5mm

Course-Hub-Carrera-Stroke:1425

mm

5

70-2-80-M.84


37/106

6

-2-80-M.84

C - REMOVING THE ANTI-ROLLOVER BAR CYLINDERS

- Set the platform in transport position (Telescope retracted, arms in

low position).

- Remove the battery covers and the batteries: see the REMOVING

THE TRACTION BATTERIESsection.

- Decompress the cylinder supply hoses: see the REMOVING THE

DISTRIBUTOR ELEMENTSsection.

- Mark and remove the hydraulic hoses 11 (Fig. C1) (No. 19 span-

ner).

- Remove the articulation shafts 12 (Fig. C1) (8 circlips, circlips

clamp).

- Remove the cylinders 13 (Fig. C1).

RE-ASSEMBLY


C1

11

12

13


38/106

120

AETJ

10C

F

38

P.A.O

12/04/02

HYDRAULIQUE(Vrinde

stabilisation)

HYDRAULIK(Stabilizerzy

linder)

HYDRAULICO(

Cilindrode

estabilizador)

HYDRAULIC(Stabilizercy

linder)

1

POCHETTE

DE

JOINTS

DICHTUNGSATZ

JUEGOD

EJUNTAS

SEALKIT

FEDCBA

2

G

3

4

A

B

C

D

E

F

5

G

1

8mm

Course-Hub-Carrera-Stroke:116

mm

7

70-2-80-M.84


39/106

70-5-M.84

HYDRAULIC PRESSURE

120 AETJ

70-5-M.84 EN

11 / 2003


40/106

1

70-5-M.84

ADJUSTING THE HYDRAULIC PRESSURES

Most of the adjustments are made by two people: one works the

controls on the base console, the other adjusts the valves

- Open the right-hand cover 1 (Fig. A) and remove it.

Adjusting the anti-rollover bar pressure reducer (Hydraulic layout

No. 2).

- Switch the platform on.

- Connect the manometer to pressure port M2 (Fig. B).

- Raise the platform a few centimetres to release deployment of the

anti-rollover bars.

- Fully extend the telescope and hold down the extend control while

making the adjustment

- Adjust the tare on pressure reducer 2 (Fig. B) (No. 17 spanner, No. 4

hex spanner) to 40 bar.

- Disconnect the manometer and re-insert the bung.

Adjusting the pressure reducer (Hydraulic layout No. 7).


- Connect the manometer to pressure port M1 (Fig. C).



- Adjust the tare on pressure reducer 3 (Fig. C) (No. 13 spanner, No.

4 hex spanner) to 100 bar.


Adjusting the main relief valve (Hydraulic layout No. 10).


- Connect the manometer to pressure port M (Fig. D) on the distribu-

tor block.



- Adjust the tare on pressure reducer 4 (Fig. C) (No. 13 spanner, No.4 hex spanner) to 180 bar.


A

B

C

D

1

M2 2

M1

3

4

M


41/106

2

70-5-M.84

Adjusting the compensation / tilt balancing valve (Hydraulic

layout No. 17).

- Switch off the machine and disconnect the electrical circuit.

- Decompress the compensation / tilt control hoses: see the REMO-

VING THE DISTRIBUTOR ELEMENTSsection.

- Remove hose 5 (Fig. E) (No. 24 spanner) connected to A5.

- Insert a T connector (M/M/F12S) 7 (Fig. E) between hose 5 and

connection 6.

- Add a straight connector (M/F 16x150-12S) 8 (Fig. E) and then

connect the manometer 9 (Fig. E) to this.

- Switch the machine on.

- Raise the telescope arm 10 (Fig. F) to mid-stroke on the cylinder and

then extend the tilting cylinder 11 (Fig. F) to the maximum extent.

- Instruct the telescope arm to lower and check the pressure displayed

on the manometer during descent: the value must be 180 bars.

- If this is not the case, adjust the tare on the balancing valve 12 (Fig.

F) (No. 24 spanner, No. 17 spanner) to 180 bars.

- Switch off the machine, remove the manometer and then reconnect

hose 5 in its original configuration.

Adjusting the compensation / tilt sequencing valve (Hydraulic

layout No. 18).


- Decompress the compensation / tilt control hoses: see the REMO-

VING THE DISTRIBUTOR ELEMENTSsection.

- Remove hose 13 (Fig. G) (No. 24 spanner) connected to B5.

- Insert a T connector (M/M/F12S) 7 (Fig. E) between hose 13 and

connection 14.

- Add a straight connector (M/F 16x150-12S) 8 (Fig. E) and then

connect the manometer 9 (Fig. E) to this.


- Raise the telescope arm 10 (Fig. F) to mid-stroke on the cylinder and

then extend the tilting cylinder 11 (Fig. F) to the maximum extent.

- Raise the telescope and adjust the tare on balancing valve 15 (Fig.

F) (No. 13 spanner, No. 4 hex spanner) during ascent to 80 bars.

- Switch off the machine, remove the manometer and then reconnect

hose 13 in its original configuration.

E

F

G

5

78

6

9

12

10

11

9

15

8

7

14

13


42/106

3

70-5-M.84

Adjusting the pressure stat (Hydraulic layout No. 19).


- Open the right-hand turret cover.

- Remove the sealing screw 16 (Fig. H) (No. 3 hex spanner) located

between the terminals on the pressure stat 17 (Fig. H) to access the

setting screw.

- Remove hose 18 (Fig. I) (No. 24 spanner) connected to B6.

- Insert a T connector (M/M/F12S) 7 (Fig. I) between hose 18 and

connection 19.

- Add a straight connector (M/F 16x150-12S) 8 (Fig. I) and then

connect the manometer 20 (Fig. I) (Minimum capacity 250 bar) to

this and take the manometer into the basket.


- Instruct the platform to travel without operating the steering and

monitor the pressure displayed on the manometer (Fig. J):

- On start-up, a pressure spike of up to 210 bar.

- Rapid drop in pressure to below 100 bar.

- Slow drop and then very slow drop in pressure down to 20

bar.

- At 20 bar, pressure stat triggers and then the pump.

Pressure increases in the brake line. Pump and pressure

stat cut out.- Repeated at regular intervals.

- If the pressure stat triggers below 20 bar, adjust it by tightening the

setting screw to increase the trigger pressure.

- If the pressure stat triggers above 20 bar, loosen the setting screw by

several turns to proceed as described above:Adjustment is always

made by tightening the screw.

- Conduct a new travel test.

- When adjustment is complete, switch the machine off, reconnect

hose 18 in its original configuration and re-insert the sealing screw

16.

H

I

17

16

18

20

7

8

19

J

20bars

P(bar)

20

40

60

80

100

120

t(s)


43/106

70-6-M.84

HYDRAULIC LAYOUT

120 AETJ

70-6-M.84 EN

11 / 2003


44/106

1

70-6-M.84

HYDRAULIC LAYOUT


45/106

ELECTRICITY

GROUPS 80


46/106

80-2-11-M.84

REMOVING THE VARIABLE SPEED

DRIVE UNIT

120 AETJ

80-2-11-M.84 EN

11 / 2003


47/106

1

80-2-11-M.84

REMOVING THE VARIABLE SPEED DRIVE UNIT

UP TO PLATFORM NO. 505490

- Switch off the electrical supply and then disconnect the batteries: see

the REMOVING THE TRACTION BATTERIESsection.

- Open the rear cover (4 bolts, No. 4 hex spanner).

- Disconnect the cable connectors.

- Remove the two variable speed drive components 1 (Fig. A) (8 bolts,

No. 13 spanner)

RE-ASSEMBLY

- Perform the above-mentioned operations in reverse order.

FROM PLATFORM NO. 505491

- Switch off the electrical supply and then disconnect the batteries: see

the REMOVING THE TRACTION BATTERIESsection.

- Open the rear cover (4 bolts, No. 4 hex spanner).

- Remove the protective cover (Fig. B) (2 bolts, No. 10 spanner).

- Disconnect the cable connectors.

- Remove the two variable speed drive components 1 (Fig. A) (8 bolts,No. 13 spanner).

RE-ASSEMBLY


A

B

1

2


48/106

80-2-12-M.84

REMOVING THE TRACTION BATTERIES

120 AETJ

80-2-12-M.84 EN

11 / 2003


49/106

1

80-2-12-M.84

REMOVING THE TRACTION BATTERIES

UP TO PLATFORM NO . 505490: BATTERIES 598121

- Raise the platform a few centimetres to release the engagement of

the anti-rollover bars 1 (Fig. A).

- Switch off the electrical supply.

- Remove the left-hand and right-hand battery covers 2 (Fig. A) (4 but-

terfly bolts).

- Disconnect the cable looms connected to the + and - terminals (No.

16 spanner).

- Remove the battery fasteners 3 (Fig. B) (4 bolts, No. 12 hex span-

ner).

- Remove the batteries (individual weight: 248.5 kg) from their housing

using a hoist and slings fastened to the side flanges on the tank 4

(Fig. B) or using a forklift truck's forks.

RE-ASSEMBLY


FROM PLATFORM NO. 505490: BATTERIES599364

- Raise the platform a few centimetres to release the engagement of

the anti-rollover bars 1 (Fig. A).

- Switch off the electrical supply.

- Remove the left-hand and right-hand battery covers 2 (Fig. A).

- Disconnect the cable looms connected to the + and - terminals (No.

16 spanner).

- Remove the battery fasteners 5 (Fig. C) (4 bolts, No. 12 hex span-

ner).

- Remove the batteries (individual weight: 263 kg) from their housing

using a hoist and slings fastened to the side flanges on the tank 6

(Fig. C) or using a forklift truck's forks.

RE-ASSEMBLY


When re-assembling, remember to fit the cross-strut 7 (Fig. C) at the

back of the tank between the tank flange and the side of the chassis.

A

B

2

3

4

C

5

6

7

1


50/106

80-2-13-M.84

REMOVING THE CABLE LOOMS

120 AETJ

80-2-13-M.84 EN

11 / 2003


51/106

1

80-2-13-M.84

INDEX

A - LOCATION OF THE CABLE LOOMS.................................................... P 2

B - BASKET CONSOLE CABLE LOOM.................................................... P 3

C - MAIN BOX CABLE LOOM................................................................ P 6

D - BASE CONSOLE CABLE LOOM ..................................................... P 10

E - OTHER CABLE LOOMS................................................................. P 12


52/106

No. CABLE LOOM

1 Basket console

2 BUS CAN extension

3 Main box

4 Base console

5 Variable speed drive

6 Distributor

7 Overload cable loom

2

-2-13-M.84

A - LOCATION OF THE CABLE LOOMS

1

4

6

5

3

7

2


53/106

3

80-2-13-M.84

B - BASKET CONSOLE CABLE LOOM- 1

No. DESCRIPTION

J4 Clip pinH6 Overload light

H7 Slope light

H8 Travel light

H9 Arms 1/2 raising lightH10 Arm 3 raising light

H14 Tilt light

H15 Telescope light

H16 Pendular arm light

H17 Buzzer

S13 Travel switch

S14 Raising arms 1/2 switchS15 Raising arm 3 switch

S17 3-position selector

S18 Tilt switch

S19 Telescope switch

S20 Pendular arm switch

S21 Horn button

S22 Emergency Stop


54/106

4

-2-13-M.84

CABLE CONNECTION CONTACT DESCRIPTION

CAN 1 Spare

CAN 2 Spare

CAN 3 Spare

CAN 4 Spare

113 CAN 5 Info. Bus Can.


315 A-IN 1 Manipulator side analogue input 0V / 2.5V / 5V

318 A-IN 2 Manipulator longitudinal analogue input 0V / 2.5V / 5V

A-IN 3 Spare

A-IN 4 Spare

A-IN 5 Spare

A-IN 6 Spare

A-IN 7 Spare

A-IN 8 Spare

0 D-OUT 1 Spare

328 D-OUT 2 0V card - lower arm LED

327 D-OUT 3 0V card - upper arm LED322 D-OUT 4 0V card - telescope LED

321 D-OUT 5 0V card - pendular arm LED

D-OUT 6 Spare

323 D-OUT 7 0V card - compensation arm LED

D-OUT 8 Spare

D-OUT 9 Spare

D-OUT 10 Spare

D-OUT 11 Spare

D-OUT 12 Spare

329 D-OUT 13 0V card - travel LED

331 D-OUT 14 0V card - overload alarm LED

320 D-OUT 15 0V card - buzzer 330 D-OUT 16 0V card - slope LED

D-OUT 17 Spare

D-OUT 18 Spare

D-OUT 19 Spare

D-OUT 20 Spare

D-OUT 21 Spare

D-OUT 22 Spare

D-OUT 23 Spare

D-OUT 24 Spare

319 D-IN 1 0V manipulator trigger

D-IN 2 Spare

311 D-IN 3 0V travel switch

D-IN 4 Spare312 D-IN 5 0V overload contactor

316 D-IN 6 0V steer left switch

317 D-IN 7 0V steer right switch

306 D-IN 8 0V movement selector

310 D-IN 9 0V lower arm switch

309 D-IN 10 0V upper arm switch

304 D-IN 11 0V telescope switch

303 D-IN 12 0V pendular arm switch

305 D-IN 13 0V compensation switch

308 D-IN 14 0V movement selector (basket rotation)

307 D-IN 15 0V movement selector (turret rotation)

302 D-IN 16 0V horn

BASKET CONSOLE CABLE LOOM- CARD CONNECTIONS


55/106

5

80-2-13-M.84

CABLE CONNECTION COLOUR DESCRIPTION

311 S13/D-IN-3 YELLOW






121 S18/S20 YELLOW

121 S20/S19 YELLOW

121 S19/S15 YELLOW

121 S15/S13 YELLOW

121 S13/S14 YELLOW


121 S21/S17 YELLOW

121 S17/S17 YELLOW



308 S17/D-IN14 YELLOW331 H6/D-OUT-14 YELLOW

330 H7/D-OUT-16 YELLOW







106 J4-106/H14 RED

121 S18/S17 YELLOW

106 H14/H16 RED

106 H16/H15 RED106 H15/H10 RED

106 H10/H8 RED

106 H8/H9 RED

106 H9/H6 RED

106 H6/H7 RED


106 H17/J4-106 RED

106 J4-106/B+ RED

316 D-IN-6/P CLIPS 6V-2 YELLOW

317 D-IN-7/P CLIPS 6V-3 YELLOW

318 A-IN-2/P CLIPS 6V-4 YELLOW

319 D-IN-1/P CLIPS 3V YELLOW

103 NEG/P CLIPS 3V WHITE106 B+/P CLIPS 3V RED

315 A-IN-1/P CLIPS 6V-1 YELLOW

BRIDGE S17/S17 YELLOW

BASKET CONSOLE CABLE LOOM- CABLE ALLOCATION


56/106

6

-2-13-M.84

C - MAIN BOX CABLE LOOM- 3


57/106

7

80-2-13-M.84

No. DESCRIPTION

J2-107 Clip pin

J2-109 Clip pin

J2-111 Clip pin

J2-118 Clip pin

J4-103 Clip pin

J4-105 Clip pin

J4-106 Clip pinJ4-121 Clip pin

J4-123 Clip pin

KA3 24V relay

KA4 24V relay

KA5 24V relay

S4 Emergency pump switch


58/106

8

-2-13-M.84

CABLE CONNECTION CONTACT DESCRIPTION

CAN 1 Spare

CAN 2 Spare

CAN 3 Spare

CAN 4 Spare



A-IN 1 Spare

A-IN 2 Spare

A-IN 3 Spare

A-IN 4 Spare

A-IN 5 Spare

A-IN 6 Spare

A-IN 7 Spare

A-IN 8 Spare

D-OUT 1 Spare

227 D-OUT 2 0V card - lower arm electro-valve

231 D-OUT 3 0V card - overload LED226 D-OUT 4 0V card - upper arm electro-valve

220 D-OUT 5 0V card - anti-rollover arm output electro-valve

224 D-OUT 6 0V card - pendular arm electro-valve

D-OUT 7 Spare

221 D-OUT 8 0V card - turret rotation electro-valve

225 D-OUT 9 0V card - telescope electro-valve

228 D-OUT 10 0V card - KA3 raise / lower selection coil

219 D-OUT 11 0V card - jib rotation electro-valve

222 D-OUT 12 0V card - basket rotation electro-valve

D-OUT 13 Spare

223 D-OUT 14 0V card - compensation / tilt electro-valve

234 D-OUT 15 0V card - steer left electro-valve229 D-OUT 16 0V card - steer right electro-valve

101 D-OUT 17 Counting info - timer input 01

D-OUT 18 Spare

217 D-OUT 19 0V card - horn

218 D-OUT 20 0V card - rotating light

230 D-OUT 21 0V card - maintenance alarm LED

233 D-OUT 22 0V card - brake reservoir electro-valve

238 D-OUT 23 0V card - anti-rollover bar return electro-valve

235 D-OUT 24 0V card - KM3 steering pump coil

215 D-IN 1 0V jib rotation right switch

214 D-IN 2 0V lower arm raising switch

213 D-IN 3 0V lower arm lowering switch

212 D-IN 4 0V upper arm raising switch211 D-IN 5 0V upper arm lowering switch

208 D-IN 6 0V turret left rotation switch rotation

207 D-IN 7 0V turret right rotation switch rotation

205 D-IN 8 0V telescope retraction switch

206 D-IN 9 0V telescope extension switch

201 D-IN 10 0V compensation raising switch

202 D-IN 11 0V compensation lowering switch

209 D-IN 12 0V pendular arm raising switch

210 D-IN 13 0V pendular arm lowering switch

204 D-IN 14 0V basket left rotation switch

203 D-IN 15 0V basket right rotation switch

216 D-IN 16 0V jib left rotation switch

MAIN BOX CABLE LOOM- CARD CONNECTIONS


59/106

9

80-2-13-M.84


















102 PL-8/VARIABLE SPEED DRIVE YELLOW122 PL-5/VARIABLE SPEED DRIVE YELLOW

101 PL-1/D-OUT-17 YELLOW

121 S3/J4-121 YELLOW

104 S2/VARIABLE SPEED DRIVE YELLOW


106 J4-106 F. AV/J4-106 C. RED

230 D-OUT-21/CI 5002001 YELLOW


110 S2/CHARGER YELLOW

105 J4-105/CHARGER YELLOW


105 J4-105/S3 YELLOW228 D-OUT-10/KA3-A1 YELLOW

106 KA3-A2/J4-106 RED

106 KA3-11/J4-106 RED

235 D-OUT-24/VAR SPEED DRIVE YELLOW

117 KA4-14/VAR SPEED DRIVE YELLOW

118 J2-118/VAR SPEED DRIVE YELLOW



106 J4-106/J4-106 RED

106 J4-106 C./VAR SPEED DRIVE RED

103 J4-103/VAR SPEED DRIVE WHITE

103 J4-103/NEG. WHITE

112 CAN-6/VAR SPEED DRIVE YELLOW113 CAN-5/VAR SPEED DRIVE YELLOW

106 J4-106/B+ RED

103 KA4-A2/J4-106 WHITE

103 KA5-A2/J4-103 WHITE

103 KA5-11/J4-103 WHITE

BRIDGE KA5-14/KA4-11 YELLOW

103 KA4-A2/J4-103 WHITE

103 J4 121/J4 103 WHITE

S4/EMERGENCY PUMP WHITE

S4/EMERGENCY PUMP BROWN

MAIN BOX CABLE LOOM- CABLE ALLOCATION


60/106

10

-2-13-M.84

D - BASE CONSOLE CABLE LOOM- 4

No. DESCRIPTION

5002001 CRESTO CIRCUIT

J4 Clip pin

PL Timer S2 Emergency Stop

S3 3-position selector

S5 Turret rotation switch

S6 Telescope switch

S7 Pendular arm switch

S8 Jib rotation switch

S9 Basket rotation switchS10 Arms 1 / 2 raising switch

S11 Arm 3 raising switch

S12 Reverse tilt switch

S23 Dead man's switch


61/106

11

80-2-13-M.84


















242 S12/S5 YELLOW242 S5/S10 YELLOW

242 S10/S11 YELLOW

242 S11/S6 YELLOW

242 S6/S8 YELLOW

242 S8/S7 YELLOW

242 S7/S9 YELLOW

106 S3/S3 RED

102 PL-8/VARIABLE SPEED DRIVE YELLOW

122 PL-5/VARIABLE SPEED DRIVE YELLOW

106 PL-2/J4-106 RED

101 PL-1/D-OUT-17 YELLOW

106 J4-106/S3 RED121 S3/J4-121 YELLOW

108 S3/S23 YELLOW

242 S23/S12 YELLOW



106 J4-106 F. AV/J4-106 C RED

106 J4-106/CI 5002001 RED



110 S2/CHARGER YELLOW


105 J4-105/S3 YELLOW

BASE CONSOLE CABLE LOOM- CABLE ALLOCATION


62/106

12

-2-13-M.84

Bridge

Bridge

E - OTHER CABLE LOOMS

VARIABLE SPEED DRIVE CABLE LOOM- 5


63/106

13

80-2-13-M.84

DISTRIBUTOR CABLE LOOM- 6


64/106

80-6-M.84

ELECTRICAL LAYOUTS

120 AETJ

80-6-M.84 EN

05 / 2004


65/106

1

80-6-M.84

INDEX

A - POWER SECTION- SINGLE MANIPULATOR..........................................P 2

B - BASE CONTROL SECTION- SINGLE MANIPULATOR..............................P 4

C - BASKET CONTROL SECTION- SINGLE MANIPULATOR..........................P 6

D - POWER SECTION- DUAL MANIPULATOR............................................P 8

E - BASE CONTROL SECTION- DUAL MANIPULATOR...............................P 10

F - BASKET CONTROL SECTION1 - DUAL MANIPULATOR........................P 12

G - BASKET CONTROL SECTION2 - DUAL MANIPULATOR.......................P 14


66/106

2

80-6-M.84

A - POWER SECTION- SINGLE MANIPULATOR


67/106

3

80-6-M.84


68/106

4

80-6-M.84

B - BASE CONTROL SECTION- SINGLE MANIPULATOR


69/106

5

80-6-M.84


70/106

6

80-6-M.84

C - BASKET CONTROL SECTION- SINGLE MANIPULATOR


71/106

7

80-6-M.84


72/106

8

80-6-M.84

D - POWER SECTION- DUAL MANIPULATOR


73/106

677523

1

4

Lower arm Telescope retracted

9

80-6-M.84


74/106

10

80-6-M.84

E - BASE CONTROL SECTION- DUAL MANIPULATOR


75/106

120 AETJ

677523

Version 1

Page 2/4

11

80-6-M.84


76/106

Emergency stop 01

DEADMAN'S

JIB rotationselection

Basket rotationselection

Horn

SlopeOverloadalarm(red)

Interface2-axis

joystick

Left joystick A5

SQ5Overloaddetection

green

yellow (x)grey (y)

brownwhite

JIBrotation

Basketrotation

12

80-6-M.84

F - BASKET CONTROL SECTION1 - DUAL MANIPULATOR


77/106

120 AETJ

677523

Version 1 - Page 3/4

Horn Slopecut-out

Slope cut-outHorn

Pendular arm selectionTelescope selectionCompensation selectionJIB rotationTurret rotationBasket rotationUpper arm selectionLower arm selectionTranslation selectionOverloadOut-of NEUTRAL

+5V supplyRotation instructionsSteer leftSteer rightTraction instructionsDead man's

BuzzerPendular arm

TelescopeCompensation

JIB rotationTurret rotation

Basket rotationUpper armLower armTranslation

SlopeFaults/alarm

(Optional)(Optional)(Optional)(Optional)(Optional)(Optional)(Optional)(Optional)(Optional)

Pendular harmTelescopeCompensationJIBRotation

TurretRotation

BasketRotation

Upperarm

Lowerarm

TravelSlope

(All the LEDs are supplied with 24V)

13

80-6-M.84


78/106

Telescopselection

Compensationselection

Pendular armselection

Pendular

arms

election

Telescop

selection

Compensationselection

DEAD MAN's

Right joystick A7

Translationgreenyellowblueblackgreyvioletredpinkbrownwhite

Traction Out -of NEUTRAL (48V) DEADMAN's led

14

80-6-M.84

G - BASKET CONTROL SECTION2 - DUAL MANIPULATOR


79/106

Lower arm selectionTelescope selection

120 AETJ677523

Version 1 - Page 4/4

Pendular selection

Compensation selection

Travel selection

Out-of NEUTRAL

Steer leftSteer rightTraction instructions

Lower armselection

Lowerarms

election

15

80-6-M.84


80/106

80-8-11-M.84

CHECKING THE OPERATION OF THE

SEVCON VARIABLE SPEED DRIVE UNIT

120 AETJ

80-8-11-M.84 EN

05 / 2004


81/106

1

80-8-11-M.84

INDEX

A - VARIABLE SPEED DRIVE PARAMETERS..............................................P 2

B - TESTING THE VARIABLE SPEED DRIVE...............................................P 4

C - ERROR MESSAGES.........................................................................P 6

D - DIAGNOSTIC LED STATUSES............................................................P 7

E - USING THE CALIBRATOR.................................................................P 8


82/106

CalibratorReference CAN Name Description

MinimumValue

MaximumValue Step

ActualValue

1.1.1A 0 Armature I Max (A) 50 350 10 5001.1.1F 1 Field I Max (A) 10 50 1 50

1.1.2 2 Traction Accel Delay (s) 0.1 5.0 0.1 1.8

1.1.3 3 Traction Decel Delay (s) 0.1 5.0 0.1 0.1

1.1.3A 100 Traction Direction Decel Delay (s) 0.1 5.0 0.1 0.8

1.1.4 4 Traction Creep Speed (%) 0 25 1 3

1.1.5 5 Flat Regen Direction Braking (A) 50 350 10 400

1.1.6 91 Tilt Regen Direction Braking (A) 50 350 10 500

1.1.7 6 Traction Regen Time (ms) 0 300 10 10

1.1.8 7 Brake Threshold (V) 0,09 3,20 0,016 0.8

1.1.9 8 Traction Maximum Speed (%) 0 100 1 100

1.1.10 9 Elevated Speed (%) 0 100 1 12

1.1.11 10 Tilt Speed (%) 0 100 1 100

1.1.12 11 Traction Cut 3 Speed (%) 0 100 1 100

1.1.13 12 Review delay (h) 0 100 1 50

1.1.14 13 Customers Options 0 7 1 0

1.1.15 102 Low Speed Traction Speed (%) 0 100 1 100

1.1.16 16 Low Battery Start (V) 14.5 48.0 0.5 18.0

1.1.17 17 Low Battery Cutout (V) 14.5 48.0 0.5 14.5

1.1.18 18 High Battery Start (V) 14.5 75.0 0.5 65.0

1.1.19 19 High Battery Cutout (V) 14.5 75.0 0.5 70.0

1.1.20 20 Battery Protection Level (V) 14.5 48.0 0.5 14.5

1.1.21 21 Battery Protection Delay (s) 0.1 2.5 0.1 0.5

1.1.22 61 Traction Alarm


MinimumValue

MaximumValue Step

ActualValue

1.4.2 22 BDI Battery Voltage (V) 24 96 2 48

1.4.3 23 BDI Reset Level (V) 2.00 2.50 0.01 2.15

1.4.4 24 BDI Discharge Level (V) 1.50 1.99 0.01 1.73

1.4.5 25 BDI Warning Level (%) 0 90 1 30

1.4.6 26 BDI Cutout Level (%) 0 90 1 20


MinimumValue

MaximumValue Step

ActualValue

1.6.1 95 CAN Mode

1.6.2 39 Chop Select

1.6.3 40.3 BDI

1.6.4 40.1 Fault Log

1.6.5 40.2 Service Log

1.6.6 40.4 EU / US Functionality

1.6.7 94 Traction Full Speed (KPH) 0 160 1 21

1.6.8 Traction Full Speed (MPH) 0 100 0 13

1.6.9 101 Accelerator Characteristic


MinimumValue

MaximumValue Step

ActualValue

1.7.1 33 Armature I Low (A) 10 240 10 90

1.7.2 34 Field I Low (A) 5 25 1 6

1.7.3 35 Armature I Mid (A) 100 500 10 200

1.7.4 36 Field I Mid (A) 5 40 1 25

1.7.5 37 Armature I High (A) 260 350 10 400

1.7.6 38 Field I High (A) 25 50 1

1.7.7 44 Armature Resistance (mOhm) 0 255 1

1.7.8 45 Field Resistance (Ohm) 0,25 2.50 0.01

1.7.9 41 Drive Proportional Gain 0 255 1

1.7.10 42 Drive Integral Gain 0 16 1

On

EU

On

On

Aboma

On

On

Centre-Pot

1.7.11 43 Brake Proportional Gain 0 255 1

1.7.12 92 Brake Integral Gain 0 16 1

1.7.13 93 Speed Estimate Gain 0 2.50 0.01

40

13

1.26

4

8

40

15

1.5

2

-8-11-M.84

A - VARIABLE SPEED DRIVE PARAMETERS

Microprocessor W598800.007 : Single manipulator

Microprocessor W598800.008 : Dual manipulator


83/106

3

80-8-11-M.84

CalibratorReference

CAN Name Description MinimumValue

MaximumValue

StepActualValue

1.8.1 31 Display Default Hours

1.8.2 32 Display Status Type

1.8.3 30 Display Contrast 0 127 1 30

1.8.4 27 FFD Indicator 1

1.8.5 28 FFD Indicator 2

1.8.6 29 Display Fault Messages


MinimumValue

MaximumValue Step

ActualValue

2.1.1 46 Pump I Max 50 350 10 350

2.1.2 47 Ramp Up Delay 0.1 5.0 0.1 3.0

2.1.3 48 Ramp Down Delay 0.1 0.5 0.1 0.5

2.1.4 49 Pump Creep Speed 0 25 1 19

CalibratorReference CAN Name Description MinimumValue MaximumValue Step

Actual

Value

2.3.1 67 Boom 1 Up Speed (%) 0 100 1 90

2.3.2 68 Boom 1 Down Speed (%) 0 100 1 40

2.3.3 56 Boom 1 Cutback Speed (%) 0 100 1 100

2.3.4 69 Boom 2 Up Speed (%) 0 100 1 63

2.3.5 70 Boom 2 Down Speed (%) 0 100 1 39

2.3.6 57 Boom 2 Cutback Speed (%) 0 100 1 100

2.3.7 71 Jib Up Speed (%) 0 100 1 40

2.3.8 72 Jib Down Speed (%) 0 100 1 25

2.3.8A 103 Jib Rotate Left Speed (%) 0 100 1 1

2.3.8B 104 Jib Rotate Right Speed (%) 0 100 1 1

32 30

3032

2.3.9 73 Tele In Speed (%) 0 100 1 100

2.3.10 74 Tele Out Speed (%) 0 100 1 1002.3.11 75 Slew Left Speed (%) 0 100 1 32

2.3.12 76 Slew Right Speed (%) 0 100 1 32

2.3.13 98 Cage Rotate Left Speed (%) 0 100 1 32

2.3.14 99 Cage Rotate Right Speed (%) 0 100 1 32

2.3.15 96 Cage Level Forward Speed (%) 0 100 1 70

2.3.16 97 Cage Level Reverse Speed (%) 0 100 1 35

2.3.17 14 Y-Axis Forward Voltage (V) 0.00 5.00 0.02 4.06

2.3.18 15 Y-Axis Reverse Voltage (V) 0.00 5.00 0.02 0.52

2.3.19 50 X-Axis Left Voltage (V) 0.00 5.00 0.02 0.52

2.3.20 51 X-Axis Right Voltage (V) 0.00 5.00 0.02 4.06

100

40

100

59

35

100

36

22

100

10026

26

20

20

67

30

4.48

0.52

4.48

0.52

Key

Off

Off

Off

Off

WithoutJIB

WithJIB

With JIB


MinimumValue

MaximumValue

StepActualValue

Boom 1 Up Speed (%) 0 100 1 10090

100

100

70

25

90

75

100

100

60

60

50

60

50

50

50

Boom 1 Down Speed (%) 0 100 1

Boom 1 Cutback Speed (%) 0 100 1

Boom 2 Up Speed (%) 0 100 1

Boom 2 Down Speed (%) 0 100 1

Boom 2 Cutback Speed (%) 0 100 1

Jib Up Speed (%) 0 100 1

Jib Down Speed (%) 0 100 1

Tele In Speed (%) 0 100 1

Tele Out Speed (%) 0 100 1

Slew Left Speed (%) 0 100 1

Slew Right Speed (%) 0 100 1

Cage Level Forward Speed (%) 0 100 1

Cage Level Reverse Speed (%) 0 100 1

Cage Rotate Left Speed (%) 0 100 1

Cage Rotate Right Speed (%) 0 100 1

Overload Cutback Speed (%) 0 100 1

EPROM

W598800.007

EPROM

W598800.008

2.5.1 7778

58

79

80

59

81

82

83

84

85

86

87

88

89

90

60

2.5.2

2.5.3

2.5.4

2.5.5

2.5.6

2.5.7

2.5.8

2.5.9

2.5.10

2.5.11

2.5.12

2.5.13

2.5.14

2.5.15

2.5.16

2.5.17


84/106

4

-8-11-M.84

Calibrator reference



1.2.1

1.2.2

1.2.3

1.2.4

1.2.5

1.2.6

1.2.7

1.2.8

1.2.9

1.2.10

1.2.11

Battery voltage

Armature Motor voltage

Field Motor Voltage

Armature Motor Current

Field Motor Current

Armature MOSFET Voltage

Controller temp.

Capacitor Voltage

Speed estimation

Speed estimation

Speed estimation

0 V

Parameter displayed Setting Min

STATUS

TRACTION VARIATOR

PUMP STATUS

0 V

0 V

12:00 AM

12:00 AM

0 V

-30C

0 V

0% 100% 0.50%

0 KPH

0 MPH

1.0 KPH

1.0 MPH

60 KPH

60 MPH

127 V

Setting Max

127 V

127 V

64 A

625 A

127 V

+225C

127 V

1C

0.5 V

65279.9 Hrs

65279.9 Hrs

Output, EOutput

0.1 V

Step

0.5 V

0.5 V

5:00 AM

0.25 A

0.5 V

0.1 Hrs

0.1 Hrs

n/a

1.2.12 Key Switch Hours Count 0 Hrs

1.2.13 Traction Pulsing Hours Count (Drive) 0 Hrs

1.2.14 CAN fail node None

1.2.15 CAN error count - - -

1.2.16 CAN error code - - -

- Service Log Reset Press + followed by - to reset service log

+

Log info

+

+

+ -

1.3.1

1.3.2

1.3.3

1.3.4

1.3.5

1.3.6

1.3.7

1.3.8

1.3.9

1.3.10

1.3.11

1.3.12

1.3.13

1.3.14

1.3.15

1.3.16

1.3.17

1.3.18

1.3.19

1.3.20

1.3.21

1.3.22

Accelerator %

Accelerator voltage

Deadman

Joystick Forward

Joystick Reverse

Steer Left

Steer Right

Horn switch

Traction select

Tilt switch

Boom rest

8m high

Brake release

BDI Input

Frame fault

Drive Inhibit

Bars sens

Joystick NTRL switch

LS traction switch

Software

Controller Serial number

Controller type

range

Input displayed

range

switch

switch

switch

switch

switch

switch

switch

switch

switch

switch

switch

switch

switch

switch

switch

switch

switch

0 %

Setting Max

0.0 V

Open

Open

Open

Open

Open

Open

Open

Open

Open

Open

Open

Open

Open

Open

Open

Open

Open

xxxxxx

0

100 %

Step

5.0 V

Closed

Closed

Closed

Closed

Closed

Closed

Closed

Closed

Closed

Closed

Closed

Closed

Closed

Closed

Closed

Closed

Closed

xxxxxx

99999999

xxnnn

1 %

0.02 V

Log info

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

2.2.1

2.2.2

Battery voltage 0 V

Parameter displayed

127 V

Max displayMin display

0.1 V

Step size

+

Motor voltage 0 V 127 V 0.5 V

2.2.3 Motor current 12:00 AM 625 A 5:00 AM +

2.2.4 MOSFET voltage 0 V 127 V 0.5 V

2.2.5 Controller temp. -30C +225C 1C + -

- Service Log Reset Press + followed by- to reset service log

Log info

B - TESTING THE VARIABLE SPEED DRIVE


85/106

5

80-8-11-M.84

UPPER BOX TEST INFORMATION


2.4.1

2.4.2

Y axis joystick % Range

Input displayed

0%

Min display

100%

Max display

1%

Y axis joystick voltage Range 0.0 V 5.0 V 0.02 V

0.02 V

2.4.3 X axis joystick % Range 0% 100% 1%

2.4.4 X axis joystick voltage Range 0.0 V 5.0 V

2.4.5 Deadman Switch Open Closed -

Open Closed -

Open Closed -

Open Closed -

Open Closed -

Open Closed -

Open Closed -

Open Closed -

Open Closed -

Open Closed -

Open Closed -

Open Closed -

Open Closed -

Joystick Forward Switch2.4.6

Joystick Reverse Switch2.4.7

Steer Left Switch2.4.8

Steer Right Switch2.4.9

Traction select Switch2.4.10

Boom 1 select Switch2.4.11

Boom 2 select Switch2.4.12

Jib select Switch2.4.13

Tele select Switch2.4.14

Slew select Switch2.4.15

Cage level select Switch2.4.16

Cage rotate Switch2.4.17

Step size


86/106

Description & comments

Traction operational and OK.

Displayed briefly when the unit is swit-

ched on.

Wrong choice of calibration protocol.

The BDI has triggered a cut-out at the

programmed battery level.

Temperature of variable speed drive

higher than 75 - Let the drive cool down.

Accelerator activated when unit swit-

ched on.

Dead man's contact activated or joystick

pushed when machine switched on.

Two directions selected at the same

time.

Battery level lower than low battery

setting.

Battery level lower than low battery

setting.

Parameters set outside the range.

One or more settings have been corrupted.

A contactor coil is short-circuiting or

wrongly connected

MOSFET short-circuiting.

The modules are not communicating.

Line contactor contacts welded shut.

If one of these messages appears, the

variable speed drive has failed one of

its internal power auto-tests.

Calibrator display

OK

TESTING

PLEASE WAIT

BDI CUTOUT

THERMAL CUTBACK

ACCEL. FAULT

SEQUENCE FAULT

2 DIR. FAULT

BATTERIE LOW

BATTERIE HIGH

PERS ERROR

CRC ERROR

COIL S/C

MOSFET S/C

SYSTEM FAULT

P. UP TRAC. WELD

VARIOUS INTERNAL

CONTROLLER POWER

UP MESSAGES

Display

Stdt

RUN TESTS

BDI CUT

OVER TEMP.

ACCEL. FAULT

SEQ. FAULT

2 DIR. FAULT

BAT. LOW

BAT. HIGH

PERS ERRORF

CRC ERROR

COIL S/C

FET S/C

CAN FAULT

P. UP WELD

FAIL

Led

YES

YES

YES

7 F

8 F

6 F

2 F

2 F

7 F

7 F

1 F

1 F

9 F

3 F

12 F

OFF

OFF

Checks-Actions

No action required.

No action required.

Set the calibration protocol to "AUTO".

Charge the batteries.

Let the variable speed drive cool down -

Check its installation, the overall cleanli-

ness and the fan.

Release the dead man's contact - Check

the accelerator cable, personality acce-

lerator zero and max.

Release the dead man's contact and the

joystick - Check the dead man's signals

and the joystick's instructions.

Release the steering and dead man's

controls - Check the steering switch

cables.Release the dead man's control or the

reverser - Check the battery voltage and

charge.

Release the dead man's control or the

reverser - Check the battery voltage and

charge and whether B+ is connected.

Change the defective settings.

Check all the settings.

Switch off the machine - Check whether

the coils are short-circuiting, whether the

control is connected directly to B+ and

the cabling.Reset FS1 or the reverser to zero -

Check A, F1, F2, the B- cable and whe-

ther MOSFET is short-circuiting.

Switch off the machine- Check the BUS

CAN cable looms and connections.

Check the line contactor and the power

and control cable looms.

Contact SEVCON.

6

-8-11-M.84

C - ERROR MESSAGES


87/106

7

80-8-11-M.84

D - DIAGNOSTIC LED STATUSES

Led status Description

Illuminated No problem, conditions normal

Unlit Problem with the internal variable speed drive

1 Flashing Personality out of reach

2 Flashing Incorrect start-up sequence

3 Flashing MOSFET short-circuiting4 Flashing Power contactor short-circuiting or motor circuit open

5 Flashing Spare

6 Flashing Problem with accelerator, slave potentiometer

or sped sensor cable

7 Flashing Low/high battery voltage or BDI cut off

8 Flashing Temperature of variable speed drive too high

9 Flashing Coil contactor short-circuiting

12 Flashing BUS CAN connection fault


88/106

8

-8-11-M.84

E - USING THE CALIBRATOR

D1

SEVCON

CAN CALIBRATOR

Controller A

Menu

Value - +

Controller B

1

D2

2

1 Traction

OK

2 Pump

OK

Mise sous tension

1.1 Traction

Personalities

1.2 Traction

Status

1.3 Traction

Test

1.4 Traction

BDI

1.5 Traction

Fault Log

1.6 Traction

Setup

1.7 Traction

Motor Setup

1.8 traction

Display

1.1.1A Trac Pers

I. Max

1.1.1F Trac Pers

I. Max

1.1.2 Trac Pers

Accel

1.1.3 Trac Pers

Decel

1.1.4 Trac Pers

Creep Speed

1.1.5 Trac Pers

Flat Regen

1.1.6 Trac Pers

...

2.1 Pump

Personalities

2.2 Pump

Status

2.3 Pump

Upper Box Pers

2.4 Pump

Upper Box Test

2.5 Pump

Lower Box Pers

2.6 Pump

Lower Box Test

Switch on

DESCRIPTION

- The calibrator (Fig. D1) (Ref. 622813) is used to adjust and configu-

re the variable speed drive. It is also used as a diagnostic tool,

displaying the variable speed drive's various voltage, current and

temperature values and the status of all its inputs.

INSTALLATION

- Please refer to the section on REMOVING THE VARIABLE SPEED

DRIVEto access the electronic module.

- Locate the loom cable connected to 2 (Fig. D2) on the electronic

module; then take the calibrator's plug 1 (Fig. D1) and, depending

on the circumstances:

- Connect it to the spare socket on the loom.

- If the loom does not have a spare socket, slip the adaptor

cable (Ref. 677519) between the loom and the module's

connector and then connect it to the spare socket on this

cable.

CALIBRATOR MENU

- See the illustration below.


89/106

80-8-85-M.84

TESTING THE MANIPULATOR

120 AETJ

80-8-85-M.84 EN

05 / 2004


90/106

1

80-8-85-M.84

INDEX

A - SINGLE MANIPULATOR....................................................................P 2

B - DUAL MANIPULATOR.......................................................................P 4


91/106

A - SINGLE MANIPULATOR

With the calibrator

- Connect the calibrator (Ref. 622813) to the variable speed drive: see

Chapter CHECKING THE OPERATION FO THE SEVCON VARIA-

BLE SPEED DRIVE, paragraph USING THE CALIBRATOR.

- Climb into the platform's basket with the calibrator.

- Select menus 2-4-2 and 2-4-4 (UPPER BOX TEST) on the calibrator

and note the voltage values from the signals from the manipulator.

- Then select menus 2-3-17, 2-3-18, 2-3-19 and 2-3-20 (UPPER BOX

PERS) on the calibrator to adjust the limit values for the voltages deli-

vered by the manipulator.

- Lastly, select menus 2-4-1 and 2-4-3 (UPPER BOX TEST) on the

calibrator and check :

- That the proportional signal shows a good progression (i.e.

0 to 100%).

- That it shows 0% in Neutral and 100% only when the mani-

pulator arrives almost at the limit switch.

This procedure must be performed every time

the manipulator is replaced.

With a voltmeter

- Take the voltmeter and climb into the access platform's basket.

- Open the front of the basket console 3 (Fig. A1) (Flat screwdriver)

and then locate the wires (Fig. A2).

2

-8-85-M.84

A2

X

Y

3W

63V - 470f

+48V+24V0V

(ALIMENTATION - GACHETTE)

(GACHETTE HOMME MORT)

( + BATTERIE)

(COMMANDE ROTATION TOURELLE)

(ALIMENTATION - TRANSLATION)

(COMMANDE TRANSLATION)

(BP DIRECTION GAUCHE)

(BP DIRECTION DROITE)

(ALIMENTATION - BP DIRECTION)

BLEU

NOIR

GRIS (Y)

VIOLET

ROUGE

ROSEMARRON

BLANC

JAUNE (X)

ANCIENNENORME

JAUNE/NOIR

GRIS/NOIR

GRIS (Y)

VERT/NOIR

MARRON/NOIR

BLANC/NOIRMARRON

BLANC

JAUNE (X)

(HORS NEUTRE - MANIPULATEUR)VERT VERT

NOUVELLENORME

Menus 2-4-2 and 2-4-4

Signals from the manipulator

noted on the calibrator 0.5 2.5 4.5

Menus 2-3-17 to 2-3-20 0 0.52 2.5 4.48 5Min/ max calibration values

for the signals from the manipulator

OLD NEW

STANDART STANDART

GREEN GREEN (NEUTRAL POSITION - MANIPULATOR)

YELLOW (X) YELLOW (X) (TURRET ROTATION)

BLUE YELLOW/BLACK (STEER LEFT BUTTON)

BLACK GREY/BLACK (STEER RIGHT BUTTON)

GREY (Y) GREY (Y) (LONGITUDINAL AXIS)

VIOLET GREEN/BLACK (DEAD MAN'S TRIGGER)

RED BROWN/BLACK (POWER SUPPLY - TRIGGER)

PINK WHITE/BLACK (POWER SUPPLY - STEERING BUTTONS)BROWN BROWN (LONGITUDINAL AXIS)

WHITE WHITE ( + BATTERY)

A1

2

1

34


92/106

- Place the voltmeter's wands on the connector's clips to take the mea-

surements.

- To test the analogue outputs: work with the manipulator's casing 2

(Fig. A1) by moving it forwards, backwards, left or right and check the

values the voltmeter displays (Fig. A3).

- To test the logic outputs: operate the manipulator's dead man's pedal

1 (Fig. A1) and check the values the voltmeter displays (Fig. A4); then

press the manipulator's steering buttons 4 (Fig. A1) and check the

values the voltmeter displays (Fig. A5).

3

80-8-85-M.84

A4

MARRON

ROUGE

VIOLET

0V

V

0V

0V

ANCIENNENORME

VERT/NOIR

MARRON/NOIR

MARRON

NOUVELLENORME

MARRON

ROUGE

VIOLET

ANCIENNENORME

VERT/NOIR

MARRON/NOIR

MARRON

NOUVELLENORME

Gachette au

NEUTRE

Gachette

ACTIONNEE

A3

J (X)

MX

Y

0V

4.5V

GRIS (Y)

MARRON

JAUNE (X)

X

Y

0V

2.5V

2.5V

M

G (Y)X

Y

0V

4.5V

J (X)

M

X

Y

0V

0.5V

M

G (Y)X

Y

0V

0.5V

Manipulateur versL'ARRIERE - RECUL

Manipulateur GAUCHE

Rotation de tourelle GAUCHE

Manipulateur DROITE

Rotation de tourelle DROIT

NEUTRE

Manipulateur vers

L'AVANT - AVANCE

Manipulator toTHE REAR

REAR TRANSLATION

NEUTRAL

Manipulator FORWARD

FORWARD TRANSLATION

YELLOW (X)

GREY (Y)

BROWN

Y (X)

B

Y (X)

B

G (Y)

B

G (Y)

B

Manipulator to THE LEFT

LEFT TURRET ROTATIONManipulator to THE RIGHT

RIGHT TURRET ROTATION

Trigger in

NEUTRAL

OLD NEW

STANDART STANDART

VIOLET GREEN/BLACK

RED BROWN/BLACK

BROWN BROWNTrigger

ACTIVATED

OLD NEW

STANDART STANDART

VIOLET GREEN/BLACK

RED BROWN/BLACK

BROWN BROWN


93/106

"V" indicates that a random voltage can be measured

on the indicated wire.

4

-8-85-M.84

A5

MARRON

ROSE

BLEU (G)

0V

V

V

M M

R M/N

B (G) J/N

0V

0V

0V

0V

ANCIENNENORME

JAUNE/NOIR

BLANC/NOIR

MARRON

NOUVELLENORMEA. N. N. N.

M M

R M/N

NOIR (D) GRIS/NOIR N (D) G/N

A. N. N. N.

Direction

GAUCHE

NEUTRE Direction

DROITE

Steer

LEFT

OLD NEW

STANDART STANDART

BLUE (L) YELLOW/BLACK

BLACK (R) GREY/BLACK

PINK WHITE/BLACK

BROWN BROWNSteer

RIGHT

O. S. N. S.

B (R) G/B

P W/B

B B

O. S. N. S.

B (L) Y/B

P W/B

B BNEUTRAL


94/106

5

80-8-85-M.84

B - DUAL MANIPULATOR

With the calibrator

- Connect the calibrator (Ref. 622813) to the variable speed drive: see

Chapter CHECKING THE OPERATION FO THE SEVCON VARIA-

BLE SPEED DRIVE, paragraph USING THE CALIBRATOR.

- Climb into the platform's basket with the calibrator.

- Select menus 2-4-2 and 2-4-4 (UPPER BOX TEST) on the calibrator

and note the voltage values from the signals from the manipulator.

- Then select menus 2-3-17, 2-3-18, 2-3-19 and 2-3-20 (UPPER BOX

PERS) on the calibrator to adjust the limit values for the voltages deli-

vered by the manipulator.

- Lastly, select menus 2-4-1 and 2-4-3 (UPPER BOX TEST) on the

calibrator and check :

- That the proportional signal shows a good progression (i.e.

0 to 100%).

- That it shows 0% in Neutral and 100% only when the mani-

pulator arrives almost at the limit switch.

This procedure must be performed every time

the manipulator is replaced.

With a voltmeter

- Take the voltmeter and climb into the access platform's basket.

- Remove and open the basket console 5 (Fig. B1) (4 bolts, No. 4 hex

spanner) and then locate the wires:

- Connected to the manipulator 6 (Fig. B1 - B2) (Translation +

Steering).

- Connected to the manipulator 7 (Fig. B1 - B3) (Turret rotation

+ Upper arm).

Menus 2-4-2 and 2-4-4

Signals from the manipulator

noted on the calibrator 0.5 2.5 4.5

Menus 2-3-17 to 2-3-20 0 0.52 2.5 4.48 5Min/ max calibration values

for the signals from the manipulator

B1

5

7

9

8

6


95/106

6

-8-85-M.84

- Place the voltmeter's wands on the connector's clips to take the mea-

surements.

- To test the analogue outputs:

- Work with the manipulator's casing 6 (Fig. B1) (Translation

+ Steering) by moving it forwards, backwards and check the

values the voltmeter displays (Fig. B4).

- Work with the manipulator's casing 7 (Fig. B1) (Turret rotation

+ Upper arm) by moving it forwards, backwards, left or right

and check the values the voltmeter displays (Fig. B5).

B4

MG (Y)Y

0V4.5VMARRONGRIS (Y)Y 0V2.5VMG (Y)Y 0V

0.5V

Manipulateur vers

L'ARRIERE - RECUL

NEUTRE Manipulateur vers

L'AVANT - AVANCE

B3

X

Y

( + BATTERIE)

(ALIMENTATION)

(COMMANDE ELEVATION BRAS 3)GRIS (Y)

MARRON

BLANC

(COMMANDE ROTATION)JAUNE (X)

(HORS NEUTRE - MANIPULATEUR)VERT

B2

Y 3W

63V - 470f

+48V+24V0V

(ALIMENTATION - GACHETTE)

(GACHETTE HOMME MORT)

( + BATTERIE)

(ALIMENTATION - TRANSLATION)

(COMMANDE TRANSLATION)

(BP DIRECTION GAUCHE)

(BP DIRECTION DROITE)

(ALIMENTATION - BP DIRECTION)

BLEU

NOIR

GRIS (Y)

VIOLET

ROUGE

ROSE

MARRON

BLANC

ANCIENNENORME

JAUNE/NOIR

GRIS/NOIR

GRIS (Y)

VERT/NOIR

MARRON/NOIR

BLANC/NOIR

MARRON

BLANC

(HORS NEUTRE - MANIPULATEUR)VERT VERT

NOUVELLENORME


REAR TRANSLATIONNEUTRAL Manipulator FORWARD

FORWARD TRANSLATION

GREY (Y)BROWN

G (Y)B

G (Y)B

OLD NEW

STANDART STANDART

GREEN GREEN (NEUTRAL POSITION - MANIPULATOR)

BLUE YELLOW/BLACK (STEER LEFT BUTTON)

BLACK GREY/BLACK (STEER RIGHT BUTTON)

GREY (Y) GREY (Y) (LONGITUDINAL AXIS)

VIOLET GREEN/BLACK (DEAD MAN'S TRIGGER)

RED BROWN/BLACK (POWER SUPPLY - TRIGGER)

PINK WHITE/BLACK (POWER SUPPLY - STEERING BUTTONS)

BROWN BROWN (POWER SUPPLY - LONGITUDINAL AXIS)

WHITE WHITE ( + BATTERY)

GREEN (NEUTRAL POSITION - MANIPULATOR)

YELLOW (X) (TURRET ROTATION)

GREY (Y) (UPPER ARM)

BROWN (POWER SUPPLY)

WHITE ( + BATTERY)


96/106

7

80-8-85-M.84

- To test the logic outputs:

- Press the manipulator's steering buttons 8 (Fig. B1) and

check the values the voltmeter displays (Fig. B6); then ope-rate the manipulator's dead man's pedal 9 (Fig. B1) and

check the values the voltmeter displays (Fig. B7).

B6

V

V

0V

0V

0V0V

Direction

DROITE

Direction

GAUCHE

NEUTRE

ROSE

ANCIENNENORME

BLANC/NOIR

BLEU (D) JAUNE/NOIR

NOUVELLENORME

R

A. N.

B/N

B (D) J/N

N. N.

R

A. N.

NOIR (G) GRIS/NOIR 0V N (G) G/N

B/N

N. N.

B5

GRIS (Y)

JAUNE (X)

MARRON0V

BLANC48V

M0V

48V

2.5V

2.5V

Manipulateur vers L'ARRIERE

DESCENTE du bras (3)

Manipulateur vers la GAUCHE

Rotation de tourelle GAUCHE

Manipulateur vers la DROITE

Rotation de tourelle DROITE

NEUTRE

Manipulateur vers L'AVANT

LEVAGE du bras (3)

M0V

B48V

M

G (Y)

0V

4.5V

M0V

B48V

B

B48V

G (Y)0.5V

J (X)0.5V J (X)4.5V

Steer

LEFT

OLD NEW

STANDART STANDART

BLUE (L) YELLOW/BLACK

BLACK (R) GREY/BLACK

PINK WHITE/BLACK

Steer

RIGHT

O. S. N. S.

B (R) G/B

P W/B

O. S. N. S.

B (L) Y/B

P W/B

NEUTRAL


UPPER ARM LOWERING

NEUTRAL

Manipulator FORWARD

UPPER ARM RAISING

YELLOW (X)

GREY (Y)

BROWN

WHITE

Y (X)

B

W

Y (X)

B

W

G (Y)

BW

G (Y)

B

W

Manipulator to THE LEFT

LEFT TURRET ROTATION

Manipulator to THE RIGHT

RIGHT TURRET ROTATION


97/106

8

-8-85-M.84

"V" indicates that a random voltage can be measured

on the indicated wire.

B7

48V

V

0V

48V

0V

0V

Gachette au

NEUTRE

Gachette

ACTIONNE

ROUGE

BLANC

ANCIENNENORME

MARRON/NOIR

BLANC

VIOLET VERT/NOIR

ROUGE MARRON/NOIR

VIOLET VERT/NOIR

NOUVELLENORME

BLANC

ANCIENNENORME

BLANC

NOUVELLENORME

Trigger in

NEUTRAL

OLD NEW

STANDART STANDART

VIOLET GREEN/BLACK

RED BROWN/BLACK

WHITE WHITE

Trigger

ACTIVATED

OLD NEW

STANDART STANDART

VIOLET GREEN/BLACK

RED BROWN/BLACK

WHITE WHITE


98/106

80-8-86-M.84

POSITIONING AND ADJUSTING

THE CONTACTORS

120 AETJ

80-8-86-M.84 EN

11 / 2003


99/106

1

80-8-86-M.84

INDEX

A - POSITION OF THE SENSORS.............................................................P 2

B - ADJUSTING THE ANTI-ROLLOVER BARS OUTPUT SENSOR....................P 3

C - ADJUSTING THE SLOPE SENSOR......................................................P 3

D - ADJUSTING THE LOW ARM SENSOR..................................................P 4

E - ADJUSTING THE RETRACTED TELESCOPE SENSOR..............................P 4

F - ADJUSTING THE OVERLOAD SENSOR.................................................P 4


100/106

2

-8-86-M.84

A - LOCATION OF THE SENSORS

Retracted telescopesensor

Low arm sensor

Stabiliser outputsensor

StabilisersSlope sensor

Overload sensor


101/106

3

80-8-86-M.84

B - ADJUSTING THE ANTI-ROLLOVER BARS' OUTPUT SENSOR

UP TO PLATFORM No. 505490:

- Raise the platform a few centimetres to release full engagement of

the anti-rollover bars.

- Remove the left-hand and right-hand battery covers (4 butterflybolts).

- Unscrew the fixing screws 1 (Fig. B1) (2 screws, flat screwdriver).

- Trigger the sensors 2 (Fig. B1), one after the other, by placing them

in contact with the anti-rollover bar

- Re-tighten the screws.

- Check the setting by instructing the basket to rise: if its ascent is

interrupted, adjust the sensor setting.

FROM PLATFORM No. 505491:

- Raise the platform a few centimetres to release full engagement of

the anti-rollover bars.

- Remove the left-hand and right-hand battery covers (toggles).

- Unscrew the fixing screws 3 (Fig. B2) (2 bolts, No. 13 spanner).

- Trigger the sensors 4 (Fig. B2), one after the other, by placing them

in contact with the stabilising bar

- Re-tighten the bolts.

- Check the setting by instructing the basket to rise: if its ascent is

interrupted, adjust the sensor setting.

C - ADJUSTING THE SLOPE SENSOR

The slope sensors are preset by the manufacturer. The only

parameter that can be adjusted is the sensor initialisation.

- Set the platform on a horizontal surface and switch it on.

- Open the right-hand cover.

- Open the LEFT-HAND battery cover (butterfly bolts or toggles).

- Grasp the unconnected cable coming from the sensor.

- Remove the plastic cap from the end of the cable (flat screwdriver).

- Take an electric cable stripped at both ends and connect the slope

sensor cable to the battery's -24V terminal: the green LED under the

sensor flashes several times and then stops when the sensor is set.

B1

B2

2

1

4

3


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-8-86-M.84

D - ADJUSTING THE LOW ARM SENSOR

UP TO PLATFORM No. 505421:

- Set the platform in transport position (Telescope retracted, arms

lowered) and leave it switched on.

- Remove the protective cover 5 (Fig. D1) (2 bolts, No. 10 spanner)situated under the left-hand side of the intermediate joint 6 (Fig. D2).

- Loosen the lock nuts 7 (Fig. D1) (No. 24 spanner)

- Tighten or loosen the sensor 8 (Fig. D1) until the LED next to the

power supply cable switches from red to green.

- Re-tighten the lock nuts.

- Refit the protective cover.

FROM PLATFORM No. 505422

- Locate the sensor 9 (Fig. D2) between the two sides of the interme-

diate joint.

- Same procedure as for adjusting platforms UP TO PLATFORM No.

505421 except for removing and refitting the protective cover.

E - ADJUSTING THE RETRACTED TELESCOPE SENSOR

- Locate the sensor 10 (Fig. E1) located at the front between the two

counterweights.

- The follow the same procedure as forADJUSTING THE LOW ARM

SENSOR.

F - ADJUSTING THE OVERLOAD SENSOR

- Raise the basket 50cm above the floor in a horizontal position.

- Remove the protective cover 11 (Fig. F1) (2 bolts, No. 10 spanner).

- Place 250kg in the basket.

- Loosen bolt 12 (Fig. F2) (No. 14 spanner) until the overload sensor

13 (Fig. F2) triggers: the platform's alarm sounds.

D1

D2

E1

8

5

7

6

9

10

F1

11


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The contactor has a certain reaction time when the bolt is being

untightened. Stop at the limit for triggering the contactor.

- Relieve the weight on the basket: the platform's alarm no longersounds.

- Replace the weight in the basket: the platform's alarm sounds.

- Refit the protective cover.

5

80-8-86-M.84

F2

12

13


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TROUBLESHOOTING

GROUPS 100


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100-M.84

TROUBLESHOOTING

120 AETJ

100-M.84 EN

11 / 2003


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TROUBLE SHOOTING

Manitou 120AETJ

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