Manitou 150 AETJ L Repair Manual Download

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HYDRAULIC

547379EN

70 (08/03/2017)

ARM 3 LIFTING CYLINDER - REMOVAL

- Raise the arm 1/2 so that the upper hinge (1

, 070 - 48

) is raised by

1m (39.37 in).

- Switch off the power supply.

- Secure the basket and arm 3 with a hoist (2

, 070 - 48

) and a sling

(stabilize with a support):

- 120 AETJL :

580 kg (1279 lbs)

- 150 AETJC - 150 AETJL - 150 AETJC 3D - AETJ 43 - AETJ 43 3D:

650 kg (1433 lbs)

- 170 AETJL - AETJ 49 :

900 kg (1984 lbs)

- Open the right-hand turret cover.

- Decompress the lifting line of arm 3 (distributor) (

70.3.10

DISTRIBUTOR - REMOVAL,

)

- Remove and plug the hoses connected to the cylinder (1

, 070 - 49

- Remove the pivot pins from the cylinder, starting with the cylinder

foot pivot pin (2

, 070 - 49

) and remove the cylinder:

- 120 AETJL :

30 kg (66 lbs)

- 150 AETJC - 150 AETJL - 150 AETJC 3D - 150 AETJL - AETJ43 -

AETJ 43 3D - 170 AETJL - AETJ 49:

50 kg (111 lbs)

NOTE

: Before attempting to disassemble the removed cylinder

(

VALVE BLOCKS AND VALVES - REMOVAL,

)

REFIT

- Lower arm 3 to the transport position.

- Raise arm 3 to its maximum extent and repeat these operations

several times

70 - 48

70 - 49

Summary of Contents for 150 AETJ L

Page 1: ...50 Ancenis FRANCE Share capital 39 548 949 euros 857 802 508 RCS Nantes Tel 33 0 2 40 09 10 11 www manitou com REPAIR MANUAL MANUEL DE RÉPARATION REPARATURANLEITUNG MANUAL DE REPARACIÓN MANUALE RIPARAZIONE This document has been printed from e doc my ...

Page 2: ...tellungen Ansichten Kommentare Hinweise und der Aufbau der Druckschrift selbst die in der vorliegenden Dokumentation enthalten sind sind geistiges Eigentum von MANITOU BF Alle Verstöße gegen das Vorstehende können zu straf oder zivilrechtlicher Verfolgung führen Die Logos und Markenzeichen sowie Unternehmens und Produktbezeichnungen sind Eigentum von MANITOU BF und dürfen ohne ausdrückliche Genehm...

Page 3: ...TJ 43 3D 150 AETJL170 AETJL AETJ 49 1 GENERAL INSTRUCTIONS AND SAFETY NOTICE GROUP 00 GENERAL CHARACTERISTICS AND SAFETY 3 1 AXLE ASSEMBLY AXLE GROUP 30 AXLE 4 1 FRONT ARMS GROUP 55 JIB BASKET 5 1 HYDRAULIC GROUP 70 HYDRAULIC 6 1 ELECTRICITY GROUP 80 ELECTRICITY 7 1 ...

Page 4: ...547379EN 08 03 2017 120 AETJL 150 AETJC AETJ 43 150 AETJC 3D AETJ 43 3D 150 AETJL 170 AETJL AETJ 49 REPAIR MANUAL ...

Page 5: ...ead office 430 Rue de l Aubinière 44150 Ancenis FRANCE Share capital 39 548 949 euros 857 802 508 RCS Nantes Tel 33 0 2 40 09 10 11 www manitou com This manual is for information purposes only Any reproduction copy representation recording transfer distribution or other in part or in whole in any format is prohibited The plans designs views commentaries and instructions even the document organizat...

Page 6: ...JIB BASKET GENERAL CHARACTERISTICS AND SAFETY ENGINE TRANSMISSION AXLE BRAKE HYDRAULIC ELECTRICITY DRIVER S CAB FRAME BODY OPTIONS ATTACHMENTS 00 20 30 40 70 80 85 90 110 55 10 ...

Page 7: ...INTERACTIVE REPAIR MANUAL 4 547379EN 08 03 2017 ...

Page 8: ...nnected to a LIN network via a wiring harness DPF FAP Diesel Particulate Filter Filtre À Particule device designed to remove diesel particulate matter or soot from the exhaust gas of a diesel engine DTC Data Trouble Code standard fault codes ECU Electronic Control Unit or Engine Control Unit machine or engine control computer FMI Failure Mode Identifier fault code description 0 The data is valid b...

Page 9: ...rol machine forward and reverse movements with one hand LIN Local Interconnect Network LLMI Limit Load Moment Indicator strain gauge ensuring machine stability LS Low Side ground side power supply LSU Load Sensing Ultra hydraulic load detection NC NF Normally Closed Normalement Fermé normally closed contact NO Normally Open normally open contact NOx Nitrogen Oxide regulated air pollutants PAD Plug...

Page 10: ...S 13 00 2 1 CHARACTERISTICS 13 00 2 2 LUBRICANTS AND FUEL 13 00 2 3 DIMENSIONS 14 DIMENSIONS 120AETJL 14 DIMENSIONS 150AETJC AETJ 43 AETJC 43 3D 16 DIMENSIONS 150AETJL 18 DIMENSIONS 170AETJL 49 AETJC 20 00 2 4 LOCATION OF NAME AND IDENTIFICATION PLATE 22 ACCESS PLATFORM MANUFACTURER S PLATE 22 LOCATION OF MANUFACTURER S PLATE 120 AETJ 22 00 3 GENERAL CONTROL AND ADJUSTMENT 23 00 3 1 STANDARD TIGHT...

Page 11: ...nance manual This manual should be found in all trucks Please follow all safety instructions Use the appropriate tools for any work to be performed Use original Manitou spare parts Any non compliance increases the risk of accidents occurring which may lead to causing grievous bodily harm and even death An eﬃcient dependable and profitable combination will be formed if the operator follows the safe...

Page 12: ...ention to important information regarding environmental protection SPECIFIC TOOLING Indicates special tools for performing a task 4 SEE Indicates a cross reference to a manual 5 SEE Indicates a cross reference to a page 0 SEE Indicates a cross reference to a picture 3 WEIGHT Indicates the weight of an item E g it helps to anticipate an action linked to a person s health or the choice of lifting eq...

Page 13: ...ine has had time to cool down AVERTISSEMENT Before carrying out any operation on an electrically powered component activate the battery cut oﬀ PRÉCAUTION Press the battery switch at least 30 seconds after disconnecting the electrical contact with the ignition key AVERTISSEMENT If the telehandler does not have a battery isolating switch disconnect the battery terminals then gather them PRÉCAUTION B...

Page 14: ... Always wear protection glasses gloves safety shoes as well as any other protection required for the work to be carried out DANGER When carrying out maintenance operations near a mobile object make sure it is securitized PROTÉGER L ENVIRONNEMENT When changing or draining oils or fuel or any other operation with liquids solids gases that are harmful to the environment make sure the necessary precau...

Page 15: ... lifting devices When using a jack make sure it is used on a flat uniform surface is sturdy enough to support the load that its lifting capacity is sufficient and that it is correctly placed and positioned under the machine PRÉCAUTION Makesurenoobjectortoolwhichcouldcauseanaccidentisleftinthemachine AVERTISSEMENT Never control any leaks using a hand PRÉCAUTION Never adjust a component to over the ...

Page 16: ... 2 734lbs 1534kg 3 389lbs 1555kg 3 428lbs REAR 1340kg 2 954lbs 1885kg 4 156lbs 1885kg 4 156lbs 1715kg 3 781lbs 1921kg 4 325lbs 1992 5kg 4 393lbs Nominal capacity 2 people 200kg 441lbs 200kg 441lbs 200kg 441lbs 230kg 507lbs 200kg 441lbs 227kg 500lbs 227kg 500lbs 227kg 500lbs 00 2 2 LUBRICANTS AND FUEL Designation Type Quantity Hydraulic tank MANITOU ISO VG 46 Hydraulic oil 18 ℓ 4 76 US gallons Whee...

Page 17: ...9EN 00 08 03 2017 00 D E B C F H G I A1 A1 C1 A 00 2 3 DIMENSIONS DIMENSIONS 120AETJL mm ft in A 5520 18 1 3 A1 3930 12 10 7 B 2000 6 6 7 C 1995 6 6 5 C1 2210 7 3 0 D 1500 4 11 1 E 153 0 6 0 F 2640 8 8 0 G 1870 6 1 6 H 3960 12 11 9 I 4520 14 9 9 ...

Page 18: ...N 00 08 03 2017 00 mm ft in mm ft in G1 2350 7 8 5 H1 9950 32 7 7 G2 3105 10 2 2 H2 8795 28 10 3 G3 6370 20 10 8 H3 4775 15 8 0 G4 5640 18 6 0 H4 545 1 9 5 G1 G2 H2 H1 G3 H3 G4 H4 12 11 10 9 8 7 6 5 4 3 2 1 4 5 6 7 13 3 2 1 0 1 2 3 5 2 3 3 2 6 7 4 ...

Page 19: ...9EN 00 08 03 2017 00 D E F H G I B C1 A1 C A DIMENSIONS 150AETJC AETJ 43 AETJC 43 3D mm ft in A 6050 19 10 2 A1 4400 14 5 2 B 2000 6 6 7 C 1965 6 5 4 C1 2080 6 9 9 D 1500 4 11 1 E 143 0 5 6 F 2640 8 7 9 G 1870 6 1 6 H 3960 12 11 9 I 4820 15 9 7 ...

Page 20: ...8 03 2017 00 mm ft in mm ft in G1 2665 8 8 9 H1 12985 42 7 2 G2 3425 11 2 8 H2 11835 38 9 9 G3 7105 23 3 7 H3 7165 23 6 1 G4 6300 20 8 0 H4 235 0 9 2 G1 G2 H2 H1 G3 H3 G4 H4 8 9 7 12 11 10 9 8 7 6 5 4 3 2 1 4 5 6 7 8 9 16 15 14 13 3 2 1 0 1 2 3 2 3 3 2 ...

Page 21: ...ETY 18 547379EN 00 08 03 2017 00 DIMENSIONS 150AETJL D E F H G I B A1 A C C1 mm ft in A 5960 19 6 6 A1 4400 14 5 2 B 2000 6 6 7 C 1970 6 5 5 C1 2080 6 9 9 D 1750 5 8 9 E 143 0 5 6 F 2880 9 5 4 G 1970 6 5 6 H 4270 14 0 1 I 4890 16 0 5 ...

Page 22: ...8 03 2017 00 mm ft in mm ft in G1 2660 8 8 7 H1 13275 43 6 6 G2 3420 11 2 6 H2 12120 39 9 1 G3 7310 23 11 8 H3 7165 23 6 1 G4 6500 21 3 9 H4 205 0 8 1 G1 G2 H2 H1 G3 H3 G4 H4 8 9 12 11 10 9 8 7 6 5 4 3 2 1 4 5 6 7 8 9 16 15 14 13 3 2 1 0 1 2 3 5 2 3 3 2 ...

Page 23: ...0 547379EN 00 08 03 2017 00 D E F H G I B A1 A C C1 DIMENSIONS 170AETJL 49 AETJC mm ft in A 6840 22 5 3 A1 5120 16 9 6 B 2000 6 6 7 C 1970 6 5 6 C1 2040 6 8 3 D 1750 5 8 9 E 140 0 5 5 F 2890 9 5 8 G 2005 6 6 9 H 4300 14 1 3 I 5600 18 4 5 ...

Page 24: ...21 GENERAL CHARACTERISTICS AND SAFETY 547379EN 00 08 03 2017 00 mm ft in G1 2840 9 3 8 G2 3600 11 9 7 G3 8930 29 3 6 G4 8130 26 8 1 H1 14905 48 10 8 H2 13750 45 1 3 H3 7160 23 5 9 H4 270 0 10 6 ...

Page 25: ...information always specify NOTE For the owner s convenience it is recommended that a note of these numbers is made in the spaces provided at the time of the delivery of the access platform ACCESS PLATFORM MANUFACTURER S PLATE Type Serial no Year of manufacture LOCATION OF MANUFACTURER S PLATE 120 AETJ The manufacturer s plate is fitted on the inside right panel of the turret LOCATION OF MANUFACTUR...

Page 26: ...24 x 2 659 5833 967 8559 M27 x 3 874 7735 1284 11364 M27 x 2 965 8541 1418 12550 M30 x 3 5 1181 10453 1735 15356 M30 x 2 1351 11957 1984 17560 M33 x 3 5 1614 14285 2371 20985 M33 x 2 1821 16117 2674 23667 M36 x 4 2068 18303 3037 26880 bFor hexagon screws with flanges NF E 25 030 1 Apply an increased torque of 10 bWhere washers are used the following coeﬃcient is to be applied FD E 25 502 Plate 0 S...

Page 27: ...nd lat libra kg kilogram x 35 274 oz av ounce avoirdupois oz lat onza km h kilometer per hour x 0 6214 mph miles per hour kW kilowatt x 1 34048 hp horsepower ℓ liter x 0 2642 gal US US gallon ℓ liter x 1 0567 qt US quart US gallon m meter x 3 2808 ft foot m meter x 39 37 in inch min minute x 1 min minute mℓ milliliter x 0 0338 fl oz fluid ounce fl fluid oz lat onza mm millimeter x 0 03937 in inch ...

Page 28: ...TABLE OF CONTENTS AXLE 30 1 CHARACTERISTICS AND SPECIFICATIONS 27 30 1 1 REAR AXLE OPERATION IN FREEWHEEL MODE 27 30 ...

Page 29: ...AXLE 26 30 547379EN 30 08 03 2017 ...

Page 30: ...y means of a connecting bar between the two machines IF POSSIBLE lift the rear of the platform 1 030 4 3 3 120 AETJL 2680 kg 5908 lbs 3 3 150 AETJC 3770 kg 8311 lbs 3 3 150 AETJL 150 AETJC 3D 3375 kg 7441 lbs 3 3 170 AETJL AETJ49 3842 kg 8470 lbs 3 3 AETJ43 AETJ43 3D 3775 kg 8322 lbs Locate the screws 2 030 4 Unscrew these screws according to the model of your platform 030 5 by 22 mm 0 87 in up to...

Page 31: ......

Page 32: ...T CONTROLS 31 55 1 1 CHECK THE CLEARANCE OF THE TELESCOPE 31 55 2 JIB BASKET REMOVAL 31 55 2 1 REMOVAL OF PADS OF TELESCOPIC CYLINDER 31 55 2 2 REMOVAL OF REAR PADS OF TELESCOPIC CYLINDER 31 55 2 3 REMOVAL OF PADS OF TELESCOPE MOVING TUBE 32 55 ...

Page 33: ...JIB BASKET 30 55 547379EN 55 08 03 2017 ...

Page 34: ... CYLINDER Remove the telescopic cylinder 6TELESCOPIC CYLINDER REMOVAL 5 63 Remove and replace the pads 1 055 6 see parts catalog 55 2 2 REMOVAL OF REAR PADS OF TELESCOPIC CYLINDER Remove the telescopic cylinder 6TELESCOPIC CYLINDER REMOVAL 5 63 Release the pads 1 055 7 by slightly raising the basket Remove the pads 1 055 7 pay attention to the position and number of adjustment plates Get new pads ...

Page 35: ...nd wiring harnesses Release the pads of the telescope jib by gently releasing the moving tube 1 055 9 Remove the pads 2 055 9 of the telescope jib pay attention to the position and number of adjustment plates Remove the moving tube by allowing it to slide towards the rear 3 3 120 AETJL 102 kg 225 lbs 3 3 150 AETJC et 150 AETJL 150 AETJC 3D AETJ43 AETJ43 3D 116 kg 256 lbs 3 3 170 AETJL AETJ49 148 k...

Page 36: ...ESCOPIC CIRCUIT PRESSURE SETTING 49 PRESSURE REDUCER SETTING 49 70 3 5 COMPENSATION TILTING CIRCUIT PRESSURE SETTING 50 DECOMPRESSION OF THE CIRCUIT 50 VALVE A ADJUSTMENT 50 VALVE B ADJUSTMENT 51 70 3 6 COMPENSATION TILTING CIRCUIT PROBLEM SOLVING 52 TEST PROCEDURE 52 ANALYSIS OF RESULTS 53 70 3 7 TURRET ROTATION MOTOR REMOVAL 54 70 3 8 ELECTRIC PUMP REMOVAL 55 70 3 9 REDUCING GEARS WHEEL BRAKES R...

Page 37: ...HYDRAULIC 34 70 547379EN 70 08 03 2017 LINKS TO REPAIR MANUALS MANUAL REFERENCE NUMBER DESIGNATION 647 187 ROTARY ACTUATORS HELICAL HYDRAULIC L20 SERIE ...

Page 38: ... 120 b 4 5 6 13 2 3 14 15 7 8 9 16 17 1 10 11 19 12 EV18 EV19 EV1 EV5 EV16 EV17 EV6 EV7 EV8 EV9 EV10 EV11 EV12 EV13 EV14 EV15 EV22 EV23 EV2b EV2 EV3 18 25 b mini 25 b 20 T P P 110b 21 150 b 679449 Index E Turret rotation Steering Basket rotation Brakes Arms 1 2 Arm 3 Pendular arm Compensation Tilt 3D JIB rotation OIL TANK Telescope See Note Only 150 AETJC 150 AETJC 3D AETJ 43 AETJ 43 3D 150 AETJL ...

Page 39: ...70 547379EN 70 08 03 2017 HYDRAULIC 36 ...

Page 40: ...Brakes 1 Safety valve AETJ Standard Taring No Function NOTE Delivery of the block with the adjustment 21 Pressure restrictor 150 b This diagram relates to lifting platforms 150 AETJC 150 AETJC 3D AETJ 43 AETJ 43 3D 150 AETJL 170 AETJL AETJ 49 AETJ standard 80 b Raising Lowering Raising Lowering Extended Retracted Raising Lowering Boost Tilt Right Left Transport Position Stop Stop steering translat...

Page 41: ...70 547379EN 70 08 03 2017 HYDRAULIC 38 ...

Page 42: ...80b 180 b 210 b 210 b 110 b 210 b 210 b 220 b 150 b 180 b 4 5 6 13 2 3 14 15 7 8 9 18 19 1 10 11 21 12 EV 18 EV 19 E V1 E V5 EV 16 E V17 E V6 E V7 E V8 E V9 E V10 E V11 E V12 E V13 E V14 E V15 E V22 E V23 E V2b E V2 E V3 20 25 b mini 25 b 120 AETJL 685268 Indice A 685268 Index A Turret rotation Steering Basket rotation Brakes Arms 1 2 Arm 3 Pendular arm Compensation Tilt 3D JIB rotation OIL TANK T...

Page 43: ...70 547379EN 70 08 03 2017 HYDRAULIC 40 ...

Page 44: ... Brakes 2 Brakes 1 Safety valve AETJ Standard Taring No Function NOTE Delivery of the block with the adjustment 21 Pressure restrictor This diagram relates to lifting platforms 150 AETJC 150 AETJC 3D AETJ 43 AETJ 43 3D 150 AETJL 170 AETJL AETJ 49 AETJ standard Raising Lowering Raising Lowering Extended Retracted Raising Lowering Boost Tilt Right Left Transport Position Stop Stop steering translati...

Page 45: ...70 547379EN 70 08 03 2017 HYDRAULIC 42 ...

Page 46: ...DRAULIC 70 547379EN 70 08 03 2017 70 2 HYDRAULIC COMPONENTS LOCATION 70 2 1 HYDRAULIC COMPONENTS OF THE CHASSIS LOCATION Reducing gear Brake of left wheel Reducing gear Brake of right wheel Steering cylinder ...

Page 47: ...EN 70 08 03 2017 70 2 2 HYDRAULIC COMPONENTS OF THE TURRET LOCATION Backup pump Accumulator 150AETJC 150 AETJC 3D 150 AETJL 170 AETJL AETJ 43 AETJ 43 3D AETJ 49 Electric pump Distributor block Turret rotation engine Oil tank ...

Page 48: ...9EN 70 08 03 2017 70 2 3 HYDRAULIC COMPONENTS OF THE JIB LOCATION 120 AETJL Compensatingcylinder Telescope cylinder Tilting cylinder Arm 3 lifting cylinder Basket rotation cylinder Jib cylinder Arm 1 2 lifting arm cylinder ...

Page 49: ... AETJC 150 AETJC 3D 150 AETJL 170 AETJL AETJ43 AETJ43 3D AETJ 49 Telescope cylinder Compensating cylinder Tilting cylinder Arm 3 lifting cylinder Jib cylinder A r m 1 2 l i f t i n g arm cylinder Basketrotationcylinder 3D JIB rotation cylinder ...

Page 50: ...form Control the lowering of arms 1 2 and maintain the control when the cylinder reaches the stop Checkthatthepressuregaugedisplaysthepressurerecommended in the hydraulic diagram As required adjust the setting of the main relief valve 2 070 11 70 3 2 STEERING BASKET TURRET ROTATION CIRCUIT PRESSURE SETTING Setting the pressure relief valve 13 070 1 1 13 070 1 2 On the distributor connect a pressur...

Page 51: ...e gauge 2 070 13 Switch on the access platform Control the travel and check that the displayed pressure follows the curve 1 070 14 If the pressure switch 2 070 15 trips BELOW the threshold 2 070 14 then with the platform stationary adjust the threshold by TIGHTENING the adjustment screw 2 070 15 If the pressure switch 1 070 15 trips ABOVE the threshold 2 070 14 unscrew the adjustment screw by a fe...

Page 52: ...R REMOVAL 5 57 Place a Tee connector on the by pass at outlet A3 1 070 16 and connect the pressure gauge 2 070 16 Switch on the access platform Move the telescope extension and keep it moving under it reaches its full extent Checkthatthepressuregaugedisplaysthepressurerecommended in the hydraulic diagram As required adjust the setting of the pressure reducer 1 070 17 0 A3 70 16 1 2 70 17 1 ...

Page 53: ...r to the access platform VALVE A ADJUSTMENT 17 070 1 1 19 070 1 2 Place a Tee connector on the by pass at outlet A5 1 070 18 and connect the pressure gauge 2 070 18 Switch on the access platform Follow steps 1 070 20 2 070 21 and 3 070 22 the verification of the setting of valve A 1 070 19 and its adjustment are to be carried out during movement 3 0 A5 70 18 2 1 70 19 1 70 20 TO ITS FULL EXTENT 1 ...

Page 54: ...the by pass at outlet B5 1 070 23 and connect the pressure gauge 1 070 23 Switch on the access platform Follow steps 1 070 25 and 2 070 26 the verification of the setting of valve A 1 070 24 and its adjustment are to be carried out during movement 2 0 B5 70 23 2 1 70 24 1 70 25 TO ITS FULL EXTENT 1 70 26 2 ...

Page 55: ... for the upper chamber 2 070 27 Remove the hoses 1 070 28 connected at A5 and B5 from the distributor block Insert tee couplings between the distributor block and the hoses 2 070 28 Take a 0 200 bar 0 2900 75 psi manometer 3 070 28 and connect it to the left hand tee coupling outlet A5 Take a 0 100 bar 0 1450 38 psi manometer 4 070 28 and connect it to the right hand tee coupling outlet B5 Switch ...

Page 56: ...distributor block Decompression of the compensation tilting circuit 670 3 11 CYLINDERS REMOVAL 5 60 Remove the valve s 1 070 30 and check the appearance of the seals Change the valves if the seals are defective see parts catalog Refit the valves then check their adjustment 670 3 5 COMPENSATION TILTING CIRCUIT PRESSURE SETTING 550 THE BASKET DROPS THE PRESSURE ON BOTH MANOMETERS TENDS TO BALANCE 10...

Page 57: ... hand turret cover Decompress the turret rotation line distributor 670 3 10 DISTRIBUTOR REMOVAL 5 57 Open the left hand turret cover 1 070 31 Remove and plug the two hoses 1 070 32 Remove the motor attachments 2 070 32 Remove the steering motor 3 070 32 3 3 36kg 80 lbs 70 31 1 70 32 3 2 1 1 ...

Page 58: ...ver 1 070 33 Following fitting see figure 070 34 see figure 070 35 Remove and plug the hose 1 070 34 1 070 35 Remove and plug the connector 2 070 34 2 070 35 Remove the attachments 3 070 34 3 070 35 and remove the electric pump 4 070 34 4 070 35 3 3 25 kg 55 lbs 70 33 1 70 34 3 1 2 4 70 35 1 4 2 3 ...

Page 59: ...s 3 070 32 and remove the wheels 3 3 53 kg 117 lbs Remove the cover 4 070 36 Mark and then remove the electric cables connected to the motors 1 070 37 Remove the fasteners from one of the motors 2 070 37 and remove this motor B 3 3 3 27 kg 60 lbs Repeat the same procedure on the second engine Remove and plug the hoses 1 070 38 Remove the fasteners from one of the reducing gears brakes 2 070 38 and...

Page 60: ...ydraulic lines Pull push the 3 non indexed controls 2 070 43 and allow them to return to their equilibrium position Pull push the 5 indexed controls 3 070 43 and return them to their center position Replace the manual indexed control protections 1 070 43 Remove and plug the hoses connected to the distributor Identify the wiring harnesses connected to the solenoids and disconnect them Remove the di...

Page 61: ...HYDRAULIC 58 70 547379EN 70 08 03 2017 ...

Page 62: ...n N m lb in 1 Distributor 2 Electrovalve Item 4 Item 4 39 51 Nm 345 18 451 39 lb in 3 Electrovalve Items 5 6 Items 5 6 4 Electrovalve Item 3 Item 3 5 Electrovalve Item 2 Item 2 6 Electrovalve Items 7 8 9 10 Items 7 8 9 10 44 56 Nm 389 43 495 64 lb in 7 Electrovalve Item 12 Item 12 8 Electrovalve Item 1 Item 1 39 51 Nm 345 18 451 39 lb in 9 Pressure reducer 100 bar 1450 38 psi Item 13 Item 13 10 Pl...

Page 63: ... 3 070 44 Decompress the steering line distributor 670 3 10 DISTRIBUTOR REMOVAL 5 57 Remove and plug the hoses connected to the steering cylinder 1 070 45 Remove the pivot pins from the steering cylinder 2 070 45 and remove the cylinder REFIT Carry out the removal operations in reverse order leaving the access platform on supports Drain the steering circuit Control the steering until it reaches it...

Page 64: ... connected to the cylinder 1 070 47 Remove the pivot pins from the cylinder starting with the cylinder head pin 2 070 47 and remove the cylinder 3 3 120 AETJL 25 kg 55 lbs 3 3 150 AETJC 150 AETJL 150 AETJC 3D 150 AETJL AETJ43 AETJ 43 3D 170 AETJL AETJ 49 70 kg 154 lbs NOTE Before attempting to disassemble the removed cylinder 6VALVE BLOCKS AND VALVES REMOVAL 5 69 REFIT Carry out the removal operat...

Page 65: ...t cover Decompress the lifting line of arm 3 distributor 670 3 10 DISTRIBUTOR REMOVAL 5 57 Remove and plug the hoses connected to the cylinder 1 070 49 Remove the pivot pins from the cylinder starting with the cylinder foot pivot pin 2 070 49 and remove the cylinder 3 3 120 AETJL 30 kg 66 lbs 3 3 150 AETJC 150 AETJL 150 AETJC 3D 150 AETJL AETJ43 AETJ 43 3D 170 AETJL AETJ 49 50 kg 111 lbs NOTE Befo...

Page 66: ...the telescopic line distributor 670 3 10DISTRIBUTOR REMOVAL 5 57 Remove the telescope base cover 1 070 51 Remove and plug the hoses connected to the cylinder 2 070 51 Remove the cylinder foot pivot pin 3 070 51 and remove the telescope cylinder 3 3 120 AETJL 34 kg 75 lbs 3 3 150AETJC 150AETJC3D AETJ43 AETJ433D 39kg 86lbs 3 3 150 AETJL 42 kg 93 lbs 3 3 170 AETJL AETJ 49 55 kg 121 lbs NOTE Before at...

Page 67: ...bly with a hoist and a sling 3 3 without rotation cylinder 3D JIB 230 kg 507 lbs 3 3 with rotation cylinder 3D JIB 267 kg 589 lbs Open the right hand turret cover Remove the cylinder pivot pins 1 070 56 and remove the cylinder from the arms while leaving it connected to the hoses 3 3 120 AETJL 18 kg 40 lbs 3 3 150 AETJC 150 AETJL 170 AETJL 20 kg 44 lbs Remove and plug the hoses connected to the cy...

Page 68: ...hile leaving it connected to the hoses 3 3 22 kg 49 lbs Remove and plug the hoses connected to the cylinder 1 070 58 and remove the cylinder NOTE Before attempting to disassemble the removed cylinder 6VALVE BLOCKS AND VALVES REMOVAL 5 69 REFIT Follow the removal operations in reverse order Purge the compensation tilting circuit by repeating steps I to VII several times I II 070 59 III IV 070 62 V ...

Page 69: ...n a stable surface Open the right hand turret cover Decompress the jib lifting line 670 3 10 DISTRIBUTOR REMOVAL 5 57 Remove and plug the hoses connected to the cylinder 1 070 64 Remove the pivot pins from the cylinder starting with the cylinder foot pivot pin 2 070 64 and remove the cylinder 3 3 15 kg 33 lbs NOTE Before attempting to disassemble the removed cylinder 6VALVE BLOCKS AND VALVES REMOV...

Page 70: ...ret cover Decompress the basket rotation line 670 3 10 DISTRIBUTOR REMOVAL 5 57 Remove and plug the hoses connected to the cylinder 1 070 49 Remove the cylinder foot pivot pin 2 070 66 and the nut of the cylinder head pin 3 070 66 and remove the cylinder NOTE Before attempting to disassemble the removed cylinder 6VALVE BLOCKS AND VALVES REMOVAL 5 69 70 65 1 70 66 2 3 1 1 ...

Page 71: ...ssary remove the harnesses and the hoses of the jib cylinder 6JIB CYLINDER REMOVAL 5 66 Remove the 3D rotation cylinder pivot pin 1 070 68 Secure the 3D rotation cylinder assembly with a hoist and a sling see figure 070 69 3 3 37 kg 82 lbs Démonter l axe d articulation du vérin d inclinaison 3 070 68 et l axe d articulation du bras 4 070 68 Remove the 3D rotation cylinder REFIT Follow the removal ...

Page 72: ...order to avoid pressurized oil leaks the operator should position the cylinder with the contact face 1 070 70 between the valve block and the cylinder vertically and then position a rubber sheet over this face 2 070 70 Secure the cylinder body in a vise Loosen the fixing screws of the block 3 070 70 one after another by a MAXIMUM of 1 4 turn for each screw Unscrew the screws by 1 4 turn WITH A SPA...

Page 73: ...HYDRAULIC 70 70 547379EN 70 08 03 2017 ...

Page 74: ...L COMPONENTS LOCATION 83 80 2 2 ELECTRICAL POWER COMPONENTS LOCATION 84 80 4 4 WIRING BASED ON SCHEMATIC DIAGRAM 676423 1ST VERSION 85 LOCATION OF WIRING HARNESSES ON THE ACCESS PLATFORM 85 BASKET CONTROL PANEL HARNESS 86 OVERLOAD SENSORS HARNESS 89 UPPER BUS CAN EXTENSION HARNESS 90 LOWER BUS CAN EXTENSION HARNESS 92 UPPER BUS CAN CONTROL PANEL OUTPUT HARNESS 93 BASE BOX HARNESS 94 VARIABLE SPEED...

Page 75: ...D ADJUSTMENT TOOLS 118 BATTERY CHARGE INDICATOR HOUR METER 119 VARIABLE SPEED CONTROLLERS USE OF CALIBRATOR 120 80 3 5 SAFETY COMPONENTS CONTROL AND SETTINGS 126 SWITCHES LOCATION 126 TILT SENSOR SETTINGS 126 ARM DOWN SENSORS SETTINGS 127 BRAKE RELEASE CIRCUIT CHECKING 128 OVERLOAD SENSORS SETTINGS 129 MULTIMETER TEST 132 80 3 6 MANIPULATOR OPERATION AND SETTINGS 133 MANIPULATOR TESTS USING CALIBR...

Page 76: ...RAMS WARNING Diagram 1st VERSION Access platform fitted with an overload sensor harness comprising a Deutsch connector with 8 way SQ5a SQ5b SQ5a WARNING Diagram 2nd VERSION Access platform fitted with an overload sensor harness comprising a Deutsch connector with 3 way SQ5b SQ5a SQ5b ...

Page 77: ......

Page 78: ... lights and actuators hyave a nominal voltage of 24 V ELECTRIC PUMP VARIABLE SPEED DRIVE power Left Right TRACTION MOTORS VARIABLE SPEED DRIVE logic arm low A supply pressure stat tel retracted A Base select tilt line trac pump telescope retracted BATTERY CHARGE POWER ON Emergency stop 2 TRACTION PUMP SWITCHING LINE CONTACTOR pressure stat brakes released pump t e l e s c o p e r e t r a c t e d a...

Page 79: ... Left compensation Down basket rot Right basket rot Left arm 3 Up arm 1 2 Down arm 1 2 Up arm 3 Down Send to tank Flashing light Turret rot Left Basket rot Left brake steer L pump pendular arm Up telescope extended arm 3 Up arms 1 2 Up Unless otherwise stated the indicator lights and actuators have a nominal voltage of 24V Tilt Arms Arm Basket rotation CONTROL CONSOLE white brown white blue blue b...

Page 80: ...otation overload maintenance warning pendular arm turret rotation basket rotation tilt alarm faults Ref Overload Ref tilt instruction rotation steer left steer right traction instruction Dead man s system Except for NEUTRAL Overload 24V 2 AXIS joystick Overload warning red Tilt ARMS ARM All the LEDs are supplied with 24V BASKET ROTATION TURRET PENDULAR ARM Overload warning Maintenance warning gree...

Page 81: ...n Unless otherwise stated the indicator lights and actuators have a nominal voltage of 24V Sector sensor control module arm low B arm low A telescope retracted A telescope retracted B overload SQ5a overload SQ5b speed reduction return overload validation return dedicated soft a r m l o w r e t r a c t e d J I H G F E D C B A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ...

Page 82: ...C PUMP 3 6 KW 48V TRACTION MOTORS SEM XP1747 48V VARIABLE SPEED DRIVE power n c A3 10V5 A1 0V A2 10V5 A4 CAN H A5 CAN L A6 678423 Index S Page 1 4 network yellow white black blue green singles LEDS RED GREEN Base Emergency Stop BASE BASKET Selector SLOPE supply arm low a r m l o w E l e c t r o v a l v e s s u p p l y retracted r e t r a c t e d pump pressure stat brakes released LINE CONTACTOR TR...

Page 83: ...o 04 arms 1 2 R Do 02 turret rot R Do 10 Steer R Do 16 basket rot R Do 18 compensation Up Do 21 brake Do 22 steer L Do 15 pump Do 24 pendular arm Up Do 07 telescope Extended Do 13 arm 3 Up Do 05 arms 1 2 Up Do 03 C NEG D NEG B NEG CAN bus socket Diagnostics MOLEX Mini Fit box for males 6 way contacts CAN L CAN 6 CAN H CAN 5 12V CAN 4 0V CAN 2 12V CAN 1 B 2 B 678423 Index S Page 2 4 Turret rotation...

Page 84: ...ion Di 08 JIB rot Di 15 turret rot Di 14 basket rot Di 10 arm 3 selection Di 09 arms 1 2 selection Di 03 translation selection Di 05 SQ5b overload Di 02 available Ai 01 rotation instruction Di 06 steer Left Di 07 steer Right Ai 02 traction instruction Di 01 Dead man s system Di 04 Except for NEUTRAL 678423 Index S Page 3 4 Basket Emergency stop Overload Overload arms 1 2 selection arm 3 selection ...

Page 85: ... 9 10 11 12 13 14 B02 arm low B B01 arm low A B03 telescope retracted A B04 telescope retracted B B05 overload SQ5b B06 overload SQ5a B07 speed reduction return BO8 overload validation return A5 CAN L A6 CAN H Out_2 Out_1 Overload Validation dedicated soft 678423 Index S Page 4 4 Sector sensor control module low arm b telescope retracted ...

Page 86: ...lt sensor Basecontrolpanel Safety control card Base module control unit Battery charge indicator hour meter LED showing charging states removed Basket module control unit Basket control panel Arm down sensors 150AETJC 150AETJC3D 150AETJL 170AETJL AETJ 43 AETJ 43 3D AETJ 49 Horn Retracted telescope sensor Low arm sensors 120 AETJL Overload sensors ...

Page 87: ...RICAL POWER COMPONENTS LOCATION Electric pump Safety control card Right hand battery Variable speed controller plate Left hand battery Battery cut off Variable speed controller plate relay Left traction motor Right traction motor ZIVAN charger IES charger ...

Page 88: ...rovalve harness 8 Tilt wiring harness 9 Horn harness 10 Flashing flight harness 11 Output sensor control panel harness 12 Intermediate inductive sensors harness 150 AETJC 150 AETJL 170 AETJL AETJ 43 AETJ 43 3D AETJ 49 Telescopic arm sensors harness 120 AETJL 13 Telescope arm sensor 14 Low arm sensor harness 15 Arm down sensor 16 Overload sensors 8 10 12 12 13 15 15 14 2 2 7 6 16 1 5 13 11 4 3 3 9 ...

Page 89: ...up LED Arm 3 up LED Tilt reverse tilt LED Telescope LED Pendular arm up LED Buzzer Overload LED 20 port female Deutsch through partition connector Ref S13 S14 S15 S17 S18 S19 S20 S21 S22 8S 8P 8P PC Designation Translation selector Arm 1 2 up down selector Arm 3 up down selector Pendular arm turret basket rotation selector Tilt reverse tilt selector Telescope extension retraction selector Pendular...

Page 90: ...19 S20 S21 S22 4S 6S 8P PC Designation Translation selector Arm 1 2 up down selector Arm 3 up down selector Pendular arm turret basket rotation selector Tilt reverse tilt selector Telescope extension retraction selector Pendular arm up down selector Horn button Emergency Stop 4 port male Deutsch connector 6 port male Deutsch connector 8 port female Deutsch through partition connector 12P PC 12 por...

Page 91: ...3 103 Wire 315 318 spare spare spare spare spare spare Pos 1 2 3 4 5 6 7 8 Wire 319 312 311 313 332 316 317 306 310 309 304 303 305 308 307 302 Pos 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Wire spare 328 327 322 321 spare 323 spare spare spare spare spare 329 331 320 330 spare 335 337 spare 336 338 spare spare Pos 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Wire spare spare spare ...

Page 92: ...RLOAD SENSORS HARNESS ITEM 16 To full basket control panel Item 1 OVERLOAD SENSORS HARNESS 678849 D Item 16 SQ5a SQ5b 1 2 3 4 5 6 7 8 Pin Wire Color 1 332 black 2 335 black white 3 312 brown 4 335 blue 5 333 black 6 335 black white 7 free 8 free ...

Page 93: ... 17 16 15 14 13 12 11 10 9 To complete basket console Ref 1 UPPER BUS CAN EXTENSION HARNESS Ref 2 To lower CAN BUS extension bundle Ref 3 Pos Wire 1 103 2 106 3 123 4 336 5 337 6 319 7 400 8 401 Pos Wire 1 112 2 113 3 135 4 137 5 332 6 333 7 402 8 338 Pos 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Wire 112 113 Spare 135 137 Spare 332 333 338 103 106 123 336 337 319 400 optional spare 401 o...

Page 94: ...ION HARNESS 52501939 150 AETJC 150 AETC 3D 150 AETJL AETJ 43 AETJ 43 3D 52501918 170 AETJL AETJ 49 Ref 2 To complete basket console Ref 1 Pos 1 2 3 4 5 6 7 8 9 10 11 12 Wire 112 113 135 137 333 103 106 123 336 337 319 332 Wire 338 400 401 402 Pos 1 2 3 4 Pos Wire 1 112 2 113 3 135 4 137 5 332 6 333 7 402 8 338 To lower BUS CAN extension harness Ref 3 Pos Wire 1 103 2 106 3 123 4 336 5 337 6 319 7 ...

Page 95: ...88 D 150 AETJ COMPACT 150 AETJC 3D 150 AETJL 170 AETJL AETJ 43 AETJ 43 3D AETJ 49 Ref 3 Pos Wire 1 103 2 106 3 123 4 336 5 337 6 319 7 400 8 401 Pos Wire 1 112 2 113 3 135 4 137 5 332 6 333 7 402 8 338 Pos Wire 1 103 2 106 3 123 4 336 5 337 6 319 7 400 8 401 Pos Wire 1 112 2 113 3 135 4 137 5 332 6 333 7 402 8 338 To BUS CAN console output bundle Ref 4 To upper BUS CAN extension harness as mountin...

Page 96: ...12 123 113 135 137 332 333 338 319 400 401 402 1 2 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 To lower BUS CAN extension harness Ref 3 Pos Wire 1 103 2 106 3 123 4 336 5 337 6 319 7 400 8 401 Pos Wire 1 112 2 113 3 135 4 137 5 332 6 333 7 402 8 338 BUS CAN CONSOLE OUTPUT HARNESS 678394 C Ref 4 To complete base box Rep 5 ...

Page 97: ...2 23 24 16 14 15 1 2 3 9 4 5 6 7 13 14 15 8 16 12 10 11 103 1 2 3 4 5 6 Electro valve harness Ref 7 Variable speed drive harness Ref 6 BUS CAN console output harness Ref 4 Flashing light harness Ref 10 Alarm harness Ref 9 Tilt harness Ref 8 ensor console output harness Ref 11 BASE BOX HARNESS 679459 G 120 AETJL 150 AETJC 150 AETJC 3D 150 AETJL 170 AETJL 52556928 AET 43 AETJ 43 3D AETJ 49 Ref 5 Pos...

Page 98: ...tor red LED Offset LED indicator green LED Overload warning LED Maintenance warning LED Electro valve supply relays Relay Relay Timer Pos S2 S3 S5 S6 S7 S8 S9 S10 S11 S12 S23 Designation Emergency Stop Base basket selector Turret rotation selector Telescope extension retraction selector Pendular arm up down selector Pendular arm rotation selector Basket rotation selector Arm 3 up down selector Arm...

Page 99: ... 5 3 2 1 2 3 4 5 6 1 2 3 7 4 5 6 11 12 10 8 9 103 121 VARIABLE SPEED HARNESS 678397 C Ref 6 To complete base box Ref 5 To variable speed drive fuses board To variable speed drive drive board To right hand battery terminal To battery cut out Pos Wire Colour 1 115 brown 2 Spare 3 116 white 4 Spare 5 Spare Shield 114 Green Pos 1 2 3 4 5 6 Wire spare spare 127 spare 113 112 Pos 1 2 3 4 5 6 7 8 9 10 11...

Page 100: ...White 2 119 Bown 1 241 Bown 2 222 White D OUT 12 1 241 Bown 2 234 White D OUT 15 1 241 Bown 2 221 White D OUT 08 1 241 Bown 2 228 White D OUT 10 1 241 Bown 2 229 White D OUT 16 1 241 Bown 2 230 White D OUT 18 1 242 Bown 2 233 White 1 242 Bown 2 233 White 1 241 Bown 2 220 White D OUT 17 1 241 Bown 2 219 White D OUT 11 To complete base box Ref 5 EV16 BASKET ROT RIGHT EV5 STEERING RIGHT EV18 TURRET R...

Page 101: ...123 Wire Colour 123 Pink 103 Dark Blue 244 Black 123 Red 103 Violet 117 Orange 123 Yellow 103 Green 245 Grey 123 Light blue 103 White 118 Brown Pos Wire Colour 1 123 Yellow 2 103 Green 3 245 Grey 4 123 Light Blue 5 103 White 6 118 Brown Pos Wire Colour 1 123 Pink 2 103 Dark Blue 3 244 Black 4 123 Red 5 103 Violet 6 117 Orange Pos Wire 1 106 2 218 To Arm low sensors bundle 120 AETJL Ref 14 telescop...

Page 102: ...RS INDUCTIF 678901 A Rep 15 SQ1b SQ1a FAISCEAU CAPTEURS BRAS BAS 678883 B Rep 14 FAISCEAU CAPTEURS TELESCOPE 678864 C Rep 12 Pin Fil 1 123 2 103 3 245 4 123 5 103 6 118 Pin Fil 1 123 2 103 3 244 4 123 5 103 6 117 Pin Fil A 123 B 103 C 244 Pin Fil A 123 B 103 C 117 Pin Fil A 123 B 103 C 245 Pin Fil A 123 B 103 C 118 Vers Faisceau pupitre CAPTEURS 678476 C Rep 11 Pin Fil A marron B bleu C noir Pin F...

Page 103: ... FAISCEAU INTERMEDIAIRE CAPTEURS INDUCTIFS 678475 C Rep 12 Pin Fil 1 123 2 103 3 244 4 123 5 103 6 117 Vers Faisceau pupitre CAPTEURS Rep 11 Pin Fil A 123 B 103 C 244 Pin Fil A 123 B 103 C 117 Pin Fil A marron B bleu C noir CAPTEURS INDUCTIF SQ1b 678901 Rep 15 Pin Fil 1 123 2 103 3 245 4 123 5 103 6 118 Pin Fil 1 123 2 103 3 244 4 123 5 103 6 117 CAPTEURS INDUCTIF 678901 A Rep 13 Pin Fil A 123 B 1...

Page 104: ...t the upper hinge 1 080 72 is raised by 1 m 39 37 in Turn the turret by 1 4 turn 2 080 73 Switch off the power supply Remove the cover 3 080 74 Remove the battery protective casings 4 080 72 Remove the cables connected to the charger from the battery 680 4 2 BATTERIES REMOVAL 5 137 Remove the cover plate 1 080 73 Remove the charger 2 080 73 80 72 3 1 4 2 80 73 1 2 ...

Page 105: ...ticker indication of settings position of capacity switch made during first installation 7 080 74 NOTE ignore this sticker when configuring the settings for the charger 6ZIVAN BATTERY CHARGER CONNECTIONS LOAD CURVES 5 104 INTERNAL VIEW Input fuse F1 1 080 75 20 A see parts catalog Output fuse F2 2 080 75 45 A see parts catalog Fans 3 080 75 Battery capacity switch C 4 080 75 Input terminals 5 080 ...

Page 106: ...RGER CONNECTIONS Auxiliary contacts to cut off load movements internal diagram see figure 080 76 5 pin plug to connection the removed LED harness external diagram see figure 080 77 NC C NO NC C AUX 1 AUX 2 NO 80 76 2 5 3 4 1 80 77 WHITE BROWN GREEN LED RED LED ...

Page 107: ...8 Charging time IULa WULa Capacity switch position 0 1 2 3 4 5 6 7 8 9 A B C D E F T1max h 10hr 45min 10hr 9hr 8hr 7hr 15min 6hr 15min 5hr 30min 4hr 30min 10hr 45min 10hr 9hr 8hr 7hr 15min 6hr 15min 5hr 30min 4hr 30min T2max h 3hr 3hr 3hr 3hr 3hr 3hr 3hr 3hr 3hr 3hr 3hr 3hr 3hr 3hr 3hr 3hr T1 T2 T3 max h 15hr 45min 15hr 14hr 13hr 12hr 15min 11hr 15min 10hr 30min 9hr 30min 15hr 45min 15hr 14hr 13hr...

Page 108: ... 100 charge LED flashing intermittent audible signal from the charger alarm situation 680 5 TROUBLESHOOTING ELECTRICAL 5 139 LED indicator removed see figure 080 80 Red permanently on initial charging phase Yellow permanently on battery at 80 charge Green permanently on battery at 100 charge LED flashing intermittent audible signal from the charger alarm situation 680 5 TROUBLESHOOTING ELECTRICAL ...

Page 109: ...0 81 is raised by 1 m 39 37 in Turn the turret by 1 4 turn 2 080 81 Switch off the power supply Remove the cover 3 080 81 Remove the battery protective casings 4 080 81 Remove the cables connected to the charger from the battery 680 4 2 BATTERIES REMOVAL 5 137 Remove the cover plate 1 080 82 Remove the charger 2 080 82 80 81 3 1 4 2 80 82 1 2 ...

Page 110: ...80 83 Auxiliary contacts 3 080 83 5 pin plug 4 080 83 IES BATTERY CHARGER CONNECTIONS Auxiliary contacts to cut off load movements internal diagram see figure 080 84 5 pin plug to connection the removed LED harness external diagram see figure 080 85 80 83 4 2 1 3 NC C NO NC C AUX 1 AUX 2 NO 80 84 2 5 3 4 1 80 85 WHITE BROWN GREEN LED RED LED ...

Page 111: ...y IES BATTERY CHARGER INDICATOR LED indicator removed see figure 080 86 Off charger not powered Red permanently on initial charging phase Yellow permanently on battery at 80 charge Green permanently on battery at 100 charge LED flashing Yellow battery balancing cycle Red alarm situation 680 5 TROUBLESHOOTING ELECTRICAL 5139 80 86 1 ...

Page 112: ...hand turret cover 1 080 87 Open the front face of the base control panel 2 080 87 Remove the plate holding the card in place 1 080 88 and remove the cards Safety control card 2 080 88 Base module control unit 3 080 88 Basket module control unit Remove the front face from the basket control panel 1 080 89 Remove the basket module control unit 2 080 89 80 87 1 2 80 88 3 2 1 80 89 2 1 ...

Page 113: ... 4 212 Arm 3 Raised 2 6 3 Boom 2 up Open Closed 0V 5 211 Arm 3 Lowered 2 6 4 Boom 2 down Open Closed 0V 6 208 Turret Left Rotation 2 6 9 Slew left Open Closed 0V 7 207 Turret Right Rotation 2 6 10 Slew right Open Closed 0V 8 205 Telescope Retracted 2 6 7 Tele in Open Closed 0V 9 206 Telescope Extended 2 6 8 Tele out Open Closed 0V 10 201 Tilt Raised 2 6 12 Cage level forward Open Closed 0V 11 202 ...

Page 114: ...URABLE 13 237 Telescope Extended NOT MEASURABLE 14 223 Compensation Lowered NOT MEASURABLE 15 234 Steering Left NOT MEASURABLE 16 229 Steering Right NOT MEASURABLE 17 220 JIB Right Rotation NOT MEASURABLE 18 230 Basket Right Rotation NOT MEASURABLE 19 217 Horn NOT MEASURABLE 20 218 Flashing Lights NOT MEASURABLE 21 231 Compensation Raised NOT MEASURABLE 22 233 Brake NOT MEASURABLE 23 Free NOT MEAS...

Page 115: ...RABLE 17 Free NOT MEASURABLE 18 Free NOT MEASURABLE 19 Free NOT MEASURABLE 20 Free NOT MEASURABLE 21 Free NOT MEASURABLE 22 Free NOT MEASURABLE 23 Free NOT MEASURABLE 24 Free NOT MEASURABLE CAN 1 NOT MEASURABLE 2 NOT MEASURABLE 3 NOT MEASURABLE 4 NOT MEASURABLE 5 112 CAN L NOT MEASURABLE 6 113 CAN H NOT MEASURABLE OUT 1 406 Validation overload Ka11 0V OUT 2 405 Free NOT MEASURABLE B 103 0V NOT MEA...

Page 116: ...9 2 312 Overload 1 NO NOT MEASURABLE _ 2 3 311 Travel selection 2 4 10 Traction select Open Closed 0V 3 4 313 Not neutral 1 3 18 Joystick NTRL sw Open Closed 0V 8 5 332 Overload SQ5b NF 2 4 9 NOT MEASURABLE 6 316 Steering G 1 3 6 Steer left Open Closed 0V 3 7 317 Steering D 1 3 7 Steer right Open Closed 0V 3 8 306 JIB Rotation NOT MEASURABLE 0V 3 9 310 Select arm 1 2 2 4 11 Boom 1 select Open Clos...

Page 117: ...e NOT MEASURABLE 1 680 3 6 MANIPULATOR OPERATION AND SETTINGS 5 133 2 See overload settings 680 3 5 SAFETY COMPONENTS CONTROL AND SETTINGS 5 126 3 Keep the selection to measure the signal 4 Negative signal 0 V intermittent LED overload 5 Negative signal 0 V intermittent if in tilt continue if overload 6 Negative signal 0 V intermittent tilt LED variable speed controller redundancy 7 See overload 6...

Page 118: ...contact KM1 A1 1 Resistance 46 1 Ω Electric pump KM3 2 080 96 Resistance 46 1 Ω Traction pump motors KM2 3 080 96 Resistance 19 2 Ω Free wheel diode 4 080 96 Resistance 44 Ω Fuse of power circuit 4 080 96 325 A see parts catalog Variable speed controller plate Variable speed controller 1 080 97 Electronic module 2 080 97 Fuse 3 080 97 100A see parts catalog 80 96 1 3 4 2 80 97 1 3 2 ...

Page 119: ...en Closed 48V 3 117 Arm down SQ1a Incoming 1 3 11 Boom rest Open Closed _ 1 4 109 Tilt Incoming 1 3 10 Tilt Open Closed 0V 3 5 108 Base selector Incoming 2 6 11 Lower box select Open Closed 0V 5 6 118 Telescope retracted SQ4a Incoming 1 3 12 Tele sw Open Closed 0V 2 7 Free 8 102 Line switch Outgoing 0V 9 130 Pump traction switch Outgoing 0V 4 10 Free 11 121 Switch KM2 Outgoing 12 12V 1 See operati...

Page 120: ...117 ELECTRICITY 80 547379EN 80 08 03 2017 Power circuit D1 S B E2 A B F1 F2 E1 A1 A2 A1 A2 E2 E1 A1 80 100 Variable speed controller plate Variable speed controller plate relay ...

Page 121: ...BLE SPEED CONTROLLERS USE OF CALIBRATOR 5 120 Incrementation buttons 3 080 101 6 VARIABLE SPEED CONTROLLERS USE OF CALIBRATOR 5 120 Connection socket 4 080 101 Fitting Open the right hand turret cover 1 080 102 Open the front face of the base control panel 2 080 102 Identify the connection cable and attach to it the connection socket 4 080 101 Switch on the access platform Adjust or check the vari...

Page 122: ...d variable speed controller fault display screen 3 080 104 Connection socket 1 080 105 Operation see instruction manual Connection PIN Signal 1 Free 2 0V masse 3 12V back lit 4 12V power supply 5 CAN_H 6 CAN_L Error messages variable speed controller 680 1 ELECTRICAL SCHEMATIC DIAGRAMS 5 73 Maintenance SEVCON h 100 0 P T 80 104 1 2 3 1 2 3 4 5 6 80 105 1 ...

Page 123: ... 16 PARAMETERS 22 PARAMETERS 5 PARAMETERS SEVCON CAN CALIBRATOR SEVCON CAN CALIBRATOR 1 5 Traction Setup 1 8 Traction Display 10 PARAMETERS 13 PARAMETERS 6 PARAMETERS SEVCON CAN CALIBRATOR SEVCON CAN CALIBRATOR 1 6 1 Trac Setup CANModeAboma 1 6 3Trac Setup BDI On 2 6 Pump Lower BoxTest 2 5 Pump LowerBoxPers 1 2 Traction Status SEVCON CAN CALIBRATOR 1 1 Traction Personalities 24 PARAMETERS 1 7 Trac...

Page 124: ...y cutout V 14 5 48 0 0 5 14 5 1 1 18 High Battery Start V High battery safe start V 14 5 75 0 0 5 65 1 1 19 High Battery Cutout V High battery cutout V 14 5 75 0 0 5 70 1 1 20 Battery Protection Level V Battery protection V 14 5 48 0 0 5 14 5 1 1 21 Battery Protection Delay s Battery protection delay S 0 1 2 5 0 1 0 5 1 1 22 Traction Alarm Battery alarm ON According to motor type According to Beep...

Page 125: ...oportional gain 0 255 1 40 1 7 12 Brake Integral Gain Brake total gain 0 16 1 15 1 7 13 Speed Estimate Gain Speed estimated gain 0 2 50 0 01 1 5 Menu Traction BDI Check Battery Charge Mini display Maxi display Pitch Value 1 8 1 Display Default Hours Select hour meter to display Aboma 1 8 2 Display Status Type Select type of status data to display On 1 8 3 Display Contrast Set contrast level standa...

Page 126: ...17 Y Axis Forward Voltage V Front travel voltage V 4 06 4 06 2 3 18 Y Axis Reverse Voltage V Rear travel voltage V 0 52 0 52 2 3 19 X Axis Left Voltage V Zero position X axis voltage V 0 52 0 52 2 3 20 X Axis Right Voltage V Max voltage X axis V 4 06 4 06 Speed travel movement over 10 m s 100 8 Speed travel working over 10 m s 13 60 Menu Pump Lower Box Pers Parameters Hydraulic Functions Base Code...

Page 127: ...or Accelerator 0 100 1 range 1 3 2 Accelerator Voltage Accelerator Voltage 0 0 V 5 0 V 0 02 V range 1 3 3 Deadman Fail safe Open Closed Switch 1 3 6 Steer left LH steering Open Closed Switch 1 3 7 Steer Right RH steering Open Closed Switch 1 3 8 Horn Horn Open Closed Switch 1 3 9 Traction select Traction select Open Closed Switch 1 3 10 Tilt Tilt input Open Closed Switch 1 3 11 Boom Rest Arm down ...

Page 128: ... Open Closed Switch 2 4 17 Cage Rotate Basket rotation selection Open Closed Switch Menu Pump Upper Box Test Test Hydraulic Functions Basket Codes Mini display Maxi display Pitch Type 2 6 1 Boom 1 Up Arm 1 Lifting Control Open Closed Switch 2 6 2 Boom 1 Down Arm 1 Lowering Control Open Closed Switch 2 6 3 Boom 2 Up Arm 2 Lifting Control Open Closed Switch 2 6 4 Boom 2 Down Arm 2 Lowering Control O...

Page 129: ... cap 3 080 107 at the end of the wire Remove the right hand battery protective cover 2 080 107 Take an electric wire 0 5 m 19 69 in long with its ends stripped connect it to the wire 2 080 107 and connect it to the terminal of the right hand battery 3 080 106 The green LED located under the sensor should flash several times It stops when the sensor has initialized It remains continuously lit CAUTI...

Page 130: ...ctive covers from arm 3 1 080 109 Loosen the lock nuts 1 080 110 Screw or unscrew the sensors 2 080 110 until their LED located next to the power supply wire switches from off to on orange the clearance remaining between the support and the sensor is approximately 3 mm 0 11 in Tighten the lock nuts Checking Retracted telescope sensor SQ4a Measure using the calibrator Multimeter Telescope LED statu...

Page 131: ...essure switch SQ3 Measure using the calibrator Multimeter Pressure in braking circuit Wire N Wire N Menu Description Message Display 0to25bar 0to362 59psi 119 119 1 3 13 Brake release Open V 25 bar 362 59 psi 119 119 Closed 0V Based on pressure switch setting NOTE in the absence of a signal from the brakes pressure switch parameter 1 3 13 open the electric pump is permanently active incorrect oper...

Page 132: ...that it remains free to rotate at the end of the operation with minimum play Overload sensor adjustment Undo the lock nuts 1 080 113 then tighten the overload screws 2 080 113 to their maximum extent Place a load in the basket and distribute it evenly across the floor 3 3 120 AETJL 230 kg 507 lbs 3 3 150 AETJC 150 AETJC 3D 230 kg 507 lbs 3 3 150 AETJL 250 kg 551 lbs 3 3 170 AETJL AETJ 49 230 kg 50...

Page 133: ... 44 lbs and check that The alarm switches off The calibrator displays CLOSED in test menu 1 3 16 SQ5a The calibrator displays OPEN in test menu 2 4 9 SQ5b Replace the 20 kg 44 lbs the alarm triggers permanent tone tighten the lock nuts 1 080 113 and put a paint mark on them to confirm the configuration ...

Page 134: ...N 662 13124 Réf CI678453 soft dédié Di 16 klaxon Di 12 sélection pendulaire Di 11 sélection télescope Di 13 sélection compensation Di 08 rot JIB Di 15 rot tourelle Di 14 rot panier Di 10 sélection bras 3 Di 09 sélection bras 1 2 Di 03 sélection translation Di 05 surcharge SQ5a circuit fermé Di 02 libre Ai 01 consigne rotation Di 06 direction GH Di 07 direction DR Ai 02 consigne traction Di 01 Homm...

Page 135: ...ght in the basket Wire N Menu Description Message To card Display 200 kg 441 lbs 333 1 3 16 Cage Ovl 2 F4 Safety F4 200 kg 441 lbs 333 Open Safety No signal Overload sensor SQ5b Measure using the calibrator Multimeter Weight in the basket Wire N Menu Description Message To card Display 200 kg 441 lbs 332 2 4 9 Cage Ovl 2 F4 Safety F4 200 kg 441 lbs 332 Open Safety No signal 24V 1 s OPEN CLOSED OPE...

Page 136: ...on the sub menu in question the status of the inputs outputs at the neutral point then when the manipulators or switches are operated TEST Lastly select menu 2 4 1 and 2 4 3 UPPER BOX TEST on the calibrator and check That the proportional signal progresses steadily i e from 0 to 100 That it is at 0 in neutral and 100 only when the manipulator almost reaches its limit Manipulator test when lifting ...

Page 137: ...played by the voltmeter see figure 080 117 80 115 1 X Y 24V 0V Y 3W 63V 470µf 48V 24V 0V 80 116 OLD NEW STANDARD STANDARD GREEN GREEN NOT NEUTRAL MANIPULATOR YELLOW X YELLOW X TURRET ROTATION CONTROL BLUE YELLOW BLACK LH STEERING PB BLACK GRAY BLACK RH STEERING PB GRAY Y GRAY Y TRAVEL CONTROL PURPLE GREEN BLACK DEADMAN TRIGGER RED BROWN BLACK POWER SUPPLY TRIGGER PINK WHITE BLACK POWER SUPPLY STEE...

Page 138: ... be measured on the wire indicated NS means that there is no signal on the wire indicated NEUTRE Direction GAUCHE Direction DROITE Bl D J N N G G N R B M Ro B N B B A N A N 24V V 24V BLEU D JAUNE NOIR NOIR G GRIS NOIR ROUGE BLANC MARRON ROSE BLANC NOIR BLANC BLANC ANCIENNE NORME NOUVELLE NORME 24V V V Bl D J N N G G N R B M Ro B N B B A N A N 24V 24V V 80 118 Gachette au NEUTRE Gachette ACTIONNEE ...

Page 139: ...right hand battery Remove the right hand battery protective cover 4 080 120 Disconnect the earth 1 080 121 Disconnect the 2 080 121 Disconnect the left hand battery following the same procedure Remove the cover 4 080 120 Remove the cover plate 1 080 122 Mark and then remove the harnesses connected to the variable speedcontrollers 2 080 122 680 3 4VARIABLESPEEDCONTROLLERS CONTROL AND SETTINGS 5 115...

Page 140: ... 080 123 Disconnect the earth 2 080 123 Disconnect the 3 080 123 Disconnect the left hand battery following the same procedure Remove the right hand battery see figure 080 124 then the left hand battery 3 3 120 AETJL 220 kg 485 lbs 3 3 150 AETJC 150 AETJC 3D 150 AETJL 170 AETJL 265 kg 584 lbs 3 3 AETJ 43 AETJ43 3D 268 kg 591 lbs 80 123 2 3 1 80 124 ...

Page 141: ...08 03 2017 80 4 3 ELECTRICAL HARNESSES REMOVAL A Wiring based on the schematic diagrams 680 1 3 SCHEMATIC DIAGRAM BASKET CONTROL PART 1ST VERSION 5 77 CAUTION In this chapter all of the connectors are shown on the wire insertion side ...

Page 142: ...Pers Error Parameter outside valid range The fault is removed by adjusting the value using the calibrator Search for and fix the parameter where the following value is displayed Switch the variable speed controller off and on check the parameters F04013 CRC Error Checksum parameter value incorrect The fault is removed by adjusting the value using the calibrator Check the value of all parameters Fo...

Page 143: ...sts change the variable speed controller or otherwise check the insulation of the variable speed controller and the switch KM3 2 2 With the line switch KM1 OPEN the voltage at terminal A of the variable speed controller is 3 V Internal fault in the variable speed controller replace it F05006 Mosfet s c Failure of power test when switching on Turn off the machine if the problem persists repeat the ...

Page 144: ...ulator its wiring 7 Flashs VOLTAGE BATTERY F04010 Battery High Battery voltage high on High V cut parameter Check the correct operation of the battery charger F04009 Battery Low Battery voltage higher than the High V cut parameter Battery voltage lower than the Low V cut parameter Battery voltage lower than the battery protection parameter beyond the delay specified by the parameter protection del...

Page 145: ...rformed 5 BUS CAN connectors disconnected Disconnect the BUS CAN harnesses wires 113 and 112 at each end variable speed controller base electronic control unit basket electronic control unit For wires 113 and 112 check the continuity between each of them and each end check that there is no continuity between wires 113 and 112 Check the connections the shielding variable speed controller section BA...

Page 146: ...lashing Loss of control of output current Logic control unit fault Stage of reading current or shunt Acoustic signal RED YELLOW LED flashing Loss of control of output voltage Battery disconnected or fault on logic control unit Stage of reading voltage or resistance of reading voltage of open battery Acoustic signal YELLOW GREEN LED flashing An unavailable configuration has been selected Check the ...

Page 147: ...Testing the manipulators 680 3 6 MANIPULATOR OPERATION AND SETTINGS 5 133 138 Troubleshooting 680 5 TROUBLESHOOTING ELECTRICAL 5 139 160 DESCRIPTION Screen 1 080 125 Scrolling buttons 2 080 125 6VARIABLE SPEED CONTROLLERS USE OF CALIBRATOR 5 120 Incrementation buttons 3 080 125 6 VARIABLE SPEED CONTROLLERS USE OF CALIBRATOR 5 120 Connection socket 4 080 125 SEVCON CAN CALIBRATOR Controller A Menu ...

Page 148: ...S 13 00 2 1 CHARACTERISTICS 13 00 2 2 LUBRICANTS AND FUEL 13 00 2 3 DIMENSIONS 14 DIMENSIONS 120AETJL 14 DIMENSIONS 150AETJC AETJ 43 AETJC 43 3D 16 DIMENSIONS 150AETJL 18 DIMENSIONS 170AETJL 49 AETJC 20 00 2 4 LOCATION OF NAME AND IDENTIFICATION PLATE 22 ACCESS PLATFORM MANUFACTURER S PLATE 22 LOCATION OF MANUFACTURER S PLATE 120 AETJ 22 00 3 GENERAL CONTROL AND ADJUSTMENT 23 00 3 1 STANDARD TIGHT...

Page 149: ...enance manual This manual should be found in all trucks Please follow all safety instructions Use the appropriate tools for any work to be performed Use original Manitou spare parts Any non compliance increases the risk of accidents occurring which may lead to causing grievous bodily harm and even death An eﬃcient dependable and profitable combination will be formed if the operator follows the saf...

Page 150: ...ention to important information regarding environmental protection SPECIFIC TOOLING Indicates special tools for performing a task 4 SEE Indicates a cross reference to a manual 5 SEE Indicates a cross reference to a page 0 SEE Indicates a cross reference to a picture 3 WEIGHT Indicates the weight of an item E g it helps to anticipate an action linked to a person s health or the choice of lifting eq...

Page 151: ...ine has had time to cool down AVERTISSEMENT Before carrying out any operation on an electrically powered component activate the battery cut oﬀ PRÉCAUTION Press the battery switch at least 30 seconds after disconnecting the electrical contact with the ignition key AVERTISSEMENT If the telehandler does not have a battery isolating switch disconnect the battery terminals then gather them PRÉCAUTION B...

Page 152: ... Always wear protection glasses gloves safety shoes as well as any other protection required for the work to be carried out DANGER When carrying out maintenance operations near a mobile object make sure it is securitized PROTÉGER L ENVIRONNEMENT When changing or draining oils or fuel or any other operation with liquids solids gases that are harmful to the environment make sure the necessary precau...

Page 153: ... lifting devices When using a jack make sure it is used on a flat uniform surface is sturdy enough to support the load that its lifting capacity is sufficient and that it is correctly placed and positioned under the machine PRÉCAUTION Makesurenoobjectortoolwhichcouldcauseanaccidentisleftinthemachine AVERTISSEMENT Never control any leaks using a hand PRÉCAUTION Never adjust a component to over the ...

Page 154: ... 2 734lbs 1534kg 3 389lbs 1555kg 3 428lbs REAR 1340kg 2 954lbs 1885kg 4 156lbs 1885kg 4 156lbs 1715kg 3 781lbs 1921kg 4 325lbs 1992 5kg 4 393lbs Nominal capacity 2 people 200kg 441lbs 200kg 441lbs 200kg 441lbs 230kg 507lbs 200kg 441lbs 227kg 500lbs 227kg 500lbs 227kg 500lbs 00 2 2 LUBRICANTS AND FUEL Designation Type Quantity Hydraulic tank MANITOU ISO VG 46 Hydraulic oil 18 ℓ 4 76 US gallons Whee...

Page 155: ...9EN 00 08 03 2017 00 D E B C F H G I A1 A1 C1 A 00 2 3 DIMENSIONS DIMENSIONS 120AETJL mm ft in A 5520 18 1 3 A1 3930 12 10 7 B 2000 6 6 7 C 1995 6 6 5 C1 2210 7 3 0 D 1500 4 11 1 E 153 0 6 0 F 2640 8 8 0 G 1870 6 1 6 H 3960 12 11 9 I 4520 14 9 9 ...

Page 156: ...N 00 08 03 2017 00 mm ft in mm ft in G1 2350 7 8 5 H1 9950 32 7 7 G2 3105 10 2 2 H2 8795 28 10 3 G3 6370 20 10 8 H3 4775 15 8 0 G4 5640 18 6 0 H4 545 1 9 5 G1 G2 H2 H1 G3 H3 G4 H4 12 11 10 9 8 7 6 5 4 3 2 1 4 5 6 7 13 3 2 1 0 1 2 3 5 2 3 3 2 6 7 4 ...

Page 157: ...9EN 00 08 03 2017 00 D E F H G I B C1 A1 C A DIMENSIONS 150AETJC AETJ 43 AETJC 43 3D mm ft in A 6050 19 10 2 A1 4400 14 5 2 B 2000 6 6 7 C 1965 6 5 4 C1 2080 6 9 9 D 1500 4 11 1 E 143 0 5 6 F 2640 8 7 9 G 1870 6 1 6 H 3960 12 11 9 I 4820 15 9 7 ...

Page 158: ...8 03 2017 00 mm ft in mm ft in G1 2665 8 8 9 H1 12985 42 7 2 G2 3425 11 2 8 H2 11835 38 9 9 G3 7105 23 3 7 H3 7165 23 6 1 G4 6300 20 8 0 H4 235 0 9 2 G1 G2 H2 H1 G3 H3 G4 H4 8 9 7 12 11 10 9 8 7 6 5 4 3 2 1 4 5 6 7 8 9 16 15 14 13 3 2 1 0 1 2 3 2 3 3 2 ...

Page 159: ...ETY 18 547379EN 00 08 03 2017 00 DIMENSIONS 150AETJL D E F H G I B A1 A C C1 mm ft in A 5960 19 6 6 A1 4400 14 5 2 B 2000 6 6 7 C 1970 6 5 5 C1 2080 6 9 9 D 1750 5 8 9 E 143 0 5 6 F 2880 9 5 4 G 1970 6 5 6 H 4270 14 0 1 I 4890 16 0 5 ...

Page 160: ...8 03 2017 00 mm ft in mm ft in G1 2660 8 8 7 H1 13275 43 6 6 G2 3420 11 2 6 H2 12120 39 9 1 G3 7310 23 11 8 H3 7165 23 6 1 G4 6500 21 3 9 H4 205 0 8 1 G1 G2 H2 H1 G3 H3 G4 H4 8 9 12 11 10 9 8 7 6 5 4 3 2 1 4 5 6 7 8 9 16 15 14 13 3 2 1 0 1 2 3 5 2 3 3 2 ...

Page 161: ...0 547379EN 00 08 03 2017 00 D E F H G I B A1 A C C1 DIMENSIONS 170AETJL 49 AETJC mm ft in A 6840 22 5 3 A1 5120 16 9 6 B 2000 6 6 7 C 1970 6 5 6 C1 2040 6 8 3 D 1750 5 8 9 E 140 0 5 5 F 2890 9 5 8 G 2005 6 6 9 H 4300 14 1 3 I 5600 18 4 5 ...

Page 162: ...21 GENERAL CHARACTERISTICS AND SAFETY 547379EN 00 08 03 2017 00 mm ft in G1 2840 9 3 8 G2 3600 11 9 7 G3 8930 29 3 6 G4 8130 26 8 1 H1 14905 48 10 8 H2 13750 45 1 3 H3 7160 23 5 9 H4 270 0 10 6 ...

Page 163: ...information always specify NOTE For the owner s convenience it is recommended that a note of these numbers is made in the spaces provided at the time of the delivery of the access platform ACCESS PLATFORM MANUFACTURER S PLATE Type Serial no Year of manufacture LOCATION OF MANUFACTURER S PLATE 120 AETJ The manufacturer s plate is fitted on the inside right panel of the turret LOCATION OF MANUFACTUR...

Page 164: ...24 x 2 659 5833 967 8559 M27 x 3 874 7735 1284 11364 M27 x 2 965 8541 1418 12550 M30 x 3 5 1181 10453 1735 15356 M30 x 2 1351 11957 1984 17560 M33 x 3 5 1614 14285 2371 20985 M33 x 2 1821 16117 2674 23667 M36 x 4 2068 18303 3037 26880 bFor hexagon screws with flanges NF E 25 030 1 Apply an increased torque of 10 bWhere washers are used the following coeﬃcient is to be applied FD E 25 502 Plate 0 S...

Page 165: ...nd lat libra kg kilogram x 35 274 oz av ounce avoirdupois oz lat onza km h kilometer per hour x 0 6214 mph miles per hour kW kilowatt x 1 34048 hp horsepower ℓ liter x 0 2642 gal US US gallon ℓ liter x 1 0567 qt US quart US gallon m meter x 3 2808 ft foot m meter x 39 37 in inch min minute x 1 min minute mℓ milliliter x 0 0338 fl oz fluid ounce fl fluid oz lat onza mm millimeter x 0 03937 in inch ...

Page 166: ...TABLE OF CONTENTS AXLE 30 1 CHARACTERISTICS AND SPECIFICATIONS 27 30 1 1 REAR AXLE OPERATION IN FREEWHEEL MODE 27 30 ...

Page 167: ...AXLE 26 30 547379EN 30 08 03 2017 ...

Page 168: ...y means of a connecting bar between the two machines IF POSSIBLE lift the rear of the platform 1 030 4 3 3 120 AETJL 2680 kg 5908 lbs 3 3 150 AETJC 3770 kg 8311 lbs 3 3 150 AETJL 150 AETJC 3D 3375 kg 7441 lbs 3 3 170 AETJL AETJ49 3842 kg 8470 lbs 3 3 AETJ43 AETJ43 3D 3775 kg 8322 lbs Locate the screws 2 030 4 Unscrew these screws according to the model of your platform 030 5 by 22 mm 0 87 in up to...

Page 169: ......

Page 170: ...T CONTROLS 31 55 1 1 CHECK THE CLEARANCE OF THE TELESCOPE 31 55 2 JIB BASKET REMOVAL 31 55 2 1 REMOVAL OF PADS OF TELESCOPIC CYLINDER 31 55 2 2 REMOVAL OF REAR PADS OF TELESCOPIC CYLINDER 31 55 2 3 REMOVAL OF PADS OF TELESCOPE MOVING TUBE 32 55 ...

Page 171: ...JIB BASKET 30 55 547379EN 55 08 03 2017 ...

Page 172: ... CYLINDER Remove the telescopic cylinder 6TELESCOPIC CYLINDER REMOVAL 5 63 Remove and replace the pads 1 055 6 see parts catalog 55 2 2 REMOVAL OF REAR PADS OF TELESCOPIC CYLINDER Remove the telescopic cylinder 6TELESCOPIC CYLINDER REMOVAL 5 63 Release the pads 1 055 7 by slightly raising the basket Remove the pads 1 055 7 pay attention to the position and number of adjustment plates Get new pads ...

Page 173: ...nd wiring harnesses Release the pads of the telescope jib by gently releasing the moving tube 1 055 9 Remove the pads 2 055 9 of the telescope jib pay attention to the position and number of adjustment plates Remove the moving tube by allowing it to slide towards the rear 3 3 120 AETJL 102 kg 225 lbs 3 3 150 AETJC et 150 AETJL 150 AETJC 3D AETJ43 AETJ43 3D 116 kg 256 lbs 3 3 170 AETJL AETJ49 148 k...

Page 174: ...ESCOPIC CIRCUIT PRESSURE SETTING 49 PRESSURE REDUCER SETTING 49 70 3 5 COMPENSATION TILTING CIRCUIT PRESSURE SETTING 50 DECOMPRESSION OF THE CIRCUIT 50 VALVE A ADJUSTMENT 50 VALVE B ADJUSTMENT 51 70 3 6 COMPENSATION TILTING CIRCUIT PROBLEM SOLVING 52 TEST PROCEDURE 52 ANALYSIS OF RESULTS 53 70 3 7 TURRET ROTATION MOTOR REMOVAL 54 70 3 8 ELECTRIC PUMP REMOVAL 55 70 3 9 REDUCING GEARS WHEEL BRAKES R...

Page 175: ...HYDRAULIC 34 70 547379EN 70 08 03 2017 LINKS TO REPAIR MANUALS MANUAL REFERENCE NUMBER DESIGNATION 647 187 ROTARY ACTUATORS HELICAL HYDRAULIC L20 SERIE ...

Page 176: ... 120 b 4 5 6 13 2 3 14 15 7 8 9 16 17 1 10 11 19 12 EV18 EV19 EV1 EV5 EV16 EV17 EV6 EV7 EV8 EV9 EV10 EV11 EV12 EV13 EV14 EV15 EV22 EV23 EV2b EV2 EV3 18 25 b mini 25 b 20 T P P 110b 21 150 b 679449 Index E Turret rotation Steering Basket rotation Brakes Arms 1 2 Arm 3 Pendular arm Compensation Tilt 3D JIB rotation OIL TANK Telescope See Note Only 150 AETJC 150 AETJC 3D AETJ 43 AETJ 43 3D 150 AETJL ...

Page 177: ...70 547379EN 70 08 03 2017 HYDRAULIC 36 ...

Page 178: ...Brakes 1 Safety valve AETJ Standard Taring No Function NOTE Delivery of the block with the adjustment 21 Pressure restrictor 150 b This diagram relates to lifting platforms 150 AETJC 150 AETJC 3D AETJ 43 AETJ 43 3D 150 AETJL 170 AETJL AETJ 49 AETJ standard 80 b Raising Lowering Raising Lowering Extended Retracted Raising Lowering Boost Tilt Right Left Transport Position Stop Stop steering translat...

Page 179: ...70 547379EN 70 08 03 2017 HYDRAULIC 38 ...

Page 180: ...80b 180 b 210 b 210 b 110 b 210 b 210 b 220 b 150 b 180 b 4 5 6 13 2 3 14 15 7 8 9 18 19 1 10 11 21 12 EV 18 EV 19 E V1 E V5 EV 16 E V17 E V6 E V7 E V8 E V9 E V10 E V11 E V12 E V13 E V14 E V15 E V22 E V23 E V2b E V2 E V3 20 25 b mini 25 b 120 AETJL 685268 Indice A 685268 Index A Turret rotation Steering Basket rotation Brakes Arms 1 2 Arm 3 Pendular arm Compensation Tilt 3D JIB rotation OIL TANK T...

Page 181: ...70 547379EN 70 08 03 2017 HYDRAULIC 40 ...

Page 182: ... Brakes 2 Brakes 1 Safety valve AETJ Standard Taring No Function NOTE Delivery of the block with the adjustment 21 Pressure restrictor This diagram relates to lifting platforms 150 AETJC 150 AETJC 3D AETJ 43 AETJ 43 3D 150 AETJL 170 AETJL AETJ 49 AETJ standard Raising Lowering Raising Lowering Extended Retracted Raising Lowering Boost Tilt Right Left Transport Position Stop Stop steering translati...

Page 183: ...70 547379EN 70 08 03 2017 HYDRAULIC 42 ...

Page 184: ...DRAULIC 70 547379EN 70 08 03 2017 70 2 HYDRAULIC COMPONENTS LOCATION 70 2 1 HYDRAULIC COMPONENTS OF THE CHASSIS LOCATION Reducing gear Brake of left wheel Reducing gear Brake of right wheel Steering cylinder ...

Page 185: ...EN 70 08 03 2017 70 2 2 HYDRAULIC COMPONENTS OF THE TURRET LOCATION Backup pump Accumulator 150AETJC 150 AETJC 3D 150 AETJL 170 AETJL AETJ 43 AETJ 43 3D AETJ 49 Electric pump Distributor block Turret rotation engine Oil tank ...

Page 186: ...9EN 70 08 03 2017 70 2 3 HYDRAULIC COMPONENTS OF THE JIB LOCATION 120 AETJL Compensatingcylinder Telescope cylinder Tilting cylinder Arm 3 lifting cylinder Basket rotation cylinder Jib cylinder Arm 1 2 lifting arm cylinder ...

Page 187: ... AETJC 150 AETJC 3D 150 AETJL 170 AETJL AETJ43 AETJ43 3D AETJ 49 Telescope cylinder Compensating cylinder Tilting cylinder Arm 3 lifting cylinder Jib cylinder A r m 1 2 l i f t i n g arm cylinder Basketrotationcylinder 3D JIB rotation cylinder ...

Page 188: ...form Control the lowering of arms 1 2 and maintain the control when the cylinder reaches the stop Checkthatthepressuregaugedisplaysthepressurerecommended in the hydraulic diagram As required adjust the setting of the main relief valve 2 070 11 70 3 2 STEERING BASKET TURRET ROTATION CIRCUIT PRESSURE SETTING Setting the pressure relief valve 13 070 1 1 13 070 1 2 On the distributor connect a pressur...

Page 189: ...e gauge 2 070 13 Switch on the access platform Control the travel and check that the displayed pressure follows the curve 1 070 14 If the pressure switch 2 070 15 trips BELOW the threshold 2 070 14 then with the platform stationary adjust the threshold by TIGHTENING the adjustment screw 2 070 15 If the pressure switch 1 070 15 trips ABOVE the threshold 2 070 14 unscrew the adjustment screw by a fe...

Page 190: ...R REMOVAL 5 57 Place a Tee connector on the by pass at outlet A3 1 070 16 and connect the pressure gauge 2 070 16 Switch on the access platform Move the telescope extension and keep it moving under it reaches its full extent Checkthatthepressuregaugedisplaysthepressurerecommended in the hydraulic diagram As required adjust the setting of the pressure reducer 1 070 17 0 A3 70 16 1 2 70 17 1 ...

Page 191: ...r to the access platform VALVE A ADJUSTMENT 17 070 1 1 19 070 1 2 Place a Tee connector on the by pass at outlet A5 1 070 18 and connect the pressure gauge 2 070 18 Switch on the access platform Follow steps 1 070 20 2 070 21 and 3 070 22 the verification of the setting of valve A 1 070 19 and its adjustment are to be carried out during movement 3 0 A5 70 18 2 1 70 19 1 70 20 TO ITS FULL EXTENT 1 ...

Page 192: ...the by pass at outlet B5 1 070 23 and connect the pressure gauge 1 070 23 Switch on the access platform Follow steps 1 070 25 and 2 070 26 the verification of the setting of valve A 1 070 24 and its adjustment are to be carried out during movement 2 0 B5 70 23 2 1 70 24 1 70 25 TO ITS FULL EXTENT 1 70 26 2 ...

Page 193: ... for the upper chamber 2 070 27 Remove the hoses 1 070 28 connected at A5 and B5 from the distributor block Insert tee couplings between the distributor block and the hoses 2 070 28 Take a 0 200 bar 0 2900 75 psi manometer 3 070 28 and connect it to the left hand tee coupling outlet A5 Take a 0 100 bar 0 1450 38 psi manometer 4 070 28 and connect it to the right hand tee coupling outlet B5 Switch ...

Page 194: ...distributor block Decompression of the compensation tilting circuit 670 3 11 CYLINDERS REMOVAL 5 60 Remove the valve s 1 070 30 and check the appearance of the seals Change the valves if the seals are defective see parts catalog Refit the valves then check their adjustment 670 3 5 COMPENSATION TILTING CIRCUIT PRESSURE SETTING 550 THE BASKET DROPS THE PRESSURE ON BOTH MANOMETERS TENDS TO BALANCE 10...

Page 195: ... hand turret cover Decompress the turret rotation line distributor 670 3 10 DISTRIBUTOR REMOVAL 5 57 Open the left hand turret cover 1 070 31 Remove and plug the two hoses 1 070 32 Remove the motor attachments 2 070 32 Remove the steering motor 3 070 32 3 3 36kg 80 lbs 70 31 1 70 32 3 2 1 1 ...

Page 196: ...ver 1 070 33 Following fitting see figure 070 34 see figure 070 35 Remove and plug the hose 1 070 34 1 070 35 Remove and plug the connector 2 070 34 2 070 35 Remove the attachments 3 070 34 3 070 35 and remove the electric pump 4 070 34 4 070 35 3 3 25 kg 55 lbs 70 33 1 70 34 3 1 2 4 70 35 1 4 2 3 ...

Page 197: ...s 3 070 32 and remove the wheels 3 3 53 kg 117 lbs Remove the cover 4 070 36 Mark and then remove the electric cables connected to the motors 1 070 37 Remove the fasteners from one of the motors 2 070 37 and remove this motor B 3 3 3 27 kg 60 lbs Repeat the same procedure on the second engine Remove and plug the hoses 1 070 38 Remove the fasteners from one of the reducing gears brakes 2 070 38 and...

Page 198: ...ydraulic lines Pull push the 3 non indexed controls 2 070 43 and allow them to return to their equilibrium position Pull push the 5 indexed controls 3 070 43 and return them to their center position Replace the manual indexed control protections 1 070 43 Remove and plug the hoses connected to the distributor Identify the wiring harnesses connected to the solenoids and disconnect them Remove the di...

Page 199: ...HYDRAULIC 58 70 547379EN 70 08 03 2017 ...

Page 200: ...n N m lb in 1 Distributor 2 Electrovalve Item 4 Item 4 39 51 Nm 345 18 451 39 lb in 3 Electrovalve Items 5 6 Items 5 6 4 Electrovalve Item 3 Item 3 5 Electrovalve Item 2 Item 2 6 Electrovalve Items 7 8 9 10 Items 7 8 9 10 44 56 Nm 389 43 495 64 lb in 7 Electrovalve Item 12 Item 12 8 Electrovalve Item 1 Item 1 39 51 Nm 345 18 451 39 lb in 9 Pressure reducer 100 bar 1450 38 psi Item 13 Item 13 10 Pl...

Page 201: ... 3 070 44 Decompress the steering line distributor 670 3 10 DISTRIBUTOR REMOVAL 5 57 Remove and plug the hoses connected to the steering cylinder 1 070 45 Remove the pivot pins from the steering cylinder 2 070 45 and remove the cylinder REFIT Carry out the removal operations in reverse order leaving the access platform on supports Drain the steering circuit Control the steering until it reaches it...

Page 202: ... connected to the cylinder 1 070 47 Remove the pivot pins from the cylinder starting with the cylinder head pin 2 070 47 and remove the cylinder 3 3 120 AETJL 25 kg 55 lbs 3 3 150 AETJC 150 AETJL 150 AETJC 3D 150 AETJL AETJ43 AETJ 43 3D 170 AETJL AETJ 49 70 kg 154 lbs NOTE Before attempting to disassemble the removed cylinder 6VALVE BLOCKS AND VALVES REMOVAL 5 69 REFIT Carry out the removal operat...

Page 203: ...t cover Decompress the lifting line of arm 3 distributor 670 3 10 DISTRIBUTOR REMOVAL 5 57 Remove and plug the hoses connected to the cylinder 1 070 49 Remove the pivot pins from the cylinder starting with the cylinder foot pivot pin 2 070 49 and remove the cylinder 3 3 120 AETJL 30 kg 66 lbs 3 3 150 AETJC 150 AETJL 150 AETJC 3D 150 AETJL AETJ43 AETJ 43 3D 170 AETJL AETJ 49 50 kg 111 lbs NOTE Befo...

Page 204: ...the telescopic line distributor 670 3 10DISTRIBUTOR REMOVAL 5 57 Remove the telescope base cover 1 070 51 Remove and plug the hoses connected to the cylinder 2 070 51 Remove the cylinder foot pivot pin 3 070 51 and remove the telescope cylinder 3 3 120 AETJL 34 kg 75 lbs 3 3 150AETJC 150AETJC3D AETJ43 AETJ433D 39kg 86lbs 3 3 150 AETJL 42 kg 93 lbs 3 3 170 AETJL AETJ 49 55 kg 121 lbs NOTE Before at...

Page 205: ...bly with a hoist and a sling 3 3 without rotation cylinder 3D JIB 230 kg 507 lbs 3 3 with rotation cylinder 3D JIB 267 kg 589 lbs Open the right hand turret cover Remove the cylinder pivot pins 1 070 56 and remove the cylinder from the arms while leaving it connected to the hoses 3 3 120 AETJL 18 kg 40 lbs 3 3 150 AETJC 150 AETJL 170 AETJL 20 kg 44 lbs Remove and plug the hoses connected to the cy...

Page 206: ...hile leaving it connected to the hoses 3 3 22 kg 49 lbs Remove and plug the hoses connected to the cylinder 1 070 58 and remove the cylinder NOTE Before attempting to disassemble the removed cylinder 6VALVE BLOCKS AND VALVES REMOVAL 5 69 REFIT Follow the removal operations in reverse order Purge the compensation tilting circuit by repeating steps I to VII several times I II 070 59 III IV 070 62 V ...

Page 207: ...n a stable surface Open the right hand turret cover Decompress the jib lifting line 670 3 10 DISTRIBUTOR REMOVAL 5 57 Remove and plug the hoses connected to the cylinder 1 070 64 Remove the pivot pins from the cylinder starting with the cylinder foot pivot pin 2 070 64 and remove the cylinder 3 3 15 kg 33 lbs NOTE Before attempting to disassemble the removed cylinder 6VALVE BLOCKS AND VALVES REMOV...

Page 208: ...ret cover Decompress the basket rotation line 670 3 10 DISTRIBUTOR REMOVAL 5 57 Remove and plug the hoses connected to the cylinder 1 070 49 Remove the cylinder foot pivot pin 2 070 66 and the nut of the cylinder head pin 3 070 66 and remove the cylinder NOTE Before attempting to disassemble the removed cylinder 6VALVE BLOCKS AND VALVES REMOVAL 5 69 70 65 1 70 66 2 3 1 1 ...

Page 209: ...ssary remove the harnesses and the hoses of the jib cylinder 6JIB CYLINDER REMOVAL 5 66 Remove the 3D rotation cylinder pivot pin 1 070 68 Secure the 3D rotation cylinder assembly with a hoist and a sling see figure 070 69 3 3 37 kg 82 lbs Démonter l axe d articulation du vérin d inclinaison 3 070 68 et l axe d articulation du bras 4 070 68 Remove the 3D rotation cylinder REFIT Follow the removal ...

Page 210: ...order to avoid pressurized oil leaks the operator should position the cylinder with the contact face 1 070 70 between the valve block and the cylinder vertically and then position a rubber sheet over this face 2 070 70 Secure the cylinder body in a vise Loosen the fixing screws of the block 3 070 70 one after another by a MAXIMUM of 1 4 turn for each screw Unscrew the screws by 1 4 turn WITH A SPA...

Page 211: ...HYDRAULIC 70 70 547379EN 70 08 03 2017 ...

Page 212: ...L COMPONENTS LOCATION 83 80 2 2 ELECTRICAL POWER COMPONENTS LOCATION 84 80 4 4 WIRING BASED ON SCHEMATIC DIAGRAM 676423 1ST VERSION 85 LOCATION OF WIRING HARNESSES ON THE ACCESS PLATFORM 85 BASKET CONTROL PANEL HARNESS 86 OVERLOAD SENSORS HARNESS 89 UPPER BUS CAN EXTENSION HARNESS 90 LOWER BUS CAN EXTENSION HARNESS 92 UPPER BUS CAN CONTROL PANEL OUTPUT HARNESS 93 BASE BOX HARNESS 94 VARIABLE SPEED...

Page 213: ...D ADJUSTMENT TOOLS 118 BATTERY CHARGE INDICATOR HOUR METER 119 VARIABLE SPEED CONTROLLERS USE OF CALIBRATOR 120 80 3 5 SAFETY COMPONENTS CONTROL AND SETTINGS 126 SWITCHES LOCATION 126 TILT SENSOR SETTINGS 126 ARM DOWN SENSORS SETTINGS 127 BRAKE RELEASE CIRCUIT CHECKING 128 OVERLOAD SENSORS SETTINGS 129 MULTIMETER TEST 132 80 3 6 MANIPULATOR OPERATION AND SETTINGS 133 MANIPULATOR TESTS USING CALIBR...

Page 214: ...RAMS WARNING Diagram 1st VERSION Access platform fitted with an overload sensor harness comprising a Deutsch connector with 8 way SQ5a SQ5b SQ5a WARNING Diagram 2nd VERSION Access platform fitted with an overload sensor harness comprising a Deutsch connector with 3 way SQ5b SQ5a SQ5b ...

Page 215: ......

Page 216: ... lights and actuators hyave a nominal voltage of 24 V ELECTRIC PUMP VARIABLE SPEED DRIVE power Left Right TRACTION MOTORS VARIABLE SPEED DRIVE logic arm low A supply pressure stat tel retracted A Base select tilt line trac pump telescope retracted BATTERY CHARGE POWER ON Emergency stop 2 TRACTION PUMP SWITCHING LINE CONTACTOR pressure stat brakes released pump t e l e s c o p e r e t r a c t e d a...

Page 217: ... Left compensation Down basket rot Right basket rot Left arm 3 Up arm 1 2 Down arm 1 2 Up arm 3 Down Send to tank Flashing light Turret rot Left Basket rot Left brake steer L pump pendular arm Up telescope extended arm 3 Up arms 1 2 Up Unless otherwise stated the indicator lights and actuators have a nominal voltage of 24V Tilt Arms Arm Basket rotation CONTROL CONSOLE white brown white blue blue b...

Page 218: ...otation overload maintenance warning pendular arm turret rotation basket rotation tilt alarm faults Ref Overload Ref tilt instruction rotation steer left steer right traction instruction Dead man s system Except for NEUTRAL Overload 24V 2 AXIS joystick Overload warning red Tilt ARMS ARM All the LEDs are supplied with 24V BASKET ROTATION TURRET PENDULAR ARM Overload warning Maintenance warning gree...

Page 219: ...n Unless otherwise stated the indicator lights and actuators have a nominal voltage of 24V Sector sensor control module arm low B arm low A telescope retracted A telescope retracted B overload SQ5a overload SQ5b speed reduction return overload validation return dedicated soft a r m l o w r e t r a c t e d J I H G F E D C B A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ...

Page 220: ...C PUMP 3 6 KW 48V TRACTION MOTORS SEM XP1747 48V VARIABLE SPEED DRIVE power n c A3 10V5 A1 0V A2 10V5 A4 CAN H A5 CAN L A6 678423 Index S Page 1 4 network yellow white black blue green singles LEDS RED GREEN Base Emergency Stop BASE BASKET Selector SLOPE supply arm low a r m l o w E l e c t r o v a l v e s s u p p l y retracted r e t r a c t e d pump pressure stat brakes released LINE CONTACTOR TR...

Page 221: ...o 04 arms 1 2 R Do 02 turret rot R Do 10 Steer R Do 16 basket rot R Do 18 compensation Up Do 21 brake Do 22 steer L Do 15 pump Do 24 pendular arm Up Do 07 telescope Extended Do 13 arm 3 Up Do 05 arms 1 2 Up Do 03 C NEG D NEG B NEG CAN bus socket Diagnostics MOLEX Mini Fit box for males 6 way contacts CAN L CAN 6 CAN H CAN 5 12V CAN 4 0V CAN 2 12V CAN 1 B 2 B 678423 Index S Page 2 4 Turret rotation...

Page 222: ...ion Di 08 JIB rot Di 15 turret rot Di 14 basket rot Di 10 arm 3 selection Di 09 arms 1 2 selection Di 03 translation selection Di 05 SQ5b overload Di 02 available Ai 01 rotation instruction Di 06 steer Left Di 07 steer Right Ai 02 traction instruction Di 01 Dead man s system Di 04 Except for NEUTRAL 678423 Index S Page 3 4 Basket Emergency stop Overload Overload arms 1 2 selection arm 3 selection ...

Page 223: ... 9 10 11 12 13 14 B02 arm low B B01 arm low A B03 telescope retracted A B04 telescope retracted B B05 overload SQ5b B06 overload SQ5a B07 speed reduction return BO8 overload validation return A5 CAN L A6 CAN H Out_2 Out_1 Overload Validation dedicated soft 678423 Index S Page 4 4 Sector sensor control module low arm b telescope retracted ...

Page 224: ...lt sensor Basecontrolpanel Safety control card Base module control unit Battery charge indicator hour meter LED showing charging states removed Basket module control unit Basket control panel Arm down sensors 150AETJC 150AETJC3D 150AETJL 170AETJL AETJ 43 AETJ 43 3D AETJ 49 Horn Retracted telescope sensor Low arm sensors 120 AETJL Overload sensors ...

Page 225: ...RICAL POWER COMPONENTS LOCATION Electric pump Safety control card Right hand battery Variable speed controller plate Left hand battery Battery cut off Variable speed controller plate relay Left traction motor Right traction motor ZIVAN charger IES charger ...

Page 226: ...rovalve harness 8 Tilt wiring harness 9 Horn harness 10 Flashing flight harness 11 Output sensor control panel harness 12 Intermediate inductive sensors harness 150 AETJC 150 AETJL 170 AETJL AETJ 43 AETJ 43 3D AETJ 49 Telescopic arm sensors harness 120 AETJL 13 Telescope arm sensor 14 Low arm sensor harness 15 Arm down sensor 16 Overload sensors 8 10 12 12 13 15 15 14 2 2 7 6 16 1 5 13 11 4 3 3 9 ...

Page 227: ...up LED Arm 3 up LED Tilt reverse tilt LED Telescope LED Pendular arm up LED Buzzer Overload LED 20 port female Deutsch through partition connector Ref S13 S14 S15 S17 S18 S19 S20 S21 S22 8S 8P 8P PC Designation Translation selector Arm 1 2 up down selector Arm 3 up down selector Pendular arm turret basket rotation selector Tilt reverse tilt selector Telescope extension retraction selector Pendular...

Page 228: ...19 S20 S21 S22 4S 6S 8P PC Designation Translation selector Arm 1 2 up down selector Arm 3 up down selector Pendular arm turret basket rotation selector Tilt reverse tilt selector Telescope extension retraction selector Pendular arm up down selector Horn button Emergency Stop 4 port male Deutsch connector 6 port male Deutsch connector 8 port female Deutsch through partition connector 12P PC 12 por...

Page 229: ...3 103 Wire 315 318 spare spare spare spare spare spare Pos 1 2 3 4 5 6 7 8 Wire 319 312 311 313 332 316 317 306 310 309 304 303 305 308 307 302 Pos 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Wire spare 328 327 322 321 spare 323 spare spare spare spare spare 329 331 320 330 spare 335 337 spare 336 338 spare spare Pos 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Wire spare spare spare ...

Page 230: ...RLOAD SENSORS HARNESS ITEM 16 To full basket control panel Item 1 OVERLOAD SENSORS HARNESS 678849 D Item 16 SQ5a SQ5b 1 2 3 4 5 6 7 8 Pin Wire Color 1 332 black 2 335 black white 3 312 brown 4 335 blue 5 333 black 6 335 black white 7 free 8 free ...

Page 231: ... 17 16 15 14 13 12 11 10 9 To complete basket console Ref 1 UPPER BUS CAN EXTENSION HARNESS Ref 2 To lower CAN BUS extension bundle Ref 3 Pos Wire 1 103 2 106 3 123 4 336 5 337 6 319 7 400 8 401 Pos Wire 1 112 2 113 3 135 4 137 5 332 6 333 7 402 8 338 Pos 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Wire 112 113 Spare 135 137 Spare 332 333 338 103 106 123 336 337 319 400 optional spare 401 o...

Page 232: ...ION HARNESS 52501939 150 AETJC 150 AETC 3D 150 AETJL AETJ 43 AETJ 43 3D 52501918 170 AETJL AETJ 49 Ref 2 To complete basket console Ref 1 Pos 1 2 3 4 5 6 7 8 9 10 11 12 Wire 112 113 135 137 333 103 106 123 336 337 319 332 Wire 338 400 401 402 Pos 1 2 3 4 Pos Wire 1 112 2 113 3 135 4 137 5 332 6 333 7 402 8 338 To lower BUS CAN extension harness Ref 3 Pos Wire 1 103 2 106 3 123 4 336 5 337 6 319 7 ...

Page 233: ...88 D 150 AETJ COMPACT 150 AETJC 3D 150 AETJL 170 AETJL AETJ 43 AETJ 43 3D AETJ 49 Ref 3 Pos Wire 1 103 2 106 3 123 4 336 5 337 6 319 7 400 8 401 Pos Wire 1 112 2 113 3 135 4 137 5 332 6 333 7 402 8 338 Pos Wire 1 103 2 106 3 123 4 336 5 337 6 319 7 400 8 401 Pos Wire 1 112 2 113 3 135 4 137 5 332 6 333 7 402 8 338 To BUS CAN console output bundle Ref 4 To upper BUS CAN extension harness as mountin...

Page 234: ...12 123 113 135 137 332 333 338 319 400 401 402 1 2 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 To lower BUS CAN extension harness Ref 3 Pos Wire 1 103 2 106 3 123 4 336 5 337 6 319 7 400 8 401 Pos Wire 1 112 2 113 3 135 4 137 5 332 6 333 7 402 8 338 BUS CAN CONSOLE OUTPUT HARNESS 678394 C Ref 4 To complete base box Rep 5 ...

Page 235: ...2 23 24 16 14 15 1 2 3 9 4 5 6 7 13 14 15 8 16 12 10 11 103 1 2 3 4 5 6 Electro valve harness Ref 7 Variable speed drive harness Ref 6 BUS CAN console output harness Ref 4 Flashing light harness Ref 10 Alarm harness Ref 9 Tilt harness Ref 8 ensor console output harness Ref 11 BASE BOX HARNESS 679459 G 120 AETJL 150 AETJC 150 AETJC 3D 150 AETJL 170 AETJL 52556928 AET 43 AETJ 43 3D AETJ 49 Ref 5 Pos...

Page 236: ...tor red LED Offset LED indicator green LED Overload warning LED Maintenance warning LED Electro valve supply relays Relay Relay Timer Pos S2 S3 S5 S6 S7 S8 S9 S10 S11 S12 S23 Designation Emergency Stop Base basket selector Turret rotation selector Telescope extension retraction selector Pendular arm up down selector Pendular arm rotation selector Basket rotation selector Arm 3 up down selector Arm...

Page 237: ... 5 3 2 1 2 3 4 5 6 1 2 3 7 4 5 6 11 12 10 8 9 103 121 VARIABLE SPEED HARNESS 678397 C Ref 6 To complete base box Ref 5 To variable speed drive fuses board To variable speed drive drive board To right hand battery terminal To battery cut out Pos Wire Colour 1 115 brown 2 Spare 3 116 white 4 Spare 5 Spare Shield 114 Green Pos 1 2 3 4 5 6 Wire spare spare 127 spare 113 112 Pos 1 2 3 4 5 6 7 8 9 10 11...

Page 238: ...White 2 119 Bown 1 241 Bown 2 222 White D OUT 12 1 241 Bown 2 234 White D OUT 15 1 241 Bown 2 221 White D OUT 08 1 241 Bown 2 228 White D OUT 10 1 241 Bown 2 229 White D OUT 16 1 241 Bown 2 230 White D OUT 18 1 242 Bown 2 233 White 1 242 Bown 2 233 White 1 241 Bown 2 220 White D OUT 17 1 241 Bown 2 219 White D OUT 11 To complete base box Ref 5 EV16 BASKET ROT RIGHT EV5 STEERING RIGHT EV18 TURRET R...

Page 239: ...123 Wire Colour 123 Pink 103 Dark Blue 244 Black 123 Red 103 Violet 117 Orange 123 Yellow 103 Green 245 Grey 123 Light blue 103 White 118 Brown Pos Wire Colour 1 123 Yellow 2 103 Green 3 245 Grey 4 123 Light Blue 5 103 White 6 118 Brown Pos Wire Colour 1 123 Pink 2 103 Dark Blue 3 244 Black 4 123 Red 5 103 Violet 6 117 Orange Pos Wire 1 106 2 218 To Arm low sensors bundle 120 AETJL Ref 14 telescop...

Page 240: ...RS INDUCTIF 678901 A Rep 15 SQ1b SQ1a FAISCEAU CAPTEURS BRAS BAS 678883 B Rep 14 FAISCEAU CAPTEURS TELESCOPE 678864 C Rep 12 Pin Fil 1 123 2 103 3 245 4 123 5 103 6 118 Pin Fil 1 123 2 103 3 244 4 123 5 103 6 117 Pin Fil A 123 B 103 C 244 Pin Fil A 123 B 103 C 117 Pin Fil A 123 B 103 C 245 Pin Fil A 123 B 103 C 118 Vers Faisceau pupitre CAPTEURS 678476 C Rep 11 Pin Fil A marron B bleu C noir Pin F...

Page 241: ... FAISCEAU INTERMEDIAIRE CAPTEURS INDUCTIFS 678475 C Rep 12 Pin Fil 1 123 2 103 3 244 4 123 5 103 6 117 Vers Faisceau pupitre CAPTEURS Rep 11 Pin Fil A 123 B 103 C 244 Pin Fil A 123 B 103 C 117 Pin Fil A marron B bleu C noir CAPTEURS INDUCTIF SQ1b 678901 Rep 15 Pin Fil 1 123 2 103 3 245 4 123 5 103 6 118 Pin Fil 1 123 2 103 3 244 4 123 5 103 6 117 CAPTEURS INDUCTIF 678901 A Rep 13 Pin Fil A 123 B 1...

Page 242: ...t the upper hinge 1 080 72 is raised by 1 m 39 37 in Turn the turret by 1 4 turn 2 080 73 Switch off the power supply Remove the cover 3 080 74 Remove the battery protective casings 4 080 72 Remove the cables connected to the charger from the battery 680 4 2 BATTERIES REMOVAL 5 137 Remove the cover plate 1 080 73 Remove the charger 2 080 73 80 72 3 1 4 2 80 73 1 2 ...

Page 243: ...ticker indication of settings position of capacity switch made during first installation 7 080 74 NOTE ignore this sticker when configuring the settings for the charger 6ZIVAN BATTERY CHARGER CONNECTIONS LOAD CURVES 5 104 INTERNAL VIEW Input fuse F1 1 080 75 20 A see parts catalog Output fuse F2 2 080 75 45 A see parts catalog Fans 3 080 75 Battery capacity switch C 4 080 75 Input terminals 5 080 ...

Page 244: ...RGER CONNECTIONS Auxiliary contacts to cut off load movements internal diagram see figure 080 76 5 pin plug to connection the removed LED harness external diagram see figure 080 77 NC C NO NC C AUX 1 AUX 2 NO 80 76 2 5 3 4 1 80 77 WHITE BROWN GREEN LED RED LED ...

Page 245: ...8 Charging time IULa WULa Capacity switch position 0 1 2 3 4 5 6 7 8 9 A B C D E F T1max h 10hr 45min 10hr 9hr 8hr 7hr 15min 6hr 15min 5hr 30min 4hr 30min 10hr 45min 10hr 9hr 8hr 7hr 15min 6hr 15min 5hr 30min 4hr 30min T2max h 3hr 3hr 3hr 3hr 3hr 3hr 3hr 3hr 3hr 3hr 3hr 3hr 3hr 3hr 3hr 3hr T1 T2 T3 max h 15hr 45min 15hr 14hr 13hr 12hr 15min 11hr 15min 10hr 30min 9hr 30min 15hr 45min 15hr 14hr 13hr...

Page 246: ... 100 charge LED flashing intermittent audible signal from the charger alarm situation 680 5 TROUBLESHOOTING ELECTRICAL 5 139 LED indicator removed see figure 080 80 Red permanently on initial charging phase Yellow permanently on battery at 80 charge Green permanently on battery at 100 charge LED flashing intermittent audible signal from the charger alarm situation 680 5 TROUBLESHOOTING ELECTRICAL ...

Page 247: ...0 81 is raised by 1 m 39 37 in Turn the turret by 1 4 turn 2 080 81 Switch off the power supply Remove the cover 3 080 81 Remove the battery protective casings 4 080 81 Remove the cables connected to the charger from the battery 680 4 2 BATTERIES REMOVAL 5 137 Remove the cover plate 1 080 82 Remove the charger 2 080 82 80 81 3 1 4 2 80 82 1 2 ...

Page 248: ...80 83 Auxiliary contacts 3 080 83 5 pin plug 4 080 83 IES BATTERY CHARGER CONNECTIONS Auxiliary contacts to cut off load movements internal diagram see figure 080 84 5 pin plug to connection the removed LED harness external diagram see figure 080 85 80 83 4 2 1 3 NC C NO NC C AUX 1 AUX 2 NO 80 84 2 5 3 4 1 80 85 WHITE BROWN GREEN LED RED LED ...

Page 249: ...y IES BATTERY CHARGER INDICATOR LED indicator removed see figure 080 86 Off charger not powered Red permanently on initial charging phase Yellow permanently on battery at 80 charge Green permanently on battery at 100 charge LED flashing Yellow battery balancing cycle Red alarm situation 680 5 TROUBLESHOOTING ELECTRICAL 5139 80 86 1 ...

Page 250: ...hand turret cover 1 080 87 Open the front face of the base control panel 2 080 87 Remove the plate holding the card in place 1 080 88 and remove the cards Safety control card 2 080 88 Base module control unit 3 080 88 Basket module control unit Remove the front face from the basket control panel 1 080 89 Remove the basket module control unit 2 080 89 80 87 1 2 80 88 3 2 1 80 89 2 1 ...

Page 251: ... 4 212 Arm 3 Raised 2 6 3 Boom 2 up Open Closed 0V 5 211 Arm 3 Lowered 2 6 4 Boom 2 down Open Closed 0V 6 208 Turret Left Rotation 2 6 9 Slew left Open Closed 0V 7 207 Turret Right Rotation 2 6 10 Slew right Open Closed 0V 8 205 Telescope Retracted 2 6 7 Tele in Open Closed 0V 9 206 Telescope Extended 2 6 8 Tele out Open Closed 0V 10 201 Tilt Raised 2 6 12 Cage level forward Open Closed 0V 11 202 ...

Page 252: ...URABLE 13 237 Telescope Extended NOT MEASURABLE 14 223 Compensation Lowered NOT MEASURABLE 15 234 Steering Left NOT MEASURABLE 16 229 Steering Right NOT MEASURABLE 17 220 JIB Right Rotation NOT MEASURABLE 18 230 Basket Right Rotation NOT MEASURABLE 19 217 Horn NOT MEASURABLE 20 218 Flashing Lights NOT MEASURABLE 21 231 Compensation Raised NOT MEASURABLE 22 233 Brake NOT MEASURABLE 23 Free NOT MEAS...

Page 253: ...RABLE 17 Free NOT MEASURABLE 18 Free NOT MEASURABLE 19 Free NOT MEASURABLE 20 Free NOT MEASURABLE 21 Free NOT MEASURABLE 22 Free NOT MEASURABLE 23 Free NOT MEASURABLE 24 Free NOT MEASURABLE CAN 1 NOT MEASURABLE 2 NOT MEASURABLE 3 NOT MEASURABLE 4 NOT MEASURABLE 5 112 CAN L NOT MEASURABLE 6 113 CAN H NOT MEASURABLE OUT 1 406 Validation overload Ka11 0V OUT 2 405 Free NOT MEASURABLE B 103 0V NOT MEA...

Page 254: ...9 2 312 Overload 1 NO NOT MEASURABLE _ 2 3 311 Travel selection 2 4 10 Traction select Open Closed 0V 3 4 313 Not neutral 1 3 18 Joystick NTRL sw Open Closed 0V 8 5 332 Overload SQ5b NF 2 4 9 NOT MEASURABLE 6 316 Steering G 1 3 6 Steer left Open Closed 0V 3 7 317 Steering D 1 3 7 Steer right Open Closed 0V 3 8 306 JIB Rotation NOT MEASURABLE 0V 3 9 310 Select arm 1 2 2 4 11 Boom 1 select Open Clos...

Page 255: ...e NOT MEASURABLE 1 680 3 6 MANIPULATOR OPERATION AND SETTINGS 5 133 2 See overload settings 680 3 5 SAFETY COMPONENTS CONTROL AND SETTINGS 5 126 3 Keep the selection to measure the signal 4 Negative signal 0 V intermittent LED overload 5 Negative signal 0 V intermittent if in tilt continue if overload 6 Negative signal 0 V intermittent tilt LED variable speed controller redundancy 7 See overload 6...

Page 256: ...contact KM1 A1 1 Resistance 46 1 Ω Electric pump KM3 2 080 96 Resistance 46 1 Ω Traction pump motors KM2 3 080 96 Resistance 19 2 Ω Free wheel diode 4 080 96 Resistance 44 Ω Fuse of power circuit 4 080 96 325 A see parts catalog Variable speed controller plate Variable speed controller 1 080 97 Electronic module 2 080 97 Fuse 3 080 97 100A see parts catalog 80 96 1 3 4 2 80 97 1 3 2 ...

Page 257: ...en Closed 48V 3 117 Arm down SQ1a Incoming 1 3 11 Boom rest Open Closed _ 1 4 109 Tilt Incoming 1 3 10 Tilt Open Closed 0V 3 5 108 Base selector Incoming 2 6 11 Lower box select Open Closed 0V 5 6 118 Telescope retracted SQ4a Incoming 1 3 12 Tele sw Open Closed 0V 2 7 Free 8 102 Line switch Outgoing 0V 9 130 Pump traction switch Outgoing 0V 4 10 Free 11 121 Switch KM2 Outgoing 12 12V 1 See operati...

Page 258: ...117 ELECTRICITY 80 547379EN 80 08 03 2017 Power circuit D1 S B E2 A B F1 F2 E1 A1 A2 A1 A2 E2 E1 A1 80 100 Variable speed controller plate Variable speed controller plate relay ...

Page 259: ...BLE SPEED CONTROLLERS USE OF CALIBRATOR 5 120 Incrementation buttons 3 080 101 6 VARIABLE SPEED CONTROLLERS USE OF CALIBRATOR 5 120 Connection socket 4 080 101 Fitting Open the right hand turret cover 1 080 102 Open the front face of the base control panel 2 080 102 Identify the connection cable and attach to it the connection socket 4 080 101 Switch on the access platform Adjust or check the vari...

Page 260: ...d variable speed controller fault display screen 3 080 104 Connection socket 1 080 105 Operation see instruction manual Connection PIN Signal 1 Free 2 0V masse 3 12V back lit 4 12V power supply 5 CAN_H 6 CAN_L Error messages variable speed controller 680 1 ELECTRICAL SCHEMATIC DIAGRAMS 5 73 Maintenance SEVCON h 100 0 P T 80 104 1 2 3 1 2 3 4 5 6 80 105 1 ...

Page 261: ... 16 PARAMETERS 22 PARAMETERS 5 PARAMETERS SEVCON CAN CALIBRATOR SEVCON CAN CALIBRATOR 1 5 Traction Setup 1 8 Traction Display 10 PARAMETERS 13 PARAMETERS 6 PARAMETERS SEVCON CAN CALIBRATOR SEVCON CAN CALIBRATOR 1 6 1 Trac Setup CANModeAboma 1 6 3Trac Setup BDI On 2 6 Pump Lower BoxTest 2 5 Pump LowerBoxPers 1 2 Traction Status SEVCON CAN CALIBRATOR 1 1 Traction Personalities 24 PARAMETERS 1 7 Trac...

Page 262: ...y cutout V 14 5 48 0 0 5 14 5 1 1 18 High Battery Start V High battery safe start V 14 5 75 0 0 5 65 1 1 19 High Battery Cutout V High battery cutout V 14 5 75 0 0 5 70 1 1 20 Battery Protection Level V Battery protection V 14 5 48 0 0 5 14 5 1 1 21 Battery Protection Delay s Battery protection delay S 0 1 2 5 0 1 0 5 1 1 22 Traction Alarm Battery alarm ON According to motor type According to Beep...

Page 263: ...oportional gain 0 255 1 40 1 7 12 Brake Integral Gain Brake total gain 0 16 1 15 1 7 13 Speed Estimate Gain Speed estimated gain 0 2 50 0 01 1 5 Menu Traction BDI Check Battery Charge Mini display Maxi display Pitch Value 1 8 1 Display Default Hours Select hour meter to display Aboma 1 8 2 Display Status Type Select type of status data to display On 1 8 3 Display Contrast Set contrast level standa...

Page 264: ...17 Y Axis Forward Voltage V Front travel voltage V 4 06 4 06 2 3 18 Y Axis Reverse Voltage V Rear travel voltage V 0 52 0 52 2 3 19 X Axis Left Voltage V Zero position X axis voltage V 0 52 0 52 2 3 20 X Axis Right Voltage V Max voltage X axis V 4 06 4 06 Speed travel movement over 10 m s 100 8 Speed travel working over 10 m s 13 60 Menu Pump Lower Box Pers Parameters Hydraulic Functions Base Code...

Page 265: ...or Accelerator 0 100 1 range 1 3 2 Accelerator Voltage Accelerator Voltage 0 0 V 5 0 V 0 02 V range 1 3 3 Deadman Fail safe Open Closed Switch 1 3 6 Steer left LH steering Open Closed Switch 1 3 7 Steer Right RH steering Open Closed Switch 1 3 8 Horn Horn Open Closed Switch 1 3 9 Traction select Traction select Open Closed Switch 1 3 10 Tilt Tilt input Open Closed Switch 1 3 11 Boom Rest Arm down ...

Page 266: ... Open Closed Switch 2 4 17 Cage Rotate Basket rotation selection Open Closed Switch Menu Pump Upper Box Test Test Hydraulic Functions Basket Codes Mini display Maxi display Pitch Type 2 6 1 Boom 1 Up Arm 1 Lifting Control Open Closed Switch 2 6 2 Boom 1 Down Arm 1 Lowering Control Open Closed Switch 2 6 3 Boom 2 Up Arm 2 Lifting Control Open Closed Switch 2 6 4 Boom 2 Down Arm 2 Lowering Control O...

Page 267: ... cap 3 080 107 at the end of the wire Remove the right hand battery protective cover 2 080 107 Take an electric wire 0 5 m 19 69 in long with its ends stripped connect it to the wire 2 080 107 and connect it to the terminal of the right hand battery 3 080 106 The green LED located under the sensor should flash several times It stops when the sensor has initialized It remains continuously lit CAUTI...

Page 268: ...ctive covers from arm 3 1 080 109 Loosen the lock nuts 1 080 110 Screw or unscrew the sensors 2 080 110 until their LED located next to the power supply wire switches from off to on orange the clearance remaining between the support and the sensor is approximately 3 mm 0 11 in Tighten the lock nuts Checking Retracted telescope sensor SQ4a Measure using the calibrator Multimeter Telescope LED statu...

Page 269: ...essure switch SQ3 Measure using the calibrator Multimeter Pressure in braking circuit Wire N Wire N Menu Description Message Display 0to25bar 0to362 59psi 119 119 1 3 13 Brake release Open V 25 bar 362 59 psi 119 119 Closed 0V Based on pressure switch setting NOTE in the absence of a signal from the brakes pressure switch parameter 1 3 13 open the electric pump is permanently active incorrect oper...

Page 270: ...that it remains free to rotate at the end of the operation with minimum play Overload sensor adjustment Undo the lock nuts 1 080 113 then tighten the overload screws 2 080 113 to their maximum extent Place a load in the basket and distribute it evenly across the floor 3 3 120 AETJL 230 kg 507 lbs 3 3 150 AETJC 150 AETJC 3D 230 kg 507 lbs 3 3 150 AETJL 250 kg 551 lbs 3 3 170 AETJL AETJ 49 230 kg 50...

Page 271: ... 44 lbs and check that The alarm switches off The calibrator displays CLOSED in test menu 1 3 16 SQ5a The calibrator displays OPEN in test menu 2 4 9 SQ5b Replace the 20 kg 44 lbs the alarm triggers permanent tone tighten the lock nuts 1 080 113 and put a paint mark on them to confirm the configuration ...

Page 272: ...N 662 13124 Réf CI678453 soft dédié Di 16 klaxon Di 12 sélection pendulaire Di 11 sélection télescope Di 13 sélection compensation Di 08 rot JIB Di 15 rot tourelle Di 14 rot panier Di 10 sélection bras 3 Di 09 sélection bras 1 2 Di 03 sélection translation Di 05 surcharge SQ5a circuit fermé Di 02 libre Ai 01 consigne rotation Di 06 direction GH Di 07 direction DR Ai 02 consigne traction Di 01 Homm...

Page 273: ...ght in the basket Wire N Menu Description Message To card Display 200 kg 441 lbs 333 1 3 16 Cage Ovl 2 F4 Safety F4 200 kg 441 lbs 333 Open Safety No signal Overload sensor SQ5b Measure using the calibrator Multimeter Weight in the basket Wire N Menu Description Message To card Display 200 kg 441 lbs 332 2 4 9 Cage Ovl 2 F4 Safety F4 200 kg 441 lbs 332 Open Safety No signal 24V 1 s OPEN CLOSED OPE...

Page 274: ...on the sub menu in question the status of the inputs outputs at the neutral point then when the manipulators or switches are operated TEST Lastly select menu 2 4 1 and 2 4 3 UPPER BOX TEST on the calibrator and check That the proportional signal progresses steadily i e from 0 to 100 That it is at 0 in neutral and 100 only when the manipulator almost reaches its limit Manipulator test when lifting ...

Page 275: ...played by the voltmeter see figure 080 117 80 115 1 X Y 24V 0V Y 3W 63V 470µf 48V 24V 0V 80 116 OLD NEW STANDARD STANDARD GREEN GREEN NOT NEUTRAL MANIPULATOR YELLOW X YELLOW X TURRET ROTATION CONTROL BLUE YELLOW BLACK LH STEERING PB BLACK GRAY BLACK RH STEERING PB GRAY Y GRAY Y TRAVEL CONTROL PURPLE GREEN BLACK DEADMAN TRIGGER RED BROWN BLACK POWER SUPPLY TRIGGER PINK WHITE BLACK POWER SUPPLY STEE...

Page 276: ... be measured on the wire indicated NS means that there is no signal on the wire indicated NEUTRE Direction GAUCHE Direction DROITE Bl D J N N G G N R B M Ro B N B B A N A N 24V V 24V BLEU D JAUNE NOIR NOIR G GRIS NOIR ROUGE BLANC MARRON ROSE BLANC NOIR BLANC BLANC ANCIENNE NORME NOUVELLE NORME 24V V V Bl D J N N G G N R B M Ro B N B B A N A N 24V 24V V 80 118 Gachette au NEUTRE Gachette ACTIONNEE ...

Page 277: ...right hand battery Remove the right hand battery protective cover 4 080 120 Disconnect the earth 1 080 121 Disconnect the 2 080 121 Disconnect the left hand battery following the same procedure Remove the cover 4 080 120 Remove the cover plate 1 080 122 Mark and then remove the harnesses connected to the variable speedcontrollers 2 080 122 680 3 4VARIABLESPEEDCONTROLLERS CONTROL AND SETTINGS 5 115...

Page 278: ... 080 123 Disconnect the earth 2 080 123 Disconnect the 3 080 123 Disconnect the left hand battery following the same procedure Remove the right hand battery see figure 080 124 then the left hand battery 3 3 120 AETJL 220 kg 485 lbs 3 3 150 AETJC 150 AETJC 3D 150 AETJL 170 AETJL 265 kg 584 lbs 3 3 AETJ 43 AETJ43 3D 268 kg 591 lbs 80 123 2 3 1 80 124 ...

Page 279: ...08 03 2017 80 4 3 ELECTRICAL HARNESSES REMOVAL A Wiring based on the schematic diagrams 680 1 3 SCHEMATIC DIAGRAM BASKET CONTROL PART 1ST VERSION 5 77 CAUTION In this chapter all of the connectors are shown on the wire insertion side ...

Page 280: ...Pers Error Parameter outside valid range The fault is removed by adjusting the value using the calibrator Search for and fix the parameter where the following value is displayed Switch the variable speed controller off and on check the parameters F04013 CRC Error Checksum parameter value incorrect The fault is removed by adjusting the value using the calibrator Check the value of all parameters Fo...

Page 281: ...sts change the variable speed controller or otherwise check the insulation of the variable speed controller and the switch KM3 2 2 With the line switch KM1 OPEN the voltage at terminal A of the variable speed controller is 3 V Internal fault in the variable speed controller replace it F05006 Mosfet s c Failure of power test when switching on Turn off the machine if the problem persists repeat the ...

Page 282: ...ulator its wiring 7 Flashs VOLTAGE BATTERY F04010 Battery High Battery voltage high on High V cut parameter Check the correct operation of the battery charger F04009 Battery Low Battery voltage higher than the High V cut parameter Battery voltage lower than the Low V cut parameter Battery voltage lower than the battery protection parameter beyond the delay specified by the parameter protection del...

Page 283: ...rformed 5 BUS CAN connectors disconnected Disconnect the BUS CAN harnesses wires 113 and 112 at each end variable speed controller base electronic control unit basket electronic control unit For wires 113 and 112 check the continuity between each of them and each end check that there is no continuity between wires 113 and 112 Check the connections the shielding variable speed controller section BA...

Page 284: ...lashing Loss of control of output current Logic control unit fault Stage of reading current or shunt Acoustic signal RED YELLOW LED flashing Loss of control of output voltage Battery disconnected or fault on logic control unit Stage of reading voltage or resistance of reading voltage of open battery Acoustic signal YELLOW GREEN LED flashing An unavailable configuration has been selected Check the ...

Page 285: ...Testing the manipulators 680 3 6 MANIPULATOR OPERATION AND SETTINGS 5 133 138 Troubleshooting 680 5 TROUBLESHOOTING ELECTRICAL 5 139 160 DESCRIPTION Screen 1 080 125 Scrolling buttons 2 080 125 6VARIABLE SPEED CONTROLLERS USE OF CALIBRATOR 5 120 Incrementation buttons 3 080 125 6 VARIABLE SPEED CONTROLLERS USE OF CALIBRATOR 5 120 Connection socket 4 080 125 SEVCON CAN CALIBRATOR Controller A Menu ...

Page 286: ......

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