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R
BP 24 249 9 Z. I. 44 158 ANCENIS CEDEX FRANCE TEL : +33 (0)2 (0)2 40 40 09 10 11
YOUR CONCESSIONAIRE
REF : 547 363 EN (05 / 04)
ACCESS PLATFORM 120 AETJ
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1st EDITION
06 / 2
ISSUE DATE
COMMENTS
06/2002
1st edition
11/2003
Updated
12/2003
Variable speed drive unit parameters modificatio
05/2004
Updated
35-8-21-M.84 80-6-M.84 80-8-11-M.84 80-8-85-M.84
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1st EDITION
06 / 2
ISSUE DATE
COMMENTS
06/2002
1st edition
11/2003
Updated
12/2003
Variable speed drive unit parameters modificatio
05/2004
Updated
35-8-21-M.84 80-6-M.84 80-8-11-M.84 80-8-85-M.84
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CONTENTS ROUPS G ROUPS
0 0-1-M.84 EN 30 30-2-63-M.84 EN
ECTIONS S ECTIONS
General Points Technical characteristics
Removing the wheel reducer / brake Steering Axle
35-8-21-M.84 EN
Free-wheeling
55-2-21-M.84 .84 EN 70
120 AETJ
Reducer
35
55
ACHINES M
120 AETJ
120 AETJ
Arms - Platform Removing the wear pads
120 AETJ
Hydraulics
70-2 70-2-5 -522-M. M.84 84 EN
Remo Removi ving ng the the dist distri ribu buto torr elem elemen ents ts
120 120 AETJ AETJ
70-2-80-M.84 .84 EN
Removing the cylinders
120 AETJ
70-5-M.84 EN
Hydraulic pressure
70-6-M.84 EN
Hydraulic layout
120 AET J Sign up to vote on this title
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CONTENTS G ROUPS
S ECTIONS
ACHINES M
80-8-85-M.84 EN
Testing the manipulator
120 AETJ
80-8-86-M.84 EN
Positioning and adjusting the contactors
120 AETJ
100 100-M.84 EN
Troubleshooting Troubleshooting
120 AETJ
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GROUPS 0
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GENERAL Unlock full access with a free trial.
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POINTS Sign up to vote on this title
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TECHNICAL CHARACTERISTI
120 AE 0-1-M.84
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CHARACTERISTICS E L ECTRIC
PUMP
- Electrical supply - Output - Cubic capacity - Pressure
E L ECTRIC 0-1-M.84
48 V 3,7 KW 4,8 cm3 200 bars
WHEEL MOTORS
- Type
T 17 - 2 KW
E L ECTRICAL
CIRCUIT
- Battery - Charger
BOARD
48 V - 300 Ah 50 Ah (single-phase)
FUSES
- Motherboard : - Output - Electric pump - Emergency pump
10 A 325 A 100 A You're Reading a Preview 100 A Unlock full access with a free trial.
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120 AETJ S PECIFICATIONS
- Use
Indoors
O
- Capacity
230 Kg 12 i.e. i.e 2 people
1
+wind - Control system
Electro-hydrau
- Turret rotation
350°
- Operating speed
0,6 km/h
- Transport speed
6 km/h
- Operating height
11950 mm
- Floor height
9950 mm
- Max off-centring - Access platform weight • Empty • Under nominal load
7000 mm
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6550 kg
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6780 kg
- No. of gears
2
- Traversable gradient
25%
- Max permissible slope
5% or 3°
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DIMENSIONS 120AETJ
0-1-M.84
A1 A2 B C D E F G H I J
5477 3740 1200 2163 1650 104 2228 1550 3250 3340 2138
G
H
I
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J F
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120AETJ
2
K1 K2 K3 K4 L1 L2 L3 L4 1
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2483 3242 6506 4353 9950 8794 4773 595 0
1
2
3
4
5
6
7
8
K1
You're Reading a 1 Preview L
Unlock full access with a free trial. 2Free Trial Download With L
K2
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FILTER EL EMENT
1
0-1-M.84 DESCRIPTION
1 - Hydraulic return oil filter cartridge
LUBRICANTS
R EFERENCE
REPLACE
599004
Every 900 H
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Download With Free Trial COMPONENTS TO BE LUBRICATED
CAPACITY
RECOMMENDATION
PACKAGING
HYDRAULIC OIL RÉSERVOIR
12 Litres
MANITOU HYDRAULIC OIL ISO 46
20 L. 55 L. 209 L.
WHEEL MOTOR (EACH ONE)
0.8 Litre
SHELL SPIRAX OIL A90
2 L. 20 L. 50 L.
TURRET ROTATION MOTOR
1.5 Litres
GENERAL GREASING BEARING TURRET RING GREASING
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SHELL RETINAX HD Useful GREASE
cartridge Not useful
SHELL ALVANIA EP LF 2
400 Gr. 1 Kg
R
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GROUPS 30
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REMOVING THE WHE
REDUCER/BRA
120 AE 30-2-63-M.84
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REMOVING THE WHEEL REDUCER / BRAKE U P
TO PLATFORM NO . 505578 : REDUCER 598694
A
- Set the lower arm to maximum for optimum accessibility. - Raise the rear of the platform and place a wedge under the chassis. - Remove the rear wheels 1 (Fig. A) (10 bolts, No. 19 spanner). - Open the rear cover 2 (Fig. A) (4 bolts, No. 4 hex spanner). - Mark and remove the electric motor power cables. 2 1
B
- Remove the electric motors 3 (Fig. B) (8 bolts, No. 9 hex spanner). - Remove the brake control hoses 5 (Fig. C) (No. 19 spanner). - Place a MA8S bung in each hose to prevent any oil leaks. - Remove the reducers 4 (Fig. B) (16 bolts, No. 10 spanner).
RE-ASSEMBLY
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3
- Same operations as above in reverse order.
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5
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C
PLATFORM NO . 505579: REDUCER 599538
- Same procedure as for removing reducer 598694.
4
RE-ASSEMBLY
- Same operations as above in reverse order.
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J T E A 0 2 1
5 2
6 2
1
4 2
30-2-63-M.84
3 2 9 1 6 1 2 2
5 1
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S E A U D O E R U G I E N R N D O I E C D U R T R D U K E U O E T D T R C E C L U R U E D D D E E A E H R R R W
1 2
4 1 3 1
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0 2 9 1
8 1
2 1
7 1
1 1
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J T E A 0 2 1
1 9 2 3 2 3 1 5 3
0 3
3 3
8 9 2 2
4 3
9 1
6 7 2 2
8 1
7 1
2 2 5 2
6 1
You're Reading a Preview
5 1
Unlock full access with a free trial. 4 2
S E A U D O E R U G I E N R N D O I E C D U R T R D U K E U O E T D T R C E C L U R U E D D D E E A E H R R R W
3
4 1
3 1
Download With Free Trial 2 1 1 1
3 2
0 1
2 2 1 2
9
0 2
8 7 6 5 4 3
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GROUPS 35
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FREE-WHEELIN
120 AE 35-8-21-M.84
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FREE-WHEELING
The platform may only be towed a short distance and only by a machine with significant braking performance, in order to hold it: the two machines must be connected by a tow bar. - To set the platform to free wheel, it must not be subject to any translation stresses from slopes. The wheels must be able to turn freely.
A 1
- If possible, raise the platform to free the drive wheels in order to facilitate the operation. - Loosen bolt 1 (Fig. A) on each wheel 22 mm from the edge, up to the resistance point, without forcing it (20 Nm). - The machine can be towed as a trailer.
Warning: do not loosen the bolt more than 22 mm, otherwise it may break.
RE-INSTALLATION
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- Turn the wheel gently from left to right to reset gear while Unlock fullthe access with a freeretightrial. tening the screws (1) (Fig. A). Pay attention to the torque when tightening (150 Nm).
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GROUPS 55
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REMOVING THE WEAR PA
120 AE 55-2-21-M.84
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INDEX
A - R EMOVING
THE TELESCOPE CYLINDER WEAR PADS ...........................
B - R EMOVING
THE TELESCOPE ARM WEAR PADS ..................................
C - R EMOVING
THE MOBILE TUBE WEAR PADS .......................................
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A - R EMOVING
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THE TELESCOPE CYLINDER WEAR PADS
- Remove the telescope cylinder: see the SCOPE CYLINDER section.
A1
REMOVING THE TELE-
- Remove the wear pads 1 (Fig. A1) (8 bolts, No. 10 spanner). 1
RE-ASSEMBLY
- Same operations as above in reverse order.
B - R EMOVING
55-2-21-M.84
THE TELESCOPE ARM WEAR PADS
- Remove the telescope cylinder: see the SCOPE CYLINDER section.
B1
REMOVING THE TELE-
- Lift the basket with a hoist to relieve the pads. - Remove the top of the jib pad fasteners 2 (Fig. B1) (16 bolts, No. 6 hex spanner). - Pay attention to the position of the adjustment plates 3 (Fig. B1). - Remove the pads.
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- Same operations as above in reverse order. - If necessary, position the adjustment plates: Plates 3 (Fig. B1): see PR catalogue for reference.
C - R EMOVING
THE MOBILE TUBE WEAR PADS
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- Remove the telescope cylinder: see the
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C2
- Remove the base of the jib pads 6 (Fig. C2) (hammer, chisel). - Pay attention to the position of the adjustment plates 7 (Fig. C2).
6
RE-ASSEMBLY
- Same operations as above in reverse order: the base of the jib pads must be forcibly emmancher with a hammer. - If necessary, position the adjustment plates: Plates 7 (Fig. C2): see PR catalogue for reference.
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4 4
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4 1 2
3 55-2-21-M.84
0 2
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0 2 2 3 1 1
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GROUPS 70
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REMOVING THE DISTRIBUTO
ELEMEN
120 AE 70-2-52-M.84
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REMOVING THE DISTRIBUTOR ELEMENTS
A
- Switch off the electrical power supply. - Open the right-hand cover. - Remove the hoses (Spanners Nos. 19, 24, 27, 30). - Mark each solenoid 1 (Fig. A) (Adhesive and marker) according to the writing on the yellow rings on the power cable looms and then remove the loom connectors 2 (Fig. A) (flat screwdriver). 2
- Remove the bolts 3 (Fig. B) (4 bolts, No. 17 spanner). - Remove the element(s) requiring to be replaced (various flat and hex spanners).
B 3
Before removing any hose or distributor component, operate the tappets on the electro-valves by pulling and then pushing them in order to decompress the circuit (Fig. C)
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3 1 V E 2 1 V E
M R A R A L U D N E P
70-2-52-M.84
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e r v l e o t a e v v l c v l i a r a v g v r t s n r o i n e r t e e r c d t c r a r u v c e i n l t r o o c t R u l a a e r e e e e v d r p u s A e l a v b e v l v l v l v d e e l l n B r v r n r e - a o a a a n r r o a o 5 i o v v v v v t t R 0 R u R d d 1 n i i c t 8 u R A 1 o A R o o o o e A V o o e b A B t E r r t r t r t r r R n n A t i B B n r - i n c g - B c c c c n g - A e e n 4 t g B l l 0 0 0 1 s u e u e e e e u B a i l 5 5 l l 8 0 l l l l o l 0 - o o o V E D P 3 1 M E P 1 8 E E E E N P 1 2 S S C M 0 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 1 1 1 1 1 2 4 E 1 T
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1 1 V E 0 1 V E
9 V E 8 V E
M 7 E V T E S S Y 6 Y 5 S V 1 S 1 G E M G N E 4 I N T S M I I E 1 S T A T Y L R S I S T M Y R S N T A G O E I E I N K S P S S N O I A C A E B S T 3 R 2 E 2 X L E E E / T 1 E P M O 7 R 5 5 B A 1 A C H S E 6 4 4 L 1 5 B É A H V T M E E 1 3 3 B A T V S E Y S 2 2 B A N M . S O E I E T S T S R P 1 A Y 1 B A T S O R G F T T N 1 T trial. 2 E I K R V S E E A E B T 8
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2 M
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REMOVING THE CYLINDE
120 AE 70-2-80-M.84
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INDEX
A - R EMOVING
THE STEERING CYLINDER .............................................
B - R EMOVING
THE TELESCOPE CYLINDER ............................................
C - R EMOVING
OLLOVER BAR CYLINDERS ............................. THE ANTI -R
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A - R EMOVING
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THE STEERING CYLINDER
A1
- Raise the front of the platform and place a wedge under the chassis. - Remove the front wheels 1 (Fig. A1) (12 nuts, No. 30 spanner). - Decompress the cylinder supply hoses: see the DISTRIBUTOR ELEMENTS section.
REMOVING THE
- Mark and remove the hydraulic hoses (No. 19 spanner). - Remove the articulation shaft 2 (Fig. A2) (1 bolt, No. 13 spanner). - Remove the articulation shaft 3 (Fig. A3) (2 circlips, circlips clamp). - Remove the steering cylinder 4 (Fig. A3).
A2 RE-ASSEMBLY
- Same operations as above in reverse order.
70-2-80-M.84
Remember to install the steering latch 5 (Fig. A2) before installing the shaft 2 (Fig. A2).
5
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6
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5
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) n ) n ó i o i t ) c ) c r c r e r e e i e r i d d d d n i n i e l e l y d d y z o c r n g g i r n d i n n r é u i l k e V ( n i e e C ( t E L S U ( O ( Q I K I C I C I L L L L U U U U A A A A R R R R D D D D Y Y Y Y H H H H
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F E A B C D G S T N I S O A J Z T T N E A U D J S E G E T N T D T I U E K O T H L G H C A E C I U O E P D J S
3
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B - R EMOVING
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THE TELESCOPE CYLINDER
B1
- Raise the basket to access the cylinder foot axle 6 (Fig. B1). - In horizontal position, extend the telescope enough to access the articulation shaft 7 (Fig. B1).
8
- Wedge the basket in place with lifting equipment. - Decompress the cylinder supply hoses: see the DISTRIBUTOR ELEMENTS section.
REMOVING THE 6
- Remove the protective casing 8 (Fig. B1) (2 bolts, No. 10 spanner). - Remove the articulation shaft 7 (Fig. A3) (2 circlips, circlips clamp). - Remove the cylinder supply hoses 9 (Fig. B2) (No. 24 spanner).
B2
- Remove the articulation shaft 6 (Fig. A2) (1 bolt, No. 13 spanner). - Remove the telescope cylinder by extending the arm from the front (Fig. B3).
6
RE-ASSEMBLY
70-2-80-M.84
- Same operations as above in reverse order.
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The cylinder's chambers contain oil under pressure. To remove the Download With Free Trial valve block, you must equalize the pressures by progressively unscrewing the 4 bolts 10 (Fig. B3) (No. 6 hex spanner) and letting the oil escape.
B3 10
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J T E A 0 2 1
H 7 G E
) ) ) e e r e j g d a n a p p i o ) o l c r c y s e z s l l d e l e n l e i o l t é t r t e y c e s d d n e o e n m r p i d o r n c é m s l a i i V e ( s C l u ( e E Z T U ( O ( Q I K I C I C I L L L L U U U U A A A A R R R R D D D D Y Y Y Y H H H H
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B C
B A
F B D E A C H G S T N I S O A J Z T T N E A U D J S E G E T N T D T I U E K O T H L G H C A E C I U O E P D J S
6
5
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C - R EMOVING
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THE ANTI -R OLLOVER BAR CYLINDERS
C1
- Set the platform in transport position (Telescope retracted, arms in low position). - Remove the battery covers and the batteries: see the THE TRACTION BATTERIES section. - Decompress the cylinder supply hoses: see the DISTRIBUTOR ELEMENTS section.
REMOVING
11
REMOVING THE
- Mark and remove the hydraulic hoses 11 (Fig. C1) (No. 19 spanner). - Remove the articulation shafts 12 (Fig. C1) (8 circlips, circlips clamp).
12
- Remove the cylinders 13 (Fig. C1).
RE-ASSEMBLY
- Same operations as above in reverse order.
70-2-80-M.84
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J T E A 0 2 1
G
) r ) o n d o a i t z a i l i s ) i ) l i r b a r e b e t d a d s t e n n s i l l e i y e d y c d z r o r r n e e i z r i z d l n i é l i i i l i b V ( b a a C t t E S ( S U ( O ( Q I K I C I C I L L L L U U U U A A A A R R R R D D D D Y Y Y Y H H H H
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F
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E D C B
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A 4
F B D E A C G S T N I S O A J Z T T N E A U D J S E G E T N T D T I U K E O T H L G H C A E C I U O E P D J S
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HYDRAULIC PRESSU 120 AE 70-5-M.84
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ADJUSTING THE HYDRAULIC PRESSURES
A Most of the adjustments are made by two people: one works the controls on the base console, the other adjusts the valves - Open the right-hand cover 1 (Fig. A) and remove it.
Adjusting the anti-rollover bar pressure reducer (Hydraulic layout No. 2).
- Switch the platform on.
B
- Connect the manometer to pressure port M2 (Fig. B). M2
- Raise the platform a few centimetres to release deployment of the anti-rollover bars. - Fully extend the telescope and hold down the extend control while making the adjustment - Adjust the tare on pressure reducer 2 (Fig. B) (No. 17 spanner, No. 4 hex spanner) to 40 bar. - Disconnect the manometer and re-insert the bung.
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C
Adjusting the pressure reducer (Hydraulic layout No. 7).
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M1
- Switch the platform on. - Connect the manometer to pressure port M1 (Fig. C). - Fully extend the telescope and hold down the extend control while making the adjustment 3
- Adjust the tare on pressure reducer 3 (Fig. C) (No. 13 spanner, No. 4 hex spanner) to 100 bar. Sign up to vote on this title - Disconnect the manometer and re-insert the bung.
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E
Adjusting the compensation / tilt balancing valve (Hydraulic layout No. 17). 5
- Switch off the machine and disconnect the electrical circuit. - Decompress the compensation / tilt control hoses: see the VING THE DISTRIBUTOR ELEMENTS section.
REMO-
- Remove hose 5 (Fig. E) (No. 24 spanner) connected to A5.
7 8
- Insert a T connector (M/M/F12S) 7 (Fig. E) between hose 5 and connection 6. - Add a straight connector (M/F 16x150-12S) 8 (Fig. E) and then connect the manometer 9 (Fig. E) to this.
F
- Switch the machine on.
10
- Raise the telescope arm 10 (Fig. F) to mid-stroke on the cylinder and then extend the tilting cylinder 11 (Fig. F) to the maximum extent. - Instruct the telescope arm to lower and check the pressure displayed on the manometer during descent: the value must be 180 bars.
70-5-M.84
- If this is not the case, adjust the tare on the balancing valve 12 (Fig. F) (No. 24 spanner, No. 17 spanner) to 180 bars.
11
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- Switch off the machine, remove the manometer and then reconnect Unlock full access with a free trial. hose 5 in its original configuration.
Download With Free Trial Adjusting the compensation / tilt sequencing valve (Hydraulic layout No. 18).
G 14
- Switch off the machine and disconnect the electrical circuit. - Decompress the compensation / tilt control hoses: see the VING THE DISTRIBUTOR ELEMENTS section.
REMO-
13
- Remove hose 13 (Fig. G) (No. 24 spanner) connected to B5. Sign up to vote on this title 7 Useful Not useful - Insert a T connector (M/M/F12S) 7 (Fig. E) between hose 13 and 8 connection 14.
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H
Adjusting the pressure stat (Hydraulic layout No. 19).
- Switch off the machine and disconnect the electrical circuit. 17
- Open the right-hand turret cover. - Remove the sealing screw 16 (Fig. H) (No. 3 hex spanner) located between the terminals on the pressure stat 17 (Fig. H) to access the setting screw. - Remove hose 18 (Fig. I) (No. 24 spanner) connected to B6.
16
- Insert a T connector (M/M/F12S) 7 (Fig. I) between hose 18 and connection 19.
I
- Add a straight connector (M/F 16x150-12S) 8 (Fig. I) and then connect the manometer 20 (Fig. I) ( Minimum capacity 250 bar ) to this and take the manometer into the basket.
19 7
- Switch the machine on. 18
- Instruct the platform to travel without operating the steering and monitor the pressure displayed on the manometer (Fig. J): - On start-up, a pressure spike of up to 210 bar. - Rapid drop in pressure to below 100 bar. Preview - Slow drop and then very slowYou're drop inReading pressureadown to 20 bar. Unlock full access withthe a freepump. trial. - At 20 bar, pressure stat triggers and then Pressure increases in the brake line. Pump and pressure stat cut out. Download With Free Trial - Repeated at regular intervals. - If the pressure stat triggers below 20 bar, adjust it by tightening the setting screw to increase the trigger pressure.
8
20
J P(bar) 120 100 80
- If the pressure stat triggers above 20 bar, loosen the setting screw by several turns to proceed as described above: Adjustment is always made by tightening the screw . - Conduct a new travel test.
60 40 20
Sign up to vote on this title - When adjustment is complete, switch the machine off, reconnect Useful Not useful hose 18 in its original configuration and re-insert the sealing screw 16.
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HYDRAULIC LAYO LAYO
120 AE 70-6-M.84
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HYDRAULIC LA LAYOUT YOUT
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GROUPS 80
ELECTRICITY Sign up to vote on this title
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REMOVING THE VARIABLE SPEE
DRIVE UN
120 AE 80-2-11-M.84
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REMOVING THE VARIABLE SPEED DRIVE UNIT U P
TO PLATFORM NO . 505490
A
- Switch off the electrical supply and then disconnect the batteries: see the REMOVING THE TRACTION BATTERIES section.
1
- Open the rear cover (4 bolts, No. 4 hex spanner). - Disconnect the cable connectors. - Remove the two variable speed drive components 1 (Fig. A) (8 bolts, No. 13 spanner)
RE-ASSEMBLY
- Perform the above-mentioned operations in reverse order.
F RO M
P LAT FO RM N O. 505491
B
- Switch off the electrical supply and then disconnect the batteries: see the REMOVING THE TRACTION BATTERIES section. - Open the rear cover (4 bolts, No. 4 hex spanner).
You're Reading a Preview
- Remove the protective cover (Fig. B) (2 bolts, No. 10 spanner).
Unlock full access with a free trial.
- Disconnect the cable connectors.
Download 1With - Remove the two variable speed drive components (Fig.Free A) (8Trial bolts, No. 13 spanner).
2
RE-ASSEMBLY
- Perform the above-mentioned operations in reverse order.
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REMOVING THE TRACTION BATTERI
120 AE 80-2-12-M.84
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REMOVING THE TRACTION BATTERIES U P
TO PLATFORM
NO . 505490 :
B ATTER IE S 598121
A
- Raise the platform a few centimetres to release the engagement of the anti-rollover bars 1 (Fig. A). - Switch off the electrical supply. - Remove the left-hand and right-hand battery covers 2 (Fig. A) (4 butterfly bolts). - Disconnect the cable looms connected to the + and - terminals (No. 16 spanner). - Remove the battery fasteners 3 (Fig. B) (4 bolts, No. 12 hex spanner). - Remove the batteries (individual weight: 248.5 kg) from their housing using a hoist and slings fastened to the side flanges on the tank 4 (Fig. B) or using a forklift truck's forks.
B 3
RE-ASSEMBLY
- Perform the above-mentioned operations in reverse order. 4
F R OM
PLATFORM NO . 505490 :
You're Reading a Preview B ATTERIES 599364 Unlock full access with a free trial.
- Raise the platform a few centimetres to release the engagement of the anti-rollover bars 1 (Fig. A). - Switch off the electrical supply.
Download With Free Trial
C
- Remove the left-hand and right-hand battery covers 2 (Fig. A).
5
- Disconnect the cable looms connected to the + and - terminals (No. 16 spanner). - Remove the battery fasteners 5 (Fig. C) (4 bolts, No. 12 hex spanner).
6
Sign up to vote on this title - Remove the batteries (individual weight: 263 kg) from their housing using a hoist and slings fastened to the side flanges on the tank 6 Useful Not useful 7 (Fig. C) or using a forklift truck's forks.
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REMOVING THE CABLE LOOM
120 AE 80-2-13-M.84
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INDEX
A - LOCATION
B - B ASKET
OF THE CABLE LOOMS ....................................................
CONSOLE CABLE LOOM ....................................................
C - M AIN
BOX CABLE LOOM ................................................................
D - B ASE
CONSOLE CABLE LOOM
E - O THER
..................................................... P
CABLE LOOMS .................................................................
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A - LOCATION
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OF THE CABLE LOOMS
2
1
7
4
You're Reading a Preview Unlock full access with a free trial. 5
Download With Free Trial 6
80-2-13-M.84
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B - B ASKET
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CONSOLE CABLE LOOM - 1
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DESCRIPT Clip p O l d
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B ASKET
Manual Manitou
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0 328 327 322 321 323
329 331 320 330
80-2-13-M.84
319 311
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CONSOLE CABLE LOOM - CARD CONNECTIONS
CABLE CONNECTION CONTACT
113 112 315 318
Troublesshooting manual 3b6.pdf
CAN CAN CAN CAN CAN CAN A-IN A-IN A-IN A-IN A-IN A-IN A-IN A-IN D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-IN D-IN D-IN D-IN
DESCRIPTION
1 Spare 2 Spare 3 Spare 4 Spare 5 Info. Bus Can. 6 Info. Bus Can. 1 Manipulator side analogue input 0V / 2.5V / 5V 2 Manipulator longitudinal analogue input 0V / 2.5V / 3 Spare 4 Spare 5 Spare 6 Spare 7 Spare 8 Spare 1 Spare 2 0V card - lower arm LED 3 0V card - upper arm LED 4 0V card - telescope LED 5 0V card - pendular arm LED 6 Spare 7 0V card - compensation arm LED 8 Spare 9 Spare 10 Spare Reading a Preview 11 You're Spare 12 Spare Unlock full access a free trial. 13 0V card -with travel LED 14 0V card - overload alarm LED 15 Download 0V card - buzzer With Free Trial 16 0V card - slope LED 17 Spare 18 Spare 19 Spare 20 Spare 21 Spare 22 Spare 23 Spare 24 Spare Sign up to vote on this title 1 0V manipulator trigger 2 Spare Useful Not useful 3 0V travel switch 4 Spare
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B ASKET
CONSOLE CABLE LOOM - CABLE ALLOCATION
CABLE
CONNECTION
311 309 304 303 310 305 121 121 121 121 121 302 121 121 306 307 308 331 330 329 328 327 323 322 321 106 121 106 106 106 106 106 106 106 320 106 106 316 317 318 319 103
S13/D-IN-3 S15/D-IN-10 S19/D-IN-11 S20/D-IN-12 S14/D-IN-9 S18/D-IN-13 S18/S20 S20/S19 S19/S15 S15/S13 S13/S14 S21/D-IN-16 S21/S17 S17/S17 S17/D-IN-8 S17/D-IN-15 S17/D-IN14 H6/D-OUT-14 H7/D-OUT-16 H8/D-OUT-13 H9/D-OUT-2 H10/D-OUT-3 H14/D-OUT-7 H15/D-OUT-4 H16/D-OUT-5 J4-106/H14 S18/S17 H14/H16 H16/H15 H15/H10 H10/H8 H8/H9 H9/H6 H6/H7 H17/D-OUT-15 H17/J4-106 J4-106/B+ D-IN-6/P CLIPS 6V-2 D-IN-7/P CLIPS 6V-3 A-IN-2/P CLIPS 6V-4 D-IN-1/P CLIPS 3V NEG/P CLIPS 3V
COLOUR DESCRIPTION
YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW You're Reading a Preview YELLOW RED Unlock full access with a free trial. YELLOW RED RED Download With Free Trial RED RED RED RED RED YELLOW RED RED YELLOW Sign up to vote on this title YELLOW YELLOW Useful Not useful YELLOW WHITE
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C - M AIN
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BOX CABLE LOOM - 3
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80-2-13-M.84
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M AI N
Manual Manitou
1
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227 231 226 220 224 221 225 228 219 222 223 234 229 101
80-2-13-M.84
217 218 230 233 238 235 215 214 213 212
Manual Engine Part SIL Linde
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BO X CAB LE LO OM - CARD CONNECTIONS
CABLE CONNECTION
113 112
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Troublesshooting manual 3b6.pdf
CAN CAN CAN CAN CAN CAN A-IN A-IN A-IN A-IN A-IN A-IN A-IN A-IN D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-OUT D-IN D-IN D-IN D-IN
CONTACT
DESCRIPTION
1 Spare 2 Spare 3 Spare 4 Spare 5 Info. Bus Can. 6 Info. Bus Can. 1 Spare 2 Spare 3 Spare 4 Spare 5 Spare 6 Spare 7 Spare 8 Spare 1 Spare 2 0V card - lower arm electro-valve 3 0V card - overload LED 4 0V card - upper arm electro-valve 5 0V card - anti-rollover arm output electro-valve 6 0V card - pendular arm electro-valve 7 Spare 8 0V card - turret rotation electro-valve 9 0V card - telescope electro-valve 10 0V card - KA3 raise / lower selection coil Previewelectro-valve 11 You're 0VReading card - jiba rotation 12 0V card - basket rotation electro-valve Unlock full access with a free trial. 13 Spare 14 0V card - compensation / tilt electro-valve 15 Download 0V card - steer electro-valve With Freeleft Trial 16 0V card - steer right electro-valve 17 Counting info - timer input 01 18 Spare 19 0V card - horn 20 0V card - rotating light 21 0V card - maintenance alarm LED 22 0V card - brake reservoir electro-valve 23 0V card - anti-rollover bar return electro-valve 24 0V card - KM3 steering pump coil Sign up to vote on this title 1 0V jib rotation right switch 2 0V lower arm raising switch Not useful Useful 3 0V lower arm lowering switch 4 0V upper arm raising switch
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BOX CABLE LOOM - CABLE ALLOCATION
CABLE
211 212 206 205 216 215 210 209 204 203 202 201 214 213 207 208 102 122 101 121 104 108 106 230 231 110 105 107 105 228 106 106 235 117 118 111 109 106 106 103 103 112
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CONNECTION
COLOUR
DESCRIPTION
S11/D-IN-5 YELLOW S11/D-IN-4 YELLOW S6/D-IN-9 YELLOW S6/D-IN-8 YELLOW S8/D-IN-16 YELLOW S8/D-IN-1 YELLOW S7/D-IN-13 YELLOW S7/D-IN-12 YELLOW S9/D-IN-14 YELLOW S9/D-IN-15 YELLOW S12/D-IN-11 YELLOW S12/D-IN-10 YELLOW S10/D-IN-2 YELLOW S10/D-IN-3 YELLOW S5/D-IN-7 YELLOW S5/D-IN-6 YELLOW PL-8/VARIABLE SPEED DRIVE YELLOW PL-5/VARIABLE SPEED DRIVE YELLOW PL-1/D-OUT-17 YELLOW S3/J4-121 YELLOW S2/VARIABLE SPEED DRIVE YELLOW S3/VARIABLE SPEED DRIVE YELLOW J4-106 F. AV/J4-106 C. RED D-OUT-21/CI 5002001 YELLOW You're Reading a Preview D-OUT-3/CI 5002001 YELLOW S2/CHARGER YELLOW Unlock full access with a free trial. J4-105/CHARGER YELLOW S3/J2-107 YELLOW J4-105/S3 YELLOW Download With Free Trial D-OUT-10/KA3-A1 YELLOW KA3-A2/J4-106 RED KA3-11/J4-106 RED D-OUT-24/VAR SPEED DRIVE YELLOW KA4-14/VAR SPEED DRIVE YELLOW J2-118/VAR SPEED DRIVE YELLOW J2-111/VAR SPEED DRIVE YELLOW J2-109/VAR SPEED DRIVE YELLOW J4-106/J4-106 RED Sign up to vote on this title J4-106 C./VAR SPEED DRIVE RED J4-103/VAR SPEED DRIVE WHITE Useful Not useful J4-103/NEG. WHITE CAN-6/VAR SPEED DRIVE YELLOW
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D - B ASE
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CONSOLE CABLE LOOM - 4
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80-2-13-M.84
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CONSOLE CABLE LOOM - CABLE ALLOCATION
CABLE
211 212 206 205 216 215 210 209 204 203 202 201 214 213 207 208 242 242 242 242 242 242 242 106 102 122 106 101 106 121 108 242 104 108 106 106 230 231 110 107 105
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CONNECTION
COLOUR DESCRIPTION
S11/D-IN-5 YELLOW S11/D-IN-4 YELLOW S6/D-IN-9 YELLOW S6/D-IN-8 YELLOW S8/D-IN-16 YELLOW S8/D-IN-1 YELLOW S7/D-IN-13 YELLOW S7/D-IN-12 YELLOW S9/D-IN-14 YELLOW S9/D-IN-15 YELLOW S12/D-IN-11 YELLOW S12/D-IN-10 YELLOW S10/D-IN-2 YELLOW S10/D-IN-3 YELLOW S5/D-IN-7 YELLOW S5/D-IN-6 YELLOW S12/S5 YELLOW S5/S10 YELLOW S10/S11 YELLOW S11/S6 YELLOW S6/S8 YELLOW S8/S7 YELLOW S7/S9 YELLOW S3/S3 RED You're Reading a Preview PL-8/VARIABLE SPEED DRIVE YELLOW PL-5/VARIABLE SPEED DRIVE YELLOW Unlock full access with a free trial. PL-2/J4-106 RED PL-1/D-OUT-17 YELLOW J4-106/S3 RED With Free Trial Download S3/J4-121 YELLOW S3/S23 YELLOW S23/S12 YELLOW S2/VARIABLE SPEED DRIVE YELLOW S3/VARIABLE SPEED DRIVE YELLOW J4-106 F. AV/J4-106 C RED J4-106/CI 5002001 RED D-OUT-21/CI 5002001 YELLOW D-OUT-3/CI 5002001 YELLOW Sign up to vote on this title S2/CHARGER YELLOW S3/J2-107 YELLOW Useful Not useful J4-105/S3 YELLOW
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E - O THER
V ARI ABL E
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CABLE LOOMS
SP EE D DRI VE CAB LE LOO M - 5
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Bridge 80-2-13-M.84
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DISTRIBUTOR
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CABLE LOOM - 6
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ELECTRICAL LAYOU
120 AE 80-6-M.84
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INDEX
A - P O WER
B - B ASE
SECTION - SINGLE MANIPULATOR ..........................................
CONTROL SECTION - SINGLE MANIPULATOR ............................
C - B ASKET
CONTROL SECTION - SINGLE MANIPULATOR ........................
D - P O WER
SECTION - DUAL MANIPULATOR ............................................
E - B ASE
CONTROL SECTION - DUAL MANIPULATOR ...............................P
F - B ASKET
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CONTROL SECTION 1
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G - B ASKET
2 - DUAL .......................P CONTROL SECTION Download WithMANIPULATOR Free Trial
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A - P O WER
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SECTION - SINGLE MANIPULATOR
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80-6-M.84
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B - B ASE
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CONTROL SECTION - SINGLE MANIPULATOR
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80-6-M.84
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C - B ASKET
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CONTROL SECTION - SINGLE MANIPULATOR
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80-6-M.84
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D - P O WER
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SECTION - DUAL MANIPULATOR
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67
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E - B ASE
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CONTROL SECTION - DUAL MANIPULATOR
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120 AE 67752 Versio Page
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F - B ASKET
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CONTROL SECTION 1
DEAD MAN'S
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DUAL MANIPULATOR
JIB rotation selection
Basket rotation selection
Emergency stop 01
n o i t a t o r
B I J
n o i t a t o r t e k s a
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green SQ5 Overload detection
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yellow (x) grey (y) brown white Left joystick A5
80-6-M.84
Interface 2-axis joystick
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Overlo alarm (red)
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120 AE 67752 Version 1 - P
Slope cut-out
Slope cut-out Horn Pendular arm selection Telescope selection Compensation selection JIB rotation Turret rotation Basket rotation Upper arm selection Lower arm selection Translation selection Overload Out-of NEUTRAL Buzzer Pendular arm Telescope Compensation JIB rotation Turret rotation Basket rotation Upper arm Lower arm Translation Slope Faults/alarm
+5V supply Rotation instructions Steer left Steer right Traction instructions Dead man's
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(Optional)
Slope
Travel
(Optional)
Lower arm
(Optional)
Upper arm
(Optional)
Basket Rotation
(Optional)
(Optional)
Turret Rotation
(All the LEDs are supplied with 24V)
JIB Rotation
(Optional)
Compensation
(Optional)
Telescope
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G - B ASKET
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DUAL MANIPULATOR
Pendular arm selection
Compensation selection
DEAD MAN's n o i t c e l e s n o i t a s n e p m o C
n o i t c e l e s m r a r a l u d n e P
Translation green yellow blue black grey violet red pink brown white
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Right joystick A7
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O ut -of NEUTR AL
(48V ) DEA D MAN's led
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120 AE 6775 Version 1 Lower arm selection Pendular selection Compensation selection
Telescope selection Lower arm selection Travel selection Out-of NEUTRAL n o i t c e l e s m r a r e w o L
Steer left Steer right Traction instructions
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CHECKING THE OPERATION OF T
SEVCON VARIABLE SPEED DRIVE UN
120 AE 80-8-11-M.84
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INDEX
A - V ARIABLE
B - T ESTING
C - E RROR
SPEED DRIVE PARAMETERS .............................................
THE VARIABLE SPEED DRIVE ..............................................
MESSAGES .........................................................................
D - D IAGNOSTIC
E - U SING
LED STATUSES ............................................................
THE CALIBRATOR .................................................................
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A - V ARIABLE
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SPEED DRIVE PARAMETERS
Microprocessor W598800.007 : Single manipulator Microprocessor W598800.008 : Dual manipulator
80-8-11-M.84
Calibrator Reference
CAN Name
1.1.1A
0
Description
Minimum Value
Maximum Value
Step
50
350
10
Armature I Max (A)
1.1.1F
1
Field I Max (A)
10
50
1
1.1.2
2
Traction Accel Delay (s)
0.1
5.0
0.1
1.1.3
3
Traction Decel Delay (s)
0.1
5.0
0.1
1.1.3A
100
Traction Direction Decel Delay (s)
0.1
5.0
0.1
1.1.4
4
Traction Creep Speed (%)
0
25
1
1.1.5
5
Flat Regen Direction Braking (A)
50
350
10
1.1.6
91
Tilt Regen Direction Braking (A)
50
350
10
1.1.7
6
Traction Regen Time (ms)
1.1.8
7
Brake Threshold (V)
1.1.9
8
0
300
10
0,09
3,20
0,016
Traction Maximum Speed (%)
0
100
1
1.1.10
9
Elevated Speed (%)
0
100
1
1.1.11
10
Tilt Speed (%)
0
100
1
1.1.12
11
Traction Cut 3 Speed (%)
0
100
1
1.1.13
12
Review delay (h)
0
100
1
1.1.14
13
Customers Options
0
7
1
1.1.15
102
Low Speed Traction Speed (%)
0
100
1
1.1.16
16
Low Battery Start (V)
14.5
48.0
0.5
1.1.17
17
Low Battery Cutout (V)
14.5
48.0
0.5
1.1.18
18
High Battery Start (V)
14.5
75.0
0.5
1.1.19
19
High Battery Cutout (V)
14.5
75.0
0.5
1.1.20
20
Battery Protection Level (V)
14.5
48.0
0.5
1.1.21
21
Battery Protection Delay (s)
0.1
2.5
0.1
1.1.22
61
Traction Alarm
Calibrator Reference
CAN Name
Minimum Value
Maximum Value
Step
1.4.2
22
24
96
2
1.4.3
23
BDI Reset Level (V)
2.00
2.50
0.01
1.4.4
24
BDI Discharge Level (V)
1.50
1.99
0.01
1.4.5
25
BDI Warning Level (%)
0
90
1
1.4.6
26
BDI Cutout Level (%)
0
90
1
Calibrator Reference
CAN Name
Minimum Value
Maximum Value
Step
1.6.1
95
CAN Mode
1.6.2
39
Chop Select
1.6.3
40.3
BDI
1.6.4
40.1
Fault Log
1.6.5
40.2
Service Log
1.6.6
40.4
EU / US Functionality
1.6.7
94
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BDI Battery Voltage (V)
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Description
Traction Full Speed (KPH)
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EPROM W598800.007 Minimum Value
Maximum Value
Actual Value
Calibrator Reference
CAN Name
1.8.1
31
Display Default Hours
1.8.2
32
Display Status Type
1.8.3
30
Display Contrast
1.8.4
27
FFD Indicator 1
Off
1.8.5
28
FFD Indicator 2
Off
1.8.6
29
Display Fault Messages
Off
Calibrator Reference
CAN Name
2.1.1
46
2.1.2
47
Ramp Up Delay
0.1
2.1.3
48
Ramp Down Delay
0.1
2.1.4
49
Pump Creep Speed
0
Calibrator Reference
CAN Name
2.3.1
67
Boom 1 Up Speed (%)
2.3.2
68
Boom 1 Down Speed (%)
0
100
1
40
2.3.3
56
Boom 1 Cutback Speed (%)
0
100
1
100
2.3.4
69
Boom 2 Up Speed (%)
0
100
1
63
2.3.5
70
Boom 2 Down Speed (%)
0
100
1
39
2.3.6
57
Boom 2 Cutback Speed (%)
0
100
1
100
2.3.7
71
Jib Up Speed (%)
0
100
1
40
2.3.8
72
Jib Down Speed (%)
100
1
25
0
100
1
1
32
0
100
1
1
32
Description
Off
0
Pump I Max
Description
2.3.8A
103
Jib Rotate Left Speed (%)
104
Jib Rotate Right Speed (%)
73
Tele In Speed (%)
74
Tele Out Speed (%)
2.3.11
75
Slew Left Speed (%)
127
Minimum Value 50
Maximum Value 350
30
1
Step
Actual Value
10
350
5.0
0.1
3.0
0.5
0.1
0.5
25
1
19
Minimum Value
Maximum Value
Step
Actual Value
0
100
1
You're Reading a Preview 0
2.3.8B 2.3.9
Step
Key
Description
2.3.10
EPR W5988
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90
100
1
100
0
100
1
100
0
100
1
32
0
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2.3.12
76
Slew Right Speed (%)
0
100
1
32
2.3.13
98
Cage Rotate Left Speed (%)
0
100
1
32
2.3.14
99
Cage Rotate Right Speed (%)
0
100
1
32
2.3.15
96
Cage Level Forward Speed (%)
0
100
1
70
2.3.16
97
Cage Level Reverse Speed (%)
0
100
1
35
2.3.17
14
Y-Axis Forward Voltage (V)
0.00
5.00
0.02
4.06
2.3.18
15
Y-Axis Reverse Voltage (V)
0.00
5.00
0.02
0.52
2.3.19
50
X-Axis Left Voltage (V)
0.00
5.00
0.02
0.52
2.3.20
51
X-Axis Right Voltage (V)
0.00
Calibrator Reference
CAN Name
2.5.1
77
Boom 1 Up Speed (%)
2.5.2
78
Boom 1 Down Speed (%)
Description
Sign up to vote on this title4.06
Minimum Value 0 0
5.00
Useful Maximum Value 100 100
With JIB
0.02
Not useful Step
Actual Value
1
100
1
90
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THE VARIABLE SPEED DRIVE
STATUS Calibrator reference
Parameter displayed
Setting Min
Setting Max
Step
Log info
1.2.1
Battery voltage
0V
127 V
0.1 V
+
1.2.2
Armature Motor voltage
0V
127 V
0.5 V
1.2.3
Field Motor Voltage
0V
127 V
0.5 V
1.2.4
Armature Motor Current
12:00 AM
625 A
5:00 AM
+
1.2.5
Field Motor Current
12:00 AM
64 A
0.25 A
+
1.2.6
Armature MOSFET Voltage
0.5 V
1.2.7
Controller temp.
1.2.8
0V
127 V
-30°C
+225°C
1°C
Capacitor Voltage
0V
127 V
0.5 V
1.2.9
Speed estimation
0%
100%
0.50%
1.2.10
Speed estimation
0 KPH
60 KPH
1.0 KPH
1.2.11
Speed estimation
0 MPH
60 MPH
1.0 MPH
1.2.12
Key Switch Hours Count
0 Hrs
65279.9 Hrs
0.1 Hrs
1.2.13
Traction Pulsing Hours Count (Drive)
0 Hrs
65279.9 Hrs
0.1 Hrs
1.2.14
CAN fail node
None
Output, EOutput
n/a
1.2.15
CAN error count
-
-
-
1.2.16
CAN error code
-
-
-
-
Service Log Reset
+ -
Press + followed by - to reset service log TRACTION VARIATOR
Calibrator reference
Input displayed
Setting Max
Step
Log info
0%
100 %
1%
0.0 V
5.0 V
0.02 V
Open
Closed
-
Open
Closed
-
switch
Open
Closed
-
Steer Left
switch
Open
Closed
-
Steer Right
switch
Open
Closed
-
1.3.8
Horn switch
switch
Open
Closed
-
1.3.9
Traction select
Closed
-
1.3.10
Tilt switch
Closed
-
1.3.11
Boom rest
Closed
-
1.3.12
8m high
switch
Open
Closed
-
1.3.13
Brake release
switch
Open
Closed
-
1.3.14
BDI Input
Closed
-
1.3.15
Frame fault
switch
Open
Closed
-
1.3.16
Drive Inhibit
switch
Open
Closed
-
1.3.17
Bars sens
switch
Open
Closed
-
1.3.18
Joystick NTRL switch
switch
Open
Closed
-
1.3.19
LS traction switch
switch
Open
Closed
-
1.3.20
Software
xxxxxx
xxxxxx
1.3.21
Controller Serial number
0
99999999
-
1.3.22
Controller type
xxnnn
-
1.3.1
Accelerator %
range
1.3.2
Accelerator voltage
range
1.3.3
Deadman
switch
1.3.4
Joystick Forward
switch
1.3.5
Joystick Reverse
1.3.6 1.3.7
You're Reading a Preview switch Open switch
Open
switch with a freeOpen Unlock full access trial.
Downloadswitch With Free Trial Open
PUMP STATUS
80-8-11-M.84
Calibrator reference
Parameter displayed
Step size Sign up to vote on this title
Min display
Max display 127 V
2.2.1
Battery voltage
0V
2.2.2
Motor voltage
0V
2.2.3
Motor current
12:00 AM
625 A
5:00 AM
2.2.4
MOSFET voltage
0V
127 V
0.5 V
Useful
127 V
0.1 V
Not useful
Log info +
0.5 V
+
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UPPER BOX TEST INFORMATION Calibrator reference
Input displayed
Min display
Max display
Step size
Range
0%
100%
1%
Y axis joystick voltage
Range
0.0 V
5.0 V
0.02 V
X axis joystick %
Range
0%
100%
1%
2.4.4
X axis joystick voltage
Range
0.0 V
5.0 V
0.02 V
2.4.5
Deadman
Switch
Open
Closed
-
2.4.6
Joystick Forward
Switch
Open
Closed
-
2.4.7
Joystick Reverse
Switch
Open
Closed
-
2.4.8
Steer Left
Switch
Open
Closed
-
2.4.9
Steer Right
Switch
Open
Closed
-
2.4.10
Traction select
Switch
Open
Closed
-
2.4.11
Boom 1 select
Switch
Open
Closed
-
2.4.12
Boom 2 select
Switch
Open
Closed
-
2.4.13
Jib select
Switch
Open
Closed
-
2.4.14
Tele select
Switch
Open
Closed
-
2.4.15
Slew select
Switch
Open
Closed
-
2.4.16
Cage level select
Switch
Open
Closed
-
2.4.17
Cage rotate
Switch
Open
Closed
-
2.4.1
Y axis joystick %
2.4.2 2.4.3
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MESSAGES
Calibrator display
Display
OK
Stdt
TESTING
RUN TESTS
Led Description & comments
Checks-Actions
YES Traction operational and OK.
No action required.
YES
Displayed briefly when the unit is switNo action required. ched on.
YES Wrong choice of calibration protocol.
PLEASE WAIT
Set the calibration protocol to "
BDI CUTOUT
BDI CUT
7F
The BDI has triggered a cut-out at the programmed battery level.
THERMAL CUTBACK
OVER TEMP.
8F
Let the variable speed drive co Temperature of variable speed drive Check its installation, the overa higher than 75° - Let the drive cool down. ness and the fan.
ACCEL. FAULT
ACCEL. FAULT
6F
Accelerator activated when unit s witched on.
SEQUENCE FAULT
SEQ. FAULT
2F
Release the dead man's contac Dead man's contact activated or joystick joystick - Check the dead man' pushed when machine switched on. and the joystick's instructions.
2 DIR. FAULT
2 DIR. FAULT
2F
Two directions selected at the same time.
Release the steering and dead controls - Check the steering sw cables.
BATTERIE LOW
BAT. LOW
7F
Battery level lower than low battery setting.
Release the dead man's contro reverser - Check the battery vo charge.
BATTERIE HIGH
BAT. HIGH
7F
Battery level lower than low battery setting.
Release the dead man's contro reverser - Check the battery vo charge and whether B+ is conn
PERS ERROR
PERS ERRORF
1F
Parameters set outside the range.
Change the defective settings.
CRC ERROR
CRC ERROR
1F
You're Preview One or Reading more settingsahave been corrupted.
Unlock full access with a free trial.
COIL S/C
COIL S/C
9 F A contactor coil is short-ci rcuiting or wrongly connected
Download With Free Trial
80-8-11-M.84
Manual Engine Part SIL Linde
3F
MOSFET short-circuiting.
Charge the batteries.
Release the dead man's contac the accelerator cable, personal lerator zero and max.
Check all the settings.
Switch off the machine - Check the coils are short-circuiting, wh control is connected directly to the cabling.
Reset FS1 or the reverser to ze Check A, F1, F2, the B- cable a ther MOSFET is short-circu
MOSFET S/C
FET S/C
SYSTEM FAULT
CAN FAULT
12 F The modules are not communicating.
Switch off the machine- Check CAN cable looms and connecti
P. UP TRAC. WELD
P. UP WELD
OFF Line contactor contacts welded shut.
Check the line contactor and th and control cable looms.
VARIOUS INTERNAL CONTROLLER POWER UP MESSAGES
FAIL
If one of these messages appears, the OFF variable speed drive has failed one of Contact SEVCON. its internal power auto-tests.
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D - D IAGNOSTIC
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LED STATUSES
Led status Illuminated Unlit 1 Flashing 2 Flashing 3 Flashing 4 Flashing 5 Flashing 6 Flashing 7 Flashing 8 Flashing 9 Flashing 12 Flashing
Description No problem, conditions normal Problem with the internal variable speed drive Personality out of reach Incorrect start-up sequence MOSFET short-circuiting Power contactor short-circuiting or motor circuit open Spare Problem with accelerator, slave potentiometer or sped sensor cable Low/high battery voltage or BDI cut off Temperature of variable speed drive too high Coil contactor short-circuiting BUS CAN connection fault
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THE CALIBRATOR
D1
DESCRIPTION - The calibrator (Fig. D1) (Ref. 622813) is used to adjust and configure the variable speed drive. It is also used as a diagnostic tool, displaying the variable speed drive's various voltage, current and temperature values and the status of all its inputs.
SEVCON
CAN CALIBRAT
ControllerA Menu
INSTALLATION
Value - +
- Please refer to the section on REMOVING DRIVE to access the electronic module.
THE VARIABLE SPEED
1
- Locate the loom cable connected to 2 (Fig. D2) on the electronic module; then take the calibrator's plug 1 (Fig. D1) and, depending on the circumstances:
D2
- Connect it to the spare socket on the loom. - If the loom does not have a spare socket, slip the adaptor cable (Ref. 677519) between the loom and the module's connector and then connect it to the spare socket on this cable.
CALIBRATOR MENU
2
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- See the illustration below.
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1 Traction
2 Pump
OK
OK
80-8-11-M.84
1.1 Traction
2.1 Pump
2.2 Pump
2.3 Pump
2.4 Pump
Personalities
Status
Upper Box Pers
Upper Box Test
1.2 Traction
1.3 Traction
1.4 Traction
1.5 Traction
2.5 Pump 2.6 Pump Sign up to vote on this title
Box Pers Test Useful Not Box useful Lower Lower
1.6 Traction
1.7 Traction
1.8 traction
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TESTING THE MANIPULATO
120 AE 80-8-85-M.84
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INDEX
A - S INGLE
B - D UAL
MANIPULATOR ....................................................................
MANIPULATOR .......................................................................
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MANIPULATOR
With the calibrator
- Connect the calibrator (Ref. 622813) to the variable speed drive: see Chapter CHECKING THE OPERATION FO THE SEVCON VARIABLE SPEED DRIVE , paragraph USING THE CALIBRATOR .
A1 3
- Climb into the platform's basket with the calibrator. - Select menus 2-4-2 and 2-4-4 (UPPER BOX TEST) on the calibrator and note the voltage values from the signals from the manipulator. - Then select menus 2-3-17, 2-3-18, 2-3-19 and 2-3-20 (UPPER BOX PERS) on the calibrator to adjust the limit values for the voltages delivered by the manipulator. Menus 2-4-2 and 2-4-4 Signals from the manipulator noted on the calibrator
0.5
Menus 2-3-17 to 2-3-20 0 0.52 Min/ max calibration values for the signals from the manipulator
2.5 2.5
2
4.5 4.48
5
- Lastly, select menus 2-4-1 and 2-4-3 (UPPER BOX TEST) on the calibrator and check : - That the proportional signal shows a good progression (i.e. 0 to 100%).
You're Reading a Preview
- That it shows 0% in Neutral and 100% only when the maniUnlock full access with a free trial. pulator arrives almost at the limit switch.
Download With Free Trial This procedure must be performed every time the manipulator is replaced.
With a voltmeter
- Take the voltmeter and climb into the access platform's basket.Sign up to vote on this title 80-8-85-M.84
Useful - Open the front of the basket console 3 (Fig. A1) (Flat screwdriver) and then locate the wires (Fig. A2).
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- Place the voltmeter's wands on the connector's clips to take the measurements. - To test the analogue outputs: work with the manipulator's casing 2 (Fig. A1) by moving it forwards, backwards, left or right and check the values the voltmeter displays (Fig. A3).
A3 Y X
4.5V GG(Y) (Y) 0V BM
Manipulateur vers Manipulator FORWARD L'AVANT AVANCE FORWARD TRANSLATION Y
Y
Y
0.5V YJ(X (X) ) X
X 0V
BM
Manipulateur à GAUCHE Manipulator to THE LEFT Rotation de tourelle à GAUCHE LEFT TURRET ROTATION
2.5V 2.5V 0V
JAUNE (X) YELLOW (X) GRIS (Y) GREY (Y) MARRON BROWN
4.5V YJ (X (X)) X
0V
B M
Manipulateur à DROITE Manipulator to THE RIGHT Rotation de tourelle à DROIT RIGHT TURRET ROTATION
NEUTRE NEUTRAL Y
You're Reading a Preview X
0.5V G G (Y) (Y) B 0V M
Unlock full access with a free trial.
Download With Manipulateur vers Free Manipulator toTHE REAR L'ARRIERE - RECUL REAR TRANSLATION
Trial
- To test the logic outputs: operate the manipulator's dead man's pedal 1 (Fig. A1) and check the values the voltmeter displays (Fig. A4); then press the manipulator's steering buttons 4 (Fig. A1) and check the values the voltmeter displays (Fig. A5).
A4
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A5
OLD NEW ANCIENNE NOUVELLE STANDART STANDART
O. S. N. S. A. N.
N. N.
NORME
0V BB(L) (G)Y/B J/N
Steer Direction LEFT GAUCHE
PR 0V BM
M/N W/B B M
NEUTRAL NEUTRE
BLEU(L) (G) V BLUE (R) V BLACK NOIR (D) ROSE PINK MARRON 0V BROWN
O. S. A. N.
NORME
YELLOW/BLACK JAUNE/NOIR GREY/BLACK GRIS/NOIR BLANC/NOIR WHITE/BLACK MARRON BROWN
Steer Direction RIGHT DROITE
0V BN(R) (D) PR 0V BM
"V" indicates that a random voltage can be measured on the indicated wire.
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80-8-85-M.84
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MANIPULATOR
With the calibrator
B1
- Connect the calibrator (Ref. 622813) to the variable speed drive: see Chapter CHECKING THE OPERATION FO THE SEVCON VARIABLE SPEED DRIVE , paragraph USING THE CALIBRATOR .
7 5
- Climb into the platform's basket with the calibrator. - Select menus 2-4-2 and 2-4-4 (UPPER BOX TEST) on the calibrator and note the voltage values from the signals from the manipulator. - Then select menus 2-3-17, 2-3-18, 2-3-19 and 2-3-20 (UPPER BOX PERS) on the calibrator to adjust the limit values for the voltages delivered by the manipulator. Menus 2-4-2 and 2-4-4 Signals from the manipulator noted on the calibrator
0.5
Menus 2-3-17 to 2-3-20 0 0.52 Min/ max calibration values for the signals from the manipulator
2.5 2.5
6
4.5 4.48
5
- Lastly, select menus 2-4-1 and 2-4-3 (UPPER BOX TEST) on the calibrator and check : - That the proportional signal shows a good progression (i.e. 0 to 100%). - That it shows 0% in Neutral and 100% only when the manipulator arrives almost at the limit switch.
This procedure must be performed every time the manipulator is replaced.
With a voltmeter
- Take the voltmeter and climb into the access platform's basket.Sign up to vote on this title
Useful - Remove and open the basket console 5 (Fig. B1) (4 bolts, No. 4 hex spanner) and then locate the wires:
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B2 OLD NEW ANCIENNE NOUVELLE STANDART STANDART NORME NORME GREEN VERT
+24V 3W
Y
GREEN VERT
(NEUTRAL POSITION - MANIPUL (HORS NEUTRE - MANIPULAT
BLEU BLUE
JAUNE/NOIR (BP DIRECTION GAUCHE) YELLOW/BLACK (STEER LEFT BUTTON) BUTTO N)
NOIR BLACK
GRIS/NOIR GREY/BLACK
(BP DIRECTION (STEER RIGHT DROITE) BUTTON) BUTTON)
GRIS (Y) GREY GR EY (Y)
GRIS GREY GR EY (Y) (Y)
(COMMANDE TRANSLATION) TRANSLATIO N) (LONGITUDIN (LONGITUDINAL AL AXIS)
VIOLET VIOLET
VERT/NOIR (GACHETTE HOMME MORT) GREEN/BLACK (DEAD MAN'S TRIGGER)
ROUGE RED
MARRON/NOIR (ALIMENTA (ALIMENTATION TION -YGACHETTE) BROWN/BLACK (POWER SUPPLY SUPPL - TRIGGER
ROSE PINK
BLANC/NOIR WHITE/BLACK
MARRON BROWN MARRON 0V BROWN BLANC BLANC WHITE +48V WHITE
(ALIMENTATION (ALIMENTA TIONY- -BP DIRECTION) (POWER SUPPLY SUPPL STEERING BU
(ALIMENTATION (POWER (POWER SUPPLY SUPPLY- -TRANSLATION) LONGITUDI LONGITUDI (+ + BATTERIE) BATTERY)
63V - 470µf
B3 VERT (HORS G REE N (NEUNEUTRE TRAL P OS O-SMANIPULATEUR) IT ITION - MANIP UL ULATOR) JAUNE (X) (COMMANDE ROTATION) YELLO YELLOW W (X) (TUR (TURRE RET T ROT ROTATION TION))
X Y
GRIS G REY(Y) (Y) MARRON BROWN
(COMMANDE BRAS 3) (UPPER ARELEVATION M)
BLANC W HITE
( +(BATTERIE) + BATTERY)
(ALIMENTATION) (POWER SUPPLY) SUPPLY)
- Place the voltmeter's wands on the connector's clips to take the measurements. - To test the analogue outputs: - Work with the manipulator's casing 6 (Fig. B1) (Translation + Steering) by moving it forwards, backwards and check the values the voltmeter displays (Fig. B4).
B4 Sign up to vote on this title
80-8-85-M.84
Y
0.5V G G (Y) (Y) 0V M B
Y
Useful
GR EY (Y) 2.5V GREY GRIS 0V MARRON BROWN
Not useful Y
4.5V G (Y) 0V M B
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B5
4.5V G G (Y) (Y) BM 0V 48V B W Manipulatorvers FORWARD Manipulateur L'AVANT L'AV ANT UPPER ARM LEVAGE du RAISING bras (3)
X) 0.5V YJ ((X)
2.5V 2.5V 0V 48V
BM W B
0V 48V
Manipulatorvers to THE LEFT Manipulateur la GAUCHE LEFT TURRET ROTATION ROTA TION Rotation de tourelle à GAUCHE
YELLOW (X) JAUNE (X) GREY GR EY (Y) (Y) GRIS BROWN MARRON WHITE BLANC
4.5V YJ ((XX)) 0V 48V
BM W B
Manipulator vers to THE RIGHT Manipulateur la DROITE RIGHT TURRET ROTAT ROT ATION ION Rotation de tourelle à DROITE
NEUTRE NEUTRAL
0.5V G G (Y) (Y) 0V BM 48V W B Manipulateur L'ARRIERE Manipulatorvers toTHE REAR DESCENTE du bras (3) UPPER ARM LOWERING
- To test the logic outputs: - Press the manipulator's steering buttons 8 (Fig. B1) and check the values the voltmeter displays (Fig. B6); then operate the manipulator's dead man's pedal 9 (Fig. B1) and check the values the voltmeter displays (Fig. B7).
B6
Sign up to vote on this title OLD NEW ANCIENNE NOUVELLE STANDART Useful Not useful NORME STANDART NORME
O. S. N. S.
A. N.
N. N.
(D) Y/BJ/N 0V BB(L)
V V
BLUE BLEU(L) (D) YELLOW/BLACK JAUNE/NOIR BLACK (R) GREY/BLACK NOIR (G) GRIS/NOIR
O. S.
A. N.
(G) 0V BN(R)
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B7
ANCIENNE NOUVELLE OLD NEW NORME STANDART NORME STANDART
0V VIOLET RED ROUGE V BLANC 48V WHITE Trigger inau Gachette NEUTRAL NEUTRE
ANCIENNE NOUVELLE OLD NEW NORME STANDART NORME STANDART
GREEN/BLACK VERT/NOIR BROWN/BLACK MARRON/NOIR WHITE BLANC
0V VIOLET VIOLET ROUGE 0V RED BLANC 48V WHITE
GREEN/BLACK VERT/NOIR MARRON/NOIR BROWN/BLACK BLANC WHITE
Trigger Gachette ACTIVATED ACTIONNE
"V" indicates that a random voltage can be measured on the indicated wire.
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80-8-85-M.84
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POSITIONING AND ADJUSTIN
THE CONTACTO
120 AE 80-8-86-M.84
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INDEX
A - P OSITION
OF THE SENSORS .............................................................
B - ADJUSTING
OLLOVER BARS OUTPUT SENSOR .................... THE ANTI -R
C - ADJUSTING
THE SLOPE SENSOR ......................................................
D - ADJUSTING
THE LOW ARM SENSOR ..................................................
E - ADJUSTING
THE RETRACTED TELESCOPE SENSOR ..............................
F - ADJUSTING
THE OVERLOAD SENSOR ..............................................
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A - LOCATION
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OF THE SENSORS
Retracted telesc sensor
Low arm sen
Overload sensor
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Useful
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B - ADJUSTING THE ANTI -ROL LOVER BARS ' OUTPUT SENSOR
B1
UP TO PLATFORM No. 505490:
- Raise the platform a few centimetres to release full engagement of the anti-rollover bars. - Remove the left-hand and right-hand battery covers (4 butterfly bolts). - Unscrew the fixing screws 1 (Fig. B1) (2 screws, flat screwdriver). - Trigger the sensors 2 (Fig. B1), one after the other, by placing them in contact with the anti-rollover bar
1
- Re-tighten the screws. - Check the setting by instructing the basket to rise: if its ascent is interrupted, adjust the sensor setting.
B2
FROM PLATFORM No. 505491:
- Raise the platform a few centimetres to release full engagement of the anti-rollover bars.
3
- Remove the left-hand and right-hand battery covers (toggles). - Unscrew the fixing screws 3 (Fig. B2) (2 bolts, No. 13 spanner).
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- Trigger the sensors 4 (Fig. B2), one after the other, by placing them in contact with the stabilising bar Unlock full access with a free trial. - Re-tighten the bolts.
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- Check the setting by instructing the basket to rise: if its ascent is interrupted, adjust the sensor setting.
C - ADJUSTING
THE SLOPE SENSOR
Sign up to vote on this title The slope sensors are preset by the manufacturer. The only Useful Not useful parameter that can be adjusted is the sensor initialisation. - Set the platform on a horizontal surface and switch it on.
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D - ADJUSTING
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THE LOW ARM SENSOR
D1
UP TO PLATFORM No. 505421:
- Set the platform in transport position (Telescope retracted, arms lowered) and leave it switched on. - Remove the protective cover 5 (Fig. D1) (2 bolts, No. 10 spanner) situated under the left-hand side of the intermediate joint 6 (Fig. D2). - Loosen the lock nuts 7 (Fig. D1) (No. 24 spanner) - Tighten or loosen the sensor 8 (Fig. D1) until the LED next to the power supply cable switches from red to green. - Re-tighten the lock nuts. - Refit the protective cover.
D2 6
FROM PLATFORM No. 505422
- Locate the sensor 9 (Fig. D2) between the two sides of the intermediate joint. - Same procedure as for adjusting platforms UP TO PLATFORM No. 505421 except for removing and refitting the protective cover.
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THE RETRACTED TELESCOPE SENSOR
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E1
- Locate the sensor 10 (Fig. E1) located at the front between the two counterweights. - The follow the same procedure as for ADJUSTING THE LOW ARM SENSOR .
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F-A
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F2 The contactor has a certain reaction time when the bolt is being untightened. Stop at the limit for triggering the contactor.
12
- Relieve the weight on the basket: the platform's alarm no longer sounds. 13
- Replace the weight in the basket: the platform's alarm sounds. - Refit the protective cover.
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GROUPS 100
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TROUBLESHOOTIN
120 AE 100-M.84
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