Manitou 80 VJR EVOLUTION 100 VJR EVOLUTION 100 VJR AUS Repair Manual 547398 - PDF DOWNLOAD

547398EN (12/03/2015)

VJR EVOLUTION VJR AUS Repair manual

80

VJR EVOLUTION

100 VJR EVOLUTION 100 VJR AUS

2

547398EN

DATE OF ISSUE

OBSERVATION

04 / 2010

- 1st ISSUE

13 / 03 / 2014

- UPDATING

12 / 03 / 2015

- UPDATING

THE TEXTS AND PICTURES IN THIS DOCUMENT CANNOT BE REPRODUCED EITHER TOTALLY OR PARTLY.

547398EN

3

HOW TO USE THIS REPAIR MANUAL ?

1 00

ENGINE

00

GENERAL, CHARACTERISTICS AND SAFETY

10

2 GENERAL, CHARACTERISTICS AND SAFETY

20

- GENERAL INSTRUCTIONS AND SAFETY NOTICE

30

TRANSMISSION

40

AXLE

50

BRAKE

70

BOOM

80

HYDRAULIC

85

ELECTRIC

FRAME - BODY

90

OPTIONS - ATTACHMENTS

110

DRIVER’S CAB

4

3

General instructions and safety notice

00

00

4

RULES FOR MAINTENANCE Do not carry out any work on the machine unless you have followed a suitable training course and have the knowledge required for it.

Make sure you have taken into consideration all the indicator plates on the machine and in the instruction manual.

GENERAL INSTRUCTIONS AND SAFETY NOTICE

Be careful not to burn yourself when touching hot liquids or parts when operations have to be done before the machine has had time to cool down.

pages PREAMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 MAINTENANCE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 RULES FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1 2

Before carrying out any operation on an electrically powered component, activate the battery cut-off.

If the telehandler does not have a battery isolation device, disconnect the battery connecters then re-assemble them.

Before carrying out any welding operations, think about disconnecting computers.

ECU

A machine operating in a contaminated environment should be specifically equipped. Moreover, local safety notices deal with maintenance and repair work on such machines.

(29/09/2011)

00-M173EN

M

R

547982 : See the repair manual N° 547982.

70 - HYDRAULIC : See the group N° 70 called «Hydraulic».

00-M173EN

(29/09/2011)

JIB - ACCESS PLATFORM

HYDRAULIC

ELECTRICITY

00 10 20 30

FRAME - BODY

90

OPTIONS - ATTACHMENTS

110

DRIVER’S CAB

40

BRAKE

55

AXLE

70

TRANSMISSION

80

ENGINE

85

GENERAL CHARACTERISTICS AND SAFETY

- GENERAL INSTRUCTIONS AND SAFETY NOTICE

00

GENERAL CHARACTERISTICS AND SAFETY

00

00

GENERAL INSTRUCTIONS AND SAFETY NOTICE

pages PREAMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 MAINTENANCE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 RULES FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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2

00

00

GENERAL INSTRUCTIONS AND SAFETY NOTICE

PREAMBLE This chapter deals with the general instructions and safety notice during inspection and maintenance work.

Other instructions and warnings are indicated in each chapter concerned.

In order to reduce accident risks, make sure to: –– Follow the instructions in the truck operating and maintenance 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 safety manual correctly and the machine is serviced properly.

When you see this symbol:

bb

It means: Warning! Be careful! Your safety, somebody else’s or the safety of the lift truck itself is at risk.

The manufacturer cannot predict all possible risky situations. Consequently, the safety instructions given in the safety manual are not exhaustive.

At any time, as an operator, you must envisage, within reason, the possible risk to yourself, to others or to the lift truck itself when you repair, service or drive it.

Manitou cannot be held responsible for the use of any lifting devices, tools or operating methods other than those specified.

00-00-M161EN

(12/03/2015)

MAINTENANCE POSITION

2

1

4

3

Before any intervention: 1 2 3 4

-

Place the machine on a flat surface and chock the wheels.

Turn off the engine and remove the ignition key.

Let the machine cool down.

Take all the pressure out of the circuits concerned.

(12/03/2015)

3

00

00

GENERAL INSTRUCTIONS AND SAFETY NOTICE

00-00-M161EN

4

GENERAL INSTRUCTIONS AND SAFETY NOTICE

00

00

RULES FOR MAINTENANCE

Do not carry out any work on the machine unless you have followed a suitable training course and have the knowledge required for it.

Make sure you have taken into consideration all the indicator plates on the machine and in the instruction manual.

Be careful not to burn yourself when touching hot liquids or parts when operations have to be done before the machine has had time to cool down.

1 2

ECU

Before carrying out any operation on an electrically powered component, activate the battery cut-off.

If the telehandler does not have a battery isolating switch, disconnect the battery terminals then gather them.

bb

efore carrying out any welding operations, think of B disconnecting computers.

A machine operating in a contaminated environment should be specifically equipped. Moreover, local safety notices deal with maintenance and repair work on such machines.

00-00-M161EN

(12/03/2015)

5

00

00

GENERAL INSTRUCTIONS AND SAFETY NOTICE

Never step on a part of the machine that has not been designed for it.

Never wear clothes, jewelry or objects that could get caught during work and cause accidents.

Always wear protection glasses, gloves, safety shoes as well as any other protection required for the work to be carried out.

When carrying out maintenance operations near a mobile object, make sure it is securitized.

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 precautions are taken to avoid contaminating the environment.

(12/03/2015)

00-00-M161EN

6

GENERAL INSTRUCTIONS AND SAFETY NOTICE

00

00

When lifting or shoring a component of the machine, make sure the equipment used is suitable for at least the load for which it is subjected by the component and that it meets the national standards for 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.

Make sure no object or tool which could cause an accident is left in the machine.

Never control any leaks using a hand.

max. min.

MAX

Never adjust a component to over the maximum capacity indicated by the manufacturer.

MIN 00-00-M161EN

(12/03/2015)

ELECTRICITY

ELECTRICAL SCHEMATIC DIAGRAMS ELECTRICAL COMPONENTS LOCATION ELECTRICAL CONTROL AND ADJUSTMENT ELECTRICAL COMPONENTS REMOVAL ELECTRICAL COMPONENTS REFIT

80

ELECTRICAL TROUBLESHOOTING

ELECTRICAL SCHEMATIC DIAGRAMS

pages UP TO N°: 921034 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

80

FROM N°: 921035 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(12/03/2015)

80-02-M161EN

2

ELECTRICAL SCHEMATIC DIAGRAMS

WIRE COLOUR CODE white white/brown white/black blue gray gray/black yellow yellow/black brown black black/salmon orange red pink green green/yellow green/black

80

bc bc/m bc/n bl g g/n j j/n m n n/s o r ro vt vt/j vt/n

80-02-M161EN

(12/03/2015)

STEERING SENSOR

o m

n

bl

TELESCOPE RETRACTED SENSOR

TELESCOPE SELECT TURRET SELECT PENDULAR ARM SELECT L ROT/LOWERING R ROT/RAISING

PENDULAR ARM SENSOR UP FLASHING LIGHTS TELESCOPE BOTTOM EV

TEMPERATURE SENSOR SUPPLY SELECTION ELECTRO-VALVE STEERING SELECTION ELECTRO-VALVE TURRET SELECTION ELECTRO-VALVE TELESCOPE LIFTING ELECTRO-VALVE TELESCOPE LOWERING ELECTRO-VALVE LEFT BRAKE ELECTRO RIGHT BRAKE ELECTRO

+24Vdc

OUTPUT

REF

GND

87a 87 85

86

30

R

4700 Ω 1 % 0.25 W

BASKET Control

BASE Control

80

TILT OVERLOAD

1 3 bc

GREEN

RED

CHARGER CUT

vt

bc vt m

Battery charger P T N

+ -

2

m

EMERGENCY STOP

C2 C1

EMERGENCY STOP + POWER SWITCH

JOYSTICK MIDPOINT LONGITUDINAL AXLE LATERAL AXLE

Transport

PENDULAR ARM

TURRET TELESCOPE

Tilt

OVERLOAD

HORN PB PENDULAR ARM SELECT. TURRET SELECT. TRANSPORT SELECT.

BATTERY

80-02-M161EN (12/03/2015)

TRIGGER LEFT STEERING PB RIGHT STEERING PB

BUZZER

RAISING PENDULAR ARM LOCKING EV

BATTERY CHARGE LEVEL INFORMATION

VARIABLE SPEED DRIVE

Up to n°: 921034 BASKET CONTROL BASE CONTROL

LOWERING PENDULAR ARM LOCKING EV

HORN

TILT

BASKET PLATE

3 ELECTRICAL SCHEMATIC DIAGRAMS

Network

braking release switch

OVERLOAD LIMIT SWITCH

OVERLOAD LIMIT SWITCH

BASKET PLATFORM

STEERING SENSOR

TEMPERATURE SENSOR SUPPLY SELECTION ELECTRO-VALVE STEERING SELECTION ELECTRO-VALVE TURRET SELECTION ELECTRO-VALVE TELESCOPE LIFTING ELECTRO-VALVE

m

o

FLASHING LIGHTS TELESCOPE BOTTOM EV

TELESCOPE SELECT TURRET SELECT PENDULAR ARM SELECT L ROT/LOWERING R ROT/RAISING

PENDULAR ARM SENSOR UP bl

REF n

GND

+24Vdc

OUTPUT

RIGHT BRAKE ELECTRO

LEFT BRAKE ELECTRO

TELESCOPE LOWERING ELECTRO-VALVE

RED GREEN

OVERLOAD LIMIT SWITCH 120 ohms

R

4700 Ω 1 % 0.25 W

BASKET Control

BASE Control

80

TILT OVERLOAD

bc

1 3

CHARGER CUT

vt

bc vt m

Battery charger P T N

+ -

2

m

TRIGGER LEFT STEERING PB RIGHT STEERING PB

BUZZER

C2 C1

EMERGENCY STOP

EMERGENCY STOP + POWER SWITCH

JOYSTICK MIDPOINT LONGITUDINAL AXLE LATERAL AXLE

RAISING PENDULAR ARM LOCKING EV

BATTERY CHARGE LEVEL INFORMATION

VARIABLE SPEED DRIVE 80 VJRE Only

Transport

PENDULAR ARM

TURRET TELESCOPE

Tilt

OVERLOAD

HORN PB PENDULAR ARM SELECT. TURRET SELECT. TRANSPORT SELECT.

BATTERY

(12/03/2015) 80-02-M161EN

BASKET CONTROL BASE CONTROL

LOWERING PENDULAR ARM LOCKING EV

HORN

TILT

From n°: 921035 Network

ELECTRICAL SCHEMATIC DIAGRAMS 4

TELESCOPE RETRACTED SENSOR

braking release switch

OVERLOAD LIMIT SWITCH

BASKET PLATFORM

BASKET PLATE

ELECTRICAL COMPONENTS LOCATION

Pages LOCATION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ELECTRIC HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 –– SPIRAL CORD HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 –– BASKET CONTROL PANEL HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 –– JIB EV HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 –– OVERLOAD END OF TRAVEL - OVERLOAD SENSORS HARNESS . . . . . . . . . . . . . . . . . . . . . 5 –– JIB DETECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 –– RETRACTED TELESCOPE DETECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 –– STEERING SENSOR HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 –– TELESCOPE BASE EV HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 –– TURRET DISTRIBUTOR HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 –– FLASHING LIGHT POWER SUPPLY HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 –– LEVELING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 –– POWER CIRCUIT CABLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 –– BRAKE - BUZZER HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 –– BASKET CONSOLE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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–– CHARGER CUT-OFF HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2

ELECTRICAL COMPONENTS LOCATION

LOCATION OF COMPONENTS Fuse

Battery cut-off Control a nd power

Telescope down sensor Variable speed drive

Pendular a rm down sensor

Battery charger Battery

Electric pump

Front

Electronic cards in the basket console

Electronic cards in the base console

Tilt sensor

80

Overload sensors

Steering angle sensor REAR

Buzzer

Right-hand traction motor Right-ha nd electric brake Battery charge indic ator

Cable-carrying chain

Left-hand traction motor Left-hand electric brake

ELECTRIC HARNESSES

bb

All connectors are shown on the wire insertion side.

WIRE COLOUR CODE: bc white j yellow bc/m white/brown j/n yellow/black bc/n white/black m brown bl blue n black g gray n/s black/salmon g/n gray/black o orange 80-03-M161EN

r ro vt vt/j vt/n

red pink green green/yellow green/black (10/03/2015)

ELECTRICAL COMPONENTS LOCATION

3

SPIRAL CORD HARNESS

Green Orange TOOLBOX CONSOLE ASSEMBLY 685114

1 2

To basket Emergency Stop push button

To basket plate 685135 Connector C

6 5 4 3 2 1

SPIRAL BELT BUNDLE 685817-B

PIN 1 2 3 4 5 6

Wire Brown Green/yellow Black Red White Blue

Signal +24V GND Overload 2 CANL Overload 1 CANH

Connection To WAGO 5-way +24V after ignition terminal strip To variable speed drive BTo 4-way clip holder To 4-way clip holder

F2 F1

P

BB+ 12

1

T1

T2

PIN 13 14 15

Green/yellow To variable speed drive

To WAGO 5-way terminal strip +24V after ignition supply - Bundle wire No. 1 685809 - Bundle brown wire 685817 - Bundle wire No. 1 685818 - Brown wire to variable speed drive PIN11 - Power contactor relay brown wire

23

24

35

Wire Green Black White

Signal Basket Emergency Stop Overload sensor 2 Overload sensor 1

Connection To basket Emergency Stop push button To basket console plate PIN3 To basket console plate PIN5

To 4-way spade holder - Bundle orange wire 685817-A - Bundle blue wire No. 50 685817-A - Bundle blue wire No.51 685817-A - Bundle red wire No. 50 685817-A - Bundle red wire No.51 685817-A - Bundle wire No. 1 685808

Orange

Brown

13

Blue N°50 Blue N°51

To 4-way spade holder bundle 685815

Red N°50 Red N°51

Diagnostics socket to PC

1

(10/03/2015)

2

PIN Wire 1 Blue N°50 Red N°50 2

Signal Connection CANH To 4-way spade holder CANL To 4-way spade holder

80-03-M161EN

80

To variable speed drive B-

ELECTRICAL COMPONENTS LOCATION

4

BASKET CONTROL PANEL HARNESS

LED OVERLOAD (Red)

LED TILT (Red)

S10 A2

14 13 12 11 10 9 8 7 6 5 4 3 2 1

Joystick

A2

Mmembrane keyboard

A3

Basket control plate

A4

LED support plate

H10

Buzzer

S10

Emergency Stop push button

PIN 1 2 3 4

Fil Bc R R M

LED PENDULAR ARM (Green)

A1

A1

LED TELESCOPE TURRET (Green)

Vers manipulateur ITT

F

E

1

2

A4

B

A

LED TRANSPORT (Green)

CD

A3

Signal +24V battery Common Steering Common Dead Man’s system Earth

1

2

PIN 1 2 3 4 5 6

Fil G J N/S Bl Vt O

A

Signal Analogue signal Y Analogue signal X Steer left Steer right Joystick Neutral Dead Man’s system contact

80

PIN 1 2 3 4 5 6 7 8 9 10 12 13 14

Fil Signal N21 Translation movement indicator light N22 Pendular arm movement indicator light N23 Telescope/turret movement indicator light N19 Tilt indicator light N20 Overload indicator light J15 Horn J13 Turret movement selection Bc1 +24V R4 +24V R5 +24V R16 +24V supply after basket Emergency Stop J14 Pendular arm movement selection J12 Translation movement selection

B

E

A PIN 3 5 8 9

B PIN 1 3 4 5 6 8 9 10 11 12 13 14

E Black N°18

Red N°17

H10

PIN 2 4 5 6 7 8 10

F PIN 1 2 3

80-03-M161EN

F

10 9 8 7 6 5 4 3 2 1

Signal axes joystick GND Earth Out of joystick Neutral X-axis analogue signal Y-axis analogue signal

Fil M10 Vert N°7 J2 G9

14 13 12 11 10 9 8 7 6 5 4 3 2 1

Fil N J12 O6 N N J14 J13 J15 N4 Bl3 N/S8 N

Signal Pendular arm down Translation movement selection Joystick trigger Telescope retracted +24V Pendular arm movement selection Turret movement selection Horn HBT2 overload Steer right Steer left +24V

10 9 8 7 6 5 4 3 2 1

Fil N°1 R17 Vt/J N20 N19 N18 N°2

Signal EV pendular +24V +24V Pendular arm raising Overload indicator light Tilt indicator light Buzzer Pendular arm lowering

6 5 4 3 2 1

Fil N23 N22 N21

Signal Telescope/turret movement indicator light Pendular arm movement indicator light Translation movement indicator light

(10/03/2015)

ELECTRICAL COMPONENTS LOCATION

5

JIB EV HARNESS

CNC

CNF

4 1 5 2 6 3

CNE

CNB

CNA

10 9 8 7 6 5 4 3 2 1

14 13 12 11 10 9 8 7 6 5 4 3 2 1

10 9 8 7 6 5 4 3 2 1

2 1

CND

EV12 PENDULAR ARM LOWERING

3 6 2 5 1 4

To basket control plate

A

B

PENDULAR ARM ELECTRO-VALVE BUNDLE 685824-B

F

E

1 PIN Wire 1 Red 2 N°2

2

Signal Sensor supply Pendular arm EV - Lowering

To 10-way connector E bundle 685825-B

PIN 2 5 10

10 9 8 7 6 5 4 3 2 1

Wire N°1 Green/Yellow N°2

Signal +24V EV pendular arm - Raising EV pendular arm - Lowering

EV11 PENDULAR ARM RAISING

E

Green/Yellow

N°1 N°2

1

2

PIN Wire Signal 1 Red Sensor supply 2 Green/Yellow EV pendular arm - Raising

OVERLOAD END OF TRAVEL - OVERLOAD SENSORS HARNESS

OVERLOAD SENSOR 685823-A Ref. XX

CNC

3 6 2 5 1 4

CNE

CNB

CNA

10 9 8 7 6 5 4 3 2 1

14 13 12 11 10 9 8 7 6 5 4 3 2 1

10 9 8 7 6 5 4 3 2 1

4 1 5 2 6 3 2 1

CND

80

CNF

To basket control plate

A

B

E

F 2

To 14-way connector B bundle 685825-B

B

PIN Wire 1 Black/White 2 Black

14 13 12 11 10 9 8 7 6 5 4 3 2 1

PIN Wire Signal 11 N°4 Overload 1 - HBT2

1

2

1

PIN Wire 1 Black/White 2 Black

2 1

N°4

PIN Wire Signal 1 N°1 Supply to sensors 2 N°2 Overload 2 - HBT3

1 PIN Wire 1 Red 2 N°4

2

Signal Supply to sensors Overload 1 - HBT2

1 PIN Wire 1 Red 2 N°2

2

Signal Supply to sensors Overload 2 - HBT3

OVERLOAD LIMIT SWITCH BUNDLE 685821-B Ref. XX OVERLOAD LS

(10/03/2015)

80-03-M161EN

6

ELECTRICAL COMPONENTS LOCATION JIB DETECTOR

CNC

CNF 3 6 2 5 1 4

4 1 5 2 6 3

CNE

CNB

CNA

10 9 8 7 6 5 4 3 2 1

14 13 12 11 10 9 8 7 6 5 4 3 2 1

10 9 8 7 6 5 4 3 2 1

2 1

CND

To basket control plate

B

14 13 12 11 10 9 8 7 6 5 4 3 2 1

A

B

F

E

PIN Wire Signal 1 Black N°1 Pendular arm down 6 Black N°2 +24V To 14-way connector B bundle 685825-B

Black N°1

Black N°2

PENDULAR ARM DOWN 685820-A

PENDULAR ARM SENSOR

RETRACTED TELESCOPE DETECTOR

CNC

CNF 3 6 2 5 1 4

CNB

CNA

14 13 12 11 10 9 8 7 6 5 4 3 2 1

10 9 8 7 6 5 4 3 2 1

80

CNE 10 9 8 7 6 5 4 3 2 1

4 1 5 2 6 3 2 1

CND

To basket control plate

B

14 13 12 11 10 9 8 7 6 5 4 3 2 1

A

B

E

F

PIN Wire Signal 5 N°1 Telescope retracted 14 N°2 +24V To 14-way connector B bundle 685825-E

N°1

N°2

TELESCOPE RETRACTED SENSOR 685811-A

TELESCOPE RETRA CTED SENSOR

80-03-M161EN

(10/03/2015)

ELECTRICAL COMPONENTS LOCATION

7

STEERING SENSOR HARNESS

F2 F1

P

To bundle 4-way spade holder 685815

BB+

T1 To variable speed drive, terminal B- Bundle green/yellow wire 685808 - Bundle green/yellow wire No. 2 685815 - Bundle wire No. 3 685818

To 4-way spade holder - Bundle orange wire 685817 - Bundle blue wire No. 50 685817 - Bundle blue wire No. 51 685817 - Bundle red wire No. N°50 685817 - Bundle red wire No. N°51 685817 - Bundle wire No.1 685808

T2

To variable speed drive

12

1 13

23

24

35

green/yellow PIN Wire Signal N°2 Steering signal 7

Connection To steering sensor

N°1

B C

STEERING SENSOR BUNDLE 685808 - B

A

PIN A B C

Wire N°1 Green/yellow N°2

Signal +12V GND Steering signal

Connection To 4-way spade holder To variable speed drive, terminal BTo variable speed drive PIN7

STEERING SENSOR

Steering sensor 684731-B

TELESCOPE BASE EV HARNESS

F2 F1 1

B-

12

13

23

24

35

80

P

B+ PIN Wire Signal 26 N°2 telescope bottom EV

T1

T2

To variable speed drive To WAGO 5-way terminal strip Protected +24V - Bundle red wires Nos. 7 & 23 685810 - Bundle wire No. 1 685812 - Bundle wire No. 1 685813 - Bundle red wire 685815

N°1 PIN Wire Signal N°1 +24V 1 N°2 telescope bottom EV 2 TELESCOPE BOTTOM ELECTRO-VALVE BUNDLE 685812 - B

1

2

TELESCOPE BOTTOM EV EV10 - TELESCOPE FUNCTION To telescope bottom unit

(10/03/2015)

80-03-M161EN

8

ELECTRICAL COMPONENTS LOCATION CHARGER CUT-OFF HARNESS

F2 F1

P

BB+

T1

T2

To variable speed drive

12

1

To WAGO 5-way terminal strip +24V after ignition supply - Bundle wire No. 1 685809 - Bundle brown wire 685817 - Bundle wire No. 1 685818 - Brown wire to variable speed drive PIN11 - Power contactor relay brown wire

13

23

24

35

PIN Wire Signal 17 N°2 Charger cut-off info

Connection To charger AMP2V connector

N°1

100% 80%

80% 20%

CHARGER CUT-OFF BUNDLE 685809-A

80

CHARGER CUT-OFF

REMOTE LED BUNDLE

N°1

Fil Signal N°1 +24V N°2 Charger cut-off info

N°2

1 2 3

PIN 1 2 3

Wire White Green Brown

Signal GND Red LED supply Green LED supply

PIN 1 2 3

Wire White Green Brown

Signal GND Red LED supply Green LED supply

To charger To charger Wire Brown Blue

Signal +24V Charger cut-off info

80-03-M161EN

1 2 3

(10/03/2015)

ELECTRICAL COMPONENTS LOCATION

9

TURRET DISTRIBUTOR HARNESS

F2 F1

P

B-

TURRET DISTRIBUTOR BUNDLE 685810 - B

B+ T1

T2

To variable speed drive

1

To WAGO 5-way terminal strip Protected +24V - Bundle red wires Nos. 7 & 23 685810 - Bundle wire No. 1 685812 - Bundle wire No. 1 685813 - Bundle red wire 685815

red N°23

PIN 16 23 25 28 30 32 34

red N°7

PIN Wire 1 Red N°6 2 Pink N°22

Signal +24V Electric pump temperature info

1

2

1

2

1

2

1

2

Signal +24V Turret rotation/steering 1 direction selection EV

2

12

13

23

24

35

Wire Pink N°22 Red N°23 Pink N°3 Pink N°4 Pink N°1 Pink N°2 Pink N°5

Signal Connection Electric pump temperature info +24V To WAGO 5-way +24V terminal strip Turret rotation EV Steering cylinder EV Telescope lowering EV Telescope raising EV Turret rotation/steering direction selection EV

TEMPERATURE SENSOR

PIN Wire 1 Red N°6 2 Pink N°3

Signal +24V Turret rotation EV

PIN Wire 1 Red N°6 2 Pink N°4

Signal +24V Steering cylinder EV

80

TURRET SELECTION EV EV6 - TURRET ROTATION

STEERING SELECTION EV EV5 - STEERING

PIN Wire 1 Red N°6 2 Pink N°1

Signal +24V Telescope lowering EV

TELESCOPE LOWERING EV TELESCOPE LOWERING - EV8

PIN Wire 1 Red N°6 Pink N°5 2

SUPPLY SELECTION EV EV4 - Turret rotation/steering direction selection

PIN Wire Red N°6 1 2 Pink N°2

Signal +24V Telescope raising EV

1

2

Telescope raising EV Telescope raising - EV7

(10/03/2015)

80-03-M161EN

10

ELECTRICAL COMPONENTS LOCATION FLASHING LIGHT POWER SUPPLY HARNESS

F2 F1

P

BB+

T1

T2

To variable speed drive To WAGO 5-way terminal strip Protected +24V - Bundle red wires Nos. 7 & 23 685810 - Bundle wire No. 1 685812 - Bundle wire No. 1 685813 - Bundle red wire 685815

12

1 13

23

24

35

PIN Wire Signal 35 N°2 Flashing light (option) N°1

FLASHING LIGHT SUPPLY BUNDLE 685813-A

PIN Wire Signal 1 N°1 +24V 2 N°2 Flashing light (option)

1

2

To flashing light (option)

FLASHING LIGHT SUPPLY

LEVELING HARNESS

F2 F1

P

80

BB+

T1 To WAGO 5-way terminal strip +24V after ignition supply - Bundle wire No. 1 685809 - Bundle brown wire 685817 - Bundle wire No. 1 685818 - Brown wire to variable speed drive PIN11 - Power contactor relay brown wire

To variable speed drive terminal B- Bundle green/yellow wire 685808-A - Bundle green/yellow wire No. 2 685815 - Bundle wire No. 3 685818

T2

To variable speed drive

12

1

N°3 N°1

13

23

24

35

PIN Wire Signal 3 N°2 TILT

TILT BUNDLE 685818-A

B C

A

PIN A B C

Wire N°1 N°3 N°2

Signal +24V GND Devers

Liaison To WAGO 5-way terminal strip To variable speed drive BTo variable speed drive PIN3

TILT

Tilt sensor

80-03-M161EN

(10/03/2015)

ELECTRICAL COMPONENTS LOCATION

11

POWER CIRCUIT CABLING

BATTERY

+ BATTERY / FUSE 685795

BATTERY CUT-OFF / ELECTRIC PUMP D1 685798

- BATTERY / VARIABLE SPEED DRIVE B685801

BATTERY CUT-OFF

FUSE / BATTERY CUT-OFF 685796

F2 F1

FUSE 250A

P BATTERY CUT-OFF / VARIABLE SPEED DRIVE B+ 685797

B-

VARIABLE SPEED DRIVE P / ELECTRIC PUMP D2 685802

VARIABLE SPEED DRIVE

B+ T1

CHARGER

T2 D1

VARIABLE SPEED DRIVE T2 / MOTOR A2 LEFT TRANSLATION 685804

ELECTRIC PUMP

80

VARIABLE SPEED DRIVE T1 / MOTOR A2 RIGHT TRANSLATION 685803

D2

ELECTRIC PUMP D1 / RIGHT TRANSLATION MOTOR A1 685799 VARIABLE SPEED DRIVE F2 RIGHT TRANSLATION MOTOR F1 LEFT TRANSLATION MOTOR F2 685806

A2 F2

MOTOR LEFT TRANSLATION

F1

A1

A1 A2

F1

F2

RIGHT TRANSLATION MOTOR

RIGHT TRANSLATION MOTOR A1 LEFT TRANSLATION MOTOR A1 685800 VARIABLE SPEED DRIVE F1 RIGHT TRANSLATION MOTOR F2 LEFT TRANSLATION MOTOR F1 685805

(10/03/2015)

80-03-M161EN

12

ELECTRICAL COMPONENTS LOCATION BRAKE - BUZZER HARNESS

PIN 1 2 3 4 5 6

Wire 1.5kw resistance Black N°1 Blue 1.5kw resistance Green/yellow N°2 Pink

Signal Beep control Beep control GND Brake release Brake release

Connection Switch bridge PIN4 To buzzer PINTo variable speed drive PIN29 Switch bridge PIN1 To variable speed drive BTo right-hand brake electro-valve supply To variable speed drive PIN12

BRAKE / BUZZER BUNDLE 685807-D

F2 F1

P

BB+

3

2

To variable speed drive terminal B-

1

T1

T2

To variable speed drive

6

5

12

1

4 To brake release switch

13

23

24

35

Green/yellow PIN Wire Signal 12 Pink Brake release 29 Blue Beep control

Connection To brake release switch PIN6 To brake release switch PIN3

orange 1

To right-hand NC contact battery cut-off

To buzzer

red

FUSE

5A 1

orange 2

2

N°1 PIN Wire Signal Connection 1 Black N°1GND To brake release switch PIN2 2 Red +24V To fuse 5A

ec t el ke

Connection Left-hand brake electro-valve / 5A fuse NC contact Emergency Stop / main contact Emergency Stop Main contact Emergency Stop / 5A fuse Battery cut-off / buzzer PIN-

br a

Signal +24V +24V +24V +24V

80

Wire N°1 Orange 1 Orange 2 Red

ro -v

al v

e

To power contactor input terminal

Orange N°1

Black N°2

Wire N°1 Orange N°2 Black

Signal +24V +24V Brake electro-valve / brake release control Brake electro-valve / brake release control

Connection To Emergency Stop 5A fuse To right-hand brake electro-valve To brake release switch To right-hand brake electro-valve To left-hand brake electro-valve

80-03-M161EN

Orange

Black Wire Signal Orange +24V Black Brake electro-valve / brake release control

Connection To left-hand brake electro-valve To left-hand brake electro-valve

To right-hand brake electro-valve

(10/03/2015)

ELECTRICAL COMPONENTS LOCATION

13

BASKET CONSOLE HARNESS

F2 F1

P

BB+

T1

To variable speed drive, terminal B- Green/yellow wire bundle 685808 - Green/yellow wire No. 2 bundle 685815 - Wire No. 3 bundle 685818

12

1 2

T2 PIN 1 6 8 9 18 19 20 21 22 24 31

To variable speed drive

Green/yellow N°2

Protected +24V on WAGO terminal strip - fwires red N°7 & N°23 bundle 685810 - wire No. 1 bundle 685812 - wire No. 1 bundle 685813 - wire red bundle 685815

BASE CONSOLE BUNDLE 685815-A

- Only on the 80VJR, to be connected to B+ on the variable speed drive

13

23

24

35

Wire Orange N°15 Browon N°31 Blue N°33 Red N°32 Yellow N°9 Yellow N°8 Yellow N°7 Yellow N°6 Yellow N°5 Blue N°13 Blue N°10

Signal Base control +12V CANH CANL Telescope lowering / turret rotation left selection Telescope raising / turret rotation right selection Telescope selection Pendular arm selection Turret rotation selection Tilt indicator light Overload indicator light

Brown N°1 Red N°12

Connection To PEB PIN11 To 4-way clip holder To 4-way clip holder To 4-way clip holder To PEB PIN6 To PEB PIN5 To PEB PIN3 To PEB PIN4 To PEB PIN5 To PEB PIN1 To PEB PIN10

Brown N°31 Orange N°14

Blue N°33 To left NC contact battery cut-off Orange N°16

To bundle 4-way spade holder 685808 685817

Red N°3 Red N°32 Blue N°4

To power contactor output terminal

Red N°11

BASE CONTROL CONSOLE 685816

P Signal Basket control Protected +24V Base control Protected +24V

6 5 4 3 2 1

orange N°1

PIN 1 2 3 4 5 6

Wire Brown N°1 Green/yellow Red N°1 Blue N°1 Spare Spare

Signal +12V GND CANL CANH

4

Connection To 4-way clip holder To variable speed drive BTo 4-way clip holder To 4-way clip holder

3

4

-6 .3A

3 S20

J1

F2

6 5 4 3 2 1

F1

-5 A

orange N°4

3 4 1 2

80

Wire Orange N°1 Orange N°2 Orange N°3 Orange N°4

A5

J2 J3

orange N°2

orange N°3

A6 12 11 10 9 8 7 6 5 4 3 2 1

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

Fil Blue N°13 Blue N°10 Yellow N°7 Yellow N°6 Yellow N°8 Yellow N°9 Red N°11 Red N°12 Yellow N°5 Orange N°16 Orange N°15 Orange N°14

Signal Tilt indicator light Overload indicator light Telescope selection Pendular arm selection Telescope lowering / turret rotation left selection Telescope raising / turret rotation right selection +24V Protected +24V Turret rotation selection Battery +24V after Emergency Stop Base control Basket control

Connection To variable speed drive PIN24 To variable speed drive PIN31 To variable speed drive PIN20 To variable speed drive PIN21 To variable speed drive PIN19 To variable speed drive PIN18 Power contactor output Protected +24V on WAGO terminal strip To variable speed drive PIN22 NC contact Emergency Stop output To variable speed drive PIN1 To 4-way clip holder

A5

Base console electronic plate

A6

Base membrane keypad

P

Hour counter

S20

Base/basket selector switch

D-FE-034

(10/03/2015)

80-03-M161EN

ELECTRICAL COMPONENTS LOCATION

80

14

80-03-M161EN

(10/03/2015)

ELECTRICAL CONTROL AND ADJUSTMENT

Pages BATTERY CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 –– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 –– DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 –– CHARGE CURVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 –– INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ELECTRONIC CONTROL UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 –– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 –– DESCRIPTION AND CABLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 VARIABLE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 –– CABLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SAFETY COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 –– SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 –– TILT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 –– TELESCOPE LOW POSITION SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 –– JIB LOW POSITION SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 –– OVERLOAD SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 –– STEERING SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 MANIPULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 –– ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 –– TEST WITH A VOLTMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

(10/03/2015)

80-04-M161EN

80

–– DIAGNOSTIC AND ADJUSTMENT TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2

ELECTRICAL CONTROL AND ADJUSTMENT

BATTERY CHARGER

A1

Front

REMOVAL 2 1

- Switch off the power supply (A1-1).

- Open and remove the left-hand turret cover (A1-2).

A2 Front

1

- Disconnect (A2): - The black and red charge cables (A2-1).

- The power supply cable (A2-2).

- The remote LED harness (A2-3).

- The charger cut-off harness (A2-4).

4

3 2

A3

FRON T

- Remove the holding nut of the base control panel and pivot the lower console assembly while holding it (A3-1).

80

1

A4

- Remove the charger (A4):

FRON T

I- Remove the charger fastening elements.

II - Lower the charger towards the tilt detector.

III - Extract it from the turret with its harnesses.

REFIT - Carry out the removal operations in reverse order.

III

80-04-M161EN

II

o "ELECTRICAL COMPONENTS REMOVAL" (10/03/2015)

ELECTRICAL CONTROL AND ADJUSTMENT

3

DESCRIPTION External view: - Mains power supply cable.....................................(B1-1) - Remote LED harness ...............................................(B1-2) - Charger cut-off harness .........................................(B1-3) - Charge cables ............................................................(B1-4) - Capacity selector (behind the cap) ...................(B1-5)

B1

4

1 5

2

bb bb bb

3

D-EL-797

For optimum operation of the VJR Evolution range, the charger can only be used with the capacity selector switched to setting 3.

Internal view: Disassembling the charger will invalidate the manufacturer warranty.

The charger comprises an internal 15A fuse. In the event of it failing, the charger should be sent to MANITOU after-sales service.

80

CHARGE CURVES

Voltage

Intensity

Voltage

U I1 24V

I2

Intensity I1

P tI1 P

(10/03/2015)

U

I2

tU

tI2

Stop

Balancing tBalancing

Stop

Slow engine speed

Stop

tStopM tSlow engine speed

Phases Temps

80-04-M161EN

4

ELECTRICAL CONTROL AND ADJUSTMENT

D1

INDICATOR Remote LED indicator (D1): - Continuous red: Charge phases I1 and P - Continuous orange: Charge phases U and I2 - Flashing green: 1st stop and equalizing phase - Continuous green: Charge complete - Flashing red: Charge fault

100% 80%

80% 20% D-EL-799

A1

Charge faults: - Mains voltage outside tolerances (85-265 V AC) - Excessive charge time.

ELECTRONIC CONTROL UNITS REMOVAL Basket module control unit - Remove the front face from the basket control panel (A1-1).

1

A2

80

- Remove the basket module control unit (A2-1).

1

A3 1

Basket control panel LED support plate: - Remove the front face from the basket control panel (A1-1).

- Remove the basket control panel LED support plate (A3-1).

80-04-M161EN

(10/03/2015)

ELECTRICAL CONTROL AND ADJUSTMENT

A4

5

Base module control unit and MDI CAN display: - Open the left-hand turret cover (A4-1).

2

- Open the front face of the base control panel (A4-2).

1

DESCRIPTION AND CABLING Basket module control unit

B1

B2

CNC

6

CNF 10

Connector

CNA

CNB

CNC

CND

CNE

CNF

(10/03/2015)

PIN 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 1 2 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6

Basket module control unit Color M-10

0 V Manipulator

VT-7

Manipulator not neutral

J-2 G-9 N J-12 O-6 N N J-14 J-13 J-15 N BL-3 N/S-8 N M V/J N R BC BL N1 N2

Signal

CNA

CNB

CNE 1

14

1

10

6 2 1

1

CND

Multimeter Not activated Activated

0V

6.2 V

Manipulator lateral axis Manipulator longitudinal axis

2.5 V 2.5 V

0.5<2.5>4.4 0.5<2.5>4.4

Jib sensor signal

17.2 V

1.6 V

Alarm signal Trigger signal Retracted telescope signal 24 V end of travel, jib raised

0V 0V 17.2 V 24 V

24 V 24 V 1.1 V 24 V

0V 0V 0V

24 V 24 V 24 V

0V 0V 24 V 24 V

24 V 24 V 24 V 24 V

Turret telescope selection signal Jib selection signal Translation selection signal HBT2 overload signal Right-hand steering signal Left-hand steering signal 24 V retracted telescope sensor 24 V control unit power supply 0 V ground HBT3 variable control overload CAN-L variable control HBT2 variable control overload CAN-H variable control HBT power supply overload HBT3 overload signal

N1

24 V jib EV power supply

24 V

24 V

R17 V/J N20 N19 N18

24 V audible beep 0 V jib EV UP Overload indicator lamp signal Tilt indicator lamp signal 0 V basket buzzer

24 V 24 V 24 V 24 V

24 V 0V 9.6 V 9.6 V

N2 N23 N22 N21

0 V jib EV DOWN Telescope selection signal Telescope selection signal Telescope selection signal

24 V 24 V 24 V 24 V

9.5 V 9.5 V 9.5 V

80-04-M161EN

80

1

1

6

ELECTRICAL CONTROL AND ADJUSTMENT Basket control panel LED support plate

B4

J2 1 2 3 4 5

B3

J1

14

Connector

J1

J2

PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5

1

Basket LED support plate Color Signal N21 Transport indicator lamp N22 Jib indicator lamp N23 Telescope/turret indicator lamp N19 Tilt indicator lamp N20 Overload indicator lamp J15 Transport selection J13 Jib selection Bc1 +24 V signal power supply and manipulator neutral R4 +24 V steering manipulator press button power supply R5 +24 V manipulator trigger power supply +24 V free R +24 V emergency stop power supply J14 Turret selection J12 Horn selection +24 V screen print BP power supply Horn press button Jib selection Turret/telescope selection Transport selection

Base module control unit

24 V 0V 0V 24 V 0V 0V 0V 0V

24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V

B6

B5

80

Multimeter Not activated Activated 24 V 9.6 V 24 V 9.6 V 24 V 9.6 V 24 V 9.6 V 24 V 9.6 V 0V 24 V 0V 24 V 24 V 24 V 24 V 24 V 24 V 24 V

1

4

J1 J2 7 1 Connector J1

J2

80-04-M161EN

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

Base module control unit Color Signal O1 +24 V after basket control O2 +24 V base control power supply O3 +24 V after base control O4 +24 V basket control power supply Bl13 Tilt indicator lamp Bl10 Overload indicator lamp J7 Telescope selection signal J6 Jib selection signal J8 Raising / right-hand rotation selection signal J9 Lowering / left-hand rotation selection signal R11 +24 V F2 fuse power supply R12 +24 V F2 fuse output J5 Turret selection signal O16 +24 V F1 fuse power supply O15 +24 V base control power supply O14 +24 V basket control power supply

J3 1 2 3 4 5

Multimeter Not activated Activated 0V 24 V 24 V 24 V 0V 24 V 24 V 24 V 24 V 9.6 V 24 V 9.6 V 0V 24 V 0V 24 V 0V 24 V 0V 24 V 24 V 24 V 24 V 24 V 0V 24 V 24 V 24 V 0V 24 V 0V 24 V (10/03/2015)

ELECTRICAL CONTROL AND ADJUSTMENT

Connector

J3

Base module control unit Color Signal N +24 V screen print BP power supply N Raising / right-hand rotation selection N Lowering / left-hand rotation selection N Jib selection N Turret selection N Telescope selection

PIN 1 2 3 4 5 6

7

Multimeter Not activated Activated 24 V 24 V 0V 24 V 0V 24 V 0V 24 V 0V 24 V 0V 24 V

B7

MDI CAN display

1 6

Connector

MDI

MDI CAN display Color M1 12 V V/J2 0 V ground R3 CAN-L Bl4 CAN-H

PIN 1 2 3 4 5 6

Multimeter Not activated Activated 12 V 12 V 0 0

Signal

VARIABLE CONTROLS CABLING Control circuit - Electronic module

B2

A 1

12

13

23

24

Connector

A

(10/03/2015)

PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Variable control logic module Color Signal O15 +24 V base control selection power supply R +24 V DC N2 Tilt signal N N2 R Blue Bl M Pink Green Black Bl Pink 22 N2

+12 V power supply Steering potentiometer mid-point CAN-L signal CAN-H signal 0 V AU coil/power contact 24 V power supply 0 V brake / brake release electrovalve +24 V basket control signal HBT3 signal HBT2 signal T° sensor signal Charger cut-off + signal

31

80

B1

35 Multimeter Not activated Activated 0V 24 V 0V 0V 0V

12 V 2.5 V

0V 0V

24 V 0V 24 V

0V

24 V 80-04-M161EN

ELECTRICAL CONTROL AND ADJUSTMENT

8

Connector

A

Variable control logic module Color Signal J9 Lowering / rotation signal J8 Raising / rotation signal J7 Telescope signal J6 Jib signal J5 Turret signal R23 +24 V electrovalve / F2 fuse power supply Bl13 0 V tilt indicator lamp Pink3 0 V turret electrovalve N2 0 V telescope base electrovalve

PIN 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Multimeter Not activated Activated 0V 24 V 0V 24 V 0V 24 V 0V 24 V 0V 24 V 0V 24 V 24 V 0V 24 V 0V 24 V 0V

Pink4 Bl Pink1 Bl10 Pink2

0 V steering electrovalve 0 V Horn 0 V telescope lowering electrovalve Overload indicator lamp 0V telescope raising electrovalve

24 V 24 V 24 V 24 V 24 V

0V 0V 0V 0V 0V

Pink5 N2

0 V power supply selection electrovalve 0V flashing light

24 V 24 V

0V 0V

Power circuit D1

B3

D2 +

-

F2 F1 P BB+

80

T1 T2

A2

F1

F2

A2

A1

F1

F2

A1

DIAGNOSTIC AND ADJUSTMENT TOOLS FAULT CODE –– Meaning of fault codes o "ELECTRICAL TROUBLESHOOTING"

80-04-M161EN

(10/03/2015)

ELECTRICAL CONTROL AND ADJUSTMENT

9

SAFETY COMPONENTS

B1

SWITCHES o "ELECTRICAL COMPONENTS LOCATION"

1

TILT SENSOR ADJUSTMENT

bb

The tilt sensors are pre-set by the manufacturer. The only parameter that can be adjusted is the sensor initialization.

B2

–– Position the access platform on level ground, keeping it switched on.

2

–– Open the right-hand turret cover (B1-1).

–– Locate the tilt sensor (B2-1).

bb

1

Check that the angle of the sensor written in (B3-1) matches that of the manufacturer's plate on the machine.

–– Take the disconnected wire (B3-2) protruding from the sensor.

B3

–– Take off the plastic cap (B2-3) at the end of the wire.

2

3

BLUE

0V

BROWN +24V GREEN

SIGNAL Tilt < 2° = 0V Tilt > 2° = Pas de signal

–– Take an electric wire 0.5 m long with its ends stripped, connect it to the wire (B3-2) and connect it to the – terminal of the right-hand battery (B2-2): –– The green LED located under the sensor should flash several times.

–– It stops when the sensor has initialized.

–– It lights up continuously.

bb

During normal operation, the green LED is lit, and only switches off if the angular tilt value is exceeded.

Flat ground < 2° Tilt > 2°

(10/03/2015)

Blue 0V 0V

Brown 24 V 24 V

Green 0V Fault

80-04-M161EN

80

1

10

ELECTRICAL CONTROL AND ADJUSTMENT

TELESCOPE LOW POSITION SENSORS

C1

ADJUSTMENT

1

–– Set the telescope to the low position, ensuring the control is activated for as long as necessary, keeping the access platform switched on.

–– Remove the upper telescope cover (C1-1) and locate the proximity sensor.

C2

- Loosen the lock nuts (C2-1).

2

- Screw or unscrew the sensors (C2-2) until their LED, located next to the power supply wire, switches from off to on (green color); the clearance remaining between the support and the sensor is approximately 3 mm.

1

- Tighten the lock nuts.

1 Led

Inductive sensor activated Inductive sensor not activated

Signal 24 V 0V

D1 JIB LOW POSITION SENSORS ADJUSTMENT 1

80

- Set the jib to the low position, ensuring the control is activated for as long as necessary, keeping the access platform switched on.

- Locate the proximity sensor (D1-1).

D2

2

1

1

Led

- Loosen the lock nuts (D2-1).

- Screw or unscrew the sensors (D2-2) until their LED, located next to the power supply wire, switches from off to on (green color); the clearance remaining between the support and the sensor is approximately 3 mm.

- Tighten the lock nuts.

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ELECTRICAL CONTROL AND ADJUSTMENT OVERLOAD SENSORS

E1

ADJUSTMENT

2

Setting the overload spring: - Place 200 kg in the basket (evenly distributed) - Tighten the prestressing screw of the spring (E2-1), leaving the “screw + lock nut” pair free in rotation (E3-1 and E3-2).

PS: The clearance between the nut and the connecting rod should be as small as possible (E3-1 and E3-2).

1

NB: Prior to any operation, tighten the two adjustment screws so as to be certain not to come into contact with the sensor.

E2

Adjusting the overload sensors (E1-1) - Place 220 kg in the basket (evenly distributed).

- Loosen screw reference E2-3 until a discontinuous beep is heard -> The sensor E1-1 is adjusted.

Adjustment screw

3

Spring + overload spacer 1 Pre-tensioning screw

E3

Checking the adjustment: - With the 220 kg still in the basket, take out 10 to 20 kg and check that the alarm stops sounding.

- Return the weight to the basket and check that the alarm is triggered as required.

- If necessary, repeat the adjustment of the sensor.

1

2

Checking the adjustment: - With the 220 kg still in the basket, take out 10 to 20 kg and check that the alarm stops sounding.

- Return the weight to the basket and check that the alarm is triggered as required.

- If necessary, repeat the adjustment of the sensor.

The overload is adjusted. Confirm the adjustment with yellow paint!

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Adjusting the overload sensor (E1-2): - The beep is still discontinuous with 220 kg in the basket (evenly distributed).

- Loosen screw reference E2-3 until a continuous beep is heard -> The sensor E1-2 is adjusted.

The smallest possible play between the nut and the oxyacetylene cut-out with 200kg in the basket

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12

ELECTRICAL CONTROL AND ADJUSTMENT

F1

STEERING SENSORS ADJUSTMENT 1 - Adjusting the potentiometer: - Disconnect the angle sensor from the circuit (COMPULSORY) - Install the potentiometer (Item 4) on the plate (Item 3) (Fig. F2).

- Tighten using the nut provided with the potentiometer - Connect a multimeter (resistance measuring device) between the green wire and the black wire (Fig. F1).

- Turn the potentiometer A until a value of 4 kΩ is obtained.

F2

F3

2- Assembling the components on the frame (Fig. F2): - Align the wheels of the access platform with the frame.

- Fit the plate (Item 1) and the screws (Item 2) on the steering hub.

- Fit the pin (Item 7).

- Install the plate (Item 3 and Item 4). (Take care not to change the sensor adjustment during installation) - Tighten the potentiometer rod using the screw (Item 6).

- Once assembly is complete, close the hub with the button (Item 5).

- Install the transparent PVC cap (protection for the screw adjustment opening (Item 6)).

3- Setting program parameters (Fig. F3): - Press the keys (Items A, B and C) for 3 seconds. > A beep will sound and the 3 LED's will flash, one by one.

- Press keys B and C simultaneously for 3 seconds. > The LED's switch off.

80

4- Adjusting the steering program (Fig. F3): - Turn the steering to its left-hand stop (Z2) and confirm with key A (press briefly).

- Turn the steering to its right-hand stop (Z1) and confirm with key C (press briefly).

- Align the wheels (Z2) with the frame and confirm with key B (press briefly).

- Complete the adjustment by pressing key A for 3 seconds; the 3 LED's should flash 3 times.

Adjustment is complete!

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ELECTRICAL CONTROL AND ADJUSTMENT

13

MANIPULATOR

Fig.1

ADJUSTMENT

Z2 Z1

A

B

1. Setting program parameters: [Fig. 1] - Press the keys (Items A, B and C) for 3 seconds [Fig. 1].

--> A beep will sound and the 3 LED's will flash, one by one.

- Press keys A + C for 3 seconds [Fig. 1].

--> The LED's switch off.

C Fig.2

X1

Y2 Neutral

Y1

X2

2. Adjusting the manipulator program: [Fig. 2] The adjustment should be carried out without activating the trigger!

- Move the manipulator to its left-hand stop (X1), then return to neutral.

- M ove the manipulator to its right-hand stop (X2), then return to neutral.

- Move the manipulator backward to its stop (X2), then return to neutral.

- Move the manipulator to its forward stop (Y2), then return to neutral.

80

Complete the adjustment by pressing key A for 3 seconds; the 3 LED's should flash 3 times.

The adjustments are backed up in the basket control unit...

Adjustment is complete!

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ELECTRICAL CONTROL AND ADJUSTMENT

B1

TEST WITH A VOLTMETER

FRONT

- Climb into the access platform with a voltmeter.

- Remove the front face from the basket control panel (B1-1).

1

- Locate the colored wires at the manipulator connector (B2).

- Take voltage measurements using the pins of the voltmeter, placing them in contact with the clips crimped to each colored wire at the manipulator connector.

B2 GREEN/BLACK

(SIGNAL - DEAD MAN’S SYSTEM TRIGGER)

WHITE/BROWN

(SUPPLY - DEAD MAN’S SYST EM TRIGGER)

YELLOW/BLACK

(STEER LE FT PUSH B UTTON)

GREY/BLACK

(STEER RIGHT PUSH BUTTON)

WHITE/BLACK

(SUPPLY – STEERING PUSH BUTTONS)

GREEN

(SIGNAL - OUT O F JOYST ICK NEUTRAL)

GREY (Y)

(DEPLACEMENT / TELESCOPE AND PENDULAR ARM MOVEMENTS)

0V

BROWN

(Ground)

24V

WHITE

( + BATTERY)

YELLOW (X)

(TURRET ROTATION)

24V

24V

Y X

Testing the analog outputs:

80

- Activate the manipulator (A1-1) forwards or backwards without activating the trigger (A1-2) and check the values displayed by the voltmeter (B3).

Manipulator LEFT : Turret rotation left

B3

Manipulator FORWARDS : Translation forwards or telescope / pendular arm raising

- 24V Gr - 0.5 Y (X) -

- 24V Gr - 4,5V G (Y)

- 0V Br - 24V Wh

- 0V Br - 24V Wh - NS Green - 2.5V Yellow(X) - 2.5V Grey(Y) - 0V Brown - 24V White

- 24V Gr -

NEUTRAL - 24V Gr - 4,5V Y (X) - 0V Br

- 0.5V G (Y) - 0V Br - 24V Wh

- 24V Wh

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Manipulator BACKWARDS : Translation backwards or telescope / pendular arm lowering

Manipulator RIGHT : Turret rotation right

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ELECTRICAL CONTROL AND ADJUSTMENT

15

Testing the logic outputs: - Press the top left-hand button followed by the top right-hand button (A1-3) without activating the trigger, and check the values displayed by the voltmeter (B4).

B4

24V 0

Y/B (L) G/B (R)

V V

YELLOW/BLACK (LEFT) GREY/BLACK (RIGHT)

0 24V

Y/B (L) G/B (D)

24V

Wh/B

24V

WHITE/BLACK

24V

Wh/B

Steer LEFT

NEUTRAL

Steer RIGHT

- Activate the trigger (A1-2) alone and check the values displayed by the voltmeter (B5).

B5

GREEN/BLACK

24V GREEN/BLACK

24V

WHITE

24V

WHITE

80

Trigger in NEUTRAL

V

Trigger ACTIVATED

bb

The “V” icon means that a random value can be measured on the indicated wire. “NS” means that there is no signal on the indicated wire.

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ELECTRICAL CONTROL AND ADJUSTMENT

80

16

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ELECTRICAL COMPONENTS REMOVAL

Pages REDUCING GEARS / WHEEL BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

80

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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80-06-M161EN

2

ELECTRICAL COMPONENTS REMOVAL

REDUCING GEARS / WHEEL BRAKES

A T ON FR

1

–– Raise the rear of the access platform and install supports under the frame: - 80VJR ..........................................................

- 100VJR ........................................................

2250kg 2650Kg

–– Control the lifting of the jib to the upper limit (A-1).

–– Remove the fastening elements from the rear wheels (A-2) and remove the wheels ...................................................... 29kg

3

2

B

–– Remove the cover (A-3).

2 3

–– Remove the flap (B-1) and the reinforcement plate (B-2).

1

–– Mark and then remove the electric cables connected to the engines (B-3).

6

–– In order to remove the right-hand engine (B-4) provided with a flange (C-6), it is first necessary to remove the lefthand engine (B-5).

5

T ON FR

4

–– Remove the right-hand engine fastening elements (C-1) and remove this engine (B-4 or C-2) from outside the frame.

C

80

2

–– Remove the left-hand engine fastening elements (B-6) and remove this engine from inside the frame (B-5).

1

3

–– Remove the brake fastening elements and remove the brakes (C-3).

5 4 6

D 2

–– Remove the reducing gear fastening nuts (C-4 and D1) and remove this reducing gear (C-5 and D-2) and the flange (C-6).

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ELECTRICAL COMPONENTS REMOVAL

E

3

–– Disassemble the reducing gear assembly as indicated below: –– Remove the ring gear (E-1).

Pay special attention to the inner pins located between the ring gear and the cams.

1

F

–– Remove the cams (F-1) and the inner sockets (G-1).

1

80

G

1

H –– Take off the eccentric bearing (H-1) and its circlips after removing its lock (H-2).

2

–– Carry out the same procedure on the second engine.

1

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ELECTRICAL COMPONENTS REMOVAL

A

FRONT

BATTERY –– Switch off the power supply (A-1).

2 1

–– Open and remove the turret covers (A-2).

2

B FRONT

–– Remove the battery (B): I II III

I - Disconnect the cables connected to ground -.

II - Disconnect the cables connected to the + terminal.

III - Loosen the battery fastening screws.

IV - Remove the battery .................................

212kg

80

III

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ELECTRICAL COMPONENTS REFIT

Pages

80

WHEEL REDUCING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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2

ELECTRICAL COMPONENTS REFIT

WHEEL REDUCING GEAR

A1 2

–– Carry out the following steps in order to reassemble the reducing gear on the engine: 1

Step 1: –– Apply grease to the plate (A1-1) and the shaft seal (A1-2).

–– Fit the seal (A1-3).

3

A2 –– Position the first cam disk (A2-1).

1

A3 Warning: note the location of the marking of the first disc (A3-1).

1

80

1

A4 –– Insert the eccentric bearing at the center (A4-1) and then push in the 7x7x30 lock.

1 2

–– Fit the circlips (A4-2) and position the spacer (A4-3).

3

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ELECTRICAL COMPONENTS REFIT

A5

3

–– Position the second cam with the marking opposite (at 180° from) that of the first (A5-1) (see A3).

1

A6

–– Position the ring gear on the engine (A6-1) and fit the inner sockets (A6-2).

–– Carefully adjust the alignment of the cams using a screwdriver, if necessary.

2

1

A7

–– Install one pin every two holes (A7-1) around the ring gear.

80

1

A8

–– Fit the paper seal (A8-1).

1

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ELECTRICAL COMPONENTS REFIT

A9

–– Cover the assembly with grease and tighten the wheel studs (A9-1) to 19 daNm with a thread-locking compound.

1

A10

–– Position the bearing (A10-1) on the ring gear.

1

A11

80

–– Tighten the nuts (A11-1).

1

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ELECTRICAL TROUBLESHOOTING

Pages A - VARIABLE CONTROLS - TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

80

B - BATTERY CHARGER - ERROR SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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ELECTRICAL TROUBLESHOOTING

A - VARIABLE CONTROLS

TROUBLESHOOTING

Interpreting the fault codes on the display:

01 = Variable control interface control unit 02 = Variable control logic control unit 08 = Basket control unit 16 = Display Hour meter message

Faults

A = Separator

Fault n°

Description and comments

Solution

01 = Variable control interface control unit LOGIC FAILURE #1

The base control unit is waiting for the variable control to complete its internal test.

This alarm can be activated from time to time during startup. Any initialization delay can cause this alarm to be activated. If the alarm is activated too often or is continuous, there is an internal error. Check the current software version or replace the controller.

VALV.DRV OFFLINE

The internal device that controls all the auxiliary outputs has a problem and is not communicating correctly with the microcontroller

Replace the controller.

OUTPUT MISMATCH

This alarm is activated by a discrepancy between the operating condition detected by the two ECU's.

The variable control has requested the base control unit to activate the output for traction or the pump but the interface control unit does not identify a command or an operating condition in which traction/the pump should be authorized.

Check if the correct software versions are installed on the two consoles. If so, there is an internal fault.

EEPROM KO

There is an error in the management/checking of the internal EEPROM.

There is an internal error. Replace the controller.

The access platform can still operate but the controller will use its default values for the internal parameters.

WRONG RAM MEMORY

The algorithm implemented to check the main RAM is registering erroneous elements.

Try to switch off the ignition.

If the alarm is still present, replace the controller.

FLASH CHECKSUM

Incorrect software has been downloaded or the Flash memory is corrupt.

Check the software version installed or replace the controller.

ANALOG INPUT

There is a fault in the A/D current converter of the microcontroller.

Replace the controller.

SERIAL ERROR #1

The variable control has not responded as expected to the request from the base control unit.

For example, the base control unit has requested the variable control to keep its EB output inactive, but it remains active.

Replace the controller,

01A02

80

01A03

01A04

01A05

01A06

01A10

01A15

01A19

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ELECTRICAL TROUBLESHOOTING

Hour meter message

Faults

Description and comments

Solution

LOGIC FAILURE #1

An undervoltage or overvoltage has been detected

If the fault occurs at startup or in the alert mode, the fault is most probably caused by an undervoltage. Check whether or not the main voltage is stable. If the fault occurs when the engine is accelerated or the pump is activated, the fault could be caused by an undervoltage.

Check the battery charge and connections. If the fault occurs during braking, the fault could be caused by an overvoltage: check the voltage of the battery during braking. In any other case, the fault could be caused by an internal problem of the controller: replace it.

EB.DRV. SHORTED

The brake electric cable is short-circuited.

Check if there is contact or low impedance occurring between the A12 pin and the battery.

If not, the circuit is damaged.

DRIVER SHORTED

The main driver switch is short-circuited

Check if there is a short circuit or low impedance between the A10 terminal and the battery.

If not, the cable is damaged.

MC coil open

Power contact coil open

Check the brown and white wire or the coil

EB DRV/COIL FAIL

The brake electric circuit is open: The EB coil cannot be activated.

Check if there is a short circuit parallel to the brake electrovalve coil.

If not, the conductor circuit is damaged and the controller needs to be replaced.

MC ENABLE SHORT.

The power contact is short-circuited

Replace the controller

EB ENABLE SHORT

The electric brake is short-circuited

Replace the controller

MISMATCH N°

The logic control unit and interface control unit check the internal parameters, for the voltages of the engine, the pump, the status of the inputs, then the CANBUS checks the communication. If an alarm is activated, there is a discrepancy between the two measured values of the same variable. The name of the alarm describes the variable that has caused the failure.

This problem can be caused by an incompatibility between the software of the logic control unit and interface control unit. Check if the correct software versions are installed. If not, there is an internal error. Replace the controller.

MULTI SELECTION

Activation of several movements simultaneously

Check the cabling or change the controller

PLAT. DOUBLE REQ.

The controller is receiving several commands simultaneously from the basket control panel.

Check the conformity of the command selectors Check the cabling or change the controller

GND DOUBLE REQ.

The controller receives several commands simultaneously from the base control panel.

Check the conformity of the command selectors Check the cabling or change the controller

TILTED

The tilt sensor triggers the audible beep

Check the conformity of the tilt sensor and its connection or change the controller.

OVERLOAD HBT.

Overload of the HBT2 and HBT1 signals Overload inconsistency

Check the condition of the overload sensors or change the controller.

01A32

01A33

01A34

3

01A36

01A37

01A40

01A45

80

01A41

01A50

01A51

01A52

01A53

01A54

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ELECTRICAL TROUBLESHOOTING

Hour meter message

Faults

Description and comments

OVERCHARGE

Overload fault

Check the condition of the overload sensors or change the controller.

BATTERY LOW

Battery voltage low

The battery needs to be recharged in order to prevent damage to it. If the alarm is activated when the battery is fully charged, change the controller.

NO CAN MSG. N

The interface control unit has not received the CAN signal "N" (1= CMD+INTERFACE; 2=MESG_EV+TRAC; 4=MESG_EV0 + TRAC; 5 = MESG_EV + IN_TRAC)

Check the connection of the CAN BUS between the modules or change the controller. If there is an internal fault in the module, a transmission error, or too much noise on the CAN BUS, error frames are generated.

NO ALERT ON THE CONSOLE

There is a large discrepancy between the hour meter stored in the MDI and the hour meter stored in the controller. The maximum acceptable difference is 10 hours: if this difference is exceeded, this alarm will be activated.

1- After two minutes, the hour meter of the controller will find the MDI automatically.

ELECTRIC PUMP TEMPERATURE HIGH

The temperature sensor of the electric pump has detected a high temperature.

The alarm should switch off when the pump engine cools.

If this does not happen, there is a connection problem with the A16 terminal or the temperature sensor.

INCORRECT START

The startup sequence has not been followed.

Please cancel all pending requests

Delete all commands and check if the alarm switches off. If the problem remains, check the cable connections.

01A62

OPERATING SWITCHES SHORTCIRCUIT

The function switch has been closed for more than 2.5 seconds.

The alarm should be switched off by deactivating the main switch or by using the emergency stop. If the problem remains, check the cable connections. If there is no problem, the alarm is caused by an internal error.

01A63

BATTERY WRONGLY ADJUSTED

The "ADJUST BATTERY" parameter differs by more than 20% from the nominal voltage of the battery (see the "TYPE OF BATTERY" parameter)

ON-LINE CHARGING

The access platform has been switched on while the battery charger is operating.

If the alarm is activated when the battery charger is disconnected from the mains, there may be a problem in the connection of the A17 terminal.

If not, there is an internal error in the controller.

ERRONEOUS ANGLE SENSOR VALUE

The value read by the potentiometer is different to the programmed value.

Check the correct operation of the angle sensor potentiometer. If not, check the cables.

LIFTING VALVE

There is a problem at one of the following outputs: (A32 terminal), (A26 terminal).

Check the condition and connection of the valves.

If not, there is an internal error in the controller.

LOWERING VALVE

There is a problem at one of the following outputs: (A30 terminal), (A26 terminal)

Check the condition and connection of the valves.

If not, there is an internal error in the controller.

ROTATION VALVE

There is a problem at one of the following outputs: (A34 terminal), (A25).

Check the condition and connection of the valves.

If not, there is an internal error in the controller.

STEERING VALVE

There is a problem at one of the following outputs: (A34 terminal), (A26).

Check the condition and connection of the valves.

If not, there is an internal error in the controller.

AUX. VALVE

There is a problem at one of the following outputs: "FLASHING LIGHT" (A35 terminal) and "TILT INDICATOR LAMP" (A24 terminal).

Check the condition and connection of the valves.

If not, there is an internal error in the controller.

01A55

01A56

01A57

01A58

01A59

01A61

01A64

80

Solution

01A65

01A80

01A81

01A82

01A83

01A84

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ELECTRICAL TROUBLESHOOTING

Hour meter message

Faults

Description and comments

BRAKE COIL OPEN

The coil of the main switch is not connected to the A12 pin of the negative electro brake.

Check the connections of the BRAKE coil. If not, the conductor circuit is damaged and the controller needs to be replaced.

HORN CONDUCTOR

There is a problem (Short circuit at the negative or positive terminal, horn absent) at the "HORN" (A29).

Check the horn and its cabling (horn output).

If the cabling is correct and the alarm remains, there is an internal error.

01A86

01A89

5

Solution

02 = Variable control logic control unit The variable control and the base control unit do not agree on the type of operation decided by the operator.

There is an internal fault. Replace the controller.

HBT DISPARITY

The HBT status is checked by the variable control and the base control unit. If a difference is found between the two, this alarm is activated.

There is an internal fault. Replace the controller.

FALSE RAM MEMORY

The algorithm implemented to check the main RAM detects an error. The folder is corrupt.

Try switching the ignition off and on again. If the alarm remains, replacer the controller.

QUICK SUM

The instantaneous sum is different to expected.

Incorrect software has been downloaded or the Flash memory is corrupt.

There is an internal fault. Replace the controller.

DEFECTIVE HEAT SENSOR

The temperature sensor is not operating correctly: its output voltage is outside the allowable range.

There is an internal fault. Replace the controller.

RIGHT STANDBY MOTOR

The current sensor of the right-hand frame detects a current different to zero when the right-hand engine is not operating.

There is an internal fault. Replace the controller.

LEFT STANDBY MOTOR

The current sensor of the left-hand frame detects a non-zero current when the left-hand engine is not operating.

There is an internal error. Replace the controller.

HIGH FIELD CURRENT

A non-zero current passes through the field circuit even if the field conductor is not active.

There is probably an internal error.

Replace the controller.

ANALOGUE INPUT

There is a fault in the A/D converter of the microcontroller.

There is an internal error in the console. Replace the controller.

TRAC. I SENS. KO

The current sensor of the frame of engine 1 and/ or engine 2 is not operating correctly: its output voltage is outside the allowable range.

There is an internal fault. Replace the controller.

STAND BY PUMP

The current sensor of the pump detects a non-zero current when the pump is not operating.

There is an internal error. Replace the controller.

PUMP I=0

The current sensor of the pump detects a zero current when the pump is operating.

Check the pump connection: if the pump is not connected, the current cannot flow and the diagnosis fails. If not, there is an internal error.

PERIODIC ERROR #1

The base control unit has not responded as expected to the request. The variable control unit has requested the base control unit to leave its traction input inactive while it is active.

There is an internal error in the console. Replace the controller.

02A07

02A08

02A09

02A10

02A11

02A12

02A13

02A14

02A15

02A16

02A17

02A18

02A19

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TYPE DISPARITY

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6

ELECTRICAL TROUBLESHOOTING

Hour meter message

Faults

Description and comments

Solution

CONDENSOR CHARGE

When the ignition is switched on, the controller tries to charge the power capacitors via a resistor, and checks if the capacitors are charged. If they do not charge, an alarm is activated. The main switch is not closed.

Possible causes: 1) there is an external charge parallel to the capacitor, which is reducing the current of the precharge circuit, thus preventing the capacitor from charging; 2) there is a problem in the charge circuit (e.g. the charge resistor is open) and the controller needs to be replaced.

INCORRECT FIELD INDICATOR

During standby, the field voltage should be around ½ Vbatt. This alarm is activated if the field voltage is different to this value.

The possible external causes are: incorrect connection of the excitation wires, leak to the frame of the access platform.

If not, there is an internal fault.

VMN LOW

The VMN voltage of one of the travel engines is low.

This alarm is activated during standby. Check: internal connections of the engine (ohmic continuity), connections of electric cables, leaks from the engine to the frame of the access platform. If everything is in the correct condition, there is an internal fault in the controller.

VMN HIGH

The VMN voltage of one of the engines is high when it should be low.

This alarm is activated at startup only. Check: internal connections of the engine (ohmic continuity), connections of electric cables, leaks from the engine to the frame of the truck. If everything is in the correct condition, there is an internal fault in the controller.

VMN PUMP LOW

The VMN voltage of the pump is low when it should be high.

This alarm can be activated during standby or during operation of the pump. Check: internal connections of the pump (ohmic continuity), connections of electric cables, leaks from the pump to the frame of the access platform.

If everything is in the CORRECT condition, there is an internal fault in the controller.

VMN PUMP HIGH

The VMN voltage of the pump is high when it should be low.

This alarm is activated during operation of the pump.

Check: internal connections of the pump (ohmic continuity), connections of electric cables, leaks from the pump to the frame of the access platform. If everything is in the correct condition, there is an internal fault in the controller.

RIGHT VMN LOW

The VMN voltage of the right-hand engine is low when it should be high.

This alarm is only activated when the travel engines are activated. Check: internal connections of the engine (ohmic continuity), connections of electric cables, leaks from the engine to the frame of the access platform. If everything is in the correct condition, there is an internal fault in the controller.

RIGHT VMN HIGH

The VMN voltage of the right-hand engine is high when it should be low.

This alarm is only activated when the travel engines are activated. Check: internal connections of the engine (ohmic continuity), connections of electric cables, leaks from the engine to the frame of the access platform. If everything is in the correct condition, there is an internal fault in the controller.

LEFT VMN LOW

The VMN voltage of the left-hand engine is low when it should be high.

This alarm is only activated when the travel engines are activated. Check: internal connections of the engine (ohmic continuity), connections of electric cables, leaks from the engine to the frame of the access platform. If everything is in the correct condition, there is an internal fault in the controller.

LEFT VMN HIGH

The VMN voltage of the left-hand engine is high when it should be low.

This alarm is only activated when the travel engines are activated. Check: internal connections of the engine (ohmic continuity), connections of electric cables, leaks from the engine to the frame of the truck. If everything is in the CORRECT condition, there is an internal fault in the controller

CONTACTOR CLOSED

Before activating the power relay, the controller checks of the contactor is closed. If this test is inconclusive, this alarm is activated.

Check the contacts of the power relay.

Replace the power relay if necessary.

CONTACTOR OPEN

The power relay is controlled by the controller, but it does not close.

The power relay probably does not work. Replace it.

02A20

02A21

02A22

02A23

02A24

02A25

02A26

80

02A27

02A28

02A29

02A30

02A31

80-08-M161EN

(27/03/2015)

ELECTRICAL TROUBLESHOOTING

Faults

An undervoltage or overvoltage has been detected. If the fault is found at startup or in the alert mode, it is very probably caused by an undervoltage. Check whether or not the main voltage is stable. If the fault is found when the travel engines or electric pump are accelerating, the fault could be caused by an undervoltage: check the battery charge and connections. If the fault is found during braking, the fault could be caused by an overvoltage: check the voltage of the battery during braking.

In any other case, the fault could be caused by an internal problem of the controller: replace it.

TRACTION SHORTCIRCUITING

The traction output of the base control unit is short-circuited.

There is an internal error.

Replace the controller.

DRIVER 3 KO

the base control unit and the variable control have carried out a check of their allowing signals for the traction conductor. If the variable control unit detects a problem in its own control circuit (rightor left-hand engine), this alarm is activated.

There is an internal error.

Replace the controller.

DRIVER2 KO

The base control unit and the variable control carry out a check of the signals for the pump. If the variable control unit detects a problem in its own control circuit, this alarm is activated.

There is an internal error.

Replace the controller.

DRIVER1 KO

The interface and logic control unit panel counterchecks the signals for the choice of direction. If the logic control unit detects a problem in its own control circuit (field conductor circuit), this alarm is activated.

There is an internal error.

Replace the controller.

NO EARTH CURRENT

when the ground connector is active, no field current is detected.

Check the connection of the engine terminals to the controller or search for possible leaks to the frame of the access platform. If everything is in the correct condition, there is an internal fault in the controller.

KO PUMP SENSOR

The current sensor of the pump is not operating correctly: its output voltage is outside the allowable range.

There is an internal fault.

Replace the controller.

PUMP SHORTCIRCUITING

The pump inputs in the base control unit are shortcircuited.

There is an internal error.

Replace the controller.

NO CAN MESSAGE

The interface control unit panel has not received the CAN message "N" (1= CMD+TRAC 2=MESG_EV+INTERFACE 5 = MESG_EV + IN_TRAC).

Check the connection of the CAN BUS between the modules. If not, there is an internal fault in a module, resulting in a transmission error, or there is too much noise on the CAN BUS line disturbing the signal.

HIGH TEMPERATURES

The power section of the fuse has reached the temperature limit: the maximum current is automatically reduced.

The alarm is deactivated when the variator cools. if this does not happen, there is a problem with the internal temperature sensor.

OUT OF RANGE STEERING

The value read by the steering sensor potentiometer is outside the programmed range.

Check the steering sensor setting If not, check its connection.

WAITING FOR VALIDATION / CONFIRMATION

The variable control unit asks the base control unit to activate the travel engines or electric pump. If they have not been activated after 400 ms, this alarm is activated.

Check the software versions installed on the interface control unit and on the logic control unit: this alarm can be caused by a software discrepancy.

If not, there is an internal error.

02A42

02A43

02A44

02A46

02A47

02A49

02A57

02A60

02A65

02A87

Solution

LOGIC FAILURE #1

02A32

02A42

Description and comments

08 = Basket control unit

08A70

(27/03/2015)

SYSTEM MONITORING

Internal monitoring of the system is implemented.

If this monitoring detects an error in the execution of this monitoring, this alarm is activated.

There is an internal error.

Replace the controller.

80-08-M161EN

80

Hour meter message

7

8

ELECTRICAL TROUBLESHOOTING

Hour meter message

Faults

Solution

EV1 INCORRECT

There is a problem (short circuit to ground or at the positive terminal) at the CNE-10 output.

Check the cabling.

If the cabling is correct and the alarm remains, there is an internal error.

EV2 INCORRECT

there is a problem (short circuit to ground or at the positive terminal) at the CNE-5 output.

Check the cabling.

If the cabling is correct and the alarm remains, there is an internal error.

EV3-4 INCORRECT

there is a problem (short circuit at the negative or positive terminal) at the CNE-1 or CNE-3 outputs.

Check the cabling.

If the cabling is correct and the alarm remains, there is an internal error.

BUS CAN INCORRECT

The basket control unit does not receive the CAN signal from the controller.

There can be an interruption in the CAN BUS signal: Check the CAN BUS connection between the modules.

If not, there is an internal fault in a module, resulting in a transmission error, or there is too much noise on the CAN BUS line.

08A72

08A73

08A74

08A75

Description and comments

16 = Display

80

16A06

NO COMMUNICATION

80-08-M161EN

(27/03/2015)

ELECTRICAL TROUBLESHOOTING

9

B - BATTERY CHARGER - ERROR SIGNALS

Flashing red: Charge fault.

80

The two existing charge faults are as follows: - Mains voltage outside tolerances (85 - 265 V AC).

- Excessive charge time.

(27/03/2015)

80-08-M161EN

ELECTRICAL TROUBLESHOOTING

80

10

80-08-M161EN

(27/03/2015)

HYDRAULIC

HYDRAULIC SCHEMATIC DIAGRAMS HYDRAULIC COMPONENTS LOCATION HYDRAULIC CONTROL AND ADJUSTMENT

70

HYDRAULIC COMPONENTS REMOVAL

HYDRAULIC SCHEMATIC DIAGRAMS

Pages KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

70

DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(10/03/2015)

70-02-M161EN

2

HYDRAULIC SCHEMATIC DIAGRAMS

KEY HYDRAULIC COMPONENTS Ref .

Designation A

Electric pump

B

Distributor block

C

Oil sump

D

Emergency pump

E

Steering cylinder

F

Turret rotation motor

G

Hydraulic reeler

H

Telescope base unit

I

Telescope cylinder

J

Pendular arm unit

K

Pendular arm cylinder

FONCTIONS

70

Réf .

Désignation

1

Electric pump

2

Main restrictor

3

Suction filter

4

Turret rotation / steering direction EV

5

Steering electro-valve

6

Turret rotation electro-valve

7

Telescope raising electro-valve

8

Telescope lowering electro-valve

9

Raising pressure restrictor

10

Telescope function electro-valve

11

Pendular arm raising electro-valve

12

Pendular arm lowering electro-valve

13

Flow regulator

70-02-M161EN

(10/03/2015)

HYDRAULIC SCHEMATIC DIAGRAMS

3

DIAGRAM K

11 +

8 + 12

11

12

7 J

2.5l/min

G

13 EV11

EV12

PP

4+6 4+5

Only 100VJR

6 F

5

H

E

EV10

7 + 10 I

10

8 + 10 100 bar A P2

Dr

P3

P5

B

100 bar B P6

P1

T2

P4

70

6 5 EV5

EV6

8 EV7

4

EV8

7

9

EV4

D 3

140 bar

20cm3

A T1

64 bar

b10=100mm

4.2cm3

2

1

M

C

(10/03/2015)

70-02-M161EN

HYDRAULIC SCHEMATIC DIAGRAMS

70

4

70-02-M161EN

(10/03/2015)

HYDRAULIC COMPONENTS LOCATION

pages GENERAL LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PUMP - DISTRIBUTOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 STEERING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TURRET ROTATION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

70

TELESCOPE - JIB CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

(11/03/2015)

70-03-M161EN

2

HYDRAULIC COMPONENTS LOCATION

GENERAL LOCATION

Lifting cylinder FRONT

Hydraulic winder

Pendular arm cylinder

70

Manual emergency pump

Lifting cylinder valve block

REAR

Steering cylinder Turret rotation motor

70-03-M161EN

Hydraulic central unit Electric pump Distributor Pressure filter Oil reservoir

(11/03/2015)

HYDRAULIC COMPONENTS LOCATION

3

PUMP - DISTRIBUTOR CIRCUIT

UIT

IRC

SEE

E

OP

ESC

L : TE

BC - JI

12

70

1

A

1

2

T1

11

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70-03-M161EN

4

HYDRAULIC COMPONENTS LOCATION

STEERING CIRCUIT

10

0V JRE

AU S

P2

70

P3

Passage in the cable-carrying chain of frame

70-03-M161EN

(11/03/2015)

HYDRAULIC COMPONENTS LOCATION

5

TURRET ROTATION CIRCUIT

P5 P6

70

T2

8 DaN.m Loctite 243 A B Dr

(11/03/2015)

70-03-M161EN

6

HYDRAULIC COMPONENTS LOCATION

TELESCOPE - JIB CIRCUIT

100 VJR

80 VJR

100 VJR

70

80 VJR

See

MP

IB

TR

DIS

UIT

IRC

RC

O UT

PU

P1

P4

70-03-M161EN

(11/03/2015)

HYDRAULIC CONTROL AND ADJUSTMENT

Pages A - MAIN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 B - TELESCOPE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

70

SPEED/PRESSURE ADJUSTMENTS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(11/03/2015)

70-04-M.16EN

2

HYDRAULIC CONTROL AND ADJUSTMENT

bb

In this chapter, unless specifically indicated, in order to view the setting pressure values and choose the appropriate pressure gage: o "70 - HYDRAULIC SCHEMATIC DIAGRAMS"

bb

Check if the aid station has been tested and that all the emergency controls have been returned to normal position: l Machine Instruction Manual.

A - MAIN CIRCUIT A1 PRESSURE ADJUSTMENT Setting the main relief valve (Hydraulic diagram n°2) –– Connect a pressure gage to the pressure test port installed on the hydraulic reel (A1-1).

1

–– Switch on the access platform.

–– Control the lifting of the jib and maintain the control when the cylinder reaches the stop.

70

A2

–– Check that the pressure gage displays the pressure recommended in the hydraulic diagram.

–– As required, adjust the setting of the main relief valve (A2-1).

B - TELESCOPE CIRCUIT PRESSURE ADJUSTMENT 1

A3

Setting the lifting relief valve (hydraulic diagram n°9) On the distributor, connect a pressure gage to the pressure test port (A1-1).

- Switch on the access platform.

–– Control the lifting of the telescope and maintain the control when the cylinder reaches the stop.

–– Check that the pressure gage displays the pressure recommended in the hydraulic diagram.

1 70-04-M.16EN

–– As required, adjust the setting of the main relief valve (A3-1).

(11/03/2015)

HYDRAULIC CONTROL AND ADJUSTMENT

3

SPEED/PRESSURE ADJUSTMENTS TABLE (Valeur une personne dans panier 80Kg) Main pressure 140 ± 5 bar TELESCOPE

Lifting

Pressure ± 5 bar

Standard parameters

Time to obtain ±5s

64

100%

52

Descent PENDULAR

Lifting

TURRET WORKING TRANSLATION (10 m)

45

12

/

25

21

Left

100

19

Right

100

19

37 Full rotation

Front

55

Rear

55

Front

8±1s

Rear

8±1s

70

TRANSPORT TRANSLATION (10 m)

Adjusted parameters

42 140

Descent

Time obtained

(11/03/2015)

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HYDRAULIC CONTROL AND ADJUSTMENT

70

4

70-04-M.16EN

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HYDRAULIC COMPONENTS REMOVAL

pages TURRET ROTATION ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ELECTRIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REDUCING GEARS / WHEEL BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 –– A - STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 –– B - TELESCOPE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 –– C - JIB CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

70

–– D - VALVE BLOCKS AND VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

(11/03/2015)

70-06-M161EN

2

HYDRAULIC COMPONENTS REMOVAL

TURRET ROTATION ENGINE

A T ON FR

- Remove the side covers (A-1) and the cover from the wheel engine (A-2).

2

- Decompress the turret rotation line (distributor) o "ELECTRIC PUMP" 1 45°

B T ON FR

- Remove the cover plate (B-3)

3

70

C - Remove the three hoses (C-4) and seal them.

5 4

4

70-06-M161EN

- Remove the engine fastening elements.

- Remove the rotation engine (C-5) ..........................

17 kg

(11/03/2015)

3

70

HYDRAULIC COMPONENTS REMOVAL

(11/03/2015)

70-06-M161EN

4

HYDRAULIC COMPONENTS REMOVAL

A

ELECTRIC PUMP FRO NT

- Open the right-hand turret cover (A-1).

1

B T ON FR

1

1

- Remove the hoses (B-1) and seal them.

2

2

2

- Remove the connectors (B-2) and seal them.

1

00

1

70

C T ON FR

- Remove the fastening elements (C-3) and remove the electric pump (C-4) .......................................................................

25kg 4

3

D 1

70-06-M161EN

- When assembling the elements of the distributor block (D-1), apply the following tightening torques: 25 Nm (+5 Nm) for all the electrovalves and the relief valve and 50 Nm (+5 Nm) for the filter (E-1).

(11/03/2015)

HYDRAULIC COMPONENTS REMOVAL

A

2

5

- When assembling the electric pump, apply the following tightening torque to the assembly screws (E-2): 6 Nm (+0.5 Nm)

2

1

EV5 EV4

EV7

70

EV8

EV6

- = Rest / E = Excited EV4 OFF

EV5

EV6

EV7

EV8

-

-

-

-

-

Direction

Right

-

E

-

-

-

Left

E

E

-

-

-

Rotation turret

Right

-

-

E

-

-

Left

E

-

E

-

-

Telescope

Monted

-

-

-

E

-

Descent

-

-

-

-

E

Pendular

Monted

-

-

-

-

-

Descent

-

-

-

E

E

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70-06-M161EN

6

HYDRAULIC COMPONENTS REMOVAL

REDUCING GEARS / WHEEL BRAKE

A T ON FR

1

- Raise the rear of the access platform and install supports under the frame: - 80VJR ............................................................... 2250kg - 100VJR ............................................................ 2650Kg - Control the lifting of the jib to the upper limit (A-1).

- Remove the fastening elements from the rear wheels (A-2) and remove the wheels ............................................................

29kg

3

2

B

- Remove the cover (A-3).

T ON FR

2 3

1

6

- Remove the flap (B-1) and the reinforcement plate (B-2).

- Mark and then remove the electric cables connected to the engines (B-3).

- In order to remove the right-hand engine (B-4) provided with a flange (C-6), it is first necessary to remove the lefthand engine (B-5).

- Remove the right-hand engine fastening elements (C-1) and remove this engine (B-4 or C-2) from outside the frame.

5 4

70

C

- Remove the left-hand engine fastening elements (B-6) and remove this engine from inside the frame (B-5).

2

1

3 5 4 6

- R emove the brake fastening elements and remove the brakes (C-3) - Remove the reducing gear fastening elements (C-4) and remove this reducing gear (C-5) and the flange (C-6).

- Carry out the same procedure on the second engine.

bb

In order to remove the left-hand engine, it is first necessary to remove the right-hand engine by unscrewing the flange, reference 6.

70-06-M161EN

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HYDRAULIC COMPONENTS REMOVAL

7

CYLINDERS

A1 FRO NT

A - STEERING CYLINDER REMOVAL

1

- Open the right-hand turret cover (A1-1).

- D e c o m p r e s s t h e s t e e r i n g l i n e ( d i s t r i b u t o r ) o "ELECTRIC PUMP" - Remove and seal the hoses connected to the steering cylinder (A2-1).

A2 T ON FR

2

2

- Remove the pivot pins from the steering cylinder (A2-2) and remove the cylinder.

REFIT - Carry out the removal operations in reverse order, leaving the access platform on supports.

1

- Drain the steering circuit: - Control the steering until it reaches its mechanical stop on both sides, simultaneously repeating the operation several times.

- Remove the supports from under the front axle and carry out steering tests while stationary, and then when moving.

Ø 25 mm

Course - Hub - Carrera - Stroke - Corsa : 174 mm

(11/03/2015)

70-06-M161EN

70

1

8

HYDRAULIC COMPONENTS REMOVAL

B1

B - TELESCOPE CYLINDER T ON FR

REMOVAL - Position the access platform over a pit in order to access the cylinder base nut.

1

- Lower the mast and switch off the machine.

- Open and remove the covers from the turret (B1-1) - Remove the cover of the mast head (B2-2)

B2

- Disconnect and remove the inductive sensor (B2-3) 2

00

T ON FR

- Decompress the lifting line (distributor)

00 3

o "ELECTRIC PUMP"

-R emove the return hose from the lifting cylinder (B2-3) and the right- or left-hand connector - Remove and seal the hoses connected to the cylinder (B3-4).

- Remove the pivot pins from the cylinder, starting with the cylinder head pin (B2-2), and remove the cylinder:

70

B3

4

- 80 VJR Evolution ................................................

63 kg

- 100 VJR Evolution..............................................

110 kg

REFIT - Carry out the removal operations in reverse order.

B4

70-06-M161EN

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HYDRAULIC COMPONENTS REMOVAL

9

80 VJR EVOLUTION Ø 45 mm

100 VJR EVOLUTION 100 VJR AUS Ø 25 mm

Course - Hub - Carrera - Stroke - Corsa : 1700 mm

(11/03/2015)

70-06-M161EN

70

Course - Hub - Carrera - Stroke - Corsa : 1413 mm

10

HYDRAULIC COMPONENTS REMOVAL

C1

C - JIB CYLINDER FRONT

REMOVAL - Control the lifting of the jib (C1-1) to horizontal.

- Switch off the power supply.

- Secure the basket with a hoist and a sling

1

170kg

- Place the assembly on a stable surface.

- Open the right-hand turret cover.

C2

- Decompress the jib lifting line o "ELECTRIC PUMP" FRONT

- Remove the pivot pins from the cylinder, starting with the cylinder base pin (C2-2), and remove the cylinder

1

2

- 80 VJR ........................................................................

15kg

70

1

- Remove and seal the hoses connected to the cylinder (C2-1).

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HYDRAULIC COMPONENTS REMOVAL

11

80 VJR EVOLUTION Ø 50 mm

100 VJR EVOLUTION 100 VJR AUS Ø 50 mm

Course - Hub - Carrera - Stroke - Corsa : 451 mm

(11/03/2015)

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70

Course - Hub - Carrera - Stroke - Corsa : 443 mm

HYDRAULIC COMPONENTS REMOVAL

12

D - VALVE BLOCKS AND VALVES

bb

REMOVAL The chambers of a cylinder equipped with valves can be at VERY HIGH PRESSURES, higher than 100 bars (tilting cylinder or cylinder with rod fully retracted or extended) even after being removed. The pressures in the chambers should be released before disassembly.

bb bb

Ideally, this procedure should only be carried out on cylinders whose ROD is at MID-STROKE. In order to work under optimum safety conditions, the operator should wear safety goggles and rubber gloves and use a rubber plate.

Removing an equipped valve block:

bb

In order to avoid pressurized oil leaks, the operator should position the cylinder with the contact face (D11) between the valve block and the cylinder, vertically, and then position a rubber plate over this face (D1-2).

D1 Top

2

- Secure the cylinder body in a vice.

Bottom

1

70

- Release the fixing screws of the block (D1-3) one after another, by a MAXIMUM of 1/4 turn for each screw.

3

D2

- Unscrew the screws by 1/4 turn WITH THE SPANNER until the pressure has been released.

Disassembling a valve:

1

- Secure the cylinder body in a vice.

bb

In order to avoid pressurized oil leaks, the operator should position a rubber plate (see D2-1) over the valve seat after positioning its spanner.

2

- Release the valves (D2-2) one after another: A MAXIMUM 1/4 turn for each valve.

- Unscrew the valves by 1/4 turn WITH THE SPANNER until the pressure has been released.

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AXLE

30

AXLE CONTROL AND ADJUSTMENT

30

AXLE CONTROL AND ADJUSTMENT

Pages REAR AXLE - OPERATION IN FREEWHEEL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 RESETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(12/03/2015)

30-04-M161EN

2

AXLE CONTROL AND ADJUSTMENT

A

REAR AXLE - OPERATION IN FREEWHEEL MODE

bb bb bb

In order to operate the access platform in freewheel mode, it should not be subjected to translational constraints resulting from a slope.

1

When the access platform is in the freewheel mode, it can move freely: fit wedges to immobilize the wheels.

30

FRON T

B FRONT

2

1

If the access platform needs to be towed, this operation should only be carried out:

- Over short distances.

- N ecessarily by a machine that has high braking power in order to hold it steady, and at a slow speed.

- By means of a connecting bar between the two machines.

- Open the left-hand turret cover (A-1).

- Locate the selector (B-1) on top of the base control panel.

- Shift the selector to the right (B-2) to switch the machine to the freewheel mode. A continuous audible beep should be heard.

- The machine can now be towed.

RESETTING - Shift the selector to the left to reactivate the traction mode.

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JIB - ACCESS PLATFORM REMOVAL

JIB - ACCESS PLATFORM REMOVAL

A - TELESCOPING CYLINDER SLIDE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 2 B - PROCEDURE FOR SETTING THE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 5 C - GREASING THE TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 7 D - LATERAL OFFSET OF THE TELESCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 8 E - CONTROLLING THE SETTING OF THE TELESCOPE . . . . . . . . . . . . . . . . . . . . P 9

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Pages

2

JIB - ACCESS PLATFORM REMOVAL

A1

T ON FR

A - TELESCOPING CYLINDER SLIDE PADS - Lower the mast and switch off the machine.

REMOVAL

- Open and remove the covers from the turret (A1-1).

- Decompress the lifting line...........  70-06-80-M.161 1

A2

T ON FR

- Remove the cover of the mast head (A2-2).

2

- Disconnect and remove the inductive sensor (A2-3).

6

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3

A3

T ON FR

- For 100 VJR, remove the return hose from the lifting cylinder (A3-4) and the right-hand connector (A3-5).

2

4

T ON FR

5

A4

- Attach the mast head / jib / basket assembly to a sling and hook this to a hoist.

- Remove the fixing screws (A2-6) from the mast head.

- Raise the mast head / jib / basket assembly and move it 50 cm from the platform towards the rear (A4), making sure not to damage the jib supply hose connected to the hose reel as well as the electric spiral cable.

- Remove the fixing nut from the telescope cylinder head (A3-2) and retrieve the washers.

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A5

T ON FR

3

Remove the two stops (A5-1).

1

A6

T ON FR

- Fix a metal flat (A6-1) on the inside tube using the fixing screws of the telescope head (steel flat length 300 mm, width 50 mm, thickness 10 mm, 2 holes 18 mm min with side center distance of 130 mm).

2 2

- Place 2 M16 clevises (A6-12) in the threaded rounds of the outside tube and remove the telescopic mast (A7-1).

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1

- Place the telescope on a workbench on clean and safe surfaces and clamp it to the workbench after having checked:

A7

T ON FR

- The leveling of the outside tube.

- That the side (A8-1) of the outside tube located towards the front of the access platform before removal is located towards the top once on the workbench: on the closing plate of the inside tube (A8-2), the M16 threaded bores should be visible, from top to bottom, in horizontal lines of 4, 2 and then 3 (A8).

1

Before placing the telescope on the workbench, check that it is firmly pegged to the ground or is heavy enough not to move during the following operations.

T ON FR

A8

TOP

- Remove the flat (A8-11).

1

2

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BOTTOM

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4

- Remove the inside tube (A9-1), taking it out from the base of the telescope.

A9 T ON FR 1

- 100 VJR :

3 2

- Slide the tubes at the cylinder head end (A9-2).

- Disassemble the stops (A9-3) and remove them from the inside of the tube.

- Remove the tubes via the base of the telescope.

- Remove and replace the slide pads (use a chisel and hammer as required) with new ones of similar thickness (10 mm or 12 mm) and without changing the setting, then check the clearances and deflection of the deployed telescope.

- If the measured values are incorrect, modify the setting after removing the telescope.

REFIT

55

- Carry out the operations described above in reverse order, then test the setting.

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5

B - PROCEDURE FOR SETTING THE TUBES LONGITUDINAL SHIMMING

A10 1 x Skid : 12 mm 2 x Shims : 1 mm 1 x Shim de 0.5 mm

Upper external shimming

Telescope head

Lower external shimming

1 x Shim de 0.5 mm 1 x Skid : 10 mm

1 x Shim de 0.5 mm 1 x Skid : 10 mm

BASKET POSIT IONING

Bottom of telescope

1 x Skid : 12 mm 2 x Shims : 1 mm 1 x Shim de 0.5 mm

A11 Play: 1,5 mm +ou- 0,5 (x12)

LONGITUDINA L SHIMMING

Play: 1 mm +ou- 0,5 (x12)

A12

Longitudinal setting: - Assemble the telescope, ensuring the pre-setting of each tube (4 tubes on the 100 VJR and 2 tubes on the 80 VJR) as indicated above: internal, external, upper and lower setting according to the thickness of the slide pads and shims (see figure A10).

Pay special attention to the direction of the tubes: ensure the correct orientation of the upper and lower faces of the tubes depending on the location of the basket.

Lateral setting: Warning: the lateral setting should initially be kept to a minimum.

Only fit slide pads 12 mm thick in order that they do not affect the upper and lower adjustments.

Lateral setting using shims should be carried out last.

Adjusting the longitudinal setting: - Adjust the top and bottom shims in steps of 0.5 mm, keeping a clearance of 1 mm at the heads and bases of the tubes (see figure A11) Warning: the telescope should extend freely and manually in a horizontal direction until it reaches its stop.

Adjusting the lateral setting: - Having carried out the longitudinal adjustment, symmetrically set each side in steps of 0.5 mm, keeping a clearance of 1.5 mm on one side (see figure A12).

LATERAL SHIMMING

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Lower internal shimming

Warning: the telescope should extend freely and manually in a horizontal direction until it reaches its stop.

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Upper internal shimming

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JIB - ACCESS PLATFORM REMOVAL

A13 - 80 VJR

0°

0,2°

0°

0,2°

EMPLACEMENT DU PANIER

A14 - 100 VJR 0°

0,2°

0°

0,4°

0,2°

0,4°

0,6°

0,6°

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EMPLACEMENT DU PANIER

- The result of the longitudinal setting in figure A10 should make it possible to compensate for the mass of the basket in the vertical position.

- This compensation is measured as follows (see figures A13 and A14).

Test conditions: - Fully deploy the telescope.

- The reference upper face should be that of the 300 x 300 tube raised to 0°.

Test: - Measure the angle of each tube by positioning a digital level on the upper face of each one as shown in figures A13 and A14.

Result to be obtained: 100 VJR : 80 VJR : - 300 x 300 tube = 0° - 220 x 220 tube = 0° - 260 x 260 tube = 0.2° - 180 x 180 tube = 0.2° - 220 x 220 tube = 0.4° - 180 x 180 tube = 0.6°

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C - GREASING THE TUBES A15

55

Lubricate the pathways for the skids on all the faces, inside and out RETINAX HDX2 grease

- Grease the slide pad paths as indicated in figure A15

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JIB - ACCESS PLATFORM REMOVAL D - LATERAL OFFSET OF THE TELESCOPE Check the lateral offset of the telescope as shown in figure A16

A16 L1

Test conditions: - Jib horizontal - Telescope head raised by 200 mm - Measurements to take with a force of 40 Nm: Result:

- L1 and L2 must be situated at a maximum of 350 mm

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L2

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E - CONTROLLING THE SETTING OF THE TELESCOPE A17

Check the setting of the telescope, following the test described below.

Test conditions: - Access platform on flat ground - Telescope extended to the maximum - Jib raised to horizontal - Carry out the test in a location free of wind Test: - Secure a load of 200 kg on the basket, having taken care to position the load’s center of gravity at the center of the basket.

- Attach a plumb line to the overload shaft (see Fig. A17).

A18

Result: - The distance between the plumb line and the turret reinforcement must not exceed 1700 mm (see Fig. A18).

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200 Kg

1700 mm maximum

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TELESCOPE TELESKOP TELESCOPIO JIB TELESCOPE BRACCIO TELESCOPICO

5 BA 574 3

80 VJR EVOLUTION

4

1

2

5

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5

3

4

3

4

P. A . O . i l l u s

5

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TELESCOPE TELESKOP TELESCOPIO JIB TELESCOPE BRACCIO TELESCOPICO

5 BA 575 5

5

6

1

100 VJR EVOLUTION

5

6

2

6

3

7

4

7

7

6

6

9

6

5

7

10

10 7

5

7 8

9

7 8

P. A . O . i l l u s

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5

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6

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