Manitou Access Platform 150 ATS Repair Manual 547330 - PDF DOWNLOAD

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REF: 547 330 EN (11/2001)

ACCESS PLATFORM 150 ATS REPAIRS MANUAL

1ère DATE D'EDITION 1st PUBLICATION DATE INFORMATION CATALOGUE CATALOGUE INFORMATION

DATE D'EDITION PUBLICATION DATE

11 / 2001 OBSERVATION REMARKS

CONTENTS Assemblies

0 0-1-M.54 EN 10 10-2-12-M.54 EN 10-3-12 EN 30 30-2-43-M.54 EN 55

Chapters

General Technical characteristics Thermal motor Dismantling the 900 Series motor Removing the 900 Series motor Axle Dismantling the front and rear axles Arms - Cradle

55-2-20-M.54 EN

Dismantling the hydraulic hoses fitted on of the arms, runners and telescopic unit

55-8-23-M.54 EN

Adjusting the overload springs on the cradle and the load detection unit

70

Hydraulics system

70-2-44-M.54 EN

Dismantling the cradle / turret rotation motor

70-2-60-M.54 EN

Dismantling the lifting jacks

70-2-61-M.54 EN

Dismantling the tilting jacks

70-2-63-M.54 EN

Dismantling the telescopic jack

70-2-64-M.54 EN

Dismantling the compensating jack

70-5-M.54 EN

Hydraulic pressure

70-6-M.54 EN

Hydraulic layout

75 75-2-5-M.54 EN

Hydrostatic system Dismantling the hydrostatic pump

75-3-5 EN

Dismantling the A10VG hydrostatic pump

75-3-24 EN

Dismantling the A2F hydrostatic motor

75-8-5-M.54 EN

Adjusting the hydrostatic pump

CONTENTS Assemblies

80

Chapters

Electricity

80-2-10-M.54 EN

Replacing the electronics board and microprocessor

80-8-81-M.54 EN

Position of the sensors

80-8-82-M.54 EN

Main electrical Cabinet l

80-8-84-M.54 EN

Parametering the machine

ASSEMBLY 0

GENERAL

TECHNICAL CHARACTERISTICS 150 ATS 0-1-M.54 EN

11 / 2001

-1-

CHARACTERISTICS MOTOR - Type - No. of cylinders - No. of strokes - Injection system - Firing sequence - Play in the rocker arms (warm) - Inlet - Exhaust - Cubic capacity - Bore - Stroke - Volume ratio - Nominal rpm - Tick-over - Maximum rpm empty - Power BS AU 141 at 1971 - Power ISO/TR 14396 - Power ISO 3046-1: 1995 - Maximum torque - Air filtration

COOLING

PERKINS 903-27 Diesel 3 in-line 4 Direct 1.2.3.

0.20mm 0.45mm 2700cm3 95mm 127mm 17.5:1 2100 rpm 1200 rpm 2400 rpm 39.5 kW at 2100 rpm 38.5 kW at 2100 rpm 37 kW at 2100 rpm 190 Nm at 2100 rpm Dry, 3 microns

CIRCUIT Water Suction 6 406.4 mm

- Type - Fan . No. of blades . Diameter - Thermostat . Opening starts . Fully open

ELECTRICAL

80 / 84°C 96°C

CIRCUIT

- Earth - Battery - Alternator - Voltage regulator - Starter

HYDROSTATIC HYDROSTATIC - Type

Negative 12 V - 105 A 14 V - 55 A Incorporated in the alternator 12 V - 2,2 kw

TRANSMISSION

PUMP

A10VG45 variable cubic capacity, with automatic power regulator.

Electromagnetic 12V

- Direction reverser - Main pump . Maximum cubic capacity . Minimum cubic capacity . Maximum flow . Operating pressure - Force feed pump . Cubic capacity . Maximum flow . Force feed pressure at max. rpm - Filtration . Gauge

45cm3 0cm3 94 l/min 350 bars 8.4cm3 17.64 l/min 25 bars (transmission in neutral) 10 microns

HYDROSTATIC - Type

MOTOR

A2FM, fixed cubic capacity

-2-

AUXILIARY

HEATING CIRCUIT

- Type of pump . Cubic capacity - Lifting, tilting, telescopic, direction, rotation circuit . Flow at max. rpm, empty . Pressure - Filtration . Pressure

CARD

Gear pump 14cm3 29.l/min 160 bars 10 microns

FUSES

CARD 1 - F1 - F2 - F3 - F4 - F5 - F6

10A 10A 10A 10A 3A 1A

CARD 2 - F1 - F2 - F3

16A 16A 3,15A

-3-

150 ATS SPECIFICATIONS - Use

Internal and external

- Capacity

250 Kg (i.e. 2 persons)

- Weight of the equipment able to be loaded : . With one person in the basket . With two people in the basket

170 kg 90 kg

- Hydrostatic transmission

4-wheel drive, 2-wheel steer

- Turret rotation

350° with end stop

- Speed of the cradle in motion . Forwards . Reverse

0 to 6 km/h 0 to 6 km/h

- Operating height - Floor height - Maximum reach

15078 mm 13033 mm 9264 mm

- Weight of the cradle . Empty . Under nominal load

7445 Kg 7695 Kg

- No. of gears

2

- Handleable slope

30%

- Ground clearance under the chassis

377 mm

- Ground clearance under the axle

305 mm

- Maximum permissible wind speed

45 km/h

- Maximum permissible inclination

9% ou 5°

- Maximum permissible horizontal manual force

40 daN

- 1 daN = 1kg

TYRES:

FRONT

&

REAR

DIMENSIONS

PRESSURE

340/80 R 18 IT 510

Foam

EMPTY LOAD PER TYRE

F 1600 Kg

R 2125 Kg

-4-

UNDER MAX. LOAD & REACH ON 1 WHEEL

4500 kg

K

DIMENSIONS

J I

F

D

C

A

B

E

A B C D E F G G1

5958 2100 2260 377 2000 305 2745 7295

G2 H H1 H2 I J K

8792 13033 6790 4652 4381 1765 3133

-5-

3

2

1

0

1

2

3

4

5

6

7

8

9

10

11 18 17 16 15 14 13

H

12 11 G

10 9 8 7 6

H1

G1

5 4

H2

G2

3 2 1 3

2

2

3

4

-6-

8

9

10

11

FILTER ELEMENTS & BELTS

1

2

3

4

DESIGNATION

5

6

REFERENCE

7

8

CLEANING

REPLACEMENT

1 - Oil filter for thermal motor

211 384

2 - Dry air filter cartridge

177 129

3 - Dry air safety filter cartridge

177 178

800 H

4 - Hydrostatic transmission oil filter cartridge

519 856

800 H

5 - Auxiliary hydraulic oil filter cartridge

519 855

400 H

6 - Fuel filter cartridge

49 660

400 H

7 - Fan belt

561 299

8 - Hydraulic reservoir strainer

77 402

-7-

400 H 50 H

800 H

400 H

ASSEMBLY 10

THERMAL MOTOR

DISMANTLING THE 900 SERIES MOTOR 150 ATS 10-2-12-M.54 EN

11 / 2001

DISMANTLING MOTOR 903-27 - Remove the motor cover : • Unscrew the nuts 1 (Fig. A) on the hinges and the pneumatic spring to release the motor cover 2 (Fig. A) (No. 10 spanner).

• Remove the air hose from the air filter • Remove the reinforcing bracket 3 (Fig. A) to release the housing (No. 13 spanner)

A 2

1 1

- Disconnect the electrical supply (disconnect from the battery) - Locate and disconnect the electrical connections : • Alternator, starter, water temperature probes, pre-heater, motor oil pressure sensor, motor cutout, etc.

- Disconnect the Earth wire 4 (Fig. B) situated beside the alternator (No. 13 spanner)

3

B

4

- Disconnect the electrical plugs 5 (Fig. C) from the hydrostatic pump using a screwdriver

C 5 5

- Place a receptacle under the chassis and disconnected the water hoses 6 (Fig. D)

D

6

6

-1-

- Remove the collar 7 (Fig. E) and release the pipe 8 (Fig. E) from its housing

E

7 8

- Locate the seven hoses 9 (Fig. F) and disconnect and seal them.

F 9 9 9 9

9

- Locate the feed and return hoses to the tank 10 (Fig. G).

9

9

G

- Remove and seal them (No. 17 spanner).

10 - Remove the screws from the motor brackets, 2 front (Fig. H) and 2 rear (Fig. 1) (No. 24 spanner).

10

- Place a sling over the motor support flanges 11 (Fig. J) provided for this purpose.

- Gently lift the motor and move it to release the radiator fan. The motor can now be removed.

H

I

J

11

11

-2-

ENGINE DISASSEMBLY 150 ATS 10-3-12 EN

11 / 2001

ASSEMBLY 30

AXLE

DISMANTLING THE FRONT & REAR AXLES 150 ATS 30-2-43-M.54 EN

11 / 2001

DISMANTLING THE FRONT AXLE - Disconnect the electrical supply (disconnect from the battery)

A

- Remove the front wheels (see the instruction leaflets)

1

- Disconnect the universal joint from the axle (No. 10 hex spanner - Disconnect the two hydraulic hoses 2 (Fig. B) and seal them (No. 19 spanner)

1

- Disconnect the front axle's sensor 3 (Fig. B) - Hold the front axle firmly with the aid of a winch.

Weight of front axle: 290 kg.

- Unscrew the 6 screws 4 (Fig. B) fastening the front axle to the chassis (No. 30 spanner)

B 3

4

- Remove the front axle Reinstalling the front axle - Follow the above actions in reverse order (Torque for the wheel nuts: 34 daNm) (Torque for tightening the axle onto the chassis: 28.5 daNm) 4

- Check the levels and adjust the oil level if required.

DISMANTLING THE REAR AXLE - Disconnect the electrical supply (disconnect from the battery)

C 5

- Remove the rear wheels (see the instruction leaflets)

5

- Disconnect the universal joint from the axle (No. 18 spanner, No. 10 hex spanner)

5 5

- Remove the hydrostatic motor cover (No. 10 spanner) - Disconnect the six hydraulic hoses 5 (Fig. C) and seal them (No. 19 spanner, No. 24 spanner, No. 10 hex spanner) and

5

- Hold the rear axle firmly with the aid of a winch. Weight of rear axle: 336 kg.

- Unscrew the 8 screws 7 (Fig. B) fastening the rear axle to the chassis (No. 30 spanner) - Remove the front axle Reinstalling the rear axle - Follow the above actions in reverse order (Torque for the wheel nuts: 34 daNm) (Torque for tightening the axle onto the chassis: 28.5 daNm)

- Check the levels and adjust the oil level if required

-1-

D 7

7

ASSEMBLY 55

ARMS - CRADLE

DISMANTLING THE HYDRAULIC HOSES FITTED IN THE ARMS, RUNNERS AND TELESCOPIC UNIT 150 ATS 55-2-20-M.54 EN

11 / 2001

INDEX

A - DISMANTLING THE HOSES FROM THE UPPER SECTION . . . . . . . . . P 2 B - DISMANTLING THE HOSES FROM THE LOWER SECTION . . . . . . . . . P 4 C - DISMANTLING THE GUIDE RUNNERS FROM THE TELESCOPIC JACK . . P 5 D - DISMANTLING THE RUNNERS FROM THE TELESCOPIC ARMS . . . . P 5 E - DISMANTLING THE RUNNERS FROM THE MOBILE TUBE . . . . . . . . . P 5 F - DISMANTLING THE TELESCOPIC UNIT (MOBILE TUBE) . . . . . . . . . . P 6

-1-

A - DISMANTLING THE HOSES FROM THE UPPER SECTION A1

A2

NB : For this operation, you will require to use needles.

- These should be sturdy but flexible - Once fixed on the hoses, they should be encased in adhesive tape to create a form of cone that will ease passage through the sleeves.

-2-

A3

E.g. DISMANTLING THE HOSES FROM THE CRADLE ROTATION MOTOR

1

- Extend the telescopic arm fully - Use the battery cut-off switch to switch off the electricity supply - Remove the chain 1 (top and bottom) (Fig. A3) (No. 4 hex spanner & No. 10 spanner).

- Remove the clamps (18 & 19 on page 5) to free the hoses (No. 10 spanner).

- Remove the retention plate 5 (Page 5) from the hose channel (No. 10 spanner).

- Remove the hose cover 4 from the fixed telescopic unit (Fig. A5) (No. 10 spanner).

A4 - Remove the spiral from the hoses on the basket rotation motor 2 (Fig. A4).

2

- Locate the rotation motor’s two hoses 3 (Fig. A4).

- Remove and seal them with bungs.

3

- Fix a needle to the end of the defective hose.

- Remove the spiral from the defective hoses located in the joint.

- Disconnect the hose from one of the connection Tees 5 (Fig. A6).

- Fix a needle and release the hose.

REINSTALLATION - Fix the needles onto a new hose.

A5

- Connect the new hose to the connecting Tee 5 (Fig. A6).

- Pass the other end of the hose through the sleeve, drawing it through with the aid of the needle still in place.

- Mount the hose along the fixed telescopic arm and place it on the chain’s lower folded plate. Then refit the hose cover on the fixed telescopic unit.

- Still pulling with the aid of the needle, draw the hose into the chain.

4

- Refit the chain.

- Position it in the hose channel and refit the retention plate - Pull it and reconnect it to the rotation motor - Replace the joint sleeves and the spirals

A6

- Refit the clamps.

5

- Before starting the cradle, check the level of the hydraulic oil.

NB :

- The procedure for dismantling the hoses from the tilting jack is identical to that for the cradle rotation motor.

- Dismantling the hoses from the telescopic jack only requires the removal of the casings on the telescopic arm and the joint.

- Be careful to replace the sleeves on the joints allowing sufficient curvature to allow for movement.

-3-

5

B - DISMANTLING THE HOSES FROM THE LOWER SECTION B1

NB : For this operation, you will require to use needles - These should be sturdy but flexible.

- Once fixed on the hoses, they should be encased in adhesive tape to create a form of cone that will ease passage through the sleeves.

- Position the arms to make this task easier E.g. Dismantling the hoses from the telescopic jack - Use the battery cut-off switch to switch off the electrical supply.

- Remove the hose cover on the lower tie-rod and the upper arm.

- Remove the right-hand turret cover.

- Remove the defective hose from the joint.

- Fix a needle to its end.

- Disconnect the defective hose from the distributor and draw it out to remove it..

REINSTALLATION - Proceed in the same way as for refitting the hoses in the upper section.

-4-

-5-

24 24 25 26

52 54 53 56 55

48 49 50 51 40 39

17 16 16 15

43

12 13 13 14 1

39 46 46

59 59

44 44 45

46 46

5 BA 211

60 61

19

48

47 50 49

14 13 13 12

29 30 28

8

7

22 23 18 23 20

2

11

FLECHE TELESCOPIQUE TELESKOPAUSLEGER AGUILON TELESCOPICO TELESCOPIC JIB

9

27

3

6

57 58

57

58

36 38 38

55

37

57 58 54 52

55 56

56

42 35

41

52 54 58 57

36

5 9 10

05 / 02 / 01

34 4

42 41

150 ATS

P.A.O

C - DISMANTLING THE GUIDE RUNNERS FROM THE TELESCOPIC JACK - To remove the guide runners 1 (Fig. C1) (No. 5 hex spanner) on the telescopic jack, it is necessary to remove the telescopic jack itself.

C1 1

- See the instructions for removing the telescopic jack.

- Remove the runners.

REINSTALLATION - Follow the above procedure in reverse.

D - DISMANTLING THE RUNNERS FROM THE TELESCOPIC ARMS - Extend the telescopic unit to facilitate access.

D1

- Remove the locking covers 2 (No. 8 screw, No. 10 spanner)

2

2

5

- Remove the fixings from the runners at the top of the boom 3 (Fig. D1) (No. 4 hex spanner, No. 13 spanner, No. 6 hex spanner, No. 19 spanner).

3 - Pay attention to the position of the adjustment plates.

- Remove the runners.

4

3

REINSTALLATION - Follow the above procedure in reverse.

- If necessary, fit adjustment plates: - Side plates 4 (Fig D1) : 516326 - Top plates 5 (Fig D1) : 516327

E - DISMANTLING THE RUNNERS FROM THE MOBILE TUBE - Dismantle the mobile tube.

E1

- Remove the fastenings from the runners at the base of the boom 6 (Fig. E1) (No. 6 hex spanner, No. 19 spanner).

6

5

- Pay attention to the position of the adjustment plates 7 (Fig. E1).

- Remove the runners.

5

REINSTALLATION - Follow the above procedure in reverse.

- If necessary, fit adjustment plates: - Adjustment plates 7 (Fig E1) : 516325

-6-

F - DISMANTLING THE TELESCOPIC UNIT (MOBILE TUBE) - Wedge the basket in place.

F1

- Extend the mobile tube to release the shaft at the top of the telescopic jack.

4

- Hold on to the mobile tube (cord A, Fig. F1).

- Dismantle the telescopic jack (see “Dismantling the telescopic jack”).

- Remove the tilting jack’s top shaft 1 (Fig. 1).

2

- Remove the basket’s articulation shaft 2 (Fig. F1) (No. 13 spanner, and circlip pincers).

1

A

- Remove the tilting jack 3 (Fig. F2) - Remove the hose channel 4 (Fig. F1) (4 screws, No. 13 spanner

F2

- Remove the hoses on the tilting jack.

- Remove the two locking covers 5 (Fig. F4) (8 screws, No. 10 spanner).

- Remove the chain 6 (Fig. F3) (2 screws, No. 4 hex spanner).

- Remove the chain cover 7 (Fig. F3) (No. 10 spanner).

- Remove the upper runner at the top of the boom 8 (Fig. F4) (No. 13 spanner, No. 4 hex spanner).

3 - Remove the lower runner at the top of the boom 9 (Fig. F4) (No. 19 spanner, No. 6 hex spanner).

- Remove the telescopic mobile tube10 (Fig. F3).

F3

REINSTALLATION 6 - Follow the above procedure in reverse

7

10

F4 5 8

9

-7-

5

ADJUSTING THE OVERLOAD SPRINGS ON THE CRADLE AND THE LOAD DETECTION UNIT 150 ATS 55-8-23-M.54 EN

11 / 2001

ADJUSTING THE OVERLOAD SPRINGS ON THE CRADLE This operation must be carried out when one of the springs has been removed.

- Adjust each spring to the settings indicated below (No. 30 spanner).

68

B

79

A

ADJUSTING THE LOAD DETECTION UNIT C - Tighten the spring’s load detection screw to the maximum (No. 16 spanner).

- Put a load of 250 kg in the basket and adjust the detection screw to achieve the following : - With a load of 250 kg the buzzer must not be activated - With a load of 260 kg the buzzer must be activated.

- The four springs must have the same constraints (see the chapter “Adjusting the overload springs on the cradle”).

1

2

- The four rocker bars 1 (Fig. C) must all have equal tension. These are adjusted by means of the fork 2 (Fig. C). The load detection must be correct whatever the position of the load in the basket (No. 18 spanner).

After these modifications, it is imperative that the regulation static and dynamic tests be conducted by an approved body).

Load detection adjusting screw

-1-

ASSEMBLY 70

HYDRAULICS SYSTEM

DISMANTLING THE CRADLE / TURRET ROTATION MOTOR 150 ATS 70-2-44-M.54 EN

11 / 2001

DISMANTLING THE BASKET ROTATION MOTOR - Locate the basket rotation motor’s hoses.

A 4

- Remove the casing ring 1 (Fig. A) (3 screws, No. 10 spanner).

2

- Remove the two hydraulic hoses 2 (Fig. A) (No. 19 spanner).

- Remove the two motor fixing screws 3 (Fig. A) (No. 10 hex spanner).

3

- Remove the motor 4 (Fig. A).

1 (Tightening torque: 8 ± 10% daNm)

DISMANTLING THE TURRET ROTATION MOTOR - Position the cradle so as to facilitate access to the turret rotation motor.

B

- Remover the internal turret casing (4 screws, No. 10 spanner).

- Locate the hoses.

9 - Remove the turret’s internal polyester casing (7 screws, No. 10 spanner).

- Remove the three hydraulic hoses 5 (Fig. B) (No. 19 spanner, No. 24 spanner) - Remove the hydraulic hose 6 (Fig. B) from these two ends (No. 19 spanner).

- Remove the four motor fixing screws 7 (Fig. B) (No. 10 hex spanner, height 35mm).

- Remove the motor 8 (Fig. B ( Tightening torque : 13,5 ± 10 % daN.m)

-1-

-2-

N TIO RA A P RÉ DE IÓN E IR ATZ ARAC A SS S EP CE UR R NÉ ARAT O DE I P RE ESAR T C KI E N AIR P RE

10 DC 26

1

A (x 6) B C D E (x 3) F (x 7) G 2

E E

MOTEUR DE ROTATION DREHUNG MOTOR MOTOR DE ROTACION ROTATION MOTOR

A B

E

C

F

D 3

G

05 / 02 / 01

150 ATS

PAO

DISMANTLING THE LIFTING JACKS 150 ATS 70-2-60-M.54 EN

11 / 2001

DISMANTLING THE LIFTING JACKS A

LOWER ARM LIFTING JACK - Remove the right-hand turret cover.

- Locate the hydraulic hoses.

2

- Position the lower arm horizontally.

- Firmly lock the lower arm in place with props or a chain hoist.

1 - Remove the lower jack’s fixing shafts 1 (Fig. A).

- Remove the jack 2 (Fig. A).

- Disconnect the hydraulic hoses (No. 19 spanner) and seal them

REINSTALLATION - Follow the above procedure in reverse.

UPPER ARM LIFTING JACK (Fig. B)

B

- Raise the intermediate arm to free access to the shaft at the base of the jack.

- Follow the same instructions as above, replacing “lower arm” with “upper arm”.

2

1

C

INTEMEDIATE ARM LIFTING JACK (Fig. C) 1 - Raise the lower and intermediate arms to free access to the shafts at the base and the top of the intermediate jack.

- Follow the same instructions as above, replacing “lower arm” with “intermediate arm”.

2

1

-1-

-2-

10 CA 158

1

3

9

8

15

6

10

14

7

13

4

12

ø50mm

6

5

11

Course - Hub - Carrera Stroke : 650mm

HYDRAULIQUE (Vérin de levage) HYDRAULIK (Aufwinden zylinder) HIDRAULICO (Cilindro de levantamiento) HYDRAULIC (Lifting cylinder)

10

2

TS IN JO DE E Z T ET AT S CH GS TA PO HTUN JUN E DIC GO D JUE L KIT A SE

17

16

05 / 02 / 01

6x2 7 9 10 x 2 18 11 12 15

150 ATS

P.A.O

-3-

;

10 CA 159

1

9

8

3

6

7

4

;;;; ;;;; ;;;; ;;;;

6

15

5

10

ø50mm

13

;;; ;;; ;;;

;;;; ;;;; ;;;;

14

12

Course - Hub - Carrera Stroke : 800mm

HYDRAULIQUE (Vérin de levage) HYDRAULIK (Aufwinden zylinder) HIDRAULICO (Cilindro de levantamiento) HYDRAULIC (Lifting cylinder)

10

;;

11

2

T OIN EJ D TTE TZ HE GSA TAS C PO HTUN JUN E DIC GO D E T I JU L K A SE

;;;; ;;;; ;;;; ;;;;

;;; ;;; ;;;

S

17

16

05 / 02 / 01

6x2 7 9 10 x 2 18 11 12 15

150 ATS

P.A.O

-4-

10 CA 160

3

;

1

15

14

9

;;;; ;;;; ;;;; ;;;;

10

8

13

6

12

ø50mm

7

;;;; ;;;; ;;;;

;;; ;;; ;;; ;;;

4

6

5

11

10

;;; ;;; ;;;

;;; ;;; ;;; ;;;

;;

Course - Hub - Carrera Stroke : 500mm

HYDRAULIQUE (Vérin de levage) HYDRAULIK (Aufwinden zylinder) HIDRAULICO (Cilindro de levantamiento) HYDRAULIC (Lifting cylinder)

TS IN JO DE E Z T ET AT S CH GS TA PO HTUN JUN E DIC GO D JUE L KIT A SE

2

17

16

05 / 02 / 01

6x2 7 9 10 x 2 18 11 12 15

150 ATS

P.A.O

DISMANTLING THE TILTING JACKS 150 ATS 70-2-61-M.54 EN

11 / 2001

DISMANTLING THE TILTING JACKS A - Locate the hydraulic hoses.

- Wedge the basket in place using lifting equipment (lifting to the maximum).

- Remove the fixing shafts 1 (Figs. A & B) (No. 13 spanner, circlip pincers).

- Remove the jack.

- Disconnect the hydraulic hoses (No. 19 spanner) and seal them.

1

REINSTALLATION B

- Follow the above procedure in reverse.

CHASSIS

1

BASKET

-1-

-2-

10 CD 68

1

;

3

15

12

14

;;; ;;; ;;; ;;;

9

8

;;;; ;;;; ;;;; ;;;;

13

12

7

;;; ;;; ;;;

ø30mm

6

;;; ;;; ;;; ;;;

11

5

4

; ;;; ;;; ;;; ;;;

10

Course - Hub - Carrera Stroke : 214mm

HYDRAULIQUE (Vérin d'inclinaison) HYDRAULIK (Neigungzylinder) HIDRAULICO (Cilindro de inclinación) HYDRAULIC (Tilting cylinder)

TS OIN EJ D TE Z ET AT S CH NGS NTA O P HTU JU E DIC GO D E T I U J LK A SE

2

16

16

05 / 02 / 01

6 7 9 10 17 12 x 2 13 15

150 ATS

P.A.O

DISMANTLING THE TELESCOPIC JACK 150 ATS 70-2-63-M.54 EN

11 / 2001

DISMANTLING THE TELESCOPIC JACK A - Position the telescopic arm horizontally.

CHASSIS

- Keep hold of the mobile tube – basket assembly for safety).

- Remove the top shaft from the telescopic jack 1 (Fig. A) (circlip pincers).

- Push the telescopic jack to the end stop.

- Remove the telescopic arm’s casing 2 (Fig. B) (2 screws, No. 10 spanner).

1 - Locate the hydraulic hoses.

BASKET

- Disconnect the hydraulic hoses 3 (Fig. C) (No. 24 spanner) and seal them.

- Extract the fixing shaft from the base of the jack 4 (Fig. D) (No. 13 spanner)

B

- Remove the jack.

2

REINSTALLATION - Follow the above procedure in reverse.

C

3

D

4

-1-

-2-

;

10 CC 74

11

9

10

3

8

1

8

7

6

16

;;; ;;; ;;;

;;;; ;;;; ;;;; ;;;;

17

14

5

15 13

; 4

;;; ;;; ;;;

14

;;; ;;; ;;; ;;;

12

;;; ;;; ;;; ;;;

2

TS OIN EJ D TE Z ET AT S CH NGS NTA O P HTU JU E DIC GO D E T I U J LK A SE

;;

ø35mm

Course - Hub - Carrera Stroke : 2800mm

HYDRAULIQUE (Vérin de télescopage) HYDRAULIK (Zusammenstroll zylinder) HIDRAULICO (Cilindro de telescopaje) HYDRAULIC (Telescope cylinder)

18

05 / 02 / 01

6 8x2 9 11 19 12 15 14 x 2 17

18

150 ATS

P.A.O

DISMANTLING THE COMPENSATING JACK 150 ATS 70-2-64-M.54 EN

11 / 2001

DISMANTLING THE COMPENSATING JACK A - Locate the hydraulic hoses.

- Raise the intermediate arm to free access to the compensating jack’s top and bottom shafts.

- Disconnect the electrical supply

1 1

- Remove the fixing shafts 1 (Fig. A) (No. 13 spanner).

- Remove the jack.

- Disconnect the hydraulic hoses (No. 19 spanner) and seal them

REINSTALLATION - Follow the above procedure in reverse.

-1-

-2-

10 CB 39

1

3

15

12

13

14

12

11

10

ø30mm

8

9

Course - Hub - Carrera Stroke : 214mm

HYDRAULIQUE (Vérin de compensation) HYDRAULIK (Konpensation Zilinder) HYDRAULICO (Cilindro de compensacion) HYDRAULIC (Compensation Cylinder)

7

6

5

4

TS OIN EJ D TE Z ET AT S CH NGS NTA O P HTU JU E DIC GO D E T I U J LK A SE

2

05 / 02 / 01

6 8 9 10 16 11 12 x 2 13 15

150 ATS

P.A.O

HYDRAULIC PRESSURE 150ATS 70-5-M.54 EN

11 / 2001

PRESSURE SENSORS

A

PRESSURE SENSORS

PRESSURE SENSORS

-1-

B

All the pressures are adjusted between 25 and 30°C. 1

- Remove the right-hand turret casing

MAIN CIRCUIT (230 BARS)

M1

- Tools required • 1 manometer (0-400 bar) ...................549885 • 1 testing hose...........................................549887 - Connect the manometer 1 (Fig. B) to the main distributor at M1 (Fig. B).

C

- Lower the lower arm to its end stop - Read off the pressure from the manometer - Main circuit pressure = 230 bars.

- Adjust the pressure restrictor A (Fig. C) with a No. 6 hex spanner (counternut) and a 1/4 “ hex spanner (setting screw).

A

DIRECTION CIRCUIT (145 BARS) D 1

Tools required M3

• 1 manometer (0-400 bar) ..............549885 • 1 testing hose ....................................549887 - Connect the manometer 1 (Fig. D) to the main distributor at M3 (Fig. D).

- Turn to the left up to the end stop.

- Read off the pressure from the manometer.

- Direction circuit pressure = 145 bars.

- Adjust the pressure restrictor DB5 (Fig. A) with a No. 19 spanner (counternut) and a 1/4 “ hex spanner (setting screw).

- Connect the manometer 1 (Fig. E) to the main distributor at M2 (Fig. E).

- Turn to the right up to the end stop.

- Read off the pressure from the manometer.

- Direction circuit pressure = 145 bars.

- Adjust the pressure restrictor DB4 (Fig. A) with a No. 19 spanner (counternut) and a 1/4 “ hex spanner (setting screw).

-2-

E M2 1

F

TILTING CIRCUIT (205 BARS)

1

Tools required • 1 manometer (0-400 bar) .............549885 • 1 testing hose ....................................549887

M

- Connect the manometer 1 (Fig. F) to the main distributor at M (Fig. F).

- Push the basket tilting unit upwards to its end stop.

- Read off the pressure from the manometer - Tilting circuit pressure = 205 bars.

- Adjust the pressure restrictor DB1 (Fig. A) with a No. 19 spanner (counternut) and a 1/4 “ hex spanner (setting screw).

G

TELESCOPIC CIRCUIT (80 BARS)

1

Tools required • 1 manometer (0-400 bar) ..............549885 • 1 testing hose ....................................549887

M1

- Connect the manometer 1 (Fig. G) to the main distributor at M1 (Fig. G).

- Extend the telescopic unit up to its end stop.

- Read off the pressure from the manometer.

- Telescopic circuit pressure = 80 bars - Adjust the pressure restrictor DB3 (Fig. A) with a No. 19 spanner (counternut) and a 1/4 “ hex spanner (setting screw).

-3-

HYDRAULIC LAYOUT 150 ATS 70-6-M.54 EN

11 / 2001

HYDRAULIC LAYOUT – 150 ATS CRADLE

1

2

Tick-over 1220 rpm Max. 2200 rpm

Thermal motor

45 cm3

25 l/mn

10 l/mn

8,4 cm3

14 cm3

COMPENSATION TILT

ARM 3

BASKET ROTATION

TELESCOPE

ARM 2

TURRET ROTATION

ARM 1

3

A B C D E F G H I J K L M P

HYDRAULIC COMPONENTS : Oil tank : 3-way rotary valve : Valve unit : DANFOSS proportional distributor : REXROTH pump : Motor : Distributor unit : Brake assembly : Pressure filter 10 m abs. : Air filter10 m nom. : Electro-valve : Electro-valve : 20cm3 hand pump : Suction strainer 100 m

DIFFERENTIAL LOCK

BRAKE

80 cm3

Compensation/tilt

Telescope retract

Telescope extend

Arm 3 down

Arm 3 up

Arm 2 down

Arm 2 up

Arm 1 down

Arm 1 up

Turret rotation

Basket rotation

Direction

Differential lock

Brake

Auxiliary pump

Force feed pump

- Max. output

- Max. speed

Hydraulic pump

FUNCTIONS

FLOW PRESSURE (l/mn) (bars)

TURRET ROTATION

MAIN DISTRIBUTOR

BASKET ROTATION

ARM 1

ARM 2

ARM 3

TELESCOPE

COMPENSATION TILT

4

8,4 cm3

45 cm3

Tick-over 1220 rpm Max. 2200 rpm

DANFOSS DISTRIBUTOR

THERMAL MOTOR

Thermal motor

10 l/mn

25 l/mn

5

14 cm3

BRAKE ASSEMBLY

BRAKE

DIFFERENTIAL LOCK

A B C D E

80 cm3

HYDRAULIC COMPONENTS : Oil tank : 3-way rotary valve : Valve unit : DANFOSS proportional distributor : REXROTH pump

A B C D E F G H I J K L M P

HYDRAULIC COMPONENTS : Oil tank : 3-way rotary valve : Valve unit : DANFOSS proportional distributor : REXROTH pump : Motor : Distributor unit : Brake assembly : Pressure filter 10 m abs. : Air filter10 m nom. : Electro-valve : Electro-valve : 20cm3 hand pump : Suction strainer 100 m

6

ASSEMBLY 75

HYDROSTATIC SYSTEM

DISMANTLING THE HYDROSTATIC PUMP 150 ATS 75-2-5-M.54 EN

11 / 2001

DISMANTLING THE A10VG PUMP - Unscrew the nuts 1 (Fig. A) on the hinges and the pneumatic spring to free the motor cover 2 (Fig. A) (No. 10 spanner).

A 2

1 1

- Disconnect the electrical supply (disconnect from the battery)

- Disconnect the hydrostatic pump’s electrical plugs 3 (Fig. B) with a screwdriver.

B 3

3

6

- Locate the seven hoses 4 (Fig. C) and disconnect and seal them (No. 19, 30 and 36 spanners, No. 8 hex spanner).

C 5

4 4

- Put a sling on the hydrostatic pump 5 (Fig. C).

4

- Unscrew the two screws 6 (Fig. B) (No. 12 hex spanner).

4

- Extract the assembly with the aid of a screwdriver.

- There is now free access to the ring.

- Place a receptacle under the pump.

4

- Disconnect the lower drainage hose 7 (Fig. C) then remove the pump (No. 46 spanner).

- Follow the reverse procedure to reinstall.

-1-

4

7

4

DISMANTLING THE A10VG HYDROSTATIC PUMP 150 ATS 75-3-5 EN

11 / 2001

REPAIRING A10VG PUMP

1

REPAIR INSTRUCTIONS TABLE OF CONTENTS - Cross section view ...................................................................................................................................

3 to 4

- General repair instructions .......................................................................................................................

5

- Packets of gaskets and sub-assemblies .................................................................................................

6 to 8

- Drive shaft seal.........................................................................................................................................

9

- Booster pump seal ...................................................................................................................................

10 to 12

- Displacement control cylinder cover seal .................................................................................................

13

- Valve seals ...............................................................................................................................................

14

- Flow cancellation valve seal.....................................................................................................................

15

- Adjustment valve seals.............................................................................................................................

16

- Removing the control mechanism ............................................................................................................

17

- Control devices.........................................................................................................................................

18

- Disassembling the pump ..........................................................................................................................

19 to 21

- Removing the rotor...................................................................................................................................

22

- Disassembling the displacement control cylinder.....................................................................................

23 to 24

- Recommendations for checking parts ......................................................................................................

25 to 27

- Assembling the cover/Turcon-Glyd ring ...................................................................................................

28

- Reassembling the pump...........................................................................................................................

29 to 31

- Fitting the rotor .........................................................................................................................................

32 to 34

- Tightening torque .....................................................................................................................................

36

- Safety measures ......................................................................................................................................

37

2

Cross section view

Repair instructions A10VG

HW

with flow cancellation and pressure maintained

without flow cancellation

HDD

EPD

3

Cross section view

DA

4

Repair instructions A10VG

General repair instructions

Repair instructions A10VG

Warning !

Whenever carrying out repairs on a hydraulic component please remember the following recommendations !

Seal all openings on the hydraulic component.

Replace all gaskets.

Use genuine HYDROMATIK spare parts only.

Check all seal and slide faces for wear.

Warning : touching up seal faces, e.g. with emery paper, can cause damage to their surfaces.

Before starting up, fill the component casing with oil from the circuit.

5

Repair instructions A10VG

Packets of gaskets and sub-assemblies

1

2

3

4

5

6

Packet of gaskets for drive shaft.

Packet of external gaskets.

Complete rotor (pump part mechanism).

Displacement control cylinder.

1. Standard cylinder head.

2. Cylinder head with flow cancellation.

3. Cylinder head for DA governing, with flow cancellation.

Packets of gaskets and sub-assemblies

Repair instructions A10VG

6

7

HW control device

HW control device with zero position indicator.

8

HD control device

9

EP control device

10

DA control device

7

Packets of gaskets and sub-assemblies

Repair instructions A10VG

10

11

8

Booster pump with wear plate.

1. HP Valve 2. HP valve with by-pass 3. PB valve

12

With flow cancellation and pressure maintained.

13

1. DA cartridge, adjustable by lever.

2. DA cartridge, set to a fixed value.

3. Sequence valve.

Drive shaft seal

Repair instructions A10VG

14

15

Protect the drive shaft.

Remove the stop collar.

16

Screw sheet metal screws in the rubber filled holes.

Extract the shaft gasket with pincers

17

Use a spacer to position the shaft gasket till it butts up.

9

Booster pump seal

Repair instructions A10VG

Warning ! * assemble the chamfered «face» on the cover side.

18 19

20

21

10

Remove the mounting screws.

Pull the cover clear

Mark the position.

Booster pump seal

Repair instructions A10VG

22

23

Remove the O ring seal.

Pull the booster pump clear.

24

1. Wear plate.

2. Mounting pin.

25

1. Kantsil seal.

2. Decompression groove.

3. Mounting pin.

26

Put the wear plate in place.

Make sure to follow the direction of rotation !

11

Booster pump seal

Repair instructions A10VG

27

Put the wear plate in place.

Rightward rotation, shaft end towards you.

Take care with the mounting pin.

coté aspiration

28

Put the wear plate in place.

Rightward rotation, shaft end towards you.

Take care with the mounting pin.

coté aspiration

rotation gauche

29

rotation droite

12

30

Mount the booster pump.

31

Mount the O ring seal and the cover.

Displacement control cylinder cover seal

Repair instructions A10VG

Warning !

Make sure that the mechanical zero setting is correct !

19 20

21

22

Remove the lock nut while holding the positioning screw.

Mark the cover. Keeping the dimension, loosen the lock nut.

Pull the cover free of the positioning screw.

Check ! the O ring seals (1), their housings (2), the body and the cover (3).

Warning !

Optimization of the mechanical zero setting must be carried out once the pump is mounted on the vehicle or on a test bench.

13

Valve seals

Repair instructions A10VG

High pressure valve (P HP)

with by-pass

Booster valve (P SP)

23 24

25 bague d’appui

Protect the screw threads before fitting the new O ring seal.

Disassemble the valve flap and the pressure setting spring. * with by-pass function.

joint torique

26

14

Protect the screw threads before fitting the new O ring seal.

Flow cancellation valve seal

Repair instructions A10VG

27 28

Change the seal nut, observing the adjustment value (*)

Warning !

Check the valve pressure setting after reassembling.

15

Adjustment valve seals

Repair instructions A10VG

29 30

31

32

16

Disassemble the adjustment valve.

Do not damage the nozzle diameter.

Check this diameter.

Protect the screw threads before fitting the new O ring seal.

Removing the control mechanism

Repair instructions A10VG

HW with neutral position switch

33 34

35

36

* Remove the mounting screws

Pull the control mechanism clear

Check : the seal face (1), the flat seal (2), the O ring seals (3).

17

Control devices

Repair instructions A10VG

calibre 28 HW control device

calibre 45 37

HD - EP control device EP

38

DA control device

39

18

Disassembling the pump

Repair instructions A10VG

flow cancellation

40

off-centring screw

41

19

Disassembling the pump

Repair instructions A10VG

46

47

20

Mark the position of the booster pump and the cylinder head.

Disassemble the booster pump.

Variant with DA regulation : Mark the position of the off-centring screw (1).

Place the off-centring screw in disassemble position (2).

46

Unscrew the cylinder head mountings. Lift and remove the cylinder head.

47

Pull clear the port plate.

Note its position.

48

Check !

The O ring seal and its housing (1).

The O ring seal and its housing (2).

The port plate mounting pin (3) In DA, no mounting pin The closing of outlet T (4).

Disassembling the pump

Repair instructions A10VG

49

Variant with DA regulation : Press the cylinder barrel downwards (1).

Remove the off-centring screw (2).

Lift and remove the rotor (3).

Disassemble : 1. the cylinder barrel.

2. the plate.

3. the knuckle pin.

50

52

Remove the stop collar and the shaft seal.

21

Removing the rotor

22

Repair instructions A10VG

53

Extract the drive shaft with light hammer strokes (rubber mallet).

54

Remove the cradles.

56

Pre-stress the spring with a tool.

57

Remove the stop collar.

Remove the spring and the pressure holding pins.

Disassembling the displacement control cylinder (Housing with liner)

Repair instructions A10VG

58

Disassemble the control device.

59

Remove the displacement control cylinder (1).

Break down the displacement control cylinder.

60 23

Disassembling the displacement control cylinder (Housing with Turcon-Glyd ring)

Repair instructions A10VG

58

59

Disassemble the control device.

Remove the displacement control cylinder (1).

Break down the displacement control cylinder.

(Housing with Turcon-Glyd ring seal).

60 24

Recommendations for checking parts

Repair instructions A10VG

61

62

Replace all bearings.

Check !

1. the spline : damaged by wear, presence of adjusting rust?

2. areas receiving the bearings.

3. for the presence of scratches due to the shaft seal.

63

Displacement control cylinder liner (1) free of scratches and wear.

64

Check ! for the absence of scratches on the displacement control cylinder (1) .

25

Recommendations for checking parts

Repair instructions A10VG

65

66

Check ! for the absence of clearance in the link between the slide piece and the journal.

67

Check ! for the absence of scratches on the return device (1), the absence of traces of binding (2) in the pad area.

68

Check ! for the absence of scratches on the contact face (1), the absence of metal deposits, the absence of axial clearance (2), (the pistons to be changed a full set at a time only).

69

26

Check ! for the absence of scratches on the contact face.

Check ! the bore of the cylinder barrel (1), the splines (2).

Recommendations for checking parts

Repair instructions A10VG

70

71

Check ! for the absence of scratches or traces of binding on the cylinder barrel sliding face (1), for the absence of deposits, the absence of scratches on the port plate (only change these parts with a whole new set).

Check ! for the absence of damage to the port plate contact face.

72

Remark : For DA regulation, this hole is open (only for A10VG 45).

73

Check ! the surfaces of the bearings (1).

74

Absence of scratches or traces of binding.

27

Assembling the cover/Turcon-Glyd ring

Repair instructions A10VG

75

76

28

Insert the seal in the mounting pliers.

77

With the pliers and its tooling, form the seal into a bean shape. Proceed with care when shaping Turcon seals so as to avoid damaging the edges of the seal.

78

Place the O ring seal in the groove.

Bring the Turcon seal into the housing and place it in its housing. Release the pressure exerted on the seal, then remove the pliers and tool. Check that the seal is properly in position, smoothing it with the finger if necessary.

79

Calibrate the seal with a test mandrel (displacement control cylinder) to an angle of 10° to 15°.

Reassembling the pump

Repair instructions A10VG

75

Put the cradles in place.

76

Place the displacement control cylinder in the housing.

Remark : Grease the front cylinder before putting it in place.

Fit the bearing, the wire, the slide piece and the knuckle pin.

Tooling : for example, clamp, rubber ring, grease.

77 78

Fit the complete plate in the housing.

Make sure the cradles are properly in place in the housing.

Disassemble the tooling.

29

Reassembling the pump

Repair instructions A10VG

Check the position of the bearings in their guides.

Incline the plate and the displacement control cylinder, this should be easy to do. Place them in a central position using a measuring instrument (dial gauge or depth gauge).

Check points 1 and 2 : they should have the same dimensions.

80

30

Put the knuckle pin in place.

Reassembling the pump

Repair instructions A10VG

Put the tooling in place.

Hold the plate in position with a threaded pin.

Do not force it.

Tooling for A4V «plate»

Section no. 3

Section no. 4

Section no. 5

Mark 1 2 3 4 5 6 7 8 9

Description square threaded pin wedge wedge wedge M12 x 25 DIN 912 cheese head screw M14 x 25 DIN 912 cheese head screw M16 x 30 DIN 912 cheese head screw M20 x 35 DIN 912 cheese head screw

quantity 2 2 2 2 2 2 2 2 2

31

Fitting the rotor

Repair instructions A10VG

82

New assembly position !

Fit the shaft together with bearings and shaft seal.

80

Put the assembling unit in place.

83

New assembly position !

Fit the shaft together with bearings and shaft seal.

84 85

32

Fit the pistons and the return device.

Remark : Grease the pistons and pads.

Fitting the rotor

Repair instructions A10VG

86

87

Disassemble the assembling unit.

Fit the cylinder barrel and the pistons, and also the return device.

Assembly hint : Hold the pistons with an O ring seal.

86

On variant with off-centring screw : Press the cylinder barrel downwards -Screw the off-centring screw to the mark x. * Notch in assembly position.

87

Calibre 28 = 31 + 0.75 mm Calibre 45 = 32 + 0.75 mm

33

Fitting the rotor

Repair instructions A10VG

88

89

90

91

Fit the port plate mounting pin.

DA adjustment : the pump has an off-centring screw but no mounting pin.

Port plate for righthand rotation. * mounting pin.

Port plate for lefthand rotation with * mounting pin.

Port plate for righthand rotation with off-centring screw.

Do not exceed the maximum thread depth.

34

Reassembling the pump

Repair instructions A10VG

92

93

Grease the surfaces of the cylinder barrel, take new O ring seals grease them and then put them in place.

Position them correctly.

Remark : HW, HD, EP adjustments : place the grease port plate on the cylinder head.

DA Adjustment : place the port plate on the cylinder barrel.

94

Tighten the cross head screw.

Position the off-centring screw on the marking.

95

Assemble the booster pump.

96

Assemble the control unit with its seal.

35

Tightening torque

Repair instructions A10VG

Tightening torque for the VSTI caps (metric fine thread)

Tightening torque for the headless screw (ISO metric coarse thread)

Ø of thread

Resistance Ø of

Tightening torque values opposite are only valid for the

thread

headless screw with ISO metric

M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30

coarse thread and head support dimensions as per DIN 912, DIN 931 and DIN 933

Also, these values are only valid for slightly greased or ungreased, untreated surfaces, and when using

exclusively

torque

wrenches or wrenches with stress limitation.

8,8

10,9

12,9

Tightening torque (Nm) 1,1 2,9 6 10 25 49 86 135 210 290 410 550 710 1050 1450

1,6 4,1 8,5 14 96 69 120 190 295 405 580 780 1000 1500 2000

1,9 4,9 10 17 41 83 145 230 355 485 690 930 1200 1800 2400

M8x1 M 10 x 1 M 12 x 1,5 M 14 x 1,5 M 16 x 1,5 M 18 x 1,5 M 20 x 1,5 M 22 x 1,5 M 26 x 1,5 M 27 x 2 M 30 x 1,5 M 33 x 2 M 42 x 2 M 48 x 2

description VSTI 8 x 1 VSTI 10 x 1 VSTI 12 x 1,5 VSTI 14 x 1,5 VSTI 16 x 1,5 VSTI 18 x 1,5 VSTI 20 x 1,5 VSTI 22 x 1,5 VSTI 26 x 1,5 VSTI 27 x 2 VSTI 30 x 1,5 VSTI 33 x 2 VSTI 42 x 2 VSTI 48 x 2

Tightening torque (Nm) - ED/SA - ED - ED - ED - ED/SA - ED/SA - ED/SA - ED - ED/SA - ED - ED/SA - ED/SA - ED/SA - ED

=5 = 10 = 20 = 30 = 30 = 40 = 50 = 60 = 70 = 90 = 100 = 120 = 200 = 300

Tightening torque for the cross-recessed button head screw as per DIN 7985 (ISO metric coarse thread)

Tightening torque for the seal-lock collar nuts (ISO metric coarse thread) resistance

resistance Ø of Tightening

torque

values

opposite are only valid for resistance class 8.8 seal-lock collar nuts with ISO metric coarse thread.

36

thread M6 M8 M10 M12 M14 M16

8,8

10,9

12,9 Ø of

tightening torque (Nm) 10 22 40 69 110 170

Tightening

torque

values

opposite are only valid for resistance class 8.8 crossrecessed button head screws as per DIN 7985 with ISO metric coarse thread.

thread M3 M4 M5 M6 M8 M10

8,8

10,9

12,9

tightening torque (Nm) 1,1 2,9 6 10 25 49

Safety measures

Repair instructions A10VG

The hydraulic plant

1. The hydraulic power plant is under high pressure !

High pressure fluids (fuel, hydraulic oil) coming out under high pressure can pass through the skin and cause very serious injury. If this occurs, call a doctor immediately, as there is a risk of serious infection !

2. Whilst searching for leaks take appropriate measures to protect against the risk of injury !

3. Before carrying out work on the hydraulic power plant it is imperative to turn off the pressure and to lower the vehicle tooling !

4. During work on the hydraulic power plant it is imperative to switch off the engine and prevent the vehicle from moving (parking brake, wedge) !

5. When connecting the cylinders and hydraulic motors, the hydraulic hoses must be connected in compliance with the instructions !

6. If the connections are made the wrong way round, the functions are also reversed (e.g. lift/lower) ˆrisk of accidents !

7. Inspect the hydraulic hoses regularly and change them if they are damaged or worn !

The replacement hoses must meet the appliance maker's technical specifications !

Take away and recycle the oil, fuels and filters in line with standard practice !

37

DISMANTLING THE A2F HYDROSTATIC MOTOR 150 ATS 75-3-24 EN

REPAIRING THE A2F ENGINE

1

2

SET OF SEALS / SUB-ASSEMBLIES

01

Set of external seals with assembling unit.

02

Rotor, mechanical parts, preset with set of seals and glue.

03

Rotor, hydraulic parts, preset with set of seals and glue.

04

Complete rotor, preset with set of seals and glue.

PAGES 2 4 6 8 9 11

SET OF SEALS SHAFT SEALS CYLINDER HEAD DISASSEMBLING THE ROTOR INSPECTION OF COMPONENTS ROTOR ASSEMBLY

3

SHAFT SEAL

4

1

For non-splined shafts : pull clear the key.

Cover the shaft end.

2

Remove the retaining ring.

3

Push back the locking ring.

4

VISUAL INSPECTION : 1 - shaft seal 2 - locking ring 3 - inlet shaft 4 - housing 5 - O ring seal

5

Disassemble the shaft seal.

SHAFT SEAL

6

Position the shaft seal ring correctly with the appropriate socket.

7

If the shaft is deeply grooved, insert a shim behind the seal.

8

Fit 1 new O ring seal, making sure it is correctly fitted. Grease the O ring seal and the shaft seal lips.

9

Fit the retaining ring with a centre punch.

10

Check that the retaining ring is properly in its housing.

5

CYLINDER HEAD/SEALS

6

11

Mark the position of the cylinder head on the body (see arrow).

Remove the mounting screw.

12

Swivel the cylinder head around the centring pin and remove.

13

Mark the position of the centring pin (see arrow).

14

Pump : Righthand rotation (viewing the face on the spherical surface side)

15

Pump : Lefthand rotation (viewing the face on the spherical surface side)

CYLINDER HEAD/SEALS

16

Engine : 2 rotation directions (viewing the face on the spherical surface side)

17

Visually inspect : O ring seal (1) groove (2) cylinder head (3)

18

Fit the seal after first lightly greasing it.

19

Reassemble the cylinder head in its former position (Fig. 11). Take care with the position of the face.

20

Reassemble the screw to the required torque see P.14

7

DISASSEMBLING THE ROTOR

8

21

Remove the cylinder head (page 6). Turn and remove the control plate.

22

Disassemble the locking ring (page 4).

23

Remove the shims.

24

Disassemble the rotor with a puller (Fig. 50).

25

Remove the retainer plate, the screws are held with loctite

INSPECTION OF THE COMPONENTS

26

Drive shaft 1) No corrosion or erosion. No damage at the splines.

2) No signs of wear, no scratches (fig. 7).

3) No cuts, bumps or pitting

27

1) Piston end play 2) Thrust collar

28

Pistons No marks, no pitting (Do not disassemble the articulation).

29

Centring head.

1) No marks, no pitting (Do not disassemble the articulation) 2) No marks

30

Retainer plate No marks or wear

9

INSPECTION OF THE COMPONENTS

10

31

Cylinder block /Control plate 1) Bore with no marks or wear.

2) Faces, smooth and flat, with no marks or markings 3) Min hardness 700 HV 10.

32

Housing No damage or wear on the bearing radiuses.

33

Change the piston unit.

When other components need changing, recalibration is necessary.

34

Cylinder block and control plate to be changed as a pair.

35

Insert a locating pin with retainer.

Fit the retainer plate correctly.

ROTOR ASSEMBLY

36

Use a little loctite for the screw only.

37

Use grease to fit the pads and the Belleville washer (use a screwdriver).

38

Ensure that all the parts are correctly assembled.

39

Assemble the pistons

40

Press firmly on the pistons in the cup with the cylinder block held in a central position.

11

ROTOR ASSEMBLY

41

Tip over the cylinder block to Max (Fig. 40) Fix the assembling tool, the shipping protector (Fig. 51).

42

Is it a new seal?

(Comparison with Fig. 7)

43

Heat the housing to 80° C Arrangement fig. 52

44

Assemble the preheated housing.

Use a holed plate to simplify the operation.

The assembling tool (fig. 51) protrudes from the housing when the rotor is fitted.

45

Fit the shim and assemble Fig. 7 - 10

et - ou

12

ROTOR ASSEMBLY

46

Push the rotor up against the locking ring.

Check that the locking ring does not move.

47

Remove the assembling tool.

48

Complete assembly (see Fig. 18 - 20)

49

Fit the caps to protect from dust.

Protection against (internal / external) corrosion

50

Puller for rotor.

13

TOOLING / TIGHTENING TORQUE

51

Protector / assembling tool.

52

Heating device.

53

Tightening torque Threading M6 M8 M 10 M 12 M 16

14

Torque Nm 9,8 24,0 48,0 84,0 206,0

Size SW 4 SW 6 SW 8 SW 10 SW 12

ADJUSTING THE HYDROSTATIC PUMP 150 ATS 75-8-5-M.54 EN

11 / 2001

ADJUSTING THE A10VG HYDROSTATIC PUMP - Tools required

Fig. A 1

• 1 tachometer ............................................490165 • 1 pressure sensor .................................477484 • 1 manometer .............................................58179 - Install the tachometer Ref. 490165 in the cradle.

- Install the pressure sensor Ref. 477484 (2) (see Fig. B) and the manometer Ref. 58179 (3) (Fig. B). No. 6 hex spanner (stopper connector) and No. 17 spanner (pressure sensor) required.

- Insert the hooks in the anchoring points C provided for this purpose (Fig. C).

Fig. B

- Start up the cradle.

3

- Read off the motor rotation speed on the tachometer = 1200 rpm ± 20 - If required adjust the settings crew 4 (Fig. D) using a No. 10 spanner B

- Move the cradle until there is tension on the belt. Hold the control lever forwards.

- Read off the pressure on the manometer = 330 bars ± 10.

5

- If required, adjust the regulator 5 (Fig. B) with a No. 13 spanner (counternut) and a No. 4 hex spanner (setting screw).

Fig. C

C

Fig. D

4

-1-

2

ASSEMBLY 80

ELECTRICITY

REPLACING THE ELECTRONICS BOARD AND THE MICROPROCESSOR 150 ATS 80-2-10-M.54 EN

11 / 2001

REPLACING THE ELECTRONIC BOARD AND THE MICROPROCESSOR A

REPLACING THE ELECTRONICS BOARD - Disconnect the electrical supply.

2

- Open the right-hand turret casing.

- Open the electrical cabinet.

1

- Disconnect the 16 connectors 1 (Fig. A) - Remove the 4 fixing screws.

- Replace the electronics board 2 (Fig. A).

NB: The electronics board is supplied without a microprocessor. You must remove this from the old board or, if required, order a new one. To install it, follow the instructions below.

REPLACING THE MICROPROCESSOR

B

- This operation must be carried out carefully since the microprocessor’s pins are very fragile.

- Lift one side of the microprocessor 3 (Fig. B) using a small screwdriver 4 (Fig. B).

4 3

- Finish releasing it by taking hold of it with your fingers and gently pulling it towards you (put your thumbs behind it to avoid dropping it).

- Before installing it, carefully check the direction for installing it. The (semicircular) insert 5 (Fig. C) on the microprocessor must match up with the notch 6 (Fig. C) screen printed onto the electronics board.

- Align the microprocessor and gently engage the bottom pins in the housing.

C

- Then tilt the microprocessor upwards and push in the upper pins - Complete the operation by exerting gentle pressure with your thumbs NB: When ordering a microprocessor, also indicate, in addition to the MANITOU reference, the complete designation inscribed on the microprocessor.

E.g.: MAN 6.4.3 10/07/95

6

5

-1-

POSITION OF THE SENSORS 150 ATS 80-8-81-M.54 EN

11 / 2001

POSITION OF THE SENSORS

Foot contact sensor: dead man’s pedal

Basket overload detection sensor

“Telescope folded” detection sensor

“Arm 4 folded” detection sensor

“Arm 2 folded” detection sensor

Reach sensor

Fuel level sensor

Motor compartment: water temperature, oil pressure and air filter clogging sensors

-1-

MAIN ELECTRICAL CABINET 150 ATS 80-8-82-M.54 EN

11 / 2001

MAIN ELECTRICAL CABINET

Card 1 (21) : all or nothing components control card comprising 25 logic inputs with visualisation via LEDs (marked A to Y) and 23 outputs via mechanical relay with visualisation via LEDs (R1 to R23). A programmed micro-controller (30) provides the operating logic (version of the MAN X.X program). When the “RUN” LED flashes, this indicates that the card is functioning correctly..

Card 2 (29) : proportional components control card controlling 4 proportional electro-valves (hydrostatic pump and DANFOSS PVG32 electro-valve) and the manipulator. It comprises 18 logic inputs and 2 outputs via mechanical relay. 3 fuse protect the card. An EPROM-type memory (34) provides the operating logic (version of the CIMM VX program). When the “RUN” LED flashes, this indicates that the card is functioning correctly.

Card 3 (24) : fuse card. 6 fuses protect card 1 (inputs and outputs) the card also has a motor starting relay (28).

-1-

INDEX

A – CARD 1 : ALL OR NOTHING ............................................................................

4

A1 - Layout ...................................................................................................................

4

A2 - Assignment of the input/output LEDs...............................................................

5

A3 - Table of the LED’s statuses according to movement ....................................

6

B – CARD 2 : PROPORTIONAL .............................................................................. 23 B1 - Layout ................................................................................................................... 23

C – CARD 3 : FUSES ................................................................................................. 24 C1 - Layout ................................................................................................................... 24

D – GENERAL ELECTRICAL LAYOUT ................................................................... 25 D1 - Main layout ........................................................................................................... 25 D2 - Electrical circuit – Parts catalogue ................................................................... 26

-2-

A - CARD 1: ALL OR NOTHING A1 - Layout

v 12 m3 v9

EV, max. motor rpm (R19)

Emergency stop,base EV, motor injection Basket control C8

C7

C6

C5

15 14

Flashing light (R17)

BASKET +12V — Emergency stop — thermal motor fault

R17 R16 R23

R13

R22

EV brake x 2 (R11)

R21

R14

R20

EV, differential lock (R13)

R19

R18

R15

v 28 v 29

R12 R11

R9 R8

RUN

v 24 v 25 v 26

MICRO W.517700-803

R10 +12V for relays - R14 - R17 - R19 - R20 +12V for relays - R7 to R13 +12V for relays - R1 to R6

R7

v 20 v 20 v 20

R6 R5

EV, tilt EV, direction EV, basket rotation EV, turret rotation EV, telescope EV, arm 3 EV, arm 2 EV, arm 1

ro 32/34 n1/ro 9 ro 8 ro 30/7 ro 6 n1/ro5 ro 4 ro 3 ro 2 ro 1

Y X W V U T S R Q P O N

30

v 53 13 12 11 10

M L

R4

9 8 7 6 5 4 3 2 1

K J I H G F E D C B A

R3 R2 R1

C1

3

v8 v7 v6 v5 v4 v3 v2

v1

1 2

1 2

v 27 v 30

Overload (card 2 — I15) Regulation OK (card 2 — S1) Slope (card 2 — I2)

+12V- base/basket control selector

Arm 2 selector Arm 3 selector Telescope selector Telescope selector Lower/retract button

Arm 1 selector

+12V Low arm LS

+12V Arm 3 LS

+12V - Card 3 — Fuse F6

Card 2 — I7 — arm 1 Card 2 — I8 — arm 2 Card 2 — I9 — arm 3 Card 2 — I10 — telescope Card 2 — I11 — turret rotation Card 2 — I12 — basket rotation Card 2 — I13 — direction Card 2 — I14 — tilt

R14 — arm low (card 2 — I4)

BASE

-3-

C13

C14

215681

2

+12V- Card 3 — Fuse 5

Output to audible vibrator (R20)

Differential lock button Overload safety Basket tilt/rotation selector Telescope/turret selector +12V Arm 3/turret selector Arm 2/turret selector Arm 1/turret selector Transfer/direction selector Max. motor rpm selector Tilt authorisation button

+12V - slope sensor Slope

A2 - Assignment of the input/output LEDS

ABBREVIATION AND ASSIGNMENT OF THE OUTPUT RELAYS AND LEDS

ABBREVIATION AND ASSIGNMENT OF THE INPUT LEDS

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 R22

A B C D E F G H I J K L M N O P Q R S T U V W X Y

= = = = = = = = = = = = = = = = = = = = = =

EV ARM 1 EV ARM 2 EV ARM 3 EV TELESCOPE EV TURRET ROTATION EV BASKET ROTATION EV DIRECTION EV TILT SPARE SPARE EV BRAKE X 2 SPARE EV DIFFERENTIAL LOCK RAPID ARM LOWERING SPEED SPARE SPARE FLASHING LIGHT SPARE EV MOTOR MAX. REVS AUDIBLE VIBRATOR SPARE CANCELLATION OF BASKET EMERGENCY STOP R23 = SPARE

-4-

= = = = = = = = = = = = = = = = = = = = = = = = =

SLOPE SENSOR FC ARM 3 FC ARM DOWN BASE SELECTOR ARM 1 BASE SELECTOR ARM 2 BASE SELECTOR ARM 3 BASE SELECTOR TELESCOPE BASE RAISE/EXTEND BUTTON BASE LOWER.RETRACT BUTTON BASKET CONTROL SPARE SPARE TILT AUTHORISATION BUTTON MAX. MOTOR REVS SELECTOR TRANSFER/DIRECTION SELECTOR TURRET SELECTOR ARM 1 TURRET SELECTOR ARM 2 TURRET SELECTOR ARM 3 TURRET SELECTOR TELESCOPE BASKET ROTATION/TILT SELECTOR OVERLOAD SAFETY DIFFERENTIAL LOCK BUTTON SPEED REGULATION OK BOARD SPARE SPARE

A3 - Table of the LED’s statuses according to movement on the “All or nothing” card

TABLEAUOF D'ETAT PAR MOUVEMENT POSSIBLE 8.3 DU 01.04.98 TABLE THE DES LEDSLEDS STATUSES ACCORDING TO REF.MICRO POSSIBLEMAN MOVEMENT REF. MICRO_MAN 8.3 OF 01.04.98 Electro-valve Electro-valve

INPUT ENTREEC1 CI

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

Y

Commande Base Base control

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Commande Panier Basket control

OUTPUT SORTIE CIC1

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 X

X

X

X

X

X

X

X

X

X

0 = Led éteinte pour avoir le mouvement 0 = LED out to have movement 1 = Led platine allumée pour avoir le mouvement 1 = Board LED lit to have movement X = Pas de prise en compte de l'état 0-1 pour avoir le mouvement X = No status 0-1 taken into account to have movement

-5-

X

X

X

X

X

X

X

X

X

X

X

TABLEAUOFD'ETAT DES LEDS PAR MOUVEMENT POSSIBLE REF.MICRO MAN 8.3 DU 01.04.98 TABLE THE LEDS STATUSES ACCORDING TO POSSIBLE MOVEMENT REF. MICRO_MAN 8.3 OF 01.04.98 Electro-valve bras 1 Arm 1 electro-valve

INPUT ENTREEC1 CI

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

Y

Commande Base Base control

X

X

X

1

0

0

0

1

X

0

X

X

X

X

X

X

X

X

X

X

1

X

1

X

X

X

X

X

1

0

0

0

X

1

0

X

X

X

X

X

X

X

X

X

X

1

X

1

X

X

Basket control Commande Panier

X

X

X

X

X

X

X

X

X

1

X

X

X

X

0

1

0

0

0

0

1

X

1

X

X

OUTPUT SORTIE CIC1

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 1

X

X

X

X

X

X

X

X

X

Ledout éteinte pourmovement avoir le mouvement 00 = =LED to have 11 = =Board Led platine allumée avoir le mouvement LED lit to havepour movement X = Pas de prise en compte de l'état to0-1have pourmovement avoir le mouvement X = No status 0-1 taken into account

-6-

X

X

X

X

X

X

X

X

X

X

X

TABLEAUOFD'ETAT DES LEDS PAR MOUVEMENT POSSIBLE REF.MICRO MAN 8.3 DU 01.04.98 TABLE THE LEDS STATUSES ACCORDING TO POSSIBLE MOVEMENT REF. MICRO_MAN 8.3 OF 01.04.98 Electro-valve bras 2 Arm 2 electro-valve

INPUT ENTREEC1 CI

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

Y

Commande Base Base control

X

X

X

0

1

0

0

1

X

0

X

X

X

X

X

X

X

X

X

X

1

X

1

X

X

X

X

X

0

1

0

0

X

1

0

X

X

X

X

X

X

X

X

X

X

1

X

1

X

X

Basket control Commande Panier

X

X

X

X

X

X

X

X

X

1

X

X

X

X

0

0

1

0

0

0

1

X

1

X

X

OUTPUT SORTIE CIC1

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 X

1

X

X

X

X

X

X

X

X

Ledout éteinte pourmovement avoir le mouvement 00 = =LED to have Led platine avoir le mouvement 11 = =Board LED litallumée to havepour movement de prise en compte de l'état to0-1have pourmovement avoir le mouvement XX = =NoPasstatus 0-1 taken into account

-7-

X

X

X

X

X

X

X

X

X

X

X

TABLEAUOFD'ETAT DES LEDS PAR MOUVEMENT POSSIBLE REF.MICRO MAN 8.3 DU 01.04.98 TABLE THE LEDS STATUSES ACCORDING TO POSSIBLE MOVEMENT REF. MICRO_MAN 8.3 OF 01.04.98 Electro-valve bras 3 Arm 3 electro-valve

INPUT ENTREEC1 CI

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

Y

Commande Base Base control

X

X

X

0

0

1

0

1

X

0

X

X

X

X

X

X

X

X

X

X

1

X

1

X

X

X

X

X

0

0

1

0

X

1

0

X

X

X

X

X

X

X

X

X

X

1

X

1

X

X

Basket control Commande Panier

X

X

X

X

X

X

X

X

X

1

X

X

X

X

0

0

0

1

0

0

1

X

1

X

X

OUTPUT SORTIE CIC1

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 X

X

1

X

X

X

X

X

X

X

Led out éteinte pourmovement avoir le mouvement 00 ==LED to have 11 ==Board Led platine allumée avoir le mouvement LED lit to havepour movement XX ==No Passtatus de prise en compte de l'état to 0-1have pourmovement avoir le mouvement 0-1 taken into account

-8-

X

X

X

X

X

X

X

X

X

X

X

TABLEAUOFD'ETAT DES LEDS PAR MOUVEMENT POSSIBLE REF.MICRO MAN 8.3 DU 01.04.98 TABLE THE LEDS STATUSES ACCORDING TO POSSIBLE MOVEMENT REF. MICRO_MAN 8.3 OF 01.04.98 Electro-valveelectro-valve Telescopique Telescope

INPUT ENTREEC1 CI

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

Y

Commande Base Base control

X

X

X

0

0

0

1

1

X

0

X

X

X

X

X

X

X

X

X

X

1

X

1

X

X

X

X

X

0

0

0

1

X

1

0

X

X

X

X

X

X

X

X

X

X

1

X

1

X

X

Basket control Commande Panier

X

X

X

X

X

X

X

X

X

1

X

X

X

X

0

0

0

0

1

0

1

X

1

X

X

OUTPUT SORTIE CIC1

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 X

X

X

1

X

X

X

X

X

X

Led out éteinte pourmovement avoir le mouvement 00 ==LED to have 11 ==Board Led platine allumée avoir le mouvement LED lit to havepour movement XX ==No Passtatus de prise en compte de l'état to 0-1have pourmovement avoir le mouvement 0-1 taken into account

-9-

X

X

X

X

X

X

X

X

X

X

X

TABLEAUOFD'ETAT DES LEDS PAR MOUVEMENT POSSIBLE REF.MICRO MAN 8.3 DU 01.04.98 TABLE THE LEDS STATUSES ACCORDING TO POSSIBLE MOVEMENT REF. MICRO_MAN 8.3 OF 01.04.98 Electro-valve Tourelle Turret rotationRotation electro-valve

INPUT ENTREEC1 CI

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

Y

Commande Base Base control

X

X

X

0

0

0

0

1

X

0

X

X

X

X

X

X

X

X

X

X

X

X

1

X

X

X

X

X

0

0

0

0

X

1

X

X

X

X

X

X

X

X

X

X

X

X

X

1

X

X

X

X

X

X

X

X

X

X

X

1

X

X

X

X

X

1

X

X

X

0

1

X

1

X

X

X

X

X

X

X

X

X

X

X

1

X

X

X

X

X

X

1

X

X

0

1

X

1

X

X

X

X

X

X

X

X

X

X

X

1

X

X

X

X

X

X

X

1

X

0

1

X

1

X

X

X

X

X

X

X

X

X

X

X

1

X

X

X

X

X

X

X

X

1

0

1

X

1

X

X

Basket control Commande Panier

OUTPUT SORTIE CIC1

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 X

X

X

X

1

X

X

X

X

X

Led out éteinte pourmovement avoir le mouvement 00 ==LED to have 11 ==Board Led platine allumée avoir le mouvement LED lit to havepour movement XX ==No Passtatus de prise en compte de l'état to 0-1have pourmovement avoir le mouvement 0-1 taken into account

-10-

X

X

X

X

X

X

X

X

X

X

X

TABLEAUOFD'ETAT DES LEDS PAR MOUVEMENT POSSIBLE REF.MICRO MAN 8.3 DU 01.04.98 TABLE THE LEDS STATUSES ACCORDING TO POSSIBLE MOVEMENT REF. MICRO_MAN 8.3 OF 01.04.98 Electro-valve Rotation Panier Basket rotation electro-valve

INPUT ENTREEC1 CI

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

Y

Base control Commande Base

X

X

X

X

X

X

X

X

X

1

X

X

X

X

0

0

0

0

0

1

1

X

1

X

X

OUTPUT SORTIE CIC1

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 X

X

X

X

X

1

X

X

X

X

Ledout éteinte pourmovement avoir le mouvement 00 = =LED to have 1 = Led platine allumée avoir le mouvement 1 = Board LED lit to havepour movement X = Pas de prise en compte de l'état to0-1have pourmovement avoir le mouvement X = No status 0-1 taken into account

-11-

X

X

X

X

X

X

X

X

X

X

X

TABLEAUOFD'ETAT DES LEDS PAR MOUVEMENT POSSIBLE REF.MICRO MAN 8.3 DU 01.04.98 TABLE THE LEDS STATUSES ACCORDING TO POSSIBLE MOVEMENT REF. MICRO_MAN 8.3 OF 01.04.98 Electro-valve Direction Direction electro-valve

INPUT ENTREEC1 CI

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

Y

Base control Commande Base

X

X

X

X

X

X

X

X

X

1

X

X

X

X

1

0

0

0

0

0

1

X

1

X

X

OUTPUT SORTIE CIC1

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 X

X

X

X

X

X

1

X

X

X

Led out éteinte pourmovement avoir le mouvement 00 ==LED to have 11 ==Board Led platine allumée avoir le mouvement LED lit to havepour movement XX ==No Passtatus de prise en compte de l'état to 0-1have pourmovement avoir le mouvement 0-1 taken into account

-12-

X

X

X

X

X

X

X

X

X

X

X

TABLEAUOFD'ETAT DES LEDS PAR MOUVEMENT POSSIBLE REF.MICRO MAN 8.3 DU 01.04.98 TABLE THE LEDS STATUSES ACCORDING TO POSSIBLE MOVEMENT REF. MICRO_MAN 8.3 OF 01.04.98 Electro-valve Inclinaison Tilt electro-valve

INPUT ENTREEC1 CI

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

Y

Base control Commande Base

X

X

X

X

X

X

X

X

X

1

X

X

1

X

0

0

0

0

0

1

1

X

1

X

X

OUTPUT SORTIE CIC1

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 X

X

X

X

X

X

X

1

X

X

Ledout éteinte pourmovement avoir le mouvement 00= =LED to have 1 = Led platine allumée avoir le mouvement 1 = Board LED lit to have pour movement X = Pas de prise en compte de l'étatto0-1have pourmovement avoir le mouvement X = No status 0-1 taken into account

-13-

X

X

X

X

X

X

X

X

X

X

X

TABLEAUOFD'ETAT DES LEDS PAR MOUVEMENT POSSIBLE REF.MICRO MAN 8.3 DU 01.04.98 TABLE THE LEDS STATUSES ACCORDING TO POSSIBLE MOVEMENT REF. MICRO_MAN 8.3 OF 01.04.98 Electro-valve Direction Crabe Sideways direction electro-valve

INPUT ENTREEC1 CI

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

Y

Base control Commande Base

X

X

X

X

X

X

X

X

X

1

0

1

X

X

1

0

0

0

0

0

1

X

X

X

X

OUTPUT SORTIE CIC1

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 X

X

X

X

X

X

X

X

1

X

Ledout éteinte pourmovement avoir le mouvement 00= =LED to have 1 = Led platine allumée avoir le mouvement 1 = Board LED lit to have pour movement X = Pas de prise en compte de l'étatto0-1have pourmovement avoir le mouvement X = No status 0-1 taken into account

-14-

X

X

X

X

X

X

X

X

X

X

X

TABLE THE LEDS STATUSES ACCORDING TO POSSIBLE MOVEMENT REF. MICRO_MAN 8.3 OF 01.04.98 TABLEAUOFD'ETAT DES LEDS PAR MOUVEMENT POSSIBLE REF.MICRO MAN 8.3 DU 01.04.98 Electro-valve 4 roues 4WD directionDirection electro-valve

INPUT ENTREEC1 CI

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

Y

Base control Commande Base

X

X

X

X

X

X

X

X

X

1

1

0

X

X

1

0

0

0

0

0

1

X

X

X

X

OUTPUT SORTIE CIC1

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 X

X

X

X

X

X

X

X

X

1

Ledout éteinte pourmovement avoir le mouvement 00 = =LED to have Led platine avoir le mouvement 11 = =Board LED litallumée to havepour movement X = Pas de prise en compte de l'état to0-1have pourmovement avoir le mouvement X = No status 0-1 taken into account

-15-

X

X

X

X

X

X

X

X

X

X

X

TABLE THE LEDS STATUSES ACCORDING TO POSSIBLE MOVEMENT REF. MICRO_MAN 8.3 OF 01.04.98 TABLEAUOFD'ETAT DES LEDS PAR MOUVEMENT POSSIBLE REF.MICRO MAN 8.3 DU 01.04.98 Electro-valve Frein Brake electro-valve

INPUT ENTREEC1 CI

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

Y

Base control Commande Base

1

X

X

X

X

X

X

X

X

1

X

X

X

X

1

0

0

0

0

0

1

X

1

X

X

X

1

1

X

X

X

X

X

X

1

X

X

X

X

1

0

0

0

0

0

1

X

1

X

X

OUTPUT SORTIE CIC1

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 X

X

X

X

X

X

X

X

X

X

Ledout éteinte pourmovement avoir le mouvement 00 ==LED to have 11 ==Board Led platine allumée avoir le mouvement LED lit to havepour movement XX ==NoPasstatus de prise en compte de l'état to 0-1have pourmovement avoir le mouvement 0-1 taken into account

-16-

1

X

X

X

X

X

X

X

X

X

X

TABLE THE LEDS STATUSES ACCORDING TO POSSIBLE MOVEMENT REF. MICRO_MAN 8.3 OF 01.04.98 TABLEAUOFD'ETAT DES LEDS PAR MOUVEMENT POSSIBLE REF.MICRO MAN 8.3 DU 01.04.98 Electro-valveelectro-valve Oscillation Oscillation

INPUT ENTREEC1 CI

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

Y

Base control Commande Base

X

1

1

X

X

X

X

X

X

1

X

X

X

X

1

0

0

0

0

0

1

X

X

X

X

OUTPUT SORTIE CIC1

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 X

X

X

X

X

X

X

X

X

X

0 ==LED Led out éteinte pourmovement avoir le mouvement to have 1 ==Board Led platine allumée avoir le mouvement LED lit to havepour movement X ==No Passtatus de prise en compte de l'état to 0-1have pourmovement avoir le mouvement 0-1 taken into account

-17-

X

1

X

X

X

X

X

X

X

X

X

TABLEAUOFD'ETAT DES LEDS PAR MOUVEMENT POSSIBLE REF.MICRO MAN 8.3 DU 01.04.98 TABLE THE LEDS STATUSES ACCORDING TO POSSIBLE MOVEMENT REF. MICRO_MAN 8.3 OF 01.04.98 Electro-valve lock Blocage différentiel Differential electro-valve

INPUT ENTREEC1 CI

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

Y

Base control Commande Base

1

X

X

X

X

X

X

X

X

1

X

X

X

X

1

0

0

0

0

0

1

1

X

X

X

X

1

1

X

X

X

X

X

X

1

X

X

X

X

1

0

0

0

0

0

1

1

X

X

X

OUTPUT SORTIE CIC1

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 X

X

X

X

X

X

X

X

X

X

Led out éteinte pourmovement avoir le mouvement 00 ==LED to have 11 ==Board Led platine allumée avoir le mouvement LED lit to havepour movement XX ==No Passtatus de prise en compte de l'état to 0-1have pourmovement avoir le mouvement 0-1 taken into account

-18-

X

X

1

X

X

X

X

X

X

X

X

TABLEAUOFD'ETAT DES LEDS PAR MOUVEMENT POSSIBLE REF.MICRO MAN 8.3 DU 01.04.98 TABLE THE LEDS STATUSES ACCORDING TO POSSIBLE MOVEMENT REF. MICRO_MAN 8.3 OF 01.04.98 Vitesse arm rapide bras basspeed Rapid lowering

INPUT ENTREEC1 CI

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

Y

Base control Commande Base

X

1

1

X

X

X

X

X

X

1

X

X

X

X

1

0

0

0

0

0

1

X

X

X

X

OUTPUT SALIDA CIC1

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 X

X

X

X

X

X

X

X

X

X

Ledout éteinte pourmovement avoir le mouvement 00 = =LED to have 11 = =Board Led platine allumée avoir le mouvement LED lit to havepour movement X = Pas de prise en compte de l'état to0-1have pourmovement avoir le mouvement X = No status 0-1 taken into account

-19-

X

X

X

1

X

X

X

X

X

X

X

TABLE THE LEDS STATUSES ACCORDING TO POSSIBLE MOVEMENT REF. MICRO_MAN 8.3 OF 01.04.98 TABLEAUOFD'ETAT DES LEDS PAR MOUVEMENT POSSIBLE REF.MICRO MAN 8.3 DU 01.04.98 Girophare light Flashing

INPUT ENTREEC1 CI

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

Y

Base control Commande Base

1

X

X

X

X

X

X

X

X

1

X

X

X

X

1

0

0

0

0

0

1

X

X

X

X

X

1

1

X

X

X

X

X

X

1

X

X

X

X

1

0

0

0

0

0

1

X

X

X

X

OUTPUT SORTIE CIC1

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 X

X

X

X

X

X

X

X

X

X

Ledout éteinte pourmovement avoir le mouvement 00 ==LED to have 11 ==Board Led platine allumée avoir le mouvement LED lit to havepour movement X = Pas de prise en compte de l'état to0-1have pourmovement avoir le mouvement X = No status 0-1 taken into account

-20-

X

X

X

X

X

X

1

X

X

X

X

TABLE THE LEDS STATUSES ACCORDING TO POSSIBLE MOVEMENT REF. MICRO_MAN 8.3 OF 01.04.98 TABLEAUOF D'ETAT DES LEDS PAR MOUVEMENT POSSIBLE REF.MICRO MAN 8.3 DU 01.04.98 Electro-valveengine régimerevs maxielectro-valve moteur Maximum

INPUT ENTREEC1 CI

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

Y

Base control Commande Base

X

1

1

X

X

X

X

X

X

1

X

X

X

1

1

0

0

0

0

0

X

X

X

X

X

OUTPUT SORTIE CIC1

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 X

X

X

X

X

X

X

X

X

X

00 ==LED Led out éteinte pourmovement avoir le mouvement to have 11 ==Board Led platine allumée avoir le mouvement LED lit to havepour movement XX ==No Passtatus de prise en compte de l'état to 0-1have pourmovement avoir le mouvement 0-1 taken into account

-21-

X

X

X

X

X

X

X

X

1

X

X

TABLEAUOFD'ETAT DES LEDS PAR MOUVEMENT POSSIBLE REF.MICRO MAN 8.3 DU 01.04.98 TABLE THE LEDS STATUSES ACCORDING TO POSSIBLE MOVEMENT REF. MICRO_MAN 8.3 OF 01.04.98 Vibreur sonore Audible vibrator

INPUT ENTREEC1 CI

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

V

W

X

Y

Base control Commande Base

0

0

0

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

0

X

X

X

X

OUTPUT SORTIE CIC1

R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 X

X

X

X

X

X

X

X

X

X

Ledout éteinte pourmovement avoir le mouvement 00 = =LED to have Led platine avoir le mouvement 11 = =Board LED litallumée to have pour movement de prise en compte de l'étatto0-1have pourmovement avoir le mouvement XX = =NoPasstatus 0-1 taken into account

-22-

X

X

X

X

X

X

X

X

X

1

X

B - CARD 2 : PROPORTIONAL B1 - Layout

REXROTH EV ON HYDROSTATIC PUMP

1

DIGICODE V31 PREDISPOSITION CONNECTOR

m 13

PROPORTIONAL EV B 1 2

m 14 m 19

PROPORTIONAL EV A

m 15

OUTPUT TO MAIN BOARD

v 52

215681

v 53

2

FORWARD MOTION

+12 VDC v 34

ALIM

REVERSE MOTION

-12 VDC S1 REGULATION OK S1 S2 S2

v 15 v 14 m 27 ro 28 v 33 v 32 ro 43

-

31

S

DANFOSS MANIPULATOR FOR BASKET CONSOLE 23

(INPUTS)

ro 42

MOVEMENT

ro 41

SELECTION

ro 40 ro 39

LATERAL

ro 38

+

24

ro 36/n 1

S

ro 37

25

v 51

26

LONGITUDINAL

I1 BASE CONTROL I2 SLOPE I3 MAX. RPM I4 ARM LOW I5 RAISING BUTTON I6 LOWERING BUTTON I7 ARM 1 I8 ARM 2 I9 ARM 3 I10 TELESCOPE I11 TURRET ROTATION I12 BASKET ROTATION I13 DIRECTION I14 TILT I15 OVERLOAD I16

27 I17 I18

m 14 m 15 31 25 27

26 24

ro 10/10 ro 23

2

PROPORTIONAL EV LATERAL AXIS

= TURRET ROTATION = BASKET ROTATION = DIRECTION

ro 23 ro 10 ro 21

2

ro 21 ro 10 ro 22

PROPORTIONAL EV LONGITUDINAL AXIS 1

1

ro 22

DANFOSS PVG32 32 DANFOSS PVG

= ARMS 1-2-3 = TELESCOPE = TILT

-23-

-12 VDC LONG. SELECTOR Contact LAT. SELECTOR +12 VDC + Manip CONTROL + CONTROL LONG. LAT.

DANFOSS EV (3<6>9V)

ro 21/21

FORWARD

DANFOSS MANIP.

23

CONTROL REVERSE

REXROTH EV (0.4>1.15A)

m 13

C - CARD 3 : FUSES C1 - Layout F1 : supply to base motor fault indicator. Emergency stop.

F2 : supply to relays R1 to R6, card 1 F3 : supply to relays R7 to R13, card 1 F4 : supply to relays R14 to R17 and R19 & 20, card 1 F5 : supply to inputs, card 1, and axle alignment detector & alternator excitation F6 : supply to card 1 RD : starter relay, motor

F1 F2 F3 F4 F5 F6

: : : : : :

10 A 10 A 10 A 10 A 3.15 A 1A

+ battery after : Start signal, motor (basket)

NEMAN position 1 NEMAN position 2

Motor fault indicator, basket (-)

Supply to card 2

Clock advance

Starter signal

Motor start-up signal NEMAN position3

Alternator excitation

Supply to card 1-C18

Motor temperature signal + indicator

Supply to inputs, card 1C10

Air filter clogging signal + indicator

Supply to relays R14 R17 and R19, R20 card 1-C3

Supply to motor/base fault

Supply to relays R7 R13 card 1-C3

Supply to motor/base fault indicators + emergency stops Supply to relays R1 to R6, card 1 – C3

-24-

C - GENERAL ELECTRICAL LAYOUT D1 - Main layout

-25-

EV, MAX. MOTOR RPM +

m1 m 2/27 m4

2

ro 11 ro 14

ro 14 ro 11

ro 16 ro 11

v 26 EV, DIFF. LOCK

EV, BRAKE

v 20

v 20

v 20

ro 32/34

ro 8/37

ro 7/30

ro 6/38

ro 5/39

ro 3/41

ro 2/42 n1

ro 1/43 n2

J/V = YELLOW/GREEN

EV, TILT TANK

ro 9/36

N = BLACK G= GREY

WIRE COLOUR ABBREVIATIONS

v 25 V= VIOLET R= RED

ro 6 ro 35 ro 5 ro 34/35 ro 8 ro 33 ro 1 ro 32/33 ro 2 ro 31 ro 3 ro 30/31 ro 4 ro 29 ro 9 ro 7/29

PROPORTIONAL EV, LONGITUDINAL AXIS

n2

EV, BASKET ROTATION EV, TURRET ROTATION

EV, DIRECTION

EV, ARM 1

EV, ARM 2

EV, ARM 3

ro 21 ro 10 ro 22

EV, TELESCOPE

EV, TILT

= TURRET ROTATION = BASKET ROTATION = DIRECTION

ro 23 ro 10 ro 21

PROPORTIONAL EV,

LONGITUDINAL AXIS

= ARMS 1-2-3 = TELESCOPE = TILT

v 34

v 52

v 53

v 15

v 14

m 27

ro 28

v 33

v 32

ro 43

ro 42

ro 41

ro 40

ro 39

ro 38

ro 37

ro 36/n 1

v 51

m 13

m 14

31

m 15

25

27

23

26

24

ro 21/21

ro 10/10

ro 23

ro 22

+12 VDC

I1

ARM DOWN

SLOPE

BASE CON

REG. OK

-12 VDC

S1

S1

S2

I2

MAX. REVS

S2

I3

I7

I6

ARM 3

ARM 2

ARM 1

LOWER BUTON

RAISE BUTON

I4

I8

I5

I9

TURRET ROT.

I12 BASKET ROT

I11

I10 TELESCOPE

I13 DIRECTION

I14 TILT

I15 OVERLOAD

I16

I17

I18

Com

REAR

FRONT

-12 VDC

Contact

S Long

+12 VDC

S late

+ Manip

Com +

Com -

Long

Late

EV DANFOSS (3<6>9V)

RAPID ARM LOWERING SPEED

ro 11

ro 11

M = BROWN B = WHITE

MANIPULATOR DANFOSS

SPARE

EV REXROT (0.4>1.15A)

R14 =

SPARE

ro 20

R15 =

SPARE

FLASHING LIGHT EV, MAX. MOTOR RPM

R16 =

R19 =

ro 28

ro 14/14

ro 16

CANCELLATION OF BASKET EMERGENCY STOP

SPARE

R17 =

jvt 16 R18 =

FUEL GAUGE

EV, BRAKE

1 AUDIBLE VIBRATOR

ALIM

m 12

bc 17

bc 10

bc 9

m8

m 11

m 12

m1 jvt 16

bc 10

m7

m5

AIR FILTER CLOGGING

D

MOTOR OIL PRESSURE

G

n

m6

ALTERNATOR

STARTER

+ n m3 m 21

m 11

m 15

m 19

m 14

m 13

bc 18

m 20 T¿ m 21

m 22

MOTOR WATER TEMPERATURE

-

B

A

2 -

R20 =

SPARE

ro 4/40 1 2

1 + FLASHING LIGHT R21 = R22 = R23 =

-26-

BATTERY BATTERY CUTOUT

EV, MOTOR INJECTION

COLD START ELECTRO-VALVE

PRE-HEATER

PROPORTIONAL EV, REVERSE MOTION PROPORTIONAL EV, FORWARD MOTION

ABBREVIATION AND ASSIGNMENT OF THE OUTPUT RELAYS AND LEDS

R1 = EV, ARM 1 R2 = EV, ARM 2 R3 = EV, ARM 3 R4 = EV, TELESCOPE R5 = EV, TURRET ROTATION R6 = EV, BASKET ROTATION R7 = EV, DIRECTION

R10 = SPARE

R9 = SPARE

R8 = EV, TILT

R12 = SPARE

R11 = EV, BRAKE X 2

2 1

n R13 = EV, DIFFERENTIAL LOCK

1 2

1 1 2 2

ro 11

v 24

OF THE INPUT LEDS

ABBREVIATION AND ASSIGNMENT

A = SLOPE SENSOR

v 21

B = LS, ARM 3

v 98

C = LS, ARM DOWN

1

v 21

v 53

v 31

m7

v 21

D = BASE SELECTOR ARM 1

v 28/22

E = BASE SELECTOR ARM 2

v 25

3

6

C4

F1 F2 F3 F4 F5 F6

FUSE BOARD

1

v 24

F = BASE SELECTOR ARM 3

m 30

G = BASE SELECTOR TELESCOPE

RD

C3

6

v 26

+

1

m 5/25

H = BASE RAISE/EXTEND BUTTON 2

C2

v 53

v 23

3

v 27

1

v 97

C1

m 4/24

I = BASE LOWER.RETRACT BUTTON

Brown

m 23

J = BASKET CONTROL

bc 18

-

bc 36

S

v 10/11/13

+

MOTOR OIL PRESSURE INDICATOR

EMERGENCY STOP

AIR FILTER CLOGGING INDICATOR

BASKET CONTROL

BASE CONTROL

ARM 2 SELECTOR ARM 3 SELECTOR

TEELSCOPE BUTTON

RAISE/EXTEND BUTTON

Blue

LOW ARM LS

LOWER/RETRACT BUTTON

1

ARM 1 SELECTOR

TURRET SELECTOR

2

m 6/26

ARM M3 LS

m8

ANGLE OF INCLINATION DETECTOR

Blue

19 Brown Black

21 Black

1

2

16

NEMAN

3 2 1 O P

518055

WATER TEMPERATURE INDICATOR

30 30 17 17 50 19 19 54 15 58

bc 17

S

m 26 m 25

v 23

1

C13

BUZZER

OVERLOAD 1

SAFETY

1

C14

m 24 v 12 v8 v7 v6 v5 v4 v3 v2

v1

v 27 v 30

bc 9

4

1

K = SPARE

B

L = SPARE

2

M = TILT AUTHORISATION BUTTON

C

N = MAX. MOTOR REVS SELECTOR

RUN

MICRO W.517700-803

1

2

1

v9 2

22 n2

O = TRANSFER/DIRECTION SELECTOR

R23 R22 R21 R20 R19 R18

C1

6

F1 = 10 AMPERES

F2 = 10 AMPERES

F3 = 10 AMPERES

F4 = 10 AMPERES

F5 = 3.15 AMPERES

pin 1 pin 2 pin 4 pin 3 pin 7 pin 6 pin 10 pin 9 pin 11 pin 12

F6 = 1 AMPERES

(+ 12V) (+ 12V)

(spare) (earth)

DIGICODE PRE-DISTRIBUTION CONNECTOR

pin 8 pin 5

-27-

3 ro 1/43

215681

v 21

4 1 D

PEDAL 1 SLOPE 1

13 2

1 ro 2/42

2

2

Black

1 1

TILT AUTHORISATION SELECTOR

3

2 E

1

2 v 14

MAX. MOTOR RPM SELECTOR

3

ro 3/41

2

2

Red

DIFFERENTIAL LOCK SELECTOR 17 3

4 F

12

White

2

TRANSFER/DIRECTION SELECTOR 4 4

18 G

g 42 3

3

TURRET/ARM1 SEELCTOR 5 5 H

P = TURRET SELECTOR ARM 1

11

TURRET/TELESCOPE SEELCTOR

5 5

9 2 A

TURRET/ARM 3 SELECTOR 6 6

Q = TURRET SELECTOR ARM 2

11

INTERNAL CONNECTION, ARM 3

11

R16

TURRET/ARM 2 SEELCTOR 7

T = BASKET ROTATION/TILT SELECTOR

12 10 N

R = TURRET SELECTOR ARM 1 13 12

v 51

U = OVERLOAD SAFETY

14 13

v 28

S = TURRET SELECTOR TELESCOPE

14 12 11

V = DIFFERENTIAL LOCK BUTTON

31 15

O

W = SPEED REGULATION OK BOARD

16 15

P

X = SPARE

16

v 20

C8

C7

CONNECTION

TO THE BASKET

R6

Y = SPARE

m3

23

R7

6

R1

17

v 20

7

ro 4/40

17 v 53

6

ro 5/39

18

Q

7

R2

18

BASKET TILT/ROTATION SELECTOR

19

R

7

AUDIBLE VIBRATOR

19

S

8

I

30

20

T

8

ro 6/38

13

21 20

R8

v 52

LATERAL

21 W

R9

BASKET CONSOLE 14

LONGITUDINAL X

v 26

8

J

24

22

U

10

R3

25

23 22

V

10

ro 7/30

DANFOS MANIPULATOR 30

23 v 29 Y

9 ro 8/37

26

24

v 24

8

STARTER BUTTON 24

v 20

K

27

25 R13

10 R4

THERMAL MOTOR FAULT 26 25

R14

9 ro 9/36

EMERGENCY STOP

26

v 25

M R5

16

27

R11

9 L ro 32/34

15

28 27

R12

v9 m2

C6

C5

15 1

19

28

R10

3

22

FUEL LEVEL 29

ro 14/14

4

18

14

30 29

ro 16

20 ro 20

CLOCK 30

R15

ABCDE

17

20

31

ro 28

1

21 31 R17 2

2 1

22 2 BUZZER

v 12

-28-

-29-

42

41 43 43

39 40

98 99 96 97 93 95 95 94 92

69

70 71

67 68

44 45

105 106 107

1

2

3

78

7 8

4 5

75

74 76 73 72 79 80 77

11 CB 326

6 10 9

108

17 11 14 16

ELECTRICITE (Détails) ELEKTRIZITÄT (Einzelteile) ELECTRICIDAD (Detalles) ELECTRICITY (Details)

102 103

101 100

12 15 13

28 30 30 29

22

88

23 25

18

27 26 27 25 24

91 89

91

90

49

50

62 64 63 61

21 21

20

19

66 65

52

85 87 86 81

48 54 55

56 58 60 59 57

104

1

2

2

05 / 02 / 01

83 84 84 82

R

OP ST

EE NT MO IE RT SO E OIT DR

55 53

51

46 47

150 ATS

P.A.O

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PARAMETERING THE MACHINE 150 ATS 80-8-84-M.54 EN

11 / 2001

PARAMETERING THE MACHINE Parametering principle All the cradle’s movements can be parametered. Three parameters define each movement:

Speed : Expressed as a percentage (%) of the total power. This parameter defines the authorised top speed. Hydraulic movement will therefore develop from 0% to the set top speed.

Gradient + : This is the acceleration gradient. An operator using the manipulator in “all or nothing” mode (zero position abruptly to maximum position) will experience a progressive acceleration according to the value defined under the “Gradient +” parameter.

Gradient - : This is the deceleration gradient. An operator using the manipulator in “all or nothing” mode (zero position abruptly to maximum position) will experience a progressive deceleration according to the value defined under the “Gradient -” parameter.

The parameters for the MANITOU cradle have been calculated in such a way as to guarantee maximum safety while offering maximum performance. The parameter table on the following page corresponds to the factory settings and must be taken as the reference when making any adjustments.

We would draw your attention to the fact that any modifications to the speed made by yourself can have serious consequences for the machine’s stability. Any such modifications are made under your sole responsibility.

-1-

-2-

-

basket

basket

basket

Direction right Direction left

Tilt in

Tilt out

-

-

-

over

over

basket

- Turret rotation (complete) - Raising/lowering base & basket

over over

Basket rotation left

-

-

over

over

Time tolerances

-

Time

basket

basket

basket

basket

basket

basket

basket

basket

basket

basket

Range

Turret rotation left

Basket rotation right

Turret rotation right

Telescope extended

Telescope retracted

Arm 3 down

Arm 3 up

Arm 2 down

Arm 2 up

Arm 1 down

Arm 1 up

basket

basket

basket

basket

Reverse motion, arm low

Slow reverse motion, arm low Reverse motion, arm raised

basket

basket

Slow forward motion, arm low

Forward motion, arm

basket

Control Manipulator Restriction (%) Gradient + Gradient -

Forward motion, arm low

Movement

Because of the repeatability of certain components, some differences in speed may be noticed (between forwards and reverse or right and left).

In this case, the machine s parameters must be specifically adjusted to achieve a balance. It is imperative that the values do not exceed : - Transfer with arms raised: 0.9 km/h

Hydraulic

Hydrostatic

Pump

Standard parameters for the EPROM V8 proportional card

Parametering list

CARD 2 PROPORTIONAL CARD

PARAMETERING TERMINAL RÉF. : 563102

Parametering terminal

-3-

Instruction manual for the parametering terminal I - STARTING

When the configuration terminal is connected to the electricity supply, an audible beep indicates that the instrument is receiving voltage. The terminal’s screen is blank and the red LED on the card flashes slowly, indicating that the configuration terminal is not in communication with the ATT 150 card.

To activate this communication, press button “O” on the terminal. The red control LED now flashes rapidly and the following message appears on the configuration terminal’s screen.

CIMM ATT 150

II - DESCRIPTION OF THE MENUS All the menus are accessible at any time by pressing down the relevant function key: Function key F1 F2 F4 F5 F6 F7 F8

Description of the relevant menu Adjusting parameters Modifying the language Viewing the pump control outputs Viewing the analog PVG control outputs Viewing the analog inputs Viewing the “All or nothing” inputs Viewing the “All or nothing” outputs

-4-

III - MENU FOR ADJUSTING THE PARAMETERS III.1 - ORDER AND LIST OF MOVEMENTS 1.

2.

3.

4.

5.

6.

7.

8 9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

FORWARD MOTION, ARM DOWN FORWARD MOTION, ARM UP REVERSE MOTION, ARM DOWN REVERSE MOTION, ARM UP RAISING ARM 1, BASE RAISING ARM 1, BASKET LOWERING ARM 1, BASE LOWERING ARM 1, BASKET RAISING ARM 2, BASE RAISING ARM 2, BASKET LOWERING ARM 2, BASE LOWERING ARM 2, BASKET RAISING ARM 3, BASE RAISING ARM 3, BASKET LOWERING ARM 3, BASE LOWERING ARM 3, BASKET RETRACTING TELESCOPE, BASE RETRACTING TELESCOPE, BASKET EXTENDING TELESCOPE, BASE EXTENDING TELESCOPE, BASKET TURRET ROTATION RIGHT, BASE TURRET ROTATION RIGHT, BASKET TURRET ROTATION LEFT, BASE TURRET ROTATION LEFT, BASKET BASKET ROTATION RIGHT, BASKET BASKET ROTATION RIGHT, BASKET DIRECTION RIGHT, BASKET DIRECTION LEFT, BASKET TILT “IN”, BASKET TILT “OUT”, BASKET

III.2 - NAVIGATION THROUGH THE MOVEMENTS By pressing the keys “Shift” and “8” simultaneously: previous movement By pressing the keys “Shift” and “2” simultaneously: previous movement III.3 - MODIFIABLE VARIABLES FOR EACH MOVEMENT 3 variables can be modified on each movement On the first line On the second line On the third line

Max. speed (in %) Acceleration gradient (in %) Deceleration gradient (in %)

III. 4 - MODIFYING THE VARIABLES The “Space” key moves the cursor indicating the selected variable Once the variable has been selected, it can be modified: The “+” key increases the indicated variable The “-“ key decreases the indicated variable

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IV - LANGUAGES MENU The language for configuring the parameters can be selected: French or English.

You can switch from one language to the other using the “Space” key.

Press the “Enter” key to confirm your selection.

V - MENU FOR VIEWING THE ANALOG PVG CONTROL OUTPUTS This menu enables you to see the instructions sent by the manipulator for lateral and longitudinal motion.

When the manipulator is in the rest position, the instructions show 50%.

These instructions vary from 25 to 75%.

VI - MENU DE VISUALISATION DES SORTIES DE COMMANDE DE POMPE This menu enables you to see as a percentage (of the maximum current) the forward and reversing pump control outputs.

These outputs vary from 0 to 100%.

VII - ANALOG INPUTS MENU This menu enables you to see the instructions sent by the manipulator for lateral and longitudinal motion. When the manipulator is in the rest position, the instructions show 50%.

These instructions vary from 25 to 75%.

VIII - VIEWING THE ALL OR NOTHING INPUTS This menu enables you to see the “All or nothing” inputs from I1 to I20 (left to right).

The inputs assigned are, from left to right: I1 I2 I3 I4 I5 I6 I7 I8 I9 I10 I11 I12 I13 I14 I15

Base control Slope Max. rpm Arm low Raising button Lowering button Arm 1 Arm 2 Arm 3 Telescope Turret rotation Basket rotation Direction Tilt Overload

IX - VIEWING THE ALL OR NOTHING OUTPUTS This menu enables you to see the “All or nothing” outputs from S1 to S4 (left to right).

The outputs assigned are, from left to right: S1 S2 S3 S4

Output to main board Spare Spare Feed to PVG head

X - EXITING MODIFICATION MODE Press down keys “Shift” and “1” (End) simultaneously.

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