Manitou Access Platform 160 ATJ PLUS Repair Manual - PDF DOWNLOAD

547405EN (04/2011)

160 ATJ PLUS Repair Manual

MANITOU BF B.P 10249 - 44158 ANCENIS Cedex Tél. 33 (0) 2 40 09 10 11 Fax commercial France : 02 40 09 10 96 // Export : 33 2 40 09 10 97 www.manitou.com

1st Publication date : 15 / 04 / 2011

547405EN

PUBLICATION DATE 15 / 04 / 2011

OBSERVATION

- 1st Publication date

THE TEXT AND THE ILLUSTRATIONS IN THIS DOCUMENT MAY NOT BE REPRODUCED, EITHER IN WHOLE OR IN PART.

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HOW TO USE THIS REPAIR MANUAL ?

1

- INSTRUCTIONS AND GENERAL SAFETY ADVICE

30

TRANSMISSION

00

00

ENGINE

GENERAL INFORMATION, CHARACTERISTICS AND SAFETY SYSTEMS

20

GENERAL INFORMATION, CHARACTERISTICS AND SAFETY SYSTEMS

10

2

40

AXLE

55

BRAKE

70

ARMS - LIFTING PLATFORM

80

HYDRAULICS

85

ELECTRICITY

CHASSIS – BODYWORK

90

OPTIONS - ACCESSORIES

110

CONTROL STATION

4

3 00

SYMBOLS : GENERAL :

INSTRUCTIONS AND GENERAL SAFETY ADVICE

Pages

HAZARD OF ANY KIND

The associated text must be READ and fully UNDERSTOOD before continuing with the procedure.

ELECTRICAL HAZARD

The associated text must be READ and fully UNDERSTOOD before continuing with the procedure.

HEAT HAZARD

The associated text must be READ and fully UNDERSTOOD before continuing with the procedure.

PRESSURE HYDRAULIC HAZARD

The associated text must be READ and fully UNDERSTOOD before continuing with the procedure.

MINIMUM WEIGHT

This is indicated during removal procedures to enable you to select the appropriate handling equipment.

General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 2 ..kg

Replacement parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 3 Ҝ 547402FR

Technical documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 4 Repairs procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 5

Please refer to Spare Parts Catalogue N° 547406.

80-07-M.172

Please refer to Section n° 80-07-M.172 in this Repairs Manual.

(A1-1)

Please refer to Paragraph B - 1 in this Section ( Figure A1 - Rep 1) Mark the anchoring points or support surfaces (for lift truck forks) to be used during removal operations.

Repair and maintenance equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 8

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Please refer to Instructions Manual N° 547402FR.

547406

§B-1

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 7

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R

547405 : Please refer to Repair Manual ref 547405.

70 - HYDRAULIC : Please refer to 70 group « Hydraulic ».

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Instructions and general safety advice

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GENERAL INFORMATION, CHARACTERISTICS AND SAFETY SYSTEMS

00 INSTRUCTIONS AND GENERAL SAFETY ADVICE

Pages General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 2 Replacement parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 3 Technical documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 4 Repairs procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 5 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 7 Repair and maintenance equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 8

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GENERAL INSTRUCTIONS : • This section lists the safety instructions that must be followed while performing repair work on a lifting platform.

• Any maintenance or repairs other than those detailed in Section 3 - MAINTENANCE of the particular lifting platform’s INSTRUCTIONS MANUAL must only be performed by qualified personnel (see your dealer) and under optimum safety conditions to protect the health both of the operator and any third parties as well as to avoid damaging the lifting platform.

• When the lifting platform’s manufacturer does not directly check the maintenance and repair operations, the operator and the establishment’s manager are responsible for the safety of these operations.

• PAY ATTENTION TO ANY LEAKS – DIESEL AND HYDRAULIC FLUID ESCAPING UNDER HIGH PRESSURE CAN PIERCE THE SKIN AND CAUSE SEVERE INJURIES. IF ANY INJURY IS CAUSED BY A JET OF HIGH-PRESSURE FLUID, SEEK IMMEDIATE MEDICAL ATTENTION. • The indications FRONT and REAR are shown in the illustrations for ease of comprehension. As a reminder: TYPE OF LIFTING PLATFORM

FRONT

REAR

ARTICULATED

Counterweight

Basket

SCISSORS

Steering axle

Steps

VERTICAL MAST

Counterweight

Basket

LIFTING PLATFORM ON CARRIER

Truck cab

Basket

TELESCOPIC

Basket extension

Steps

• We operate a constant product improvement policy: certain improvements may therefore be introduced into our lifting platform range without the requirement of notifying our valued customers in advance.

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Instructions and general safety advice

REPLACEMENT PARTS : • Our lifting platforms must only be serviced using MANITOU original replacement parts. By AUTHORISING THE USE OF NON-ORIGINAL PARTS, YOU RISK : - From a legal standpoint, incurring liability in the event of an accident.

- From a technical standpoint, causing operating malfunctions or reducing the lifting platform’s service life.

• The use of counterfeit parts or components not approved by the manufacturer causes loss of the benefits of the contractual warranty. On the other hand, by using MANITOU original parts in your maintenance operations: YOU BENEFIT from KNOW-HOW

Through its network, MANITOU provides operators with - Know-how and skills.

- A guarantee of the quality of the work performed.

- Original replacement parts.

- Help with preventive maintenance.

- Efficient diagnostic help.

- Improvements from feedback and experience.

- Training of the operators.

- Only the MANITOU network knows the design of the lifting platform in detail and therefore has the best technical capabilities for maintaining it.

• FOR TRADE COMPONENTS (CYLINDERS, ELECTRIC PUMPS, VARIABLE SPEED DRIVES, CHARGERS, ENGINES, ETC.) DURING THE LIFTING PLATFORM’S WARRANTY PERIOD: - Removal of components ................................... AUTHORISED - Disassembling of components ....................... STRICTLY FORBIDDEN UNDER PENALTY OF LOSS OF WARRANTY • Original replacement parts are only distributed by MANITOU and its dealer network.

• The list of dealers in the network is available on MANITOU’s website : www.manitou.com

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TECHNICAL DOCUMENTATION :

• READ and UNDERSTAND the contents of the lifting platform’s INSTRUCTIONS MANUAL (this manual must be stored in the black storage compartment in the lifting platform’s basket). In particular, comply with the contents of Section 1 – SAFETY INSTRUCTIONS AND ADVICE as well as all the elements with a heading marked with a HAZARD symbol.

• READ and UNDERSTAND the safety instructions and/or advice indicated on the STICKERS on the lifting platform.

• Before starting any procedure in this REPAIRS MANUAL, READ the manual completely and fully understand what you have read.

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Instructions and general safety advice

REPAIRS PROCEDURES :

GENERAL : • PLACE the lifting platform in a level working area free of any items and mark off the area. If you cannot comply with these conditions (the lifting platform is on a building site, in a refrigeration unit, etc.), chock the wheels, mark off the area around the lifting platform and take note of any hazards associated with the surroundings.

• SWITCH OFF THE LIFTING PLATFORM, using the battery cut-out, before embarking on any procedure (unless specifically instructed otherwise).

• As soon as the weight of a component or an assembly exceeds 20kg, the procedure indicates this and it is advisable to use HANDLING EQUIPMENT for dismantling them, provided that their characteristics (as indicated on the manufacturer’s info plates or the tare plates) are suitable for the operation to be performed.

• For cleaning purposes, use appropriately approved, non-flammable solvents.

• When removing or refitting any component, scrupulously follow the procedure stated, step by step; always finish the current step before moving on to the next one.

• If you experience any resistance when removing a component, DO NOT FORCE IT. Check that the nuts, screws, and cables have been removed and that no nearby component is interfering with the work.

• The most important factor in preserving the lifting platform’s service life is to maintain a high level of cleanliness in its vital components.

• Where not stated, the refitting operations consist of performing the removal operations in reverse order.

MECHANICAL ENGINEERING : • Use screws with the same characteristics as those of the original screws and of an appropriate length.

• When the procedures do not state a value for the tightening torques to be applied to the nuts and bolts, you should use the standard values appropriate for the characteristics of the particular components.

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HYDRAULICS : • Some of the hydraulic lines are under VERY HIGH PRESSURE, even when the lifting platform is not operating.

To avoid any accidents: - Follow the hydraulic line pressure release procedure before starting to work on one of their components.

• Some cylinders are fitted with valves used for putting the lifting platform into safe mode when the movements stop by retaining hydraulic pressure in the cylinder’s chambers. This means that a cylinder once removed may still have VERY HIGH PRESSURE in its chambers (over 100 bars, especially in the tilt compensation circuit). It is therefore advisable to: - Follow the pressure release operations for the cylinder to be removed.

- Eliminate the pressure in the chambers before starting to remove a cylinder.

• Before working on a hydraulic component, clean the immediate surroundings and provide receptacles or cloths for catching any oil likely to escape during the removal procedure and plugs or caps for sealing off the holes and to prevent foreign bodies getting into the circuit.

• The covers, hatches, seals and filters are intended to keep the hydraulic oil pure and prevent any foreign bodies from getting into the circuit. For these parts, therefore, you must periodically: - Check that there is no damage.

- Maintain a correct level of cleanliness.

• Cloudy oil is a sign of a significant proportion of moisture, which will cause oxidisation / corrosion of the circuit’s metal parts: purge and clean the whole circuit; then refill the circuit with new oil.

• If the circuit should be contaminated by the presence of foreign bodies (metal, rubber, etc.), purge and clean the whole circuit; then refill the circuit with new oil.

• We do not recommend that you mix different types or different brands of oil in that there is no guarantee that they are of equivalent composition or viscosity.

• Please refer to Section 3 - MAINTENANCE in the INSTRUCTIONS MANUAL to select the appropriate oil to use for the lifting platform.

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Instructions and general safety advice

SYMBOLS :

GENERAL :

..kg

HAZARD OF ANY KIND

The associated text must be READ and fully UNDERSTOOD before continuing with the procedure.

ELECTRICAL HAZARD

The associated text must be READ and fully UNDERSTOOD before continuing with the procedure.

HEAT HAZARD

The associated text must be READ and fully UNDERSTOOD before continuing with the procedure.

PRESSURE HYDRAULIC HAZARD

The associated text must be READ and fully UNDERSTOOD before continuing with the procedure.

MINIMUM WEIGHT

This is indicated during removal procedures to enable you to select the appropriate handling equipment.

 547402FR

Please refer to Instructions Manual N° 547402FR.

 547406

Please refer to Spare Parts Catalogue N° 547406.

 80-07-M.172

Please refer to Section n° 80-07-M.172 in this Repairs Manual.

§ B - 1

Please refer to Paragraph B - 1 in this Section

(A1-1)

( Figure A1 - Rep 1) Mark the anchoring points or support surfaces (for lift truck forks) to be used during removal operations.

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MAINTENANCE AND REPAIRS EQUIPMENT : • Toolbox.

• MANITOU hydraulic kit: the specific reference is to be selected according to the type of lifting platform in catalogue 547406.

• Male and female plugs for sealing off hoses and hydraulic connections.

• Calibrator: the specific reference depends on the type of lifting platform; see the section concerned.

• Multimeter.

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ENGINE

- REMOVING THE ENGINE

547996EN Perkins S400 Engine R

- CHECKING AND ADJUSTING THE ENGINE

M

- ENGINE CHARACTERISTICS AND SPECIFICATIONS

10 400 SERIES ENGINE, MODELS 403C-15 and 404C-22 REPAIRS MANUAL

Pages 403C-15 THREE-CYLINDER DIESEL ENGINES, NATURALLY ASPIRATED 404C-22 FOUR-CYLINDER DIESEL ENGINES, NATURALLY ASPIRATED INDEX SECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

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10-01-16-678630-M172

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10

INDEX SECTIONS

SECTIONS

1

GENERAL INFORMATION

2

SPECIFICATIONS

3

CYLINDER HEAD ASSEMBLY

4

PISTON AND CONNECTING ROD ASSEMBLIES

5

CRANKSHAFT ASSEMBLY

6

DISTRIBUTION CASING AND DRIVE UNIT

7

CYLINDER BLOCK ASSEMBLY

8

ENGINE TIMING

9

INTAKE SYSTEM

10 LUBRICATION CIRCUIT 11 SUPPLY CIRCUIT 12 COOLING CIRCUIT 13 FLYWHEEL AND CASING 14 ELECTRICAL EQUIPMENT 15 AUXILIARY EQUIPMENT 16 SPECIAL TOOLS

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INDEX SECTIONS

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S erie 400

Contents 1 General information Introduction .............................................................................................................................................................. 11 Safety precautions ....................................................................................................................................................... 12 Recommended POWERPART consumables ..................................................................................................... 14 Views of the engine .................................................................................................................................................... 16 Engine identification ............................................................................................................................................. 17 Engine lifting equipment ......................................................................................................................................... 18

2 Specifications Basic engine characteristics ............................................................................................................................... 19 Standard tightening torques ............................................................................................................................ 20 Special tightening torques ................................................................................................................................ 21 Compression test characteristics ..................................................................................................................... 22

3 Cylinder head assembly Rocker arm cover and intake collector Operation 3-1 Removal and re-installation ........................................................................................... 23

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INDEX SECTIONS

Serie 400 Rocker arm array Operation 3-2 Removal and re-installation ................................................................................................... 24 Operation 3-3 Removal and re-installation .................................................................................................. 25 Operation 3-4 Checking ...................................................................................................................................... 26 Exhaust manifold and gasket Operation 3-5 Removal and re-installation .................................................................................................. 27 Injection pipes/fuel return pipes Operation 3-6 Removal and re-installation ................................................................................................ 28 Cylinder head screws Operation 3-7 Removal and re-installation ............................................................................................... 29 Cylinder head Operation 3-8 Tightening sequence 403C-15 ........................................................................................... 30 Operation 3-9 Tightening sequence 404C-22 .......................................................................................... 31 Cylinder head gasket Operation 3-10 Removal and re-installation .............................................................................................. 32 Operation 3-11 Selecting the correct thickness for the cylinder head gasket ............................... 33 Valve and valve spring Operation 3-12 Removal and re-installation ............................................................................................. 34 Operation 3-13 Checking – valve spring ..................................................................................................... 35 Operation 3-14 Checking – valve stem and valve head ........................................................................ 36 Play between the cylinder head and the valve stem Operation 3-15 Checking ............................................................................................................................... 37 Cylinder head Operation 3-16 Checking ............................................................................................................................... 38 Seat width Operation 3-17 Checking and correction ................................................................................................. 39 Valve depth Operation 3-18 Checking ................................................................................................................................. 40 Operation 3-19 Erosion of the valve seat’s contact surface ................................................................ 41 Play in the tappets Operation 3-20 Checking and setting ....................................................................................................... 42

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INDEX SECTIONS

Serie 400

10

4 Piston and connecting rod assemblies Bearing and connecting rod head cover Operation 4-1 Removal and re-installation ................................................................................................... 43 Piston and connecting rod Operation 4-2 Removal and re-installation .................................................................................................... 44 Operation 4-3 Removal and re-installation .................................................................................................... 45 Segments Operation 4-4 Installation .................................................................................................................................... 46 Operation 4-5 Measuring the segment play ................................................................................................ 47 Operation 4-6 Measuring the segment section ........................................................................................... 48 Piston and connecting rod assemblies Operation 4-7 Removal and re-installation ................................................................................................... 49 Piston and segment Operation 4-8 Checking ....................................................................................................................................... 50 Connecting rod Operation 4-9 Checking ....................................................................................................................................... 51 Connecting rod base ring Operation 4-10 Removal and re-installation ............................................................................................... 52

5 Crankshaft assembly Crankshaft pulley Operation 5-1 Removal and re-installation ................................................................................................ 53 Crankshaft and crankshaft fixing bolts ......................................................................................................... 54 Operation 5-2 Removal and re-installation ................................................................................................ 55 Crankshaft Operation 5-3 Checking the flexing ............................................................................................................... 56 Play in the connecting rod bearings Operation 5-4 Checking .................................................................................................................................... 57 Bearings Operation 5-5 Removal and re-installation ............................................................................................... 58 Bearing carrier ...................................................................................................................................................... 59

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INDEX SECTIONS Serie 400

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6 Distribution casing and drive unit Distribution casingde distribution Operation 6-1 Removal and re-installation ................................................................................................... 61 Operation 6-2 Installation ..................................................................................................................................... 62 Angleich Operation 6-3 Removal and re-installation .................................................................................................... 63 Sliding block Operation 6-4 Removal and re-installation .................................................................................................... 64 Camshaft retaining plate Operation 6-5 Removal and re-installation ................................................................................................... 65 Camshaft and tappets Operation 6-6 Removal and re-installation ................................................................................................... 66 Camshaft assembly Operation 6-7 Checking ........................................................................................................................................ 67 Maximum fuel screw and maximum engine speed screw Operation 6-8 Positioning .................................................................................................................................... 68 Front oil seal and PDF cover Operation 6-9 Removal and re-installation ................................................................................................... 69 Intermediate pinion and oil pump Operation 6-10 Removal and re-installation ................................................................................................. 70 Intermediate pinion hub Operation 6-11 Removal and re-installation ................................................................................................ 71 Pinion teeth play Operation 6-12 Checking ..................................................................................................................................... 72 Oil pump axial play Operation 6-13 Checking and setting ............................................................................................................ 73 Regulator springs Operation 6-14 Checking ..................................................................................................................................... 74

7 Cylinder block assembly Front crankshaft ring Operation 7-1 Removal and re-installation ................................................................................................ 75 10-01-16-678630-M172

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INDEX SECTIONS

Crankshaft ring Operation 7-2 Checking ........................................................................................................................................... 76 Upper surface of the cylinder block Operation 7-3 Checking .......................................................................................................................................... 77 Cylinder bore Operation 7-4 Checking .......................................................................................................................................... 78

8 Engine timing Operation 8-1 Injection timing ................................................................................................................................. 79 Operation 8-2 Checking the injection pump timing ....................................................................................... 80

9 Intake system Snifter valve system Operation 9-1 Closed circuit – cleaning and replacement ........................................................................... 83

10 Lubrication circuit Lubricating oil cartridge Operation 10-1 Installation .................................................................................................................................. 85 Pressure relief valve Operation 10-2 Removal and re-installation ................................................................................................ 86 Lubricating oil sump Operation 10-3 Removal and re-installation ................................................................................................ 87 Lubricating oil strainer and inlet hose Operation 10-4 Removal and re-installation ................................................................................................ 88 Lubricating oil pump Operation 10-5 Removal and re-installation ............................................................................................... 89 Rotor end play Operation 10-6 Checking .................................................................................................................................... 90 Oil pressure switch Operation 10-7 Removal and re-installation ................................................................................................91

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Serie 400

8

INDEX SECTIONS

10

Serie 400 Lubricating oil pipes Operation 10-8 Removal and re-installation ................................................................................................... 92

11 Supply circuit Injectors Operation 11-1 Removal and re-installation ................................................................................................. 93 Feed pump Operation 11-2 Removal and re-installation ................................................................................................. 94 Injection pump Operation 11-3 Removal and re-installation .................................................................................................. 95 Operation 11-4 Bleeding air from the supply circuit ................................................................................... 96

12 Cooling circuit Coolant pump Operation 12-1 Removal and re-installation ................................................................................................. 97 Operation 12-2 Checking ...................................................................................................................................... 98 Fan and fixing Operation 12-3 Removal and re-installation ................................................................................................. 99 Thermostat Operation 12-4 Removal and re-installation ............................................................................................... 100 Operation 12-5 Draining the cylinder block ................................................................................................ 101 Operation 12-6 Testing and checking ........................................................................................................... 102

13 Flywheel and casing Flywheel Operation 13-1 Removal and re-installation .............................................................................................. 103 Operation 13-2 Checking concentricity and alignment of the flywheel housing ......................... 104 Operation 13-3 Checking the radial run-out of the flywheel and the alignment of the flywheel surface ........................................................................................................................................ 105 Starter ring Operation 13-4 Removal and re-installation .............................................................................................. 106

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INDEX SECTIONS

Serie 400 Rear plate and rear oil seal Operation 13-5 Removal and re-installation ..................................................................................................... 107

14 Electrical equipment Fuel cut-off solenoid Operation 14-1 Removal and re-installation .................................................................................................... 109 Bus bar / glow plugs Operation 14-2 Removal and re-installation .................................................................................................... 110 Drive crown Operation 14-3 Checking and adjusting ............................................................................................................. 111 Alternator Operation 14-4 Removal and re-installation .................................................................................................... 112 Starter Operation 14-5 Removal and re-installation .................................................................................................... 113 Wiring diagrams ........................................................................................................................................................... 114 Automatic stop connector ....................................................................................................................................... 115 Automatic stop charging circuit ........................................................................................................................... 116

15 Auxiliary equipment Operation 15-1 Nothing fitted ...................................................................................................................... 117

16 Special tools List of special tools ................................................................................................................................................ 119

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INDEX SECTIONS

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GENERAL INFORMATION

11

Serie S erie 400

10

1 General information Introduction This manual has been compiled to assist technicians responsible for maintaining and overhauling engines 40 and 404C-22. It is presupposed that the engine has been removed from the application.

The engine complies with USA and EU EPA/CARB anti-pollution legislation for agricultural and industrial appl Where the information only applies to certain types of engines, this is indicated in the text.

Special tools are available, the list of which appears in Section 16. The list of the recommended POWERPART consumables is also given in this section. The relevant special tools and consumables are shown at the begin of each operation.

A hazard is shown in the text in 2 ways: Warning! This indicates a possible hazard for people.

Attention: This indicates a possible hazard for the engine.

NB: Pay attention to particular important information, but without indicating a hazard.

Warning! Read the “Safety precautions” and take them into account. They have been provided to protect the technicians and must be used constantly.

In general, if new seals must be fitted, it is understood that the surfaces of the seal will be cleaned, this being normal workshop practice. It is also understood that during fitting and checking, all the components must be carefully cleaned and greased and, where applicable and burrs and deposits have been removed.

All the open apertures in the precision components, for example, the injection equipment, must be sealed wi plugs until fitted, to avoid any foreign bodies penetrating.

The “left-hand” or “right-hand” side of the engine means as seen from the flywheel side.

When fitting locking screws or pins in holes opening into the oil, coolant or air channels, a suitable sealing pro must be used to prevent any leaks.

The threads have been coated with a micro-capsule, anaerobic sealing product (M.E.A.S.), rather than sealing compound or other sealing products, when the fixings are installed in holes opening on to the oil or coolant channels. These fastenings are identified on delivery by the colour of the sealing product.

The end of the pins sealed with M.E.A.S. must be fitted in the component. The threaded holes must have a chamfer of 1.59mm and 45° to prevent the M.E.A.S. sealing product from pulling away when fitting new fastenings. If the fastenings must be removed and then re-fitted, the threads must be cleaned and coated with an appropriate sealing product.

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GENERAL INFORMATION

1

S erie400 400 Serie

10

Safety precautions These safety precautions are important. Also consult the local regulations in force in the country of use.

Some precautions only relate to specific applications Only use these engines for the type of application for which they are intended.

Do not change the engine’s specification.

Do not smoke while filling up with fuel Wipe up any split fuel. Any material contaminated with fuel must be stored in a safe and secure place.

Do not fill up with diesel fuel while the engine is running (unless absolutely necessary).

Do not add lubricating oil or adjust the engine while it is running (unless you have received appropriate training and, even in this case, the greatest care and rigor must be exercised to avoid injuries).

Do not attempt to make adjustments without understanding them.

Do not run the engine in an area where there is the risk of causing a build-up of toxic gases.

The other people present must be kept at a safe distance while the engine or the auxiliary equipment is running.

Do not approach any moving parts when wearing loose-fitting clothing or long hair.

Do not approach moving parts while the engine is running.

Warning! Some moving parts are not clearly visible while the engine is running.

Do not run the engine if a protective device has been removed.

Do not remove the filling cap or any component in the coolant circuit while the engine is warm and the coolant is under pressure because dangerously hot fluid may escape.

Do not create sparks or bring a naked flame near to batteries (especially while they are being charged) because gas that their electrolyte emits is highly flammable. Battery fluid is dangerous to the skin and especially the eyes.

Disconnect the battery terminals before starting any work on the electrical equipment.

Only one person must control the engine.

Only control the engine from the control panel or the driving position.

If any fuel under high pressure comes in contact with the skin seek medical attention immediately.

Diesel and lubricating oil (especially used lubricating oil) can cause skin injuries in certain people.

You must therefore wear gloves or protect your hands with a special skin product.

Do not wear garments contaminated with lubricating oil. Do not put oily rags in garment pockets.

Dispose of used lubricating oil in accordance with the local regulations to avoid pollution.

Ensure that the transmission control lever is set to dead centre (Neutral) before starting the engine.

Proceed very carefully if urgent repairs must be performed under difficult conditions.

The combustible material in certain engine components (for example certain seals) may become extremely dangerous if burnt. Never let this burnt material come into contact with the skin or the eyes.

Always use a safety cage to protect the operator when components must be subjected to a pressure test in a water bath. Position metal safety wires to hold the plugs for the hose connectors on any components subjected to a pressure test.

Do not let compressed air come into contact with the skin. If compressed air penetrates the skin, seek medical attention immediately.

The turbo-compressors run at high speed and high temperatures. Do not move your fingers, tools or any other articles close to the turbo-compressors’ inlet or outlet holes and avoid contact with hot surfaces.

Do not clean an engine while it is running. If cold cleaning fluids are applied to a hot engine, some of the engine components could be damaged.

Only fit Perkins original parts.

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GENERAL INFORMATION

1

Serie 400 S erie 400

Warning!

Some gaskets and seals used in engines and in the components fitted on engines are made of Viton.

This is used by many manufacturers and is a non-hazardous material under normal conditions of use. .

On the other hand, if Viton is burnt, it produces an extremely dangerous acid. Never let burnt Viton come into contact with the skin or the eyes. If you must touch parts that have been burnt, always take the following precautions: Ensure that the components have cooled down.

Wear neoprene gloves and dispose of them after use in accordance with the safety regulations.

Wash the affected surface with a solution of calcium hydroxide and then with fresh water.

Dispose of the contaminated components and gloves in accordance with the local regulations.

If your skin or eyes should become contaminated, wash the affected surface liberally with fresh water and a solution of calcium hydroxide for 15 to 60 minutes. Seek medical attention immediately.

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Viton gaskets

10

14

GENERAL INFORMATION

1

S erie 400

Recommended POWERPART consumables Perkins offers the following recommended products to facilitate the correct use, servicing and maintenance of the engines and the machines. The method of use is indicated on each product’s packaging. All these products are available from Perkins distributors.

POWERPART Antifreeze This protects the coolant circuit against frost and corrosion.

POWERPART Easy Flush (rinsing product) This cleans the coolant circuit.

POWERPART Gasket and flange sealant (sealing product) This seals the flat surfaces of components when there is no seal provided. It is particularly useful for aluminium components.

POWERPART Gasket remover (adhesive and sealing product remover) Aerosol for removing sealing and adhesive products.

POWERPART Griptite (adherence product) This improves the grip of worn tools and fastening components.

POWERPART Hydraulic threadseal (thread sealing product) This locks and seals finely threaded connectors. It is particularly useful for hydraulic and pneumatic systems.

POWERPART Industrial grade super glue (industrial adhesive) An instantaneous glue for metal, plastic and rubber.

POWERPART Lay-Up 1 (protective product) Additive for diesel fuel protecting against corrosion.

POWERPART Lay-Up 2 (protective product) Protection for the inside of the engine and other closed systems.

POWERPART Lay-Up 3 (protective product) Protection for the external metal parts.

POWERPART Metal repair putty (mastic for metals) Designed for exterior repairs on metals and plastics

547405 EN (09/2010)

15

GENERAL INFORMATION

1 10

S erie 400 POWERPART Pipe sealant and sealant primer (pipework sealing product) This locks and seals wide thread pipe connectors. Pressurized systems can be used immediately.

POWERPART Radiator stop leak (leak repair product) For repairing radiator leaks.

POWERPART Retainer (high-resistance retention product) This holds tightly adjusted components. Currently Loctite 638.

POWERPART Safety cleaner (cleaning product) Universal cleaning product in an aerosol can.

POWERPART Silicone adhesive (silicon adhesive) RTV silicon adhesive for application with low-pressure tests before the adhesive hardens.

Used for sealing clamps and seals subject to movement against oil.

POWERPART Silicone RTV sealing and jointing compound (silicon sealing paste) Silicon rubber sealing paste preventing leaks through interstices. Currently Hylosil.

POWERPART Stud and bearing lock (high-resistance sealing product) To prove a high level of sealing to components only lightly tightened.

POWERPART Threadlock and nutlock (light locking product) This locks small fasteners that must still remain easy to unscrew.

POWERPART Universal jointing compound (universal jointing paste) A universal sealing paste for joints. Currently Hylomar.

547405 EN (09/2010)

16

GENERAL INFORMATION

1

S erie 400

10

Engine views

H1029

H1030

547405 EN (09/2010)

17

GENERAL INFORMATION

1

Serie 400 Engine identification

10

Engine fitting list numbering system The standard engine fitting list numbering code is defined as follows: Code Example

I

II

III

IV

V

HP

TBA

U

000001

D

Code I: Engine fitting Code Engine

HL 403C-15

HP 404C-22

Code II: Engine fitting list The fitting list is drawn up in increasing numerical order for manufacturers and distributors.

Code III: Country of manufacture Code

J

Country of manufacture

Made in Japan

U Made in UK

Code IV: Engine serial number Individual serial number starting at 000001 and then in increasing numerical order.

Code V: Year of manufacture Code Year

H 2001

J 2002

Perkins No. LISTE

TYPE

No. SERIE

TYPE

H1031

547405 EN (09/2010)

18

GENERAL INFORMATION

1

Serie 400

10

Engine lifting equipment Recommended tightening torque: lifting rings Engine

Nm (kgf m)

All models

26 (2,6)

Maximum engine weight Engine 404C-22

403C-15

Long flywheel casing specification

Maximum engine weight (1) (empty) 220 kg

Short flywheel casing specification

196 kg

Rear plate specification

184 kg

Long flywheel casing specification

176 kg

Short flywheel casing specification

154 kg

Rear plate specification

150 kg

Engine specification

(1) The engine may vary depending on its final specification

H1032

547405 EN (09/2010)

19

SPECIFICATIONS

Serie 400

10

2 Specifications

2

Basic engine characteristics Engine model Engine fitting code N ombre de c y lindre s Number of cylinders

403C-15

404C-22

HL

HP

3

4 Vertical, in line

C y c le Direction of rotation Intake system Combustion system

Four time Clockwise seen by the front Natural aspiration Indirect injection

Nominal bore

8 4 mm

Stroke

9 0 mm

1 0 0 mm

Compression rates

22. 5: 1

23. 3: 1

1 , 4 9 6 litre s

2 , 2 1 6 litre s

1, 2, 3

1, 3, 4, 2

Cubic capacity Ignition sequence Tappet play (cold) Intake

0 , 2 mm

Exhaust

0 , 2 mm

Regulator I nje c tion

mechanical at all speeds cassette type injection pump

Electrical system Lubricating oil pressure relief valve Lubricating oil pressure switch on the upper cover Lubricating oil pressure switch on the cylinder block lubrication system

1 2 volts 262 - 359 kPa

352 - 448 kPa 29,4 kPa 98,0 kPa

547405 EN (09/2010)

20

SPECIFICATIONS

2

Serie 400

10

Standard tightening torques Most of the engine tightening torques are standard. The special tightening torques are indicated in the separate specific tightness tables. The standard tightening torques indicated in the tables below can be used when a specific torque is not required.

The tightening torques below relate to components lightly lubricated with clean engine oil before installation.

Standard tightening torques for the locking screws and nuts Wide thread Thread size

R esistance

Pitch mm

Fine thread

Tightening Tightening Tightening torque torque torque Nm

M4

8.8 11T

M5

Pitch mm

kgf m

Tightening torque

Tightening Tightening torque torque

Nm

kgf m

0,7

3 4

2 3

0,3 0,4

-

-

-

-

8.8 11T

0,8

6 8

4 6

0,6 0,8

-

-

-

-

M6

8.8 11T

1,0

10 14

7 10

1,0 1,4

-

-

-

-

M8

8.8 11T

1,25

26 32

19 24

2,7 3,3

1,0

30 35

22 26

3,0 3,6

M10

8.8 11T

1,5

50 62

37 46

5,1 6,3

1,25

56 66

41 49

5,7 6,7

M12

8.8 11T

1,75

75 104

55 77

7,6 10,6

1,25

84 113

62 83

8,6 11,5

M14

8.8 11T

2,0

118 157

87 116

12,0 16,0

1,5

132 167

97 123

13,5 17,0

M16

8.8 11T

2,0

167 230

123 170

17,0 23,4

1,5

175 245

129 181

17,8 25,0

Bolt resistance 8.8 11T

547405 EN (09/2010)

Examples of suitable material S45C SCM435

21

SPECIFICATIONS

2

Serie 400

10

Special tightening torques Tightening torque Nm (kgf m) A ngle ic h

5 (0, 5)

Injector

64 (6, 4)

Sealing plug behind the cylinder block

7 (0,7)

Crankshaft block support

27 (2,7)

Connecting rod nuts Crankshaft nut Crankshaft sub-assembly

52 (5, 2) 3 03 (3 0, 3) 52 (5,2)

Exhaust manifold

25 (2, 5)

Flywheel

74 (7, 4)

Injection pump

15 (1, 5)

Pre-heating plugs

18 (1, 8)

Cylinder head screw Injection pipes Fuel return pipe

1 01 (1 0, 3) 23 (2 , 3) 27 (2,7)

Feed pump banjo bolt

12 (1,2)

Feed pump support locking screw

6 (0,6)

Oil pipe

12 (1, 2)

Oil strainer

10 (1 , 0)

Discharge valve

64 (6, 4)

Distribution casing

10 (1, 0)

Rocker arm array nuts

33 (3,3)

Rocker cover

14 (1 , 4)

Oil sump drain plug

35 (3,5)

Thermo-contact

27 (2, 7)

Thermostat locking screw

14 (1,4)

547405 EN (09/2010)

22

SPECIFICATIONS

2

Serie 400

10

Compression test characteristics Several factors affect the compression pressures. The condition of the battery, the starter, the ambient conditions and the type of compressiometer used can produce results that vary considerably for a given engine.

Standard value >2940 kPa @ 250 tr/min

To be repaired <2450 kPa @ 250 rpm

The compression tests must only be used for comparisons between the cylinders in an engine.

If one cylinder or more varies by more than 350 kPa, the relevant cylinders may be defective.

The compression tests must not be the only method used to indicate an engine’s condition; they must be used with other symptoms and checks.

How to perform a compression test NB: Before starting a compression test, ensure that the battery is in good condition and fully charged.

Also ensure that the starter is in good condition.

1 - Ensure that the play in the tappets is correct.

2 - Remove the injectors.

3 - Position an appropriate compressiometer in the injector hole of the cylinder to be checked.

4 - Disconnect the stopping solenoid or set the solenoid in feed shut-off position.

Operate the starter and note the pressure shown on the compressiometer.

Attention: Do not remove the stopping solenoid because this enables the engine to start.

5 - Repeat the operation for each cylinder.

H1033

547405 EN (09/2010)

23

CYLINDER HEAD ASSEMBLY

Serie 400

10

3 Cylinder head assembly

3

Rocker cover and intake manifold Removal and re-installation

Operation 3-1

Tightening torque Nm (kgf m) Cap nut

14 (1, 4)

Locking screw

14 (1, 4)

NB : There is an O-ring (1) in the rocker cover’s groove.

Inspect the O-ring and replace it, if necessary.

1

H1034

547405 EN (09/2010)

24

CYLINDER HEAD ASSEMBLY

3

Serie 400

10

Rocker arm array Removal and re-installation

Operation 3-2

Tightening torque Nm (kgf m) Rocker arm array nuts

33 (3,3)

Attention: Ensure that the valve stem caps are in place on the valve stems and that the pushrods are in place on the rockers after fitting.

NB: There is an O-ring (1) in the rocker arm array’s groove.

1

H1035

547405 EN (09/2010)

25

CYLINDER HEAD ASSEMBLY

3

Serie 400

Operation 3-3

10

Removal and fitting Tightening torque Nm (kgf m) Tappet adjustment nut

14 (1,4)

Use an appropriate extraction device to remove the rocker shaft.

NB: Note the recess position (1) for fitting.

1

H1036

547405 EN (09/2010)

26

CYLINDER HEAD ASSEMBLY

3

Serie 400

10

s

Checking

Operation 3-4

Rocker shaft diameter Engine

Diameter (mm) Standard

Service limit

4 0 3 C -1 5

11, 65 - 11, 67

11, 57

4 0 4 C -2 2

14, 95 - 14, 97

14, 87

Play between the rocker shaft and the rocker Engine

Diameter (mm) Standard

Service limit

4 0 3 C -1 5

0, 032 - 0, 068

0, 2

4 0 4 C -2 2

0, 030 - 0, 093

0, 2

H1037

547405 EN (09/2010)

27

CYLINDER HEAD ASSEMBLY

3

Serie 400

Removal and re-installation

Operation 3-5

Tightening torque Nm (kgf m) Locking screw

25 (2, 5)

Nuts

25 ( 2, 5)

H1038

547405 EN (09/2010)

10

Exhaust manifold and gasket

28

CYLINDER HEAD ASSEMBLY

3

Serie 400

10

Injection pipes / fuel return pipes Removal and re-installation

Operation 3-6

Tightening torque Nm (kgf m) Injection pipes Banjo nut

(1)

23 ( 2 , 3) 2, 5 (0, 25)

1

H1039

547405 EN (09/2010)

29

CYLINDER HEAD ASSEMBLY

3

Serie 400

Removal and re-installation

Operation 3-7

NB: If the cylinder head must be replaced, the initial setting for the fuel control screw must not be altered.

The maximum engine speed unladen must be checked after installation.

H1040

547405 EN (09/2010)

10

Cylinder head screw

30

CYLINDER HEAD ASSEMBLY

3

Serie 400

10

Cylinder head Tightening sequence 403C-15

Operation 3-8

Tightening torque Nm (kgf m) Cylinder head screw

1 01 ( 1 0, 3)

NB : All the tightening torques must be rechecked after tightening.

During fitting, lubricate the cylinder head screws with fresh oil.

9

11

13

7 3

1

5

2

4

8

14

10

6

12

H1041

547405 EN (09/2010)

31

CYLINDER HEAD ASSEMBLY

Tightening sequence 404C-22

Operation 3-9

Tightening torque Nm (kgf m) Cylinder head screw

101 ( 10, 3)

NB : All the tightening torques must be rechecked after tightening During fitting, lubricate the cylinder head screws with fresh oil.

12

4

5

8

16

15

7

11

3

13

1

9

2

10

6

17

18

14

H1042

547405 EN (09/2010)

10

3

Serie 400

32

ENSEMBLE CULASSE

3

Serie 400

Removal and re-installation

Operation 3-10

Align the gasket on the cylinder block’s centring pins Attention : The gaskets must only be fitted with the markings (1) facing upwards.

Always replace a gasket with a new gasket of the same thickness as the original gasket.

The correct piston height must be maintained to avoid damage to the pistons and valves and ensure compliance with anti-pollution legislation.

NB: Always fit gaskets dry.

Ma

cle

an

1

A nd y

10

Cylinder head gasket

547405 EN (09/2010)

H1043

33

ENSEMBLE CULASSE

3

Serie 400

Operation 3-11

Attention: If the correct piston height above and below the cylinder block is not attained, the engine risks being damaged. The difference between the highest and lowest piston heights must not exceed 0.1mm.

1 - Position the piston height setting tool (A) on the surface of the cylinder block and set the dial gauge to zero.

2 - Turn the crankshaft to bring the piston head approximately to top dead centre (TDC) 3 - Carefully position the tool on the top of the piston, with the sensor in contact with the piston above the piston shaft.

4 - Turn the crankshaft to confirm that the piston is in the highest position and note the value shown on the dial gauge.

NB : If the cylinder block, the crankshaft, the connecting rods or the pistons are replaced, the piston height must be checked and a gasket of the correct thickness must be used.

If the original piston is re-used, ensure that it is fitted on the correct connecting rod and that it is used in the original cylinder.

403C-15 Selecting the cylinder head gasket Projecting above the top surface of the cylinder block

Gasket thickness

0,60 to 0 , 6 9

1 , 3 mm

0,70 to 0 , 7 9

1 , 4 mm

404C-22 Selecting the cylinder head gasket Depth under the top surface of the cylinder block -0,45 to

Gasket thickness

-0 , 3 0

0 , 4 mm

-0,29 to -0 , 2 0

0 , 5 mm

H1044

547405 EN (09/2010)

10

Selecting a cylinder head gasket’s correct thickness

34

CYLINDER HEAD ASSEMBLY

3

Serie 400

10

Valve and valve spring Removal and re-installation

Operation 3-12

Special tools Description

Reference

Valve spring removal tool

21825663

Valve stem seal fitting tool

21825623

Nb : The intake valve stem’s oil seal is identified by a silver-coloured circular spring.

The exhaust valve stem’s oil seal is identified by a black-coloured circular spring (not shown) and bears the letters “EX” (exhaust).

Warning! Goggles must be worn for this operation.

547405 EN (09/2010)

H1045

35

CYLINDER HEAD ASSEMBLY

Checking – valve spring

Operation 3-13

Visually inspect the valve spring’s condition.

Use a spring tester to check the spring’s force and free length. Replace the spring if it is outside the service limit.

Free length (1) mm

Engine model

Standard

All models

Service limit

35, 0

33, 5

Calibration of the spring when it is compressed at 30.4 mmN N (kgf)

Engine model

Standard All models

Service limit

79 (8, 1)

69 (7, 0)

1

New

Used

H1046

547405 EN (09/2010)

10

3

Serie 400

36

CYLINDER HEAD ASSEMBLY

10

3

Serie 400

Checking – valve stem and thickness of the valve head

Operation 3-14

Use a micrometer to check the valve stem diameters in positions 1, 2 and 3: if they are lower than the service limit, replace them.

Check the wear and the condition of the valve stems: if they are outside the service limit, replace them.

Intake valve Diameter (mm) Standard

Service limit

6, 955 - 6, 970

6, 89

Exhaust valve Diameter (mm) Standard

Service limit

6, 940 - 6, 950

6, 84

Valve head thickness Thickness (mm) Standard

Service limit

0, 925 - 1, 075

0, 5

If the valve head thickness (4) is lower than the service limit, replace the valve.

1

2

3

1

2

3

4 H1047

547405 EN (09/2010)

37

CYLINDER HEAD ASSEMBLY

3

Serie 400

Checking

Operation 3-15

Check the play (3) between the valve stem and the cylinder head. If the play is greater than the service limit, check the wear on the valves, see Operation 3-14. If the valves are within the service limits, replace the cylinder head.

1 - Put a new valve in the valve guide.

2 - Put a dial gauge with a magnetic support (1) on the surface of the cylinder head.

3 - With the valve raised 15.0mm and the dial gauge (2) in contact with the edge of the valve head, move the dial gauge valve laterally to distance it. With the head in this position, set the dial gauge to ‘0’.

4 - Bring the valve close to the dial gauge by moving it radially across the axis of the cylinder head.

Note the value shown on the dial gauge. If the value is higher than the service limit, replace the cylinder head.

Maximum permissible play for a valve lift of 15mm.

Intake valve Play (mm) Standard

Service limit

0, 03 - 0, 06

0, 2

Exhaust valve Play (mm) Standard

Service limit

0, 05 - 0, 075

0, 25

1 2

3

H1048

547405 EN (09/2010)

10

Play between the cylinder head and the valve stem

38

CYLINDER HEAD ASSEMBLY

3

Serie 400

Cylinder head Checking

Operation 3-16 Maximum rectification limit mm

Deformation

Maximum service limit

0 , 0 5 or less

Maximum rectification

0, 12

0, 15

Use a rule and a thickness gauge to check six places on the cylinder head for any deformation.

Attention : Do not rectify beyond the maximum limit.

1

4

3 5

6 2 H1049

547405 EN (09/2010)

39

CYLINDER HEAD ASSEMBLY

3

Serie 400

#

Checking and correction

Operation 3-17

Special tools Description Valve seat cutter

Reference 27610030

Intake valve Engine

Play (mm) Standard

Service limit

4 0 3 C -1 5

1, 66 - 1, 87

2, 5

4 0 4 C -2 2

1, 50 - 2, 00

2, 5

Exhaust valve Engine

Play (mm) Standard

Service limit

4 0 3 C -1 5

1, 66 - 1, 73

2, 5

4 0 4 C -2 2

1, 94 - 2, 16

2, 5

If the valve seat’s contact surface (1) is greater than the service limit, check the wear on the valve stem, see Operation 3-14 and the play between the cylinder head and the valve stem, see Operation 3-15.

If the play is greater than the service limit, use a 45° valve seat cutter to correct the valve seat.

If the valve stem play exceeds the service limit, replace the valve.

If the bore of the cylinder head holding the valves is worn, replace the cylinder head. If the valve seat in the cylinder head is damaged or worn, cut a new valve seat so that the valve depth stays within the tolerances.

1

45°

Contact width H1050

547405 EN (09/2010)

10

Seat width

40

CYLINDER HEAD ASSEMBLY

3

Serie 400

10

Valve depth Checking

Operation 3-18

If the valve depth (1) is greater than the service limit, use a new valve to check the valve depth.

If the valve depth still exceeds the service limit, replace the cylinder head. If the depth is within the service limit, replace the valves.

Engine

Depth (mm) Standard

Service limit

4 0 3 C -1 5

0, 85 - 1, 15

1, 8

4 0 4 C -2 2

0, 65 - 0, 95

1, 8

1

547405 EN (09/2010)

H1051

41

CYLINDER HEAD ASSEMBLY

Erosion of the valve seat contact surface

Operation 3-19

Use the valve seat cutter to establish the correct valve seat contact width and the correct seat recess on a new cylinder head. Use a valve grinding tool or an abrasive product for the finishing work.

H1052

547405 EN (09/2010)

10

3

Serie 400

42

CYLINDER HEAD ASSEMBLY

3

Serie 400

10

Tappet play Checking and adjustment

Operation 3-20

The sequence for adjusting the valves is as viewed from the front of the engine.

Turn the crankshaft clockwise as viewed from the front.

Attention: Only adjust the valve play with the engine cold.

Valve crossover

Engine

403C-15

404C-22

Adjusting the valves

Cylinder No. 1

3 and 6

Cylinder No. 2

2 and 5

Cylinder No. 3

1 and 4

Cylinder No. 4

1 and 2

Cylinder No. 2

5 and 6

Cylinder No. 1

7 and 8

Cylinder No. 3

3 and 4

Tappet adjustment (cold) Intake

0 , 2 mm

Exhaust

0 , 2 mm

Tightening torque Nm kgf m Tappet adjustment nut

14 1,4

H1053

547405 EN (09/2010)

43

PISTON AND CONNECTING ROD ASSEMBLIES

Serie 400

10

4 Piston and connecting rod assembly

4

Bearing and valve head connecting rod Removal and re-installation

Operation 4-1

Tightening torque Nm (kgf m) Nut Play standard 0,1 - 0,3 mm

52 (5,2) Service limit 0,7 mm

Attention: Ensure that the connecting rod bolts (2) do not damage the crankshaft when the connecting rod is removed or refitted.

After refitting the connecting rods, check the axial movement.

Notes : The connecting rods and the head caps are numbered matched pairs and must be kept together when they are removed from the engine. The numbers (1) must be aligned during fitting.

The pistons and connecting rods are matched to the corresponding cylinder; note the position of each connecting rod and piston for correct fitting.

2

1

H1054

547405 EN (09/2010)

PISTON AND CONNECTING ROD ASSEMBLIES

44

4

Serie 400

10

Piston and connecting rod Removal and re-installation

Operation 4-2

The name Shibaura inside the piston must be oriented towards the feed pump during fitting. For fitting the connecting rod assembly, see page 35.

1

H1055

547405 EN (09/2010)

45

PISTON AND CONNECTING ROD ASSEMBLIES

Removal and fitting

Operation 4-3

123A MA C

The name Shibaura (1) inside the piston must be aligned to the number stamped on the connecting rod (1).

The numbers stamped on the connecting rods and head caps must be the same and aligned.

1

H1056

547405 EN (09/2010)

10

4

Serie 400

PISTON AND CONNECTING ROD ASSEMBLIES

46

4

Serie 400

Fitting

Operation 4-4

All the letters and all the markings on the surface of the segment must always be positioned on the upper surface (oriented upwards). Use an appropriate segment spreader for fitting the segments.

1 - Fit the scraper segment spring (6) in the lower neck of the piston with the axis of the join (1) inside both ends of the spring. Fit the scraper segment (4) on the spring (6). Ensure that the segment cut is 180° to the axis of the join.

2 - Fit the second segment (3) with the conical surface in the second neck, with the word "TOP" facing the top of the piston.

The new second segments have an identification mark located on the left of the segment cut when the segment is fitted vertically.

The second segment (5) has a step on the upper inside edge of the conical surface.

3 - Fit the upper segment (2) with the word “TOP” facing the top of the piston.

The new upper segments have an identification mark located on the left of the segment cut when the segment is fitted vertically.

4 - Ensure that the segment cuts are spaced 90°.

1

2 90°

3 A

M

4

AM

10

Segments

90°

6

5

H1057

547405 EN (09/2010)

47

PISTON AND CONNECTING ROD ASSEMBLIES

Measuring the segment play

Operation 4-5

Use a thickness gauge to measure the play between the segment neck and the segment. If the play is greater than the service limit, use a new segment and check the play.

If the play is still within the service limit, replace the segments. If it is not, replace the piston.

Tightening torque Nm kgf m Segment No

1

Segment No

2

Scraper segment

Standard 0,07 - 0,11 mm 0,04 - 0,08 mm 0,02 - 0,06 mm

Service limit 0,25 0,25 0,15

H1058

547405 EN (09/2010)

10

4

Serie 400

PISTON AND CONNECTING ROD ASSEMBLIES

48

10

4

Serie 400

Measuring the segment cut

Operation 4-6

If the segment is worn or damaged, replace it.

Segment cut Decarbonise the top of the cylinder bore.

Insert the segment in the cylinder at right angles with respect to the cylinder block and measure the cut with a thickness gauge. If the cut is greater than the service limit, replace the segment.

Segment number

S ta n d a r d

Service limit

Segment No.

1

0 , 2 0 - 0 , 3 5 mm

1 , 0 mm

Segment No.

2

0 , 2 0 - 0 , 4 0 mm

1 , 0 mm

0 , 2 0 - 0 , 4 0 mm

1 , 0 mm

Scraper segment

547405 EN (09/2010)

H1059

49

PISTON AND CONNECTING ROD ASSEMBLIES

4

Serie 400

Removal and fitting

Operation 4-7

Piston shaft Check the external diameter of the piston shaft. If it is lower than the service limit, replace the piston shaft.

External diameter 27,996 - 28,000 mm Play standard - 0 , 0 0 1 - +0 , 0 0 7 mm

Service limit 27,98 mm Service limit 0 , 0 2 mm

547405 EN (09/2010)

10

Piston and connecting rod assemblies

PISTON AND CONNECTING ROD ASSEMBLIES

50

4

Serie 400

10

Piston and segment Checking

Operation 4-8

Piston If the exterior surface of the piston is damaged (cracks, scratches, burns, etc.), replace it.

Piston skirt Check the outside diameter of the piston skirt (10 mm from the bottom).

Check the cylinder’s inside diameter (in the push direction). Calculate the play between the cylinder and the piston. If the play is greater than the service limit or if the piston’s diameter is less than the service limit, replace the piston.

Engine All models

Cylinder diameter 83,948 - 83,963 mm

Service limit 83,7 mm

Engine

Play between the piston and the cylinder

Service limit

All models

0,038 - 0,072 mm

0,25 mm

547405 EN (09/2010)

51

PISTON AND CONNECTING ROD ASSEMBLIES

4

Serie 400

Checking

Operation 4-9 S ta n d a r d

Service limit

Deformation by 100mm

< 0 , 0 8 mm

0 , 2 0 mm

Toe-in by 100mm

< 0 , 0 5 mm

0 , 1 5 mm

The connecting rod top and bottom bores must be fully square and parallel with respect to each other within tolerances of ± 0.31mm when measured 100mm from each side of the connecting rods’ axis on a test mandrel.

Check the connecting rod bottom ring and replace it if it is worn or damaged.

Check the piston shaft’ setting in the connecting rod’s bottom ring and check for wear on the piston shaft.

100 mm ± 0 , 3 1 mm

100 mm ± 0 , 3 1 mm

H1060

547405 EN (09/2010)

10

Connecting rod

PISTON AND CONNECTING ROD ASSEMBLIES

52

4

Serie 400

10

Connecting rod bottom ring Removal and re-installation

Operation 4-10

Calculate the play between the connecting rod bottom ring and the piston shaft. If the play is greater than the service limit, replace the ring.

Play (mm) 0, 010 - 0, 025

547405 EN (09/2010)

Service limit 0, 1

H1061

53

CRANKSHAFT ASSEMBLY

Serie 400

10

5 Crankshaft assembly

5

Crankshaft pulley Removal and re-installation

Operation 5-1

Tightening torque Nm (kgf m) Crankshaft nut

Special tools 304 (30,9)

Crankshaft pulley removal tool

NB: Store the cotter pin (1) in a safe place until fitting.

1

H1062

547405 EN (09/2010)

54

CRANKSHAFT ASSEMBLY

5

Serie 400

10

Crankshaft fixing bolts and crankshaft Removal and re-installation

Operation 5-2

Tightening torque Nm (kgf m) Crankshaft bearing carrier locking screw

52 (5,2)

Block crankshaft bearing carrier (Allen screw)

27 (2,7)

Attention : Ensure that the lubricating oil pressure relief valve has been removed before removing or refitting the crankshaft.

Ensure that the bearings’ oil channels are aligned on the cylinder block’s oil channels.

Remove the bearing-carrier’s locking screw (1) and lift the crankshaft assembly vertically to extract it.

Note: If the crankshaft or the crankshaft bearings are replaced, the fuel adjustment screw’s initial setting must not be altered. The maximum engine speed unladen must be checked after installation.

1

H1063

547405 EN (09/2010)

55

CRANKSHAFT ASSEMBLY

5

Serie 400

Checking the flexion

Operation 5-3

1 - Chock up the crankshaft on the V-shaped chocks.

2 - Adapt a dial gauge to the crankshaft’s central trunnion and turn the crankshaft progressively one complete turn.

3 - If the value indicated by the dial gauge is greater than the service limit, replace or rectify the crankshaft.

Flexion (mm) Standard

Service limit

0,03 or less

0,06

4 - When the measured diameter is less than the service limit, rectify and use reduced bearings and rings.

Checking the crankshaft 1 - Check the wear and condition of the oil seal contact surface.

2 - Check that the lubricating holes are not clogged.

3 - Check that the trunnion (A4) and the crank pin (A3) show no step wear. Measure the diameters (A5-A5) and (A6-A6) in positions (A1) and (A2). If the maximum difference between the measurements (step wear) is greater than the service limit of 0.05mm, correction is required.

Rectification specification When rectifying the crankshaft, work to the following specifications: Crank bearing/trunnion radius (B1)

3 mm ± 0,2 mm

Finishing precision (B2)

1.6Z (

Radius around the greasing hole (B3)

) 2 mm maximum / 5 mm minimum

Note: Use emery cloth No. 400 for the final polishing.

1

2

1

2 5

6

3

6

5

4 A

1

2 B

3 H1064

547405 EN (09/2010)

10

Crankshaft

56

CRANKSHAFT ASSEMBLY

5

Serie 400

10

Trunnion diameter Standard diameter 6 7 , 9 5 7 - 6 7 , 9 7 0 mm

Service limit

Reduction 0 , 2 5 mm

6 7 , 7 0 7 - 6 7 , 7 2 0 mm

6 7 , 6 5 mm

Reduction 0 , 5 0 mm

6 7 , 4 5 7 - 6 7 , 4 7 0 mm

6 7 , 4 0 mm *

S ta nda rd

6 7 , 9 0 mm

Crank bearing diameter

S ta nda rd

Standard diameter 5 1 , 9 6 4 - 5 1 , 9 7 5 mm

Service limit 5 1 , 9 0 mm

Reduction 0 , 2 5 mm

5 1 , 7 1 4 -5 1 , 7 2 5 mm

5 1 , 6 5 mm

Reduction 0 , 5 0 mm

5 1 , 4 6 4 -5 1 , 4 7 5 mm

5 1 , 4 0 mm *

NB: If the diameter is less than the maximum reduced service limit (*), the crankshaft must be replaced.

1

2 B

547405 EN (09/2010)

3 H1065

57

CRANKSHAFT ASSEMBLY

5

Serie 400

Checking

Operation 5-4

Check the play between the crankshaft’s trunnion and the bearing head.

1 - Clean the bearing surfaces and the half of the trunnion exposed.

2 - Fit the bearing head and tighten it to the specified torque rating.

3 - Remove the bearing head relating to the play to be checked.

4 - Place a piece of Plastigauge® all along the width of the bearing surface on the crankshaft trunnion, fit the bearing head and tighten its locking screw to the specified tightness.

5 - Remove the bearing head but do not move the Plastigauge® 6 - Use the Plastigauge® envelope to measure the Plastigauge’s widest point. This value indicates the play in the bearings in thousandths of an inch.

7- If the bearing play does not comply with the specifications, the crankshaft must be rectified or reduced bearings fitted.

Tightening torque Nm (kgf m) Bearing head locking screw

52 (5,2)

Standard play

Service limit

0,035 - 0,085 mm

0,20 mm

1.0

PLASTIGAUGE

2.0 2.5 3.0 4.0 5.0 6.0 7.0 POUCE

H0166

547405 EN (09/2010)

10

Play in the connecting rod bearings

58

CRANKSHAFT ASSEMBLY

5

Serie 400

10

Bearings Removal and fitting

Operation 5-5

Tightening torque Nm (kgf m) Bearing-carrier locking screw

52 (5,2)

Axial play If the axial play is greater than the service limit, check the wear on the end stop washers.

NB: Component (1) only used on 404C-22 Standard play

Service limit

0,10 - 0,40 mm

0,50 mm

End stop washer thickness 2,95 - 3,00 mm

Service limit 2,80 mm

1 - Identify the location of the bearing carriers on the crankshaft and mark them before removing them.

2 Fit the bearing carriers on the crankshaft, ensuring that the lubricating oil holes are aligned to the cylinder block supply holes.

3 Check the axial play.

NB: Ensure that the end stop washers are correctly aligned and fitted with their lubrication grooves facing the crankshaft.

4 - Check the end stop washers’ wear, condition and contact; replace them if they are damaged.

1

H1067

547405 EN (09/2010)

59

CRANKSHAFT ASSEMBLY

5

Serie 400

Centre bearing 1 -

Remove the bearing carrier and check that there are no signs of detachment, splitting, irregular wear or damage. Replace it if it is damaged.

2 - Use Plastigauge® to measure the lubrication play (see Operation 5-4) between the central trunnion and the bearing. If the lubrication play is greater than the service limit, replace the beari9ngs or rectify the central trunnion and use reduced bearings Engine

Standard lubrication play

Service limit

4 0 3 C -1 5

0 , 0 4 4 - 0 , 1 0 2 mm

0 , 2 0 mm

4 0 4 C -2 2

0 , 0 4 4 - 0 , 1 0 2 mm

0 , 2 0 mm

Engine / bearing size mm

Trunnion

Crankshaft’s centre diameter mm

403C-15 S ta nda rd

1, 2, 3

67, 957 - 67, 970

Reduction 0 , 2 5

1, 2, 3

67, 707 - 67, 720

Reduction 0 , 5 0

1, 2, 3

67, 457 - 67, 470

S ta nda rd

1, 2, 3, 4

67, 957 - 67, 970

Reduction 0 , 2 5

1, 2, 3, 4

67, 707 - 67, 720

Reduction 0 , 5 0

1, 2, 3, 4

67, 457 - 67, 470

404C-22

547405 EN (09/2010)

10

Bearing carrier

CRANKSHAFT ASSEMBLY

10

60

547405 EN (09/2010)

61

DISTRIBUTION CASING AND DRIVE UNIT

Serie 400

10

6 Distribution casing and drive unit

6

Distribution casing Removal and re-installation

Operation 6-1

Special tools Description Front oil seal protection Removal Attention : If the distribution casing assembly or the regulator’s internal components are replaced, the fuel adjustment screw must not be reset. The maximum engine speed unladen must be checked after installation.

The injection pump, see Operation 11-3 and the cotter pin in the crankshaft must be removed before removing the distribution casing.

Ensure that the stopping lever arm (1) is held under tension clockwise for removal and fitting.

1 - Ensure that the front oil seal protection (3) is in place before removing the distribution casing.

2 - To remove the PDF cover, see Operation 6-9.

3 - To remove and fit the crankshaft pulley, see Operation 5-1.

NB: If the distribution casing is replaced, a new emissions test label must be affixed as shown (2).

1

2

3 H1068

547405 EN (09/2010)

62

DISTRIBUTION CASING AND DRIVE UNIT

6

Serie 400 Operation 6-2

10

Fitting Special tools Description Front oil seal protection Fitting

1 - The injection pump, see Operation 11-3 and the cotter pin in the crankshaft must be removed before removing the distribution casing. Fit the front oil seal protection.

2 - To fit the PDF cover, see Operation 6-9.

3 - Ensure that the oil plug (3) is adapted to the hole in the intermediate pinion and that the stopping lever arm (1) is held under tension clockwise for removal and fitting.

4 - Remove the oil seal protection (4) after fitting the distribution casing. Fit the cotter pin in the keyslot in the crankshaft’s nose.

5 - For fitting the crankshaft pulley, see Operation 5-1.

NB: If the distribution casing is replaced, a new emissions test label must be affixed as shown (2).

Attention: If the distribution casing assembly or the regulator’s internal components are replaced, the fuel adjustment screw must not be reset. The maximum engine speed unladen must be checked after installation.

1

3 2

4 547405 EN (09/2010)

H1069

DISTRIBUTION CASING AND DRIVE UNIT

63

6

Serie 400

Removal and re-installation

Operation 6-3

Tightening torque Nm (kgf m) A ngle ic h ( 1 )

5 (0, 5)

NB: Lightly coat the threads (2) with Loctite 275 before fitting.

1

2

H1070

547405 EN (09/2010)

10

Angleich

64

DISTRIBUTION CASING AND DRIVE UNIT

6

Serie 400

10

Sliding block Removal and re-installation

Operation 6-4

The sliding block (2) must be fitted with the slot (4) blocked by the pin (3).

When fitting the distribution casing, ensure to align correctly the sliding block contact (1) on the regulator lever.

Attention: Incorrectly aligning the distribution casing can cause loss of control of the engine speed.

1 2 4

3

547405 EN (09/2010)

H1071

DISTRIBUTION CASING AND DRIVE UNIT

65

6

Serie 400

Removal and re-installation

Operation 6-5

Tightening torque Nm (kgf m) Camshaft retaining plate locking screw

11 (1,1)

The camshaft retaining plate is fitted between the cylinder block and the camshaft pinion.

The camshaft retaining plate is fastened by a locking screw and an Allen screw.

NB: If the camshaft assembly is replaced, the fuel adjustment screw’s initial setting must not be altered.

The maximum engine speed unladen must be checked after the installation.

H1072

547405 EN (09/2010)

10

Camshaft retaining plate

66

DISTRIBUTION CASING AND DRIVE UNIT

6

Serie 400

10

Camshaft and tappets Removal and re-installation

Operation 6-6

Attention: Remove all the tappets (1) before removing the camshaft, see Operation 10-2.

Remove the feed pump, see Operation 11-2.

Remove the injection pump, see Operation 11-3.

NB: If the camshaft assembly is replaced, the fuel adjustment screw’s initial setting must not be altered.

The maximum engine speed unladen must be checked after the installation.

Lubricate the tappets with fresh lubricating oil before installation.

1

H0173

547405 EN (09/2010)

DISTRIBUTION CASING AND DRIVE UNIT

67

6

Serie 400

Checking

Operation 6-7

Cam lifting height for the intake and exhaust valves (1).

Height (mm) Standard

Service limit

34,065 - 34,120

33,7

Cam lifting height for the feed pump (2) Height (mm) Standard

Service limit

31,900 - 32,000

30,0

Cam lifting height for the injection pump (3) Height (mm) Standard

Service limit

41,940 - 42,060

41,8

1

3

2

H1074

547405 EN (09/2010)

10

Camshaft assembly

68

DISTRIBUTION CASING AND DRIVE UNIT

6

Serie 400

10

Maximum fuel screw and maximum engine speed screw Positioning

Operation 6-8

Nb : The maximum fuel screw (1) and maximum engine speed screw (2) must not be adjusted by the technician.

In certain cases, it may prove necessary to remove these sacrosanct devices (3).

Any adjustment of the maximum fuel screw requires an engine test brake as well as checking the maximum engine speed unladen to confirm the settings Attention: This procedure may only be performed by a Perkins distributor. The servicing procedure is available from Perkins on request only for approved Perkins distributors.

1

3 2

H1075

547405 EN (09/2010)

DISTRIBUTION CASING AND DRIVE UNIT

69

6

Serie 400

Removal and re-installation

Operation 6-9

An O-ring (1) is fitted in the groove (2) at the front of the distribution casing.

A seal (3) is used behind the PDF cover on the distribution casing.

3

2 1

H1076

547405 EN (09/2010)

10

Front oil seal and PDF cover

70

DISTRIBUTION CASING AND DRIVE UNIT

6

Serie 400

10

Intermediate pinion and oil pump Removal and re-installation

Operation 6-10

To check the axial play, see Operation 6-13

H1077

547405 EN (09/2010)

DISTRIBUTION CASING AND DRIVE UNIT

71

6

Serie 400

Removal and re-installation

Operation 6-11

To remove the lubricating pump’s intermediate pinion with a suitable extraction device.

1 - Fit the positioning pin (1) in the block.

2 - Put the intermediate pinion (4) in the intermediate pinion hub fitting tool (3) and fit it on the positioning pin (1).

3 - Use a hammer (2) to tap the intermediate pinion hub fitting tool until the hub is fitted.

Special tools D e s c r i p ti o n Intermediate pinion hub fitting tool Attention: Always fit a new intermediate pinion hub; do not refit the removed hub because it may have been damaged during its removal.

1

2

3

1

4

H1078

547405 EN (09/2010)

10

Intermediate pinion hub

72

DISTRIBUTION CASING AND DRIVE UNIT

6

Serie 400

10

Pinion teeth play Checking

Operation 6-12

Distribution pinion tolerances mm Standard

Service limit

0, 08

0, 25

Measure the play in the teeth with a thickness gauge; if it is not within the service limit, replace the pinions.

H0179

547405 EN (09/2010)

DISTRIBUTION CASING AND DRIVE UNIT

73

6

Serie 400

Checking and setting

Operation 6-13

Use a thickness gauge to check the oil pump’s axial play (2).

Adjust it with shims (1) 0.1 – 0.15 – 0.2 and 0.5 mm thick.

Standard play (mm) 0,10 - 0,15

Service limit mm 0,20

1

2 H1080

547405 EN (09/2010)

10

Oil pump axial play

74

DISTRIBUTION CASING AND DRIVE UNIT

6

Serie 400

10

Regulator springs Checking

Operation 6-14

The diagram shows the correct position for the starting spring (1) and the regulator spring (2).

1

2

H0181

547405 EN (09/2010)

75

CYLINDER BLOCK ASSEMBLY

Serie 400

10

7 Cylinder block assembly

7

Front crankshaft ring Removal and re-installation

Operation 7-1

Attention: Ensure that the lubricating hole in the ring is aligned with the lubrication system in the block.

The ring must be fitted with the chamfered side (2) towards the cylinder block, with the seal (1) at the top.

To remove the ring, use the tool from inside the block.

1 2

H1082

547405 EN (09/2010)

76

CYLINDER BLOCK ASSEMBLY

7

Serie 400

10

Crankshaft ring Checking

Operation 7-2

1 - Check the ring’s condition, wear and contact. If there is any damage, wear or poor contact, replace the ring.

2 - Using a cylinder caliper and a micrometer, measure the play between the ring and the crankshaft trunnion.

3 - Measure the internal diameter at positions A1 and A2; measure A3 and A4 in both directions for each position.

The lubricating play is the difference between the largest value and the maximum crankshaft trunnion diameter

Standard lubricating play 0,044 - 0,116 mm

Service limit 0,20 mm

4 - If the lubricating play exceeds the service limit, replace the ring or rectify the crankshaft trunnion and use a reduced ring.

5 - Use a pressing tool to fit the crankshaft trunnion ring.

Ring size

Finished dimension of the external diameter of the crankshaft trunnion

S ta nda rd

6 7 , 9 5 7 - 6 7 , 9 7 0 mm

0 , 2 5 mm

6 7 , 7 0 7 - 6 7 , 7 2 0 mm

0 , 5 0 mm

6 7 , 4 5 7 - 6 7 , 4 7 0 mm

547405 EN (09/2010)

H1083

77

CYLINDER BLOCK ASSEMBLY

7

Serie 400

Checking

Operation 7-3

Check that there are no cracks, damage or deformation on the upper surface of the cylinder block in the same way as for the cylinder head, see Operation 3-16.

If it is not within the service limit, replace the cylinder block.

If the cylinder block is replaced, the engine must be checked with an engine test brake and the fuel adjustment screw set.

If a suitable engine test brake is not available, a semi-complete engine is available on standard exchange.

Standard value

Service limit

Less than 0.05 mm

0,12 mm

1

4

3 5

6 2

H1084

547405 EN (09/2010)

10

Upper surface of the cylinder block

78

CYLINDER BLOCK ASSEMBLY

7

Serie 400

10

Cylinder bores Checking

Operation 7-4

1 - Visually inspect the cylinder bores. There must be no scratches or corrosion.

2 - Measure the cylinder bores with a cylinder calliper at the top, in the middle and at the bottom (segment contact area) in the direction of the crankshaft (1) and at a right angle to the crankshaft (2).

3 - The upper part of the cylinder block is where the upper segment is in contact with the cylinder bore when the piston is at TDC (top dead centre) (approx 10 mm under the cylinder block’s upper surface). The lower part is where the scraper segment is in contact with the cylinder bore when the piston is at BDC (bottom dead centre) (approx 10mm from the upper surface).

Attention: the range of engines in the 400 series must not be ground with Flexihone.

If the bore diameter is greater than 84.2 mm, replace the cylinder block with a semi-complete engine.

If the cylinder block is replaced, the engine must be checked with an engine test brake and the fuel adjustment screw set.

If a suitable engine test brake is not available, a semi-complete engine is available on standard exchange.

Type of engine 403C-15 404C-22

New cylinder block bore diameter 8 4 , 0 0 0 - 8 4 , 0 1 9 mm

1

547405 EN (09/2010)

Service limit 8 4 , 2 0 0 mm

2

H1085

79

ENGINE TIMING

Serie 400

10

8 Engine timing

8

Injection timing

Type of engine

Operation 8-1

Nominal engine speed rpm

Injection timing (TDC/BDC)

403C-15 Generator unit

1500

1 4 ° ±1°

403C-15 Generator unit

1800

1 4 ° ±1°

403C-15 Generator unit

3000

2 0 ° ±1°

403C-15 Generator unit

3600

2 0 ° ±1°

4 0 3 C - 1 5 I ndus tria l

2200

2 2 ° ±1°

4 0 3 C - 1 5 I ndus tria l

2400

2 2 ° ±1°

4 0 3 C - 1 5 I ndus tria l

2600

2 2 ° ±1°

4 0 3 C - 1 5 I ndus tria l

2800

2 0 ° ±1°

4 0 3 C - 1 5 I ndus tria l

3000

2 0 ° ±1°

404C-22 Generator unit

1500

1 2 ° ±1°

404C-22 Generator unit

1800

1 2 ° ±1°

404C-22 Generator unit

3000

1 8 ° ±1°

4 0 4 C - 2 2 I ndus tria l

2200

1 8 ° ±1°

4 0 4 C - 2 2 I ndus tria l

2 400

1 8 ° ±1°

4 0 4 C -2 2 I ndus tria l

2600

2 0 ° ±1°

4 0 4 C - 2 2 I ndus tria l

2800

2 0° ±1°

4 0 4 C -2 2 I ndus tria l

3000

2 0 ° ±1°

If the injection pump is reused or replaced, shims of the same thickness as the original shims must be used.

The fuel adjustment screw’s initial setting must not be altered. The maximum engine speed unladen must be checked after installation.

No spare part is available for the injection pump in the 400 series.

547405 EN (09/2010)

80

ENGINE TIMING

10

8

Serie 400

Checking the injection pump timing

Operation 8-2

Special tools Return pipe 1 - Set the piston of cylinder number one to TDC in its compression stroke. Turn the crankshaft a quarter turn counterclockwise.

2 - Remove the ESOS unit and the high-pressure and low-pressure fuel hoses from the injection pump.

3 - Ensure that the supply lever is in the maximum fuel position.

4 - Remove the outlet valve carrier from cylinder number 1 and remove the outlet valve. Keep the outlet valve in clean fuel until you refit it.

NB: The injection pump may have to be set in vertical position to remove it and fit the outlet valves.

5 - Connect the injection pump return pipe (1) to the outlet valve carrier for cylinder number 1.

Continued

1

H1086

547405 EN (09/2010)

81

ENGINE TIMING

6 - Connect a suitable fresh fuel reservoir (1), fitted with a tap and containing approx 0.2 litres of fresh fuel, on the intake side of the injection pump.

7 - Set a suitable receptacle for collecting the used fuel (3) under the hose spout and open the tap; if the setting is correct, the fuel should flow out.

NB: The fuel reservoir must be approx 152mm above the injection pump.

8 - Slowly turn the crankshaft until the flow of fuel is reduced to a drop every 7 to 10 seconds.

This is then the timing point.

9 - Use the value shown by the timing mark (2) with the injection timing tables on page 69.

Continued

30

20

10

TOP

1

3

2

H1087

547405 EN (09/2010)

10

8

Serie 400

82

ENGINE TIMING

8

Serie 400

10

10 If the engine timing is wrong, adjust the thickness of the injection pump shim.

NB: An alteration of 0.1mm to injection pump shimming alters the timing by approx one degree. Thicker shims relay the timing and finer shims advance the timing.

11 Fit the outlet valve (1) and tighten the outlet valve carrier.

12 The engine must be checked with an engine test brake to check the maximum engine speed unladen and the engine settings after installation.

NB: No spare part is available for the injection pump in the 400 series.

Tightening torque Nm (kgf m) Outlet valve carrier

42 (4,2)

1

547405 EN (09/2010)

H1088

83

INTAKE SYSTEM

9 Intake system

9

Snifter valve system Closed circuit – cleaning and replacement

Operation 9-1

Cleaning the engine snifter assembly The snifter assembly must be replaced every 2000 hours.

Attention: Ensure that the snifter assembly’s components are fitted in the correct position (1 to 6). The engine may be damaged if they are not correctly fitted.

1 - Loosen the four locking screws (2) and remove the snifter valve cover (1), the spring (6) and the diaphragm assembly (4).

Attention: It is important for the area around the snifter hole (3) to be very clean.

2 - Clean the snifter cavity (5) in the rocker arm cover.

3 - Clean the snifter in fresh diesel fuel.

4 - Fit the snifter assembly in the cavity in the rocker arm cover, ensuring that the snifter cover, the diaphragm and the spring are all correctly fitted Tighten the four locking screws.

Only clean the snifter valve with fresh diesel fuel. If the snifter is damaged or the diaphragm is perforated, replace the snifter valve.

1

2 3

6 4 5

H1089

547405 EN (09/2010)

10

Serie 400

84

10

INTAKE SYSTEM

547405 EN (09/2010)

85

LUBRICATION CIRCUIT

Serie 400

10

10 Lubrication circuit

10

Lubricating oil cartridge Fitting

Operation 10-1

1 - Lubricate the seal with fresh engine oil before fitting it.

2 - Tighten the cartridge by hand until the seal makes contact with the block’s installation surface.

3 - Tighten the cartridge only by hand by an additional ½ to ¾ of a turn.

NB: Do not tighten excessively.

H1090

547405 EN (09/2010)

86

LUBRICATION CIRCUIT

10

Serie 400

10

Pressure relief valve Removal and re-installation

Operation 10-2

Tightening torque Nm (kgf m) Pressure relief valve

64 (6,5)

Replace the O-ring (1) when fitting the pressure relief valve on the cylinder block.

Attention: When removing or fitting the crankshaft, first remove the pressure relief valve.

1

H1091

547405 EN (09/2010)

87

LUBRICATION CIRCUIT

10

Serie 400

Removal and re-installation

Operation 10-3

Tightening torque Nm (kgf m) Oil sump locking screw

11 (1,1)

Oil sump drain plug

35 (3,5)

NB: Replace the seal (1) when fitting the oil sump.

1

H1092

547405 EN (09/2010)

10

Lubricating oil sump

88

LUBRICATION CIRCUIT

10

Serie 400

10

Lubricating oil strainer and intake pipe Removal and re-installation

Operation 10-4

Tightening torque Nm (kgf m) Intake strainer locking screw

11 (1,1)

Replace the O-ring (1) before fitting the intake pipe.

1

H1093

547405 EN (09/2010)

89

LUBRICATION CIRCUIT

Serie 400

10

Removal and re-installation

Operation 10-5

To check the axial play, see Operation 6-13.

H1094

547405 EN (09/2010)

10

Lubricating oil pump

90

LUBRICATION CIRCUIT

10

Serie 400

10

Rotor end play Checking

Operation 10-6

Standard limit on play 0,01 - 0,15 mm

Service limit 0,25 mm

Inner rotor to outer rotor (1)

1

H1095

547405 EN (09/2010)

91

LUBRICATION CIRCUIT

10

Serie 400

Removal and re-installation

Operation 10-7

Tightening torque Nm (kgf m) Oil pressure switch

10 (1,0)

The lubricating oil pressure switch may be in either of two locations.

1 - If it is fitted on the upper cover, the switch (1) is coloured brown and calibrated to 0.3 kgf/cm².

2 - If it is fitted on the upper cover, the switch (2) is coloured blue and calibrated to 1.0 kgf/cm².

1

2

H1096

547405 EN (09/2010)

10

Oil pressure switch

92

LUBRICATION CIRCUIT

10

Serie 400

10

Lubricating oil pipes Removal and re-installation

Operation 10-8

Tightening torque Nm (kgf m) Banjo bolt

12 (1,2)

NB: The lubricating oil circulating in the banjo bolt (2 and 4) is restricted.

Check the tightness and condition of the pipe.

When fitting, use new washers (1) and (3).

1 2

3 4 H1097

547405 EN (09/2010)

93

SUPPLY CIRCUIT

11 Feed circuit

11

Injectors Removal and re-installation

Operation 11-1

Tightening torque Nm (kgf m)

Test pressure kgf/cm2 (ats)

Injector

64 (6, 5)

Injector high-pressure pipes

23 (2,3) 27 (2,7)

Return pipe nut

150 (145)

Attention : Only use deep adaptors for this operation.

The connectors must be plugged until fitted The washer (1) has two small holes 180° apart.

Dispose of the used washer (2) and fit a new injector washer during installation.

NB: If the injector or injection hoses are replaced, you must not alter the initial settings on the fuel adjustment screw.

The maximum engine speed unladen must be checked after installation.

1

2

H1098

547405 EN (09/2010)

10

Serie 400

94

SUPPLY CIRCUIT

11

Serie 400

10

Feed pump Removal and re-installation

Operation 11-2

Tightening torque Nm (kgf m) Feed pump locking screw Feed pump inlet adjustment bolt (1)

6 (0,6) 2,5 (0,25)

The feed pump’s fuel inlet can turn 360° and be adjusted in increments of 15°.

The feed pump’s clamp has two series of positioning holes enabling it to be fitted in four different positions for the outlet connector.

1

H1099

547405 EN (09/2010)

95

SUPPLY CIRCUIT

11

Serie 400

Removal and re-installation

Operation 11-3

Tightening torque Nm (kgf m) Injection pump fasteners

15 (1,5)

Attention: The connectors must be plugged until fitted.

NB : If the injection pump is replaced, shims of the same thickness as the original shims must be used.

If a new injection pump is fitted, it must have the same reference as the original pump.

If the injection pump is replaced, you must not alter the fuel adjustment screw’s initial setting.

The maximum engine speed unladen must be checked after installation

H1100

547405 EN (09/2010)

10

Injection pump

96

SUPPLY CIRCUIT

10

11

Serie 400

Bleeding the air from the feed circuit

Operation 11-4

1 - Loosen the bleed screw on the fuel filter (1).

2 - Press the manual primer until bubble-free air flows from the bleed screw. Tighten the bleed screw (1).

3 - Loosen the bleed screw on the injection pump (2). Press the manual primer until bubble-free air flows out.

Tighten the bleed screw (2).

4 - Try to start the engine with the starter for 15 seconds maximum. Wait 30 seconds before trying again.

Attention : When using the starter, do not operate the starter continuously for any longer than 15 seconds at a time.

If the engine does not start the first time, wait 30 seconds before trying again.

The connectors must be plugged until they are fitted.

1

2

H1101

547405 EN (09/2010)

97

COOLING CIRCUIT

Serie 400

10

12 Coolant circuit

12

Coolant pump Removal and re-installation

Operation 12-1

Fit a new seal (1) during installation.

1

H1102

547405 EN (09/2010)

98

COOLING CIRCUIT

10

12

Serie 400

Checking

Operation 12-2

Start the engine and check that there are no coolant leaks from the coolant pump testing hole (1).

1

547405 EN (09/2010)

H1103

99

COOLING CIRCUIT

12

Serie 400

Removal and re-installation

Operation 12-3

When fitting, check the tension of the belt, see Operation 14-3.

To remove and refit the alternator, see Operation 14-4 Tightening torque Nm (kgf m) Locking screw

11 (1, 1)

Allen screw

11 ( 1, 1)

H1104

547405 EN (09/2010)

10

Fan and fasteners

100

COOLING CIRCUIT

12

Serie 400

10

Thermostat Removal and re-installation

Operation 12-4

Tightening torque Nm (kgf m Locking screw

14 ( 1 , 4)

Attention: Ensure that the thermostat is correctly in place in the thermostat housing.

H1105

547405 EN (09/2010)

101

COOLING CIRCUIT

Draining the cylinder block

Operation 12-5

Tightening torque Nm (kgf m) Cylinder block drain plug

30 (3,0)

1

H1106

547405 EN (09/2010)

10

12

Serie 400

102

COOLING CIRCUIT

10

12

Serie 400

Testing and checking

Operation 12-6

Visually inspect the thermostat’s condition; replace it if the shutter is open at ambient temperature.

1 - Place the thermostat in water.

2 - Gradually increase the water temperature.

3 - Note the shutter’s opening temperature and when the shutter lifts Thermostat shutter initial opening temperature °C 80 to 8 4

Thermostat shutter full opening temperature °C 95

Nb : The temperature for the shutter to start to open is marked on the thermostat.

The shutter takes 3 to 5 minutes before starting to operate.

H1107

547405 EN (09/2010)

103

FLYWHEEL AND CASING

Serie 400

10

13 Flywheel and casing

13

Flywheel Removal and re-installation

Operation 13-1

Tightening torque Nm (kgf m) Flywheel locking screw

74 (7,4)

H1108

547405 EN (09/2010)

104

FLYWHEEL AND CASING

10

13

Serie 400

Checking the flywheel casing’s concentricity and alignment

Operation 13-2

Check the casing’s concentricity with a dial gauge (A). The maximum radial run-out is shown in the table below.

If any adjustment is necessary, it must be made on the casing and the concentricity checked again.

Radial run-out of the flywheel casing’s bore

Flywheel casing SAE 5

All models

0 , 2 0 mm

Flywheel casing SAE 4 0 , 2 3 mm

Check the casing’s alignment (B). the maximum tolerance is shown in the table below. Any adjustment necessary must be made on the casing and not on the cylinder block.

Faux-rond de la face du volant moteur

Flywheel casing SAE 5

Flywheel casing SAE 4

0 , 2 0 mm

0 , 2 3 mm

All models

A 547405 EN (09/2010)

A0177

B

A0178

105

FLYWHEEL AND CASING

Checking the radial run-out of the flywheel and the alignment of the flywheel’s surface

Operation 13-3

1 - Check the flywheel’s concentricity with a dial gauge (A). The maximum reading must be less than 0.20mm.

2 - Check the alignment of the flywheel’s surface (B). During this check, hold the crankshaft pulled forwards to eliminate the effect of axial play from the crankshaft.

A

A0279

B

A0280

547405 EN (09/2010)

10

13

Serie 400

106

FLYWHEEL AND CASING

13

Serie 400

10

Starter ring Removal and re-installation

Operation 13-4

Replace the ring if there is excessive wear.

If the wear is not excessive, remove the ring and refit it 90° from its initial position.

To fit the ring, heat it between 120° and 150°C. Attention: Heat it uniformly; do not cause any local hot spots.

H1109

547405 EN (09/2010)

107

FLYWHEEL AND CASING

13

Serie 400

Removal and re-installation

Operation 13-5

The rear plate and the casing are only fitted together on engines / models 404C-22.

Tightening torque Nm (kgf m) Rear plate locking screw Casing locking screw

15 (1,5) 27 (2,7)

Note: When fitting, ensure that Powerpart silicon sealing product is used between the cylinder block and the rear oil seal.

1

2

H1110

547405 EN (09/2010)

10

Rear plate and rear oil seal

FLYWHEEL AND CASING

10

108

547405 EN (09/2010)

ELECTRICAL EQUIPMENT

109

14 Electrical equipment

14

Fuel cut-off solenoid Removal and re-installation

Op eration 14-1

Special requirements Tightening torque Nm (kgf m) Solenoid

17 (1, 7)

Nb : The washer has a built-in O-ring.

Always use a new washer when fitting.

H1111

547405 EN (09/2010)

10

S erie 400

110

ELECTRICAL EQUIPMENT

14

S erie 400

10

Bus bar / pre-heating plugs Removal and re-installation

Op eration 14-2

Tightening torque Nm (kgf m) Pre-heating plugs Bus bar nut

547405 EN (09/2010)

18 (1,2) 1,2 (0,12)

111

ELECTRICAL EQUIPMENT

14

S erie 400

Checking and adjustment

Op eration 14-3

Press with your finger on the centre of the belt on the longest strand, exerting a force of around 49 Newtons, 5 kgf.

Engine

Beam (mm)

403C-15

6

404C-22

7

Check that the belt is not cracked or contaminated with oil or grease.

H1113

547405 EN (09/2010)

10

Drive belt

112

ELECTRICAL EQUIPMENT

14

S erie 400

10

Alternator Removal and re-installation

Op eration 14-4

When fitting, check the drive belt’s tension, see Operation 14-3.

H1114

547405 EN (09/2010)

113

ELECTRICAL EQUIPMENT

S erie 400

14

Removal and re-installation

Op eration 14-5

Warning! The battery must be disconnected before removing the starter.

H1115

547405 EN (09/2010)

10

Starter

114

ELECTRICAL EQUIPMENT

14

S erie 400

10

Wiring diagrams Load circuit Cable number

Circuit

Circuit current

Maximum circuit voltage drop

Maximum circuit resistance

Remarks

Alternator charging

4, 7, 11

55 A

0,0143 ohm

0.50 Volt

See the pre-heating plus circuit

Starter solenoid

4, 5, 6

15.75 A

0,0400 ohm

0.63 Volt

See the pre-heating plus circuit

STD pre-heating plugs (via the preheating signal)

4, 5, 8, 9, 10

(Max feed) 0,0139 ohm

0.50 Volt

-

52 A

Attention: Diode capacity: current 3A, inverse voltage 6000V; this is compulsory.

Nb : The maximum size of the cable for the Lucar 375 terminals on the alternator is 65/0.3mm; consequently, paired cables are required on the alternator connection.

The maximum current consumed by the standard oil pressure switch is 0.42A (5 Watt bulb maximum).

A delayed action fuse may be fitted, if necessary.

Alternator charging indicator, 55 A Alternator load indicator nominal, output: 12 V – 2.2 W at 850 rpm When the engine is stopped, the alternator charging indicator light comes on up via the battery. The indicator goes out when the engine is running and the alternator is operating.

The use of a lower wattage bulb increases the speed with which the alternator operates; for example, a charging indicator with a bulb whose wattage is less than a nominal output of 12V – 1.2W at 1300 rpm.

2 DIODE

D2 Altr.

Oil pressure

Water temperature D1 Sol enoid

1

2 diode

Alternator W

11

B+ B

IND 1

7 65 A 80/0,4 (10) B

2

3 12 V Battery

S

Starter

3

4

Pre-heating plugs 10

Thermocontact

Oil pressure switch

Fuse AC

5

17 30

6

50

19

9 8

Pre-heating signal Ignition contactor

K1091/2

547405 EN (09/2010)

115

ELECTRICAL EQUIPMENT

14

S erie 400 Automatic stopping connector

Connector pin number 1

10

Wiring diagram for automatic stopping device (where applicable) Wire colour

Connection

Red

Ignition contactor – AC

2

O ra nge

Ignition contactor – 50

3

Red/Black

4

Brown

5

Blue

Coolant thermocontact

6

Black

Earth

S olenoid Oil pressure switch

3

2

1

4

5

6

Connector H1116

547405 EN (09/2010)

116

ELECTRICAL EQUIPMENT

14

S erie 400

10

Automatic charging circuit stopping device Automatic stopping conditions If the conditions listed below persist for more than ten seconds during starting or for two seconds while the engine is running, the engine will stop.

If the water temperature exceeds 110°C ± 3 °C If the oil pressure drops below 0.3 kgf / cm² (top cover option) or 1.0 kgf / cm² (lubricating array option).

Atte ntion : There is no automatic stop for low water levels.

Diode capacity: current 3A; inverse voltage 6000V; this is compulsory.

Nb : The standard oil pressure switch’s maximum current consumption is 0.42 A (5 Watt bulb max).

A delayed-action fuse may be fitted, if necessary.

6

4

5

1

2

Automatic stopping device

3 D1 *2 Diode

D2 Altr.

Water temperature

Oil pressure

Sol enoid *1

*2 Diode

Alternator

Mano-contact

11

W

Oil-Thermo

Pré-heating plug

B+ B

Fuse

Ind 65 A 80/0,4 (10) AC

B

12 V Battery

S

17 30

*3

50

19

Pré-heating Signal

Ignition contactor

Starter K1094/2

547405 EN (09/2010)

117

AUXILIARY EQUIPMENT

S erie 400

Auxiliary equipment None fitted

10

15 15 Op eration 15-1

547405 EN (09/2010)

10

118

547405 EN (09/2010)

119

SPECIAL TOOLS

S erie 400

10

16 Special tools

16

List of special tools

D e s c r i p ti o n

I l l u s tr a ti o n

Valve spring removal tool

Valve stem gasket fitting tool

Crankshaft pulley removal tool

Intermediate pinion hub fitting tool

547405 EN (09/2010)

120

SPECIAL TOOLS

16

S erie 400

10

D e s c r i p ti o n

Injection pump return pipe

Front oil seal protective cover

Valve seat cutter

547405 EN (09/2010)

I l l u s tr a ti o n

10 ENGINE SPEED SOLENOID – REMOVAL AND ADJUSTMENT

Pages A - Solenoid - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 2 B - Solenoid - Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 4

(04/2011)

10-04-17-M172EN

2

Engine speed solenoid – Removal and adjustment

10

A - SOLENOID: REMOVAL

A1

NT T A ON FR V A

- From the base console, instruct arms 1/2 to rise up to the upper articulation point (A1-1), i.e. 1m above the counterweight.

1

MACHINES WITHOUT MAINTENANCE ARMS - Place a sling connected to a hoist on the articulation point.

- From the base console, instruct arms 1-2 to lower until the strap tightens: then release the controls.

A2

- Switch off the engine.

T NNT RAO

1

A VF

MACHINES WITH MAINTENANCE ARMS

2

- Climb onto the chassis, remove the locking pin, manually lift the maintenance arms (A2-2) and fit the supporting stand.

- From the base console, instruct arms 1-2 to lower until the upper articulation point (A2-1) comes into contact with the maintenance arms: then release the controls.

- Switch off the engine.

(A3-3).

- Remove the battery cover (A3-3)

A3

T NNT RAO

A VF

3

A4

(A4-4), and then the - Remove the engine inspection hatch (A4-4) central protective casing (A4-5) (A4-5).

4 5 NT T A ON FR V A

10-04-17-M172EN

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3

Engine speed solenoid – Removal and adjustment

NT T ON A FR AV

A5

10

- Remove the engine protective casing (A5-6) (A5-6).

6

A6

- Locate the engine speed solenoid on the right-hand side of the engine (A6-7) A6-7).

8

- Disconnect its supply cable bundle.

- Remove the linkage between the solenoid and the engine (A6-8). speed valve lever (A6-8) - Remove the solenoid fixing bolts (A6-9) and remove the solenoid.

7

9

REASSEMBLY - Repeat the removal operations described above in reverse order and then check the solenoid’s setting § B

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4

Engine speed solenoid – Removal and adjustment

10

B - SOLENOID: ADJUSTMENT

B1 2

- Turn the ignition key to switch on the lifting platform.

3

- Remove the solenoid fixing bolts (B1-1) (B1-1).

1

D-MT-021

B2

- Locate the low-temperature engine starting assistance knob on the base console (B2-1) and switch it to the SNOW position: the (B1-3). solenoid (B1-2) moves towards the engine speed lever (B1-3)

To avoid injury, keep your hands away from the solenoid, the end stops and the engine speed lever during this phase.

- Take a set of thickness gauges and place a 1mm gauge against the rear stop (B3-1); then manually move the solenoid/engine speed lever assembly (B3-2) backwards until the lever is resting on the thickness gauge (B3-3) (B3-3).

1

4

B3 2

- Check that the fixing holes in the solenoid bracket match those on the solenoid itself (B3-4) : - If the fixing holes match, refit the solenoid and tighten the fixing bolts.

- If the fixing holes do not match, follow the steps below.

5 3 1mm

(B3-5).

- Remove the articulation shaft (B3-5)

1

D-MT-033

- Push back the solenoid/engine speed lever assembly and disengage the ball joint (B4-1) from the fitting on the lever (B4-2) (B4-2).

- Loosen the lock nuts (B4-3) (B4-3).

B4 3

1

2

- Increase or reduce the length of the ball joint screw and the silent block as necessary (B5) (B5).

D-MT-034

10-04-17-M172EN

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Engine speed solenoid – Removal and adjustment

B5

10

- Engage the ball joint (B4-1) in the fitting on the lever (B4-2), refit the articulation shaft and tighten the lock nuts (B4-3) (B4-3).

- Repeat the test: - Check that the distance between the max engine speed stop (B3-3) and the engine speed lever (B3-5) is 1mm

Return the machine to operating condition - Restore the low-temperature engine starting assistance knob (B1-1) to the SUN position.

(04/2011)

5

10-04-17-M172EN

Engine speed solenoid – Removal and adjustment

10

6

10-04-17-M172EN

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10 ENGINE - REMOVAL

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2

Engine - Removal

10

Set the basket in the Low position.

- Switch off the engine.

A FR V ON AT N

A T

- Switch off the lifting platform.

- Open and then remove the left-hand turret cover (A-1) as follows: - Remove the cylinder head: WARNING: take care to hold onto the cover (weight approx. 18kg).

1 - Remove the cover/hinge fastenings.

- Remove the cover.

- Remove the lower cover (B-2) (B-2).

A FR VO ANT N

B T

- Locate and disconnect the electrical bundles and cables: - Alternator.

- Starter - Water temperature sensors - Preheating.

- Engine oil pressure.

- Stop engine.

- Earth...

2

C

- Remove the fastenings for the filter (C-3) leaving all the hoses connected.

3

- Remove the air inlet hose (D-4) (D-4).

A FR V ON AT N

D T

4

10-06-16-M172EN

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3

Engine - Removal

- Remove the complete air filter (E-5) (E-5).

E T

10

A FR V ON AT N

5

F

- Remove the side shackle (F-6) (F-6).

6

A FR V ON AT N

- Remove the exhaust manifold (G-7) (G-7).

- Locate the radiator drain tap on the bottom left of the radiator (G-8) (G-8).

A FR V ON AT N

T

G T

- Take a rubber hose, 5mm internal diameter, 150`200mm long, and slide it around the drain pipe.

- Place a receptacle under this hose, open the drain tap and then the radiator filling cap.

- Locate the coolant circuit plug (H-9) located on the right-hand side of the engine behind the dipstick and unscrew it to drain the coolant in the engine.

7

8

H

- Refit the plug and close the drain tap.

9 NT T AON FR V A

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10-06-16-M172EN

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Engine - Removal

10

- Remove both hoses from the coolant circuit (I-10) (I-10).

I

- Locate, remove and plug the hydraulic hoses connected to the hydrostatic generator and the auxiliary generator (for information, when stopped, the pressure in these hoses is low or non-existent). Proceed as follows:

10

- Place a receptacle under the generators.

- Slowly loosen the nut on the hose or its fixing bolts a quarter turn at a time to let any residual pressure escape.

A FR V ON AT N

T

- When the pressure has fallen, completely remove the hose, plug it and move on to the next one.

J

- Locate, remove and plug the two diesel supply and return hoses.

- Hook a sling connected to a hoist onto both the engines sling points (J11) 250kg

A FR V ON AT N

13

T

11 12

- Remove the engine / silent block connection bolts (J-12) (J-12).

- Remove the engine: - Adjust the position of the winch’s hook on the sling (J-13) so that the engine rises horizontally.

12

14

- Raise the engine 2~3cm.

- Move it backwards (J-14) to remove the fan from its housing in the radiator: WARNING: pay attention to the hoses and other components still in place.

K 15

- Lift the engine and finish removing it.

16 RE-INSTALLATION

A FR V ON AT N

- Perform the removal operations in reverse order.

- Fill the radiator (K-15) with 8 litres of coulant

 547402FR

- Re-prime the fuel circuit by pressing the priming bulb on the fuel supply hose several times in succession.

- Switch the machine on, start the engine and perform a full test of all the machine’s movements.

- Switch off the engine, check the hydraulic oil level in the reservoir (K-16) and top it up if necessary.

10-06-16-M172EN

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T

AXLE

- AXLE REMOVAL

30

- SETTING IN FREEWHEELING MODE

30

REAR AXLE - REMOVAL

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2

Rear axle - removal

A

- Set the lifting platform in Transport position on a horizontal surface.

To restrict the pressure in the steering control hoses, you must have the wheels straight.

N TT A ON V R AF

1

- Switch off the engine and switch off the lifting platform.

30

- To prevent the lifting platform from subsequently moving, set wooden chocks in front of and behind the front wheels.

The weight of the components to be removed is significant; 2 people are required to perform most of the following operations.

B

NT AONT A FVR

2 - Remove the sealing plate (A-1).

- Locate the translation motor (B-2) fitted on the rear axle and remove it. Once you have removed it, leave it hooked up to the hoses.

- Locate the cardan shaft linking the 2 axles: - Remove both fixing clamps (C-3) from the front axle.

C

- Free the head of the cardan shaft (C-4) from its housing in the axle by moving it backwards; hold on to the shaft.

- Remove both fixing clamps (C-5) from the rear axle and remove the cardan shaft.

4

- Hook a sling connected to a hoist onto the holes in the rear of the chassis: 160 ATJ FC / 160 ATJ FC RC 4600kg

3

5 N TT AON V R AF

- Lift the rear axle a few centimetres so that the wheels are only slightly in contact with the ground.

D - Locate the hoses supplying the steering cylinder (D-6) and those supplying the brakes (D-7) and then remove them as follows:

7 - Place a receptacle under the centre of the axle.

8

- Simultaneously loosen the nuts on the hoses, a quarter turn at a time, to allow the residual pressure to escape.

- When the pressure has fallen, remove the hoses completely and plug them with 12S male plugs for the steering hoses and 8S male plugs for the brake hoses.

30-06-12-M172EN

6

N TT AON V R AF

(04/2011)

3

Rear axle - removal

- Loosen the wheel nuts and remove them.

- Free each rear wheel by moving it to and fro and remove them

E 210kg

- Set chocks under the chassis in front of the axle and outside the chassis’ cut away section (D-8) and then set the chassis on the chocks, paying attention to the translation motor.

- Retrieve the sling and pass it around the axle as close to the hub as possible or use a lift truck and place the forks under the axle.

NT A NT O V R A

F

- Remove the rear axle (E)

30

- Remove the fasteners holding the axle onto the chassis.

370kg

RE-INSTALLATION - Perform the removal operations in reverse order.

- Tighten the wheel nuts with a torque wrench (34 daN.m ±15 %).

- Switch the machine ON, start the engine and perform a complete test of all the machine’s movements.

- Switch off the engine, check the level of hydraulic oil in the reservoir and top up the oil if necessary.

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4

30

Rear axle - removal

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30

FRONT AXLE - REMOVAL

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2

Front axle - Removal

- Set the lifting platform in transport position on a horizontal surface.

To restrict the pressure in the steering control hoses, you must set the wheels straight.

160 ATJ FC / 160 ATJ FC RC 160 ATJ FC / 160 ATJ FC RC (Oscillation option)

30

- Remove the covers from the oscillation locking cylinders (A-1).

- Place a wooden chock in front of the right-hand front wheel (A-2).

A

NTT ON RA V F A

1

- Disconnect the connector for the left-hand oscillation locking cylinder’s electro-valve (B-3).

2

- Instruct the lifting platform to move forward on to the chock.

7

- Disconnect the connector for the right-hand oscillation locking cylinder’s electro-valve (B-4).

- Place a wooden chock 1 centimetre thick under the LEFT-hand oscillation locking cylinder’s piston.

B

T

A

NT A ON FVR

3 4

- Connect the connector for the left-hand oscillation locking cylinder’s electro-valve (B-3).

- Instruct the lifting platform to reverse off the chock.

- Disconnect the connector for the left-hand oscillation locking cylinder’s electro-valve.

All machine versions - Switch off the engine and switch off the lifting platform.

The weight of the components to be removed is significant; 2 people are required to perform most of the following operations.

- Locate the cardan shafts linking the 2 points: - Remove both the fixing clamps (C-5) on the front axle.

C

NTT ON RA V F A

- Free the head of the cardan shaft (C-6) from its housing on the axle by moving the shaft to and fro.

- Remove both the fixing clamps (C-7) on the rear axle and remove the cardan shaft.

7 AV

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5

6

A

NT

(04/2011)

3

Front axle - Removal

- Hook a sling connected to a hoist to the sling attachment points on the front of the chassis: - 160 ATJ 3500kg

AV

A

D

NT

8

- Raise the front axle a few centimetres so that the wheels are only slightly in contact with the ground.

- Place a receptacle under the middle of the axle.

- Simultaneously loosen the nuts on the hoses, a quarter turn at a time, to allow the residual pressure to escape.

NTT A ON

R A FV

9

30

- Locate the hoses (D-8) supplying the steering cylinder and then remove them as follows:

E

- When the pressure has fallen, completely remove the hoses and plug them with 12S male plugs.

- Loosen the wheel nuts and remove them.

- Free each front wheel by moving it to and fro and remove them 210kg

NT T

AN O

R A FV

- Set chocks under the chassis behind the axle and outside the chassis’ cut away section (D-9) and then set the chassis on these chocks.

- Retrieve the sling and pass it around the axle as close to the hub as possible or use a lift truck and place the forks under the axle.

- Remove the fasteners holding the axle onto the chassis.

- 160 ATJ FC / 160 ATJ FC RC : 8 bolts, 2 plates.

- Remove the front axle (E)

290kg

RE-INSTALLATION Perform the removal operations in reverse order.

- Tighten the wheel nuts with a torque wrench (34 daN.m ±15 %).

- Switch the machine ON, start the engine and perform a complete test of all the machine’s movements.

- Switch off the engine, check the hydraulic oil level in the reservoir and top up the oil if necessary.

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30

Front axle - Removal

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SETTING IN FREEWHEELING MODE

(04/2011)

30-08-21-M172EN

2

Setting in freewheeling mode

The lifting platform may only be towed a short distance by means of a connecting bar and must necessarily be towed by a machine with significant braking force in order to hold the lifting platform.

- To prevent the lifting platform from moving while in freewheeling mode, chock the wheels (front or rear).

A

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

1

30

- Mark the hydrostatic generator’s HP restrictors (A-2) and draw alignment marks with a marking pen on all the calibration components.

- Screw the restrictors down to the sticking point plus one and a half turns. WARNING! Note the number of turns made by the restrictors because this information will be useful later.

A

V

A

N

2 T

B

- On the rear axle, locate the two screws (B and C-3) on the front and the rear, on the left-hand side.

3

AV

A

NT

C

- Unscrew them sufficiently to be able to remove the cotter pins (C-4) and then screw them in: the lifting platform is completely unbraked.

4

3 AV

A

NT

RESTORING THE BRAKES TO OPERATION Perform the above operations in reverse order.

- Set both restrictors (A-2) by unscrewing them the number of turns noted down during the first stage; line up the markings.

- Perform a translation test on a level surface and then on a sloping surface and check that the lifting platform is immobilised as soon as the forward motion control is no longer being activated.

30-08-21-M172EN

(04/2011)

TRANSMISSION

20

- CHECKING AND ADJUSTING THE TRANSMISSION - HYDROSTATIC GENERATOR – REMOVAL AND DISMANTLEMENT M

R

647 255FR Rexroth A10VG45 pump

- REXROTH GENERATOR CHARACTERISTICS & SPECIFICATIONS

647 256FR Rexroth A2FM engine R

- REXROTH MOTOR CHARACTERISTICS & SPECIFICATIONS

M

- HYDROSTATIC MOTOR – REMOVAL AND DISMANTLEMENT

20

HYDROSTATIC PRESSURE

Pages A - Hydrostatic pump (rexroth) - Description 1 - Pressure sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 2 2 - Adjustment points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 2 B - Hydrostatic pressure (rexroth) - Settings 1 - Engine speed unladen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 3 2 - LP force-feed valve - Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 4 3 - Servo-control piston – neutral point adjustment . . . . . . . . . . . . . . . . . . P 5 4 - DA regulation valve - Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 6 5 - HP valve - Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 7 6 - DR flow-cancellation valve - Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . P 8

(04/2011)

20-04-M172EN

2

Hydrostatic pressure

A - HYDROSTATIC PUMP (REXROTH) : DESCRIPTION 1 - PRESSURE SOCKETS :

A1

20

AV

AN T

Crankcase Pression de carter pressure XA Pression and XB pilot de pilotage pressure XA et XB

HPPression Pressure,HP line Ligne - RECUL A -A REVERSE

Pression Booster de gavage pressure

HPPression Pressure,HP line Ligne B - AVANCE B - FORWARD

2 - ADJUSTMENT POINTS :

A2 AV

Zéro mécanique Mechanical zero

AN T

flowValveDR d'annulation de débit DR cancellation valve HP Valve Pressure, HPline Ligne A - RECUL A - REVERSE

Regulation de Vis excentrique fin completion de régulation eccentric screw

Valve de LP booster gavage valveBP

DAValve regulation de régulation valve DA

HP Valve Pressure, HPline Ligne B - AVANCE B - FORWARD 20-04-M172EN

(04/2011)

3

Hydrostatic pressure

B - HYDROSTATIC PRESSURE (REXROTH) : SETTINGS

B1

20

Before performing the calibrations described in this section, provide yourself with two hydraulic manometers: - 1 manometer 0 - 400 bar.

- 1 manometer 0 - 100 bar.

1 - Engine revs unladen - Start the engine and then display the ENGINE menu (B1) on the computer screen computer  80-04-07-M.172 - Check the engine’s idling speed and its maximum speed - Adjust the speed settings, if necessary

(04/2011)

 547402EN

 10-04-17-M.172

20-04-M172EN

4

Hydrostatic pressure

B2

2 - LP FORCE-FEED VALVE - CALIBRATION:

FR A VOAN NTT

- Install a T connection (B2-1) between port “G” on the hydrostatic generator and the connecting hose for the brakes and the differential locking control (B2-2).

20

- Take a straight connector (B2-3) (M/F 16x150-8S) and fasten it on the end of the hose; then connect the manometer to this connector (B2-4) (0-100 bars).

1 0 100

- Start the engine, measure the pressure while the engine is idling unladen and then at maximum engine speed unladen.

4

3

- The pressure should vary from 12 to 30 bars approx, depending on the engine speed.

- If the pressure is incorrect, remove the force-feed pressure restrictor (B3-1).

AFRVO ANNT T

B3

- The restrictor is adjusted by increasing or reducing the number of shims (B3-2) between the spring and the restrictor’s slide.

2 1

NB: For every 1mm of shims added, the pressure increases by approx. 4 bars.

20-04-M172EN

(04/2011)

5

Hydrostatic pressure

3 - SERVO-CONTROL PISTON – NEUTRAL POINT ADJUSTMENT:  547402EN

- Remove the plugs sealing piloting points XA and XB and then take adapter connectors (B4-1) threaded M12x1.5 on one side for insertion instead of the plugs.

B4 B4

FRV A OANN TT

2 1

20

- Set the machine on stands

- Connect a hose (B4-2) to both the connectors so that the pressure is equalised on both sides of the servo-control piston - Start the engine.

Take care when performing this operation; the machine’s wheels start to turn: ensure that there is no one nearby.

5 4

3

- Loosen the lock nut (B4-3) to turn the piston screw (B4-4).

- Turn the screw in one direction until the machine’s wheels start to turn in one direction.

- Mark the position of the screw.

- Turn the screw in the other direction until the machine’s wheels start to turn in the opposite direction.

- Mark the position of the screw: the piston’s neutral point lies in the middle of these two points.

- For greater accuracy, install a precision digital manometer (0-400 bars) on each HP outlet (B4-5).

- Repeat the above procedure and mark the position of the piston’s setting screw as soon as any variation in pressure is shown on the manometer.

(04/2011)

20-04-M172EN

6

Hydrostatic pressure

4 - DA REGULATION VALVE - CALIBRATION: - Locate the brake/steering hydraulic unit on the chassis

B5  70-03-M.172

AFR

VOAN NTT

20

- Disconnect the control bundle from the brake electro-valve: this enables you to keep the wheels locked even during a translation movement.

1

- Install a manometer (0-400 bars) on each HP outlet (B5-1).

- Start the engine.

2

Warning! During this test, the pressure in the hydrostatic circuit may drive the wheels: the machine is only immobilised by its brakes.

Ensure that there is no one inside the safety perimeter

- Ensure that the lifting platform is in transport position.

- Check the engine’s idling speed on the computer screen and adjust if necessary §B-1 - Instruct a forward translation movement (High speed mode) and hold down the control lever - Read the pressure on the manometer: the theoretical pressure is 330 bars.

- Adjust the setting on the regulatory valve (B5-2).

20-04-M172EN

(04/2011)

7

Hydrostatic pressure

B6

5 - HP VALVES - CALIBRATION: Warning! Before setting the HP valves, you must first overcalibrate the DR14 valve (B6-1). .................................. §B-6

1

FAR

VOAN NTT

20

- Install a manometer (0-400 bars) on each HP outlet (B6-2).

- Adjust the DR valve’s calibration.

3

Warning! Because of the DR valve’s technical design, under no circumstances must you attempt to adjust the valve while it is still under pressure. Ensure that the engine is switched off before starting to adjust the valve.

2

- Loosen the valve’s lock nut and then tighten the calibration screw a halfturn.

- Disconnect the control bundle from the brake electro-valve on the brake/ steering hydraulic unit.

- Select High speed (Hare setting) on the basket console and instruct movement forwards at full speed.

B7

- Read the pressure on the manometer connected to the lower pressure bars. socket (line A): the theoretical pressure is 365 bars - Make the same checks, instructing reverse movement at full speed and checking the manometer connected to the upper pressure socket (line B).

- If the pressure values are incorrect, switch off the engine and follow the procedure below: - Remove the valves to be adjusted (B6-3) and remove the shockabsorption system (B7).

B8

- Remove the locking screw (B8-1).

- Tighten (increase the HP pressure) or loosen (reduce the HP pressure) the calibration screw on the spring (B8-2): for information, 1 turn of the screw adjusts the calibration by around 45 bars.

1

- Re-install the valves and then repeat the procedure until the settings are correct.

- Calibrate the DR valve

§B-6

2

(04/2011)

20-04-M172EN

8

Hydrostatic pressure

6 - DR FLOW-CANCELLATION VALVE - CALIBRATION:

20

Warning! During this test, the pressure in the hydrostatic circuit may drive the wheels: the machine is only immobilised by its brakes. Ensure that there is no one inside the safety perimeter.

B9 2

AFVRO ANNT T

- Disconnect the control bundle from the brake electro-valve on the brake/ steering hydraulic unit.

- Install a manometer (0-400 0-400 bars bars) on each HP outlet (B9-1).

- Ensure that the arms are folded and the telescope is retracted.

1

- Check the engine’s idling speed on the computer screen ................ § B - 1 - Select High speed (Hare setting) on the basket console and instruct movement forwards at full speed.

- Read the pressure on the manometer connected to the lower pressure bars. socket (line A): the theoretical pressure is 340 bars - If the pressure values are incorrect, switch off the engine and adjust the DR valve’s calibration (B9-2).

20-04-M172EN

(04/2011)

(04/2011)

20

HYDROSTATIC PUMP - REMOVAL

20-06-05-M172EN

2

Hydrostatic pump - Removal

- Set the basket in the Low position.

FARVO

ANNT T

A

- Switch off the engine.

1

- Use the battery cut-out (preliminary series) to switch off the lifting platform.

20

- Open and then remove the left-hand turret cover (A-1) as follows: - Remove the gas cylinder head.

- Remove the cover/hinge fasteners.

- Remove the cover.

- Remove the air inlet hose (B-2).

FARVO

ANNT T

B

2

- Remove the complete air filter (C-3).

FARVO

ANNT T

C

3

FARVO

- Mark and disconnect the hydrostatic generator’s electrical control bundles (D-4).

ANNT T

D 4

- Mark, remove and seal the hydraulic hoses connected to the hydrostatic generator and the auxiliary generator (for information, when stopped, the pressure in these hoses is low or non-existent). Proceed as follows: - Place a receptacle under the generators.

5

- Slowly loosen the nut on the hose or its fixing bolts a quarter turn at a time to let any residual pressure escape.

- When the pressure has fallen, completely remove the hose, plug it and move on to the next one.

- Place a sling connected to a hoist around both generators

20-06-05-M172EN

40kg

(04/2011)

Hydrostatic pump - Removal

3

- Remove the bolt connecting the generators to the engine (D-5).

- Remove the generators.

RE-INSTALLATION

20

Perform the removal operations in reverse order.

- Use the battery cut-out (preliminary series) to switch the lifting platform on and then start the engine and perform a full test of all the machine’s movements.

- Switch off the engine, check the hydraulic oil level in the reservoir and top it up if necessary.  547402EN

(04/2011)

20-06-05-M172EN

Hydrostatic pump - Removal

20

4

20-06-05-M172EN

(04/2011)

(04/2011)

20

HYDROSTATIC MOTOR – REMOVAL

20-06-24-M172EN

2

Hydrostatic motor - Removal

Set the lifting platform in transport position on a horizontal surface.

T N NT

A

A O AFVR

- Switch off the engine and switch off the lifting platform.

20

- Remove the sealing plate (A-1).

1 - Mark, remove and plug the motor supply hoses:

B

- Place a receptacle under the motor.

- Loosen the hose fixing screws (B-2) slowly a quarter turn at a time, to allow the residual pressure to escape.

2

- When the pressure has fallen, completely remove the hoses and plug them with cloths.

3

- Remove the drain hose (B-3) and plug it with an 8S male plug.

- Remove the motor (C-4) ..............................................................................

NTT

AN O

20kg

AFVR

C

RE-INSTALLATION - Perform the removal operations in reverse order.

4 N TT AN O V R AF

- Switch the machine ON using the (preliminary series) batter cut-out. Start the engine and conduct a translation test forwards and then backwards.

- Switch off the engine, check the hydraulic oil level in the reservoir and topup with oil if necessary  547402FR

20-06-24-M172FR

(04/2011)

ELECTRICITY

- ELECTRICITY - WIRING DIAGRAM - ELECTRICAL COMPONENTS - LOCATION - ELECTRONIC MODULES - OPERATIONAL CONTROL - SENSORS AND SETTINGS - JOYSTICKS - TESTING

80

- ELECTRICAL BUNDLES - REMOVAL

80

ELECTRICITY – SCHEMATIC DRAWING

(04/2011)

80-02-677917-M172EN

ELECTRICITY – SCHEMATIC DRAWING

80

2

80-02-677917-M172EN

(04/2011)

3

ELECTRICITY Electricity - Wiring WIRINGdiagram DIAGRAM

white

PLAN 832649

cap emergency pump button

white

ENGINE SPEED FORCING

BASKET/BASE SELECTOR

BASE EMERGENCY STOP

IGNITION KEY

blue: base

grey/pink

white

red/blue

brown

grey:+12V

brown

brown

Connector

Start-up button

violet:+12V

Connector

white

LOW ARM SENSOR N2

pink: basket

cap

LOW ARM SENSOR N1

red

blue

grey

green

yellow

pink

violet

brown

black

white

red/blue

brown connector

grey/pink: axle sensors +12V black: axle sensors Earth red/blue: rear axle sensor white: rear axle sensor pink: diff block electro-valve brown: brake electro-valve violet: brake and diff block electro-valves Earth yellow: crab steering electro-valve grey: 4-wheel steering electro-valve green: steering electro-valve Earth blue: electro-oscillo 1/2 red: electro-oscillo Earth

turret

ELECTRICAL COLLECTOR chassis

green

blue:emergency stop

blue

red

red

red:+12V (+APC)

grey: basket earth

grey

brown

grey: 12V

DIFFERENTIAL LOCK

white +12V

blue

green

red

blue

grey

yellow

green

violet

brown

pink

red/blue

red

CONNECTOR INTO UPPER ARTICULATION yellow

common black

green:basket earth

blue

common red:GND

yellow

grey green

blue

common red:GND

yellow:spare

grey green

FRONT AXLE SENSOR red:GND

violet

common black

violet:12V (+Bat)

common black:GND

violet

common black:GND

grey

violet

REAR AXLE SENSOR

pink

common black:GND

brown

yellow green:GND

brown:CAN High

common red:GND

pink brown

marron

pink

white common red:12V

black:GND common black:GND rose violet:GND

yellow

commun blanc brown

white +12V

white

brown

yellow

grey/pink:12V common red:12V

red/blue

red/blue:emergency stop

CONNECTOR

blue

green

grey/pink black

black:BP start-up white:CAN Low pink:+12V (+Bat)

yellow

yellow grey: 12V

red/blue

grey/pink:BP emergency pump

white

white marron

green

white +12V common white

grey: 12V

blue

white

Connector grey/pink black red/blue

red/blue

brown

black

grey/pink Connector grey/pink black

common red:GND

green

TELESCOPE ARM SENSOR N2

CONNECTOR

brown

TELESCOPE ARM SENSOR N1

CONNECTOR

white +12V

connector

blue

common white

brown:start-up

white:+12V(+APC) green

brown

Connector

grey/pink

green:GND

Connector common white

brown:+12V(+Bat)

yellow:contact

white

CONNECTOR

green:+12V(+Bat)

CONNECTOR

white

CONNECTOR

BRAKE ELECTROVALVE

CRAB STEERING

4 -WHEELS STEERING

N.1

OSCILLATION N.2

BASKET CONSOLE

blue:GRD

connector FLASHING LIGHT

CONNECTOR brown blue:GRD

pink:+12V (+Bat)

BUZZER brown: 12V

red:+12V (+APC)

CONNECTOR

CONNECTOR

Fuse

EV ARMS 1/2 PROPORTIONAL

EV TELESCOPE PROPORTIONAL

EV ARM 3 PROPORTIONAL

emergency stop

Start-up

blue:emergency stop grey/pink:emergency pump button

emergency pump

Connector

Trigger

right

left

Connector

Arms 1/2

Telescope

Arm 3

Turret

12 crab

13 4-wheels

16 left

17 right

11 Hare

19 Lowering

18 Raising

14 Tilt angle

15 BOOST

black:start-up button red/blue:emergency stop

yellow:spare violet:12V (+Bat)

Spare Work light

grey: basket earth

Calculator

CONNECTOR

HYDRAULIC SAFETY

FUEL GAUGE

Forward motion joystick - 679 253

STEERING

BASKET ROTATION

SPEED

Connector

brown

green:GND

brown

green:GND

brown

green:GND

brown

green:GND

brown

green:GND

brown

green:GND

brown

green:GND

brown

green:GND

brown

green:GND

brown

green:GND

brown

PENDULAR ARM

Connector CONNECTOR

EMERGENCY PUMP

green:GND

brown

green:GND

white

green:GND

brown:12V

white

green:GND

brown:12V

white

green:GND

brown:12V

white

green:GND

brown:12V

white

brown:Earth

CONNECTOR

brown

blue:GRD

TILT

Arms 1/2 and telescope joystick - 679 256

Arm 3 and turret rotation joystick - 679 256

10 Tortoise

CONNECTOR DEUTSCH 3 PTS

DIFFERENTIAL LOCK

HORN

White TILT SENSOR

TILT UNLOCKING

green:GRD

EV N.4 PROPORTIONAL

LEFT RIGHT BASKET BASKET ROTATION ROTATION

LEFT TURRET ROTATION

RIGHT TURRET ROTATION

STEERING RIGHT

STEERING LEFT

TILTING ANGLE

PENDULAR ARM PENDULAR RAISING ARM LOWERING

green:basket earth Connector

ELECTRIC GENERATOR

white:CAN Low

Engine earth

Buzzer

CONNECTOR

FRONT AXLE Green light

REAR AXLE Green light

ENGINE FAULT Red light

TILT FAULT Red light

OVERLOAD FAULT Red light

Turret earth

PRE-HEATING Yellow light

REAR

LOW DIESEL LEVEL Yellow light

Chassis earth

white

common red:+12V

OVERLOAD SENSOR

BATRERY 12V

DEAD MAN PEDAL Connector

Connector

(09/2010) (04/2011)

80-02-677917-M172EN

80

brown:+12V

white: pedal

green:overload green

brown:+12V black

black/white

blue

CONNECTOR

main earth

common red:+12V

+12V (+BAT): systeme

+12V (+BAT): pre-heating brown brown

FORWARD MOTION

red

black

blue:PWM0+

white/black:PWM1+

black: PWM1-

white/violet:PWM0-

yellow (1,5mm²)

white/red (1,5mm²):GND

ENGINE INJECTION

FRONT

Fuse holder

ENGINE MAX SPEED ELECTRO

white (6mm²)

red (2,5mm²)

white (2,5mm²):GRD

white/blue (1,5mm²)

brown: GND (1,5mm²)

black (10mm)

red (1,5mm): start-up

ENGINE OIL PRESSURE (Earth return)

PRE-HEATING

ALTERNATOR

ENGINE WATER TEMPERATURE (Earth return)

STARTER

grey (1,5mm²):GND

green (1,5mm²)

Black (10mm)

Black/Violet (1,5mm²)

White/brown (0,75mm²)

BOSCH pump

black

+12V (+BAT): general

brown:CAN High

ELECTRICITY – SCHEMATIC DRAWING

80

4 4

80-02-677917-M172EN 80-02-677917-M172EN

(04/2011)

ELECTRICAL COMPONENTS – LOCATION

Pages A - Electrical controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 2

80

B - Electrical power components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 3

(04/2011)

80-03-M172EN

ELECTRICAL COMPONENTS – LOCATION

80

2

80-03-M172EN

(04/2011)

3

ELECTRICAL COMPONENTS – LOCATION

Retracted telescope sensor Capteur télescope rentré TT N N A O FR AV

Buzzersonore Avertisseur

Battery Batterie

Flashing light Gyrophare

Base console Pupitre base

Rear axle de wheel Détecteur rouestraight droites detector Pont arrière

UPC 101 Calculateur Calculator UPC 101

Tilt sensor Capteur de devers

Low armbras sensor Capteur bas

Front axlede wheel Détecteur rouesstraight droites detector Pont avant

6-Track sliding Joint tournant 2 seal pistes 160 ATJ FC 180 ATJ

CEK 20CEK Screen Ecran 20

6-Track sliding Joint tournant seal 6 pistes Overload sensor Capteur de surcharge

160 ATJ FC RC 180 ATJ RC

60A Fuse Fusible 60 A Dead homme man pedal Pédale mort

A (09/2010) (04/2011)

E IAR E R RR

RE

UPC 301 Calculateur Calculator UPC 301 BRC Coffret 301 Box BRC 301

30A Fuse Fusible 30 A

80-03-M172EN 80-03-M172FR

80

Basket Pupitreconsole panier

4

ELECTRICAL COMPONENTS – LOCATION

Moteur thermique Engine Alternator Alternateur Waterde temperature sensor Sonde température d'eau Starter Démarreur Oil pressure gauge Jauge de pression d'huile Pre-heating circuit Circuit de préchauffage Injection electro-valve Electrovannecut-off de coupure d'injection

Engine speed Solénoïde de solenoid régime moteur

Left oscillation Electrovanne delocking blocage electro-valve oscillation gauche

NTT N A O R AFV Fuel gauge Jauge

Carburant

Distributor Bloc block

distributeur

Hydrostatic generator Pompe hydrostatique Proportional distributor Distributeur proportionnel

Left oscillation Electrovanne delocking blocage electro-valve oscillation gauche Emergency Pompe de pump secours

80

Proportional Distributeur distributor proportionnel

Brake unit

Bloc frein Connection block Bloc de raccordement Safety electro-valve Electrovanne de sécurité

A

RR E A I RE RR

80-03-M172EN

E

(09/2010) (04/2011)

80

ELECTRONIC MODULES – OPERATIONAL CONTROL

(04/2011)

80-04-07-M172EN

2

Electronic modules – Operational control

80

Pages A - Electronic modules - Location 1 - Base console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 3 2 - Basket console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 3 B - Electronic modules - Description 1 - CEK 20 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 4 2 - UPC 301 Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 5 3 - BRC 301 Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 7 4 - UPC 101 Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 10 C - Program – How to use the computer 1 - Controls used on the base console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 12 2 - Engine start-up - Level 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 12 3 - Checking for faults - Level 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 13 4 - Access to Levels 2, 3 and 4 – Entry of the secret code . . . . . . . . . . . . . . . P 14 5 - Settings menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 15 6 - Maintenance menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 16 7 - Engine menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 17 8 - Inputs/outputs sub-menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 17 9 - Internal screen parameters - Level 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 24 10 - Machine parameters - Level 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 25 11 - Adjusting the speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 29 D - Program – How to use the computer 1 - Controls used on the base console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 30 2 - Engine start-up – User Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 30 3 - Checking for faults – User Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 31 4 - Screen settings – User Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 33 5 - Settings menu – Dealer / Lessor and Manufacturer’s Levels. . . . . . . . . P 34 6 - Maintenance menu - Dealer / Lessor and Manufacturer’s Levels . . . . P 35 7 - Engine menu - Dealer / Lessor and Manufacturer’s Levels . . . . . . . . . . P 36 8 - Inputs/outputs sub-menu - Dealer / Lessor and Manufacturer’s Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 36 9 - Parameters - Dealer / Lessor and Manufacturer’s Levels . . . . . . . . . . . P 43 10 - Adjusting the speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 49

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Electronic modules – Operational control

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A - Electronic modules - Location 1 - Base console

A1 T

ON

FR

UPC 301 computer BRC 301 box CEK 20 screen

80

2 - Basket console

A2 FR

(04/2011)

ON

T

UPC 101 computer

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Electronic modules – Operational control

A - Electronic modules - Description 1 - CEK 20 4 screen Front Face Key board

Screen

Rear Face

CEK20 screen serial number

80

CEK 20

Connector J1 Pin N° Designation 1 NC 2 CANL 3 NC 4 NC 5 NC 6 NC 7 CANH 8 NC 9 NC

PinN° 1 2 3 -

Connector J2 Designation +BAT (Permanent) GND +APC (Ignition) -

10-32V

SUB D 9-POINT F. (J1) connector SUB D 3pts F. (J2) Connector

Important general remarks Do not reverse the screen supply’s polarity, otherwise the screen may be damaged.

Disconnect the screen supply before performing any welding work on the machine.

When cutting off the +BAT supply to the screen (by disconnecting the devices battery terminals), wait approximately 10 seconds after switching off the screen normally (by cutting the ignition); failure to follow this procedure may result in poor saving of the internal parameters (e.g. the hour counters).

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2 - UPC 301 computer Front face

UPC30

Rear face

Connector AMP 42pts M.(C1)

Orange LED: CAN dialogue Red LED: FAULT status Green LED: RUN in operation Green LED: SUPPLY present

Connector AMP 42pts M.(C2)

Serial N° UPC 301

UPC30

SUB D 9pts F. (J3) Connector SUB D 9pts M. (J1) Connector SUB D 9pts M. (J2) Connector

Connector J1 Pin N° Designation 1 NC 2 CANL 3 NC 4 NC 5 NC 6 NC 7 CANH 8 NC 9 NC

Connectors C1 and C2 Designation Permanent supply (Battery): +BAT Earth GND After ignition +APC Inputs/outputs Connector J2 Pin N° Designation 1 NC 2 CANL 3 GND 4 NC 5 NC 6 NC 7 CANH 8 NC 9 NC

Remark: NC = do not connect LED NORMAL OPERATION Orange Flashing Red Unlit Green (Run) Flashing Green (Supply.)

Lit (04/2011)

80

Pin N° 1, 15, 29 28, 42 14 2..14, 16..27, 30..41

Connector J3 Pin N° Designation 1 NC 2 NC 3 NC 4 NC 5 NC 6 NC 7 NC 8 NC 9 NC

BUS CAN FAULT Unlit Lit Flashing Lit 80-04-07-M172EN

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Electronic modules – Operational control

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Pin N° 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Connector C1 Type Pin N° +BAT 22 Outtor0 23 Outtor1 24 Outtor2 25 Outtor3 26 Outtor8 27 Outtor9 28 Outtor10 29 Outtor11 30 Outtor12 31 Outtor13 32 Pwm033 Pwm0+ 34 +APC 35 +BAT 36 Inactive 37 Inactive 38 Inactive 39 Inactive 40 Hsce0 41 Intor12 42

Type Outana0 Outana1 Outana2 Outana3 Pwm1Pwm1+ GND +BAT Intor0 Intor1 Intor2 Intor3 Intor4 Intor5 Intor6 Intor8 Intor9 Intor10 Intor11 Intor7 GND

INTOR OUTTOR INANA OUTANA

= DIGITAL INPUT = DIGITAL OUTPUT = ANALOG INPUT = ANALOG OUTPUT

Connector C2 Pin N° Type Pin N° Type 1 +BAT 22 Outana4 2 Outtor14 23 Outana5 3 Outtor15 24 Inactive 4 Outtor16 25 Inactive 5 Outtor17 26 Inactive 6 Outtor18 27 Inactive 7 Outtor19 28 GND 8 Outtor20 29 +BAT 9 Outtor21 30 Inactive 10 Outtor22 31 Inactive 11 Outtor23 32 Inactive 12 Outtor24 33 Inactive 13 Outtor25 34 Inactive 14 +APC 35 Inactive 15 +BAT 36 Outtor4 16 Outtor26 37 Outtor5 17 Outtor27 38 Outtor6 18 Outtor28 39 Outtor7 19 Outtor29 40 Inactive 20 Inactive 41 Inactive 21 Inactive 42 GND Important general remarks Do not reverse the computer supply’s polarity to avoid damaging the computer.

Do not cause short-circuits [AU + battery (+BAT) or to Earth (GND)] on the computer’s input/ output terminals to avoid damaging it.

The computer must be installed in a sealed environment so as not to risk damage to it.

Disconnect the computer supply before performing any welding work on the machine.

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3 - BRC 301 box Front face Coffret de raccordement BRC 301

Rear face

1 BRC30

Exploded Serial N° BRC 301 Relay +APC

Anti-start relays Engine accelerator relays

80

Starting relays

Fuse 7,5A (emergency pump)

Base/basket selector relay

Fuses 20A (+BAT)

Preheating relays Fuse 20A (+ basket BAT)

Fuse 5A (+APC)

The casing must only be removed when the lifting platform is switched off: otherwise you RISK destroying the electronic card..

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Installation of the components on the BRC 301 card LED Preheating LED Accelerator

LED Switching on

LED Start

80

LED Anti-start

LED Switching on

VIEW fuse status Emergency pump

VIEW fuse status Base SUPPLY

INTOR OUTTOR INANA OUTANA 80-04-07-M172EN

VIEW fuse status Basket SUPPLY

VIEW fuse status +APC

= DIGITAL INPUT = DIGITAL OUTPUT = ANALOG INPUT = ANALOG OUTPUT (04/2011)

Electronic modules – Operational control

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BRC 301 box electrical diagram

Base EM S

OUTTOR 4 Contact

BASE

Basket starting

Starting BASKET EM S

BASKET

Basket button

Base button

+ General BAT SELECTOR

+Basket BAT Ignition key

+ Base BAT +BAT Screen

OUTTOR 9

Max engine revs OUTTOR 17

Emergency generator control

BRC 301

+ Preheating BAT

+ Screen +BAT System

Preheating Engine injection Starter +APC

Fuse F1 F2 F3 F4 F5

Description Emergency pump + Base BAT +Basket BAT +APC

Caliper 7.5A 20A 20A 20A 5A

Relays K1 K2 K3 K4 K5 K6

Description Anti-start Max engine revs Starter Preheating +APC Basket ES inhibition

80

+APC = +12V after ignition. It supplies: - The input sensors (front & rear axle alignment, telescope, low arm, overload, tilt).

- The switches.

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Electronic modules – Operational control

4 - UPC 101 computer Front face

Computer UPC 101

1

0 -3

2

V

UPC 101 Computer serial N°

AMP 42pts M.(A1) Connector Green LED: SUPPLY present Green LED: RUN in operation Orange LED: CAN dialogue Red LED: FAULT status

Rear face

1 0 -3 2 V

SUB D 9pts M. (J1) Connector

80

SUB D 9pts M. (J2) Connector SUB D 9pts F. (J3) Connector

Pin N° 1, 15, 29 28, 42 14 2..14, 16..27, 30..41 Connector J1 Pin N° Designation 1 NC 2 CANL 3 NC 4 NC 5 NC 6 NC 7 CANH 8 NC 9 NC

Connectors C1 et C2 Designation Permanent supply (Battery): +BAT Earth GND After ignition +APC Inputs/outputs Connector J2 Pin N° Designation 1 NC 2 CANL 3 NC 4 NC 5 NC 6 NC 7 CANH 8 NC 9 NC

Connector J3 Pin N° Designation 1 NC 2 NC 3 NC 4 NC 5 NC 6 NC 7 NC 8 NC 9 NC

Remark: NC = do not connect LED Orange Red Green (Run) Green(Supply) 80-04-07-M172EN

NORMAL OPERATION Flashing Unlit Flashing Lit

BUS CAN FAULT Unlit Lit Flashing Lit (04/2011)

11

Connector C1 Pin N° Type Pin N° Type 1 +BAT 22 Intor17 INTOR = DIGITAL INPUT 2 Outtor0 23 Intor16 OUTTOR = DIGITAL OUTPUT 3 Outtor1 24 Intor15 INANA = ANALOG INPUT 4 Outtor2 25 Intor14 OUTANA = ANALOG OUTPUT 5 Outtor3 26 Intor13 6 Outtor4 27 Intor12 7 Outtor5 28 GND 8 Outtor6 29 +BAT 9 Outtor7 30 Intor0 10 Outtor8 31 Intor1 11 Outtor9 32 Intor2 12 Inana4 33 Intor3 13 Inana5 34 Intor4 14 +APC 35 Intor5 15 +BAT 36 Intor6 16 Inana0 37 Intor8 17 Inana1 38 Intor9 18 Inana2 39 Intor10 19 Inana3 40 Intor11 20 Inana19 41 Intor7 21 Inana18 42 GND Important general remarks Do not reverse the computer supply’s polarity to avoid damaging the computer.

Do not cause short-circuits [AU + battery (+BAT) or to Earth (GND)] on the computer’s input/ output terminals to avoid damaging it.

The computer must be installed in a sealed environment so as not to risk damage to it.

Disconnect the computer supply before performing any welding work on the machine.

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Electronic modules – Operational control

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Electronic modules – Operational control

C - Program W678600-001 C - PROGRAMME W678600-001

How to use the computer UTILISATION DU CALCULATEUR

11--Controls used on the base console COMMANDES UTILISÉES SUR LE PUPITRE BASE Ignition Clé de key contact

C1

Valid

Menu ESC

Emergency Bouton Stop d’arrêt button d’urgence

DEF

22--Engine start-up - Level DÉMARRAGE DU MOTEUR - N1IVEAU 1 Actionssur on the base console Action les commande controls du pupitre base

Screen display Affichage ecran

80

Switching on Mise sous tension

Switching on: -Machines up to N°506427 – actions on the battery cut-out.

- All machines – re-arming Mise sous tension : the Emergencyjusqu’au Stop - Machines N°506427 - action sur le coupe-batterie.

- Toutes machines réarmement de l’arrêt d’urgence

Screen off Ecran éteint

Switching on the computer Mise sous - How to use the ignition tension du key. calculateur - Utilisation de la clé de contact.

ENGINE PRE-HEATING Pages PRÉCHAUFFAGE MOTEURpages THERMIQUE

Starting the engine Démarrage - How to use the ignition key. moteur

FAULT PAGE(S) DEFAUT(S) PAGE(S)

- Utilisation de la clé de contact.

WAIT screen Ecran ATTENTE Lifting d'élévation rate/Machine’s hour Régime / Compteur counter/Base/basket control horaire machine / Commande base / panier

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OR OU

FAULT page Page DÉFAUT paragraph 3 VoirSee le paragraphe 3 CHECKINGDES FOR CONTRÔLE FAULTS DÉFAUTS

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- Checking forDÉFAUTS faults - Level 3 3- C ONTRÔLE DES NIVEAU11 - There arede three types of Fault THESE PAGES APPEAR DIRECTLY ON À THE SCREEN - Trois types pages défaut : CESpages: PAGES APPARAISSENT DIRECTEMENT L’ÉCRAN MINOR faults, other than Tilt and Défaut(S) MINEUR(S) autres que Overload faults: Devers et Surcharge :

MINOR TILT or OVERLOAD faults: Défaut(s) MINEUR(S) de DEVERS et (ou) display de SURCHARGE - Continuous of one of the:faults or both simultaneously - Affichage continu de l’un des ou des deuxofsimultanément.

-défauts Intermittent display the Hazard - Affichage intermittent du triangle triangle. danger.

BIP panier CONTINU ou INTER--CONTINUOUS or INTERMITTENT BEEP MITTENT. in the basket

-- Intermittent display of the Affichage intermittent du Hazard triangle triangle. danger.

MAJOR faults: Défaut(S) MAJEUR(S) : Intermittent display of the and - Affichage intermittent du fault défaut etthe Hazard triangle. du triangle danger.

-- CONTINUOUS BIP pupitre base BEEPCONTINU from the base console

- Description of the :faults: - Description des défauts

Minor faults Défauts mineurs - From the MINOR FAULTS - A partir des the pages pages, access faults pages DÉFAUT(S) by pressing theMINEUR(S), DEF (Fault) keyaccès (C1). aux pages défauts par

appui sur la touche DEF (C1).

- Scroll the pages or return to the Work page bypages pressing - Défilement des ou theretour VALIDà (OK) key (C1). par la page travail

Faultdéfaut page Page TURRET ROTATION MANIPULATEUR ROTATION TOURELLE JOYSTICK

Faultdéfaut page Page OVERLOAD SURCHARGE

Fault Page page défaut TILT DEVERS

Fault Page page défaut LOWER ARMS UP MANIPULATEUR ELEVATION JOYSTICKBRAS

Faultdéfaut page Page TELESCOPE JOYSTICK MANIPULATEUR

INFERIEURS

Faultdéfaut page Page UPPER ARM UP MANIPULATEUR ELEVATION BRAS JOYSTICK SUPERIEUR

Faultdéfaut page Page ALIMENTATION LT SUPPLYBASSE

Fault page Page défaut BUS BUS CAN CAN

Fault Page page défaut DIESEL LEVEL LOW NIVEAU BAS GASOIL

Faultdéfaut page Page PRESSION HUILE ENGINE OIL MOTEUR PRESSURE

Fault page Page défaut BATTERY CHARGECHARGING BATTERIE

Fault page Page défaut ARMS POSITIONAL SENSOR CAPTEUR DE POSITION DE (WORKING SPEED – BRAS (VITESSE TRAVAIL TRANSPORT SPEED) VITESSE TRANSPORT)

Fault Page page défaut FORWARD MOTION MANIPULATEUR JOYSTICK AVANCEMENT

80

appui sur la touche VALID (C1).

TELESCOPE

Major faults Défauts majeurs - Scroll the pages or return - Défilement des pages ou to theretour Workàpage by pressing la page travail par the VALID (OK) key (C1). appui sur la touche VALID (C1).

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Fault page Page défaut ENGINE WATER TEMPERATURE EAU TEMPERATURE MOTEUR

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Electronic modules – Operational control

Access to Levels 2,2,3 3and 4 -– SSecret code entry 44 -- A CCÈS AUX NIVEAUX ET 4 AISIE DU CODE SECRET

SECRET Saisie duCODE CODE SECRET entry

(A partir de l’écran d’attente) (from the wait screen) -- Display Affichage depage: la page of the SECRET CODE SECRET : CODE ENTRY: MENU - Choix desMENU chiffres : - Number selection: - / + (bas) - Validation du(low) chiffre, pas-I+ sage au chiffre suivant et - Confirmation of the number, validation du code entier : move on to the next number and confirmationVALID of the complete code:

IMAGINARY Code FICTIF Code

Valid

Valid

Valid

Menu

Menu

Menu

ESC

ESC

ESC

DEF

DEF

DEF

SECRET CODE Page CODE Page SECRET

WAITATTENTE Screen Ecran

VALID (OK)

VALID

MENUS MENUS - Menu selection (3 menus):

- Choix entre les menus (3 - I + (high) menus) : - / + (haut)

Menu Menu SETTINGS REGLAGES § C5) C 5) ((§

Valid

Valid

Valid

Menu

Menu

Menu

ESC

ESC

ESC

DEF

DEF

Menu MAINTENANCE MAINTENANCE  §§ C 6) ( ( C6)

DEF

Menu Menu ENGINE MOTEUR C7) 7) (( §§ C

80

- Il existe permettant d’accéder à 3 niveaux menus qui to 3 types of users of the - There are33codes secretsecrets codes allowing access to 3 menu levels,de corresponding machine ...................................................................................................................... correspondent aux 3 types d’utilisateurs de la machine .............. § C §9 C9

- LEVEL 2 access code (operator code): - Code d’accès au NIVEAU 2 (code utilisateur) : - Adjustment of the screen parameters.

- View of the maintenance counters. écran.

- Réglage des paramètres - View of the inputs/outputs - Visualisation des compteurs de maintenance.

- View of the Engine page.

- Visualisation des entrées/sorties.

- Visualisation de la page moteur.

- Code d’accès au NIVEAU 3 (code concessionnaire) : - LEVEL 3 access code (dealer code): - Réglage des paramètres écran.

- Adjustment of the screen parameters.

- View/initialisation of the maintenance and hire counter.

- Visualisation/Initialisation descounters compteurs dethe maintenance et - View of thedu inputs/outputs compteur de location.

- View of the Engine page.des entrées/sorties.

- Visualisation - Visualisation de la page moteur.

- LEVEL 4 access codeau (manufacturer’s code): - Code d’accès NIVEAU 4 (code constructeur) : - Adjustment of the screen parameters.

- Réglage écran.parameters.

- View/adjustment of des the paramètres screen’s internal Visualisation/Réglages des paramètres internes écran.

- View/adjustment of the machine’s internal parameters.

- Visualisation/Réglages des paramètres internes machine.

- View/initialisation of all the counters.

- View of the inputs/outputs - Visualisation/Initialisation de tous les compteurs.

- View of the Faults list. des entrées/sorties.

- Visualisation - View of the Engine page.de la liste des défauts.

- Visualisation - Visualisation de la page moteur.

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Electronic modules – Operational control

- Settings menu 5-5 MENU RÉGLAGES

Valid

Valid

Valid

Valid

Valid

Menu

Menu

Menu

Menu

Menu

ESC

ESC

ESC

ESC

ESC

DEF

DEF

DEF

DEF

CONTRAST Page réglage adjustment page CONTRASTE.

SETTINGS Menu menu RÉGLAGE - Sub-menu selection (3 submenus): - Choix entre les sous- I + (low) menus (3 sous-menus) : - Confirmation of the selection: - / + (bas) VALID - Validation du(OK) choix : VALID

BRIGHTNESS Page réglage adjustment page LUMINOSITE

TIME/DATE Page réglage adjustment page HEURE / DATE

DEF

Pageactivation/ activation / BEEP désactivation BIP deactivation page

SCREEN PARAMETERS Sous menusub-menu - Parameter selection (4 pages): ÉCRAN PARAMÈTRES - I + (high) Choix du paramètre (4 pages) : - -Adjustment of the settings: - -/I ++ (low) (haut) - Modification du/des réglages : - Parameter change (TIME/DATE page only): - / + (bas) VALID (OK)(page HEURE / - Changement de paramètre DATE seulement) : VALID

LEVELS 22AND NIVEAUX ET 3

INTERNAL Sous SCREEN PARAMETERS menu sub-menu PARAMÈTRES INTERNES ÉCRAN

Valid

Menu ESC

- Parameter selection (58 pages): - Choix du paramètre- I(58 pages) : + (high) - Adjustment of the setting: - / + (haut) - I + (low) - Modification du réglage : - / + (bas)

§ C9 - INTERNAL SCREEN PARAMETERS - LEVEL 4 § C 9 - PARAMÈTRES INTERNES ÉCRAN NIVEAU 4

DEF

Valid

Menu ESC DEF

- Parameter group selection (19 pages): - Choix du groupe de -paramètres (19 pages) : I + (low) - / + (bas) rmation the selection: -- Confi Validation duofchoix : VALID (OK) VALID (number of pages depending onle the -- Parameter Choix du selection paramètre (nombre de pages selon group): : groupe) I + (high) - / + (haut) - Modification du réglage : - Adjustment of the setting - / + (bas) - I + (low)

§ C 10 - PARAMÈTRES MACHINES - NIVEAU 4 § C10 - MACHINE PARAMETERS - LEVEL 4

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MACHINE INTERNAL PARAMETERS Sous menu PARAMÈTRESsub-menu INTERNES MACHINE

LEVELS 44 NIVEAU

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Electronic modules – Operational control

66 -- M ENU MAINTENANCE MENU MAINTENANCE

COUNTERS Sous menu sub-menu COMPTEURS - Counter selection (8

Valid

Valid

Valid

Valid

Menu

Menu

Menu

Menu

ESC

ESC

ESC

ESC

DEF

DEF

DEF

DEF

P 3/3 - Maint.

P 3/3 - MAINT.

PP2/3 2/3- -Maint.

MAINT.

1/3 - Maint.

PP 1/3 MAINT. Vidangethe huile.

- -Draining oil.

Filtre huile.

- Oil filter.

Filtre - -Air filterair.

- Choix du compteur (8 menus): compteurs) : --I /++(high low) (hautand et bas)

- Graissage.

- Lubrication.

- CTRL mécanique.

Filtre figasoil.

- -Diesel lter.

- -Hydraulic filter.

Filtre hydraulique.

- -Hydrostatic filter.

Filtre hydrostatique.

LEVELS22 NIVEAU

- Mechanical inspection.

COUNTERS sub-menu

COUNTERS menu Menu

Sous menu

- CounterCOMPTEURS selection (8 menus):

- Sub-menu selection (2 or MAINTENANCE 3 sub-menus – depending on the secret code): - Choix entre les sous-I+ menus (2 ou(low) 3 sous - Confirmation of the du menus - en fonction selection code secret) : - -/ VALID + (bas)

- I + (high and low)

- Choix du compteur (9

- Validation du choix : VALID

Valid

Valid

Valid

Menu

Menu

Menu

ESC

ESC

ESC

DEF

DEF

3/3 - Maint.

PP 3/3 - MAINT.

PP2/3 2/3- -Maint.

MAINT.

1/3 - Maint.

PP 1/3 MAINT. Vidangethe huile.

- -Draining oil.

Filtre huile.

- -Oil filter.

Filtre - -Air filterair.

compteurs) :of the - Reinitialisation - / + (haut et bas) maintenance counters:

- Réinitialisation des - VALID (OK) (twice): compteurs d’entretien (2 fois) - Reset ofVALID the hire counter to - Remisezero: à zéro du compteur de location : VALID (2 fois) - VALID (OK) (twice)

DEF

Graissage.

--Lubrication.

CTRL mécanique.

--Mechanical inspection.

Compteur location.

--Hire counter.

Filtre figasoil.

- -Diesel lter.

- -Hydraulic filter.

Filtre hydraulique.

- -Hydrostatic filter.

Filtre hydrostatique.

LEVELS33 NIVEAU

Valid

Valid

Valid

Valid

Valid

Valid

Menu

Menu

Menu

Menu

Menu

Menu

ESC

ESC

ESC

ESC

ESC

ESC

DEF

DEF

DEF

DEF

DEF

1/5- VISU - Visu IN/OUT IN/OUT P P1/5 INTOR. --INTOR.  § CC8-1) ( (§ 8 - 1)

PP 2/5 IN/OUT 2/5 -- VISU Visu IN/OUT - OUTTOR.

- OUTTOR.

PP 3/5 VISUIN/OUT IN/OUT 3/5 -- Visu - INANA.

- INANA.

C8-2) § C ( (§ 8 - 2)

§ C C8-3) ( (§ 8 - 3)

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INPUTS/OUTPUTS sub-menu Sous menu ENTRÉES/SORTIES

P 4/5 -- Visu VISUIN/OUT IN/OUT P 4/5 - INHSCE.

- INHSCE.

 § C8-4) ( (§ C 8 - 4)

DEF

5/5-- VISU Visu IN/OUT PP5/5 IN/OUT - OUTANA. - OUTANA. OUTPWM. - OUTPWM. C8-5) § C 8 - 5) ( (§

- Page selection (5 pages):

- Choix de la page (5 pages) : VALID VALID (OK)

LEVELS 2,43, 4 NIVEAU 2, 3 ET

14 FAULT CATEGORIES Valid

100 FAULTS

Menu

MAXIMUM

ESC DEF

80-04-07-M172EN

FAULTS Sub-menu Sous menu - Page selection (up to 12 DÉFAUTS pages): - Choix de laVALID page (jusqu’à (OK)12 pages) : VALID

LEVELS NIVEAU 4 4

(04/2011)

Electronic modules – Operational control

17

Engine menu 7 -7M- ENU MOTEUR

ENGINE menu

Menu of the - Confirmation MOTEUR selection: - VALID - Validation du(OK) choix : VALID Valid

Valid

Menu

Menu

ESC

ESC

DEF

DEF

LEVELS NIVEAUX 2, 3 2, ET3,44

8 -8S-OUS -MENU ENTRÉESsub-menu /SORTIES Inputs/outputs 8 - 1 - Page 1/5 - INTOR

8 - 1 - Page 1/5 - INTOR

Intor 0 Intor 8

Intor 7 Intor 12

Intor 0 Intor 8 Intor 16

Intor 7 15 Intor 12 Intor 19

ClavMvt 0 ClavMvt 8 ClavFct 0

80

ClavMvt 7 ClavMvt 12 ClavFct 7

Bit

Bit

BASE BASE UPC UPC Description Status 0 Status 1 Description Etat 0 Etat 1

Intor0Intor0 Base/basket selector Sélecteur base/panier Intor1Intor1 Tilt sensor Capteur devers Intor2Intor2 Low arm sensor 1 bas 1 Capteur bras Intor3Intor3 Telescope retracted sensor 1 1 Capteur telescope rentré Intor4Intor4 Low arm sensor 2 bas 2 Capteur bras Intor5Intor5 Battery charge level batterie Retour charge Intor6Intor6 DieselNiveau level low bas gasoil Intor7Intor7 SensorCapteur telescope retracted 2 2 telescope rentré Intor8Intor8 EngineTemperature water temperature high haute eau moteur Intor9Intor9 EnginePression oil pressure basselow huile moteur Intor10Intor10 Front axle sensor Détecteur pont avant Intor11Intor11 Rear axle sensorpont arrière Détecteur Intor12Intor12 Max engine speed, forcing NON AFFECTEE

Base station

Basket station

Pos. base Pos. panier Outside tilt En Under deverstilt Hors devers Work position Transport pos.

Pos.travail Pos transport Extended Rentré Retracted Sorti Worktravail position Pos. Pos. Transport transport pos.

Normal Faible Low Normal Low Normal Bas Normal Extended Rentré Retracted Sorti Abnormal Normal Normal Anormal Anormal Normal Normal MisalignedAligné Aligned Désaligné MisalignedAligné Aligned Désaligné Normal / Forced /

INTOR = DIGITAL INPUT

INTOR = ENTRÉE NUMÉRIQUE (04/2011)

80-04-07-M172EN

18

Electronic modules – Operational control

UPC BASE UPC PANIER Bit Description Status 0 Status 1 Intor0 Steering control - Left Inactive Active Bit Description Etat 0 Inactive Etat 1 Active Intor1 Steering control - Right Intor0 Cde direction - Droite Non actionnée Actionnée Intor2 Tilt control - forward Inactive Active Intor1 Cde direction - Gauche Non actionnée Actionnée Intor3 Tilt control back Inactive Active Intor2 Cde inclinaison - Déversement Non actionnée Actionnée Intor4 Pendular arm control- UP Inactive Active Intor3 Cde inclinaison - Cavage Non actionnée Actionnée Intor5 Pendular arm control DOWN Inactive Intor4 Cde pendulaire - Montée Non actionnée Actionnée Active Intor6 Cde Speed control – Slow speed Inactive Intor5 pendulaire - Descente Non actionnée Actionnée Active Intor7 Cde Speed control – High speed Inactive Intor6 vitesse - Tortue Non actionnée Actionnée Active Intor8 Cde Basket rotation Inactive Intor7 vitesse - Lièvrecontrol - Left Non actionnée Actionnée Active Intor9 Cde Basket rotation - Right Non actionnée Inactive Intor8 rotation paniercontrol - Gauche Actionnée Active Intor10Cde Steering Crab Inactive Intor9 rotationcontrol panier -- Droite Non actionnée Actionnée Active Intor11Cde Steering Speed control – 4-wheel Inactive Intor10 direction - Crabe Non actionnée Actionnée Active Intor11 direction - 4 roues Non actionnée/ Actionnée Intor12Cde Joystick switch - arms 1/2 + telescope / Intor12 AFFECTEE / Joystick switch - arm 3 + turret rotation / / / Intor13NON Intor13 AFFECTEE / Intor14NON Forward motion joystick trigger / Inactive Active Intor14 manip. avancement Non actionnée Actionnée Active Intor15Gâchette Differential lock button Inactive Intor15 pouss.

- Blocage différentiel Non actionné Actionné Active Intor16Bouton Overload safety system Inactive Intor16 surcharge Non actionnée Actionnée Active Intor17Sécurité Dead Man’s pedal Inactive Intor17 homme mort Non actionnée Actionnée Active Intor18Pédale Tilt unlocking selector Inactive Intor18 Sélecteur - Déverrouillage devers Non actionné Actionné Intor19 Horn button Inactive Active Intor19 Bouton pouss. - Klaxon

Non actionné

Actionné

80

677718

677719

UPC BASE Bit

CLAVIER ECRAN Description

ClavMvt0Description Key - pendular arm UP Bit ClavMvt1Touche Key -pendulaire pendular -arm DOWN ClavMvt0 Montée ClavMvt2Touche Key -pendulaire telescope-retraction ClavMvt1 Descente ClavMvt3Touche Key -telescope telescope- Rentrée extension ClavMvt2 ClavMvt4Touche Key -telescope arm 3 - UP ClavMvt3 - Sortie ClavMvt5Touche Key -bras arm33-- Montée DOWN ClavMvt4 ClavMvt6Touche Key -bras arms3 1/2 - UP ClavMvt5 - Descente ClavMvt6 - Montée ClavMvt7Touche Key -bras arms1/2 1/2 - DOWN ClavMvt7 1/2rotation - Descente ClavMvt8Touche Key –bras turret left ClavMvt8 tourelle - right Gauche ClavMvt9Touche Key –rotation turret rotation ClavMvt9 tourelle - Droite ClavMvt10Touche Key -rotation tilt forward ClavMvt10 ClavMvt11Touche Key -inclinaison tilt back - Déversement ClavMvt11 - Cavage ClavFct12Touche Key -inclinaison FCT ClavMvt12 FCT ClavFct0Touche Key --PLUS1 ClavFct0 Touche - PLUS1 ClavFct1 Key - PLUS2 ClavFct1 Touche - PLUS2 ClavFct2 Key – VALID (OK) ClavFct2 Touche - VALID ClavFct3 Key - MENU ClavFct3 Touche - MENU ClavFct4Touche Key --ESC ClavFct4 ESC ClavFct5Touche Key –- DEF ClavFct5 DEF (Fault) ClavFct6Touche Key --MOINS2 ClavFct6 MOINS2 (Minus 2) ClavFct7Touche Key --MOINS1 ClavFct7 MOINS1 (Minus 1) 80-04-07-M172EN

Status 0

Status 1

Etat 0 Inactive Etat 1 Active Inactive Non actionnée Actionnée Active Inactive Non actionnée Actionnée Active Inactive Non actionnée Actionnée Active Inactive Non actionnée Actionnée Active Inactive Non actionnée Actionnée Active Inactive Non actionnée Actionnée Active Non actionnée Actionnée Active Inactive Non actionnée Actionnée Active Inactive Non actionnée Actionnée Active Inactive Non actionnée Actionnée Active Inactive Non actionnée Actionnée Active Inactive Non actionnée Actionnée Active Inactive Non actionnée Actionnée Active Inactive Non actionnée Actionnée Inactive Active Non actionnée Actionnée Inactive Active Non actionnée Actionnée Inactive Active Non actionnée Actionnée Inactive Non actionnée Actionnée Active Inactive Non actionnée Actionnée Active Inactive Non actionnée Actionnée Active Inactive Non actionnée Actionnée Active (04/2011)

Electronic modules – Operational control

19

8 - 2 - Page 2/5 - OUTTOR

8 - 2 - Page 2/5 - OUTTOR

Outtor Outtor Outtor Outtor

Outtor 0 Outtor 8 Outtor 16 Outtor 24 Outtor 0 Outtor 8

7 15 23 31

Outtor 7 Outtor 9

Bit Outtor0 Outtor1 Outtor2 Outtor3 Outtor4 Outtor5 Outtor6 Outtor7 Outtor8 Outtor9 Outtor10 Outtor11 Outtor12 Outtor13 Outtor14 Outtor15 Outtor16 Outtor17 Outtor18 Outtor19 Outtor20 Outtor21 Outtor22 Outtor23 Outtor24 Outtor25 Outtor26 Outtor27 Outtor28 Outtor29 Outtor30 Outtor31

Description Proportional distributor supply - arms 1/2 Proportional distributor supply - arm 3 Proportional distributor supply - telescope Proportional distributor supply - N°4 Max engine revs NOT ASSIGNED NOT ASSIGNED NOT ASSIGNED Electro-valve - hydraulic safety system Anti-start security system Rotating flashing light Buzzer Preheating Electro-valve - Generator unit (option) Electro-valve - Crab steering Electro-valve - 4WD steering Electro-valve - Brake Electro-valve - Differential lock Electro-valve - Oscillation N°1 Electro-valve - Oscillation N°2 Electro-valve - Basket rotation left Electro-valve - Basket rotation right Electro-valve - Turret rotation left Electro-valve - Turret rotation right Electro-valve - Steer left Electro-valve - Steer right Electro-valve - Tilt forward Electro-valve - Tilt back Electro-valve - Pendular arm UP Electro-valve - Pendular arm DOWN INACTIVE INACTIVE

Status 0

Status 1

Inactive Inactive Inactive Inactive Inactive / / / Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive Inactive / /

Active Active Active Active Active / / / Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active Active / /

OUTTOR = DIGITAL OUTPUT

OUTTOR = SORTIE NUMÉRIQUE (04/2011)

80-04-07-M172EN

80

UPC BASE

20

Electronic modules – Operational control

UPC PANIER BASKET UPC

BitBit

Outtor0 Outtor0 Outtor1 Outtor1 Outtor2 Outtor2 Outtor3 Outtor3 Outtor4 Outtor4 Outtor5 Outtor5 Outtor6 Outtor6 Outtor7 Outtor7 Outtor8 Outtor8 Outtor9 Outtor9

Description Description

Vibreur Buzzer Sonore Témoin Pont Avant Indicator light Front axle Témoin Pont arrière Indicator light Rear axle Témoin Défaut Moteur fault Thermique Indicator light Engine Témoin Défaut Devers Indicator light Fault Tilt Témoin Surcharge Indicator light Overload Témoin Préchauffage Indicator light Preheating Témoin Niveau Bas Gasoil Indicator light Diesel level low NON NOT AFFECTÉE ASSIGNED NOT AFFECTÉE ASSIGNED NON

Etat 0 0 Status

Non actionné Inactive Eteint Unlit Eteint Unlit Eteint Unlit Eteint Unlit Eteint Unlit Eteint Unlit Eteint Unlit / / / /

Etat 11 Status

Actionné Active Allumé Lit Allumé Lit Allumé Lit Allumé Lit Allumé Lit Allumé Lit Allumé Lit / / / /

80

677718

80-04-07-M172EN

(04/2011)

Electronic modules – Operational control

21

8 - 3 - Page 3/5 - INANA

8 - 3 - Page 3/5 - INANA

INANA = ANALOG INPUT INANA = ENTRÉE ANALOGIQUE

MANIPULATEURS JOYSTICKS BitBit

Description Description

25% 25%to à 50% 50%

50% 50%

Inana0 Inana0 Inana1 Inana1 Inana2 Inana2 Inana3 Inana3 Inana4 Inana4

Joystick - arms 1/2 Manipulateur - Bras1/2 Joystick - telescope Manipulateur - Telescope Joystick - arm- Bras 3 Manipulateur 3 Joystick - Rotation turret Manipulateur - Rotation tourelle Joystick – Forward motion Manipulateur - Avancement

UP Levage Retracted Rentrée UP Levage Right rotation Rotation à droite Back Recul

Neutral Down Neutre Descente Neutral Extended Neutre Sortie Neutral Down Neutre Descente Neutral Rotation Left rotation Neutre à gauche Neutral Forward Neutre Avance

Arm Levage bras 3

3 raising

Avance forward

Telescope Rentrée télescope retracted

Rotation Sortie Telescope télescope extended

Recul reverse

Rotation

677719

Descente Arm 3 bras 3

lowering

Bit

Bit

+APC

Descente Arms 1/2 bras 1/2 lowering

BASE UPC SUPPLY ALIMENTATION UPC BASE Engine nominal value Engine nominal value Description Valeur nominal Valeur when stopped whennominal started Description moteur moteur~13,5V démarré Computer supply after ignition (key) ~12,5Và l’arrêt

+APC Alimentation après contact +BAT Computer permanent supply (clé) calculateur +BAT Alimentation permanente calculateur UPC BASKET UPC101 supply after ignition (key) UPC PANIER Alimentation après contact (clé) UPC101 SCREEN CEK20 supply after ignition (key) ECRAN Alimentation après contact (clé) CEK20 (04/2011)

~12,5V ~12,5V ~12,5V ~12,5V ~12,5V ~12,5V ~12,5V

~13,5V ~13,5V ~13,5V ~13,5V ~13,5V ~13,5V ~13,5V

80-04-07-M172EN

80

Levage1/2 Arms bras 1/2 raising

Right Rotation tourelle à turret droite Rotation Left tourelle à turret gauche

50%àto75% 75% 50%

22

Electronic modules – Operational control

8 - 4 - Page 4/5 - INHSCE

8 - 4 - Page 4/5 - INHSCE

INHSCE = HSCE INPUT INHSCE = ENTRÉE HSCE

ENGINE speed

Bit

Bit

Raw

Description

Description

Régime MOTEUR

Frequency signal coming from the alternator

Idling

~202Hz

Forced

Ralenti

Forcé

~398Hz

80

Brut Signal de fréquence issu de l’alternateur ~202Hz ~398Hz Echelle Régime moteur en Hz converti ~2590rpm Scale Engine speed (signal(signal in HZ converted to rpm) en tr/min) ~1317rpm ~1317rpm ~2590rpm

80-04-07-M172EN

(04/2011)

23

Electronic modules – Operational control

- Page - OUTANA/OUTPWM 8 - 58 -- 5 Page 5/55/5 - OUTANA / OUTPWM

Description

Description

Outana0 - Bras Outana0 Commande Proportionaldistributeur distributorproportionnel control - arms 1/2 1/2 Outana1 Commande distributeur proportionnel Bras 3 Outana1 Proportional distributor control - arm 3 Outana2 Commande distributeur proportionnel - Telescope Outana2 Proportional distributor control - telescope Outana3 Distributeur proportionnel - N°4 Outana3 - N° 4 O utana4 NProportional ON AFFECTdistributor ÉE Outana4 ASSIGNED O utana5 NNOT ON A FFECTÉE

25% to 50% 50% to 25%50% à 45% 50% 55% à75% 75% Levage UP Levage UP Sortie Extended Alimenté Supplied / //

Outana5 NOT ASSIGNED

BitBit

/

Neutre Neutral Descente Down Neutre Neutral Descente Down Neutre Rentrée Neutral Retracted Neutre Retour au bac Return Neutral / / to tank / / / /

/

/

POMPE AVCT AVCT PUMP 0 to 350 to 1200mA DescriptionDescription 0 à 350 mA mA 350 350 à 1200 mA

PWM0 Pompe Translation generator - Forwards PWM0 translation - Avance PWM1 translation PWM1 Pompe Translation pump -- Recul Reverse

movement Pas de No mouvement Pas de No mouvement movement

Forward Avance Recul Reverse

OUTANA = ANALOG OUTPUT

OUTANA = SORTIE ANALOGIQUE

(04/2011)

80-04-07-M172EN

80

Bit Bit

PVG PVG

24

Electronic modules – Operational control

9 -9Internal screen parameters - Level 4 - PARAMÈTRES INTERNES ÉCRAN - NIVEAU 4 N UMÉRO NUMBER

DESCRIPTION DESCRIPTION

VVALUE ALEUR

SCREEN DATA DONNÉES ECRAN

0 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 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58

Version:Vx VxDate Date Version: Code secretsecret clientcode Customer’s Code secret Dealer’s secretconcession code Languelanguage Anglaise English Timer process Process timer Tempo clignotement Flashing time delay Tempo page démarrage Page start-up time delay Tempo préchauffage Preheating time delay Tempo page préchauffage Preheating OKOK page time delay Tempo page défaut Fault page time delay Reset EEPROM EEPROM reset Reset FLASH FLASH reset Tempo défaut CAN fault time CAN delay Buzzerbuzzer écran ON/OFF Screen ON/OFF Valeur contraste Contrast value Offset contraste Contrast offset Valeur luminosité Brightness value Seuil régime démarrage moteur Engine start-up speed threshold Initialisation maintenance Engine oil maint init OK huile moteur OK Périodeoil initialisation Engine init period huile moteur Alerte initialisation Engine oil init alert huile moteur Périodeoil huile moteur Engine period Alerte huile moteur Engine oil alert Initialisation maintenance filtre huile OK Oil filter maint init OK Période initialisation Oil filter init period filtre huile Alerte Oil filterinitialisation init alert filtre huile Période filtre huile Oil filter period Alerte Oil filterfiltre alerthuile Initialisation maintenance filtre air OK Air filter maint init OK Période initialisation Air filter init period filtre air Air filterinitialisation init alert filtre air Alerte Air filter period Période filtre air Air filterfiltre alertair Alerte Diesel filter maint init OK filtre gasoil OK Initialisation maintenance Diesel filter init periodfiltre gasoil Période initialisation Diesel init alertfiltre gasoil Alerte filter initialisation Diesel filter period Période filtre gasoil Diesel Alerte filter filtre alert gasoil Hydraulic filter maint init OKfiltre hydrau. OK Initialisation maintenance Hydraulic filter init period Période initialisation filtre hydraulique Hydraulic filter init alert Alerte initialisation filtre hydraulique Hydraulic filterhydraulique period Période filtre Hydraulic filter alert Alerte filtre hydraulique Hydrostatic Initialisationfilter OK maint Maint init filtreOK hydrostatique Hydrostatic filter init period Période Initialisation filtre hydrostatique Hydrostatic filter initfiltre alerthydrostatique Alerte Initialisation Hydrostatic filter period Période filtre hydrostatique Hydrostatic filter alert Alerte filtre hydrostatique General lubrication maint init OK général OK Initialisation maintenance graissage General init period général Période lubrication initialisation graissage General lubrication graissage init alert général Alerte initialisation General period Période lubrication graissage général General lubrication alert Alerte graissage général Mechanical inspection maint init OK OK Init maintenance contrôle mécanique Mechanical inspectioncontrôle init period Période initialisation mécanique Mechanical inspection init alert Alerte initialisation contrôle mécanique Mechanical inspection period Période contrôle mécanique Mechanical inspection alert Alerte contrôle mécanique

0 1000 0241 0 30 8 7 60 15 8 0 0 50 0 50 90 100 600 0 50 10 400 10 0 50 10 400 10 0 50 10 400 10 0 50 10 400 10 0 50 10 800 10 0 50 10 800 10 0 50 10 100 10 0 50 10 100 10

80

SO US-GROUPE SUB-GROUP

80-04-07-M172EN

(04/2011)

Electronic modules – Operational control

25

10 - Machine parameters - Level MACHINE

- NIVEAU 4

SOSUB-GROUP US-GROUPE INPUT CONTROL GESTION ENTREES

NNUMBER UMÉRO

OUTPUT CONTROL GESTION SORTIES

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Inversion - Sens PVG bras 1-2 Arms 1-2 PVG direction reversal Inversion Sens PVG télescope Telescope PVG direction reversal Inversion - Sens PVGreversal bras 3 Arm 3 PVG direction Inversion Sens PVG 4 PVG 4 direction reversal Inversion Sens PVG PVG steering directiondirection reversal Inversion - Sens PVG inclinaison Tilt PVG direction reversal Inversion - Sens PVG pendulaire Pendular arm PVG direction reversal Inversion Sens PVG rotation panier Basket rotation PVG direction reversal Inversion Sens PVG rotation tourelle Turret rotation PVG direction reversal Inversion Sens pompe avancement Forward motion generator PVG direction reversal Marche - Courant mini.

Forwardavant motion - min current.

Marche avant Courant maxi.

Forward motion - max current.

Marche arrière Courant mini.

Reverse motion - min current.

Marche arrière Courant maxi.

Reverse motion - max current.

Tempo arrêt sécurité hydraulique Hydraulic safety system stop time delay Tempo sécurité mouvement hydraulique autorisé Authorised hydraulic movement safety time delay Active avance sélection direction Steering selection advance active Tempo sélection Steeringarrêt selection stopdirection time delay

1 1 1 0 0 0 0 0 1 0 350 1200 350 1200 0 1 0 10

FORWARD CONTROL GESTIONMOTION AVANCEMENT

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Travail - Vitesse maxi. avant Max forward speed, Work mode Travail - Rampe accélération avant Acceleration forward, Work mode Deceleration forward, Work mode Travail - Rampe décélération avant Max reverse speed, Work mode Travail - Vitesse maxi. arrière Reverse Work mode Travail - acceleration, Rampe accélération arrière Reverse Work mode Travail - deceleration, Rampe décélération arrière Max slow speed mode Transport tortue -forward, Vitesse Transport maxi. avant Slow acceleration forward, Transport avant mode Transport tortue - Rampe accélération Slow deceleration forward, Transport avant mode tortue - Rampe décélération Transport Max slow speed mode Transport tortue -reverse, VitesseTransport maxi. arrière Slow acceleration reverse, Transportarrière mode Transport tortue - Rampe accélération Slow deceleration reverse, Transport mode Transport tortue - Rampe décélération arrière Max high speed, mode Transport lièvre - Transport Vitesse maxi. avant High acceleration forward, Transport mode Transport lièvre - Rampe accélération avant High deceleration forward, Transportavant mode Transport lièvre - Rampe décélération Max high speed mode Transport lièvre -reverse, Vitesse Transport maxi. arrière High acceleration reverse, Transportarrière mode Transport lièvre - Rampe accélération High deceleration reverse, Transportarrière mode Transport lièvre - Rampe décélération Transport Vitesse maxi. avant Max ramprampe speed,-Transport mode Transport rampe - Rampe accélération Ramp acceleration forward, Transport avant mode Transport rampe - Rampe décélération Ramp deceleration forward, Transport avant mode

37 24 10 37 24 10 80 20 4 80 20 4 100 15 10 100 15 10 40 26 15

(04/2011)

0 1 2 3 4 5 6 7 8 9 10 11 12 13

DESCRIPTION VA LEUR DESCRIPTION VALUE 650 Régime moteur coefficient calcul Engine speed coefficient calculation Régime moteur retard Engine speed delay filterfiltre 15 Recouvrement mini. manipulateurs Joysticks min recovery 4500 Recouvrement maxi. manipulateurs Joysticks max recovery 5500 Inversion sens manipulateur bras 1-2 Arms 1-2 joystick direction reversal 1 Inversion joystick sens manipulateur télescope Telescope direction reversal 0 Inversion sens manipulateur bras 3 Arm 3 joystick direction reversal 1 Inversion sens manipulateur tourelle Turret joystick direction reversal 1 Inversion sens manipulateur avancement Forward motion joystick direction reversal 0 Filtre manipulateur avancement travail Forward motion joystick filter, work mode 10 Filtre manipulateur avancement transport tortue Forward motion joystick filter, slow speed transport 14 Filtre manipulateur avancement transport lièvre Forward motion joystick filter, high speed transport 40 Filtre manipulateur avancement rampe Forward motion joystick filter, ramptransport speed transport 18 Tempomotion détection neutre manipulateur Forward joystick neutral detection timeavanct delay 5

80-04-07-M172EN

80

10 - PARAMÈTRES

26

Electronic modules – Operational control

80

SOUSUB-GROUP S-GROUPE

21 22 23 24 25 26 27 28

VVALUE ALEUR Max ramp rampe speed -reverse, mode Transport VitesseTransport maxi. arrière 40 Ramp acceleration reverse, Transport arrière mode Transport rampe - Rampe accélération 26 Ramp deceleration reverse, Transport mode Transport rampe - Rampe décélération arrière 15 Time delay in forward motion Tempo avancement après arrêtafter stop 0 Time delay in translation stop detection Tempo détection arrêt translation 1 Curve type forward motion Avancement type courbe 0 Tempo détection Fcd transport 0 Transport mode end stop detection time delay Tempo détection Fcd travail 0 Work mode end stop detection time delay

SPEED CONTROL GESTION VITESSES

0 1

Mode vitesse mouvements panier Basket movement speed mode Modemovement vitesse mouvements Base Base speed mode

3 2

ARMS 1-2 CONTROL GESTION BRAS 1-2

0 1 2 3 4 5 6 7 8 9

Arms 1-2 montée UP - Max- speed.

Bras 1-2 VitesseV1 maxi. V1 Arms 1-2 montée UP - Max- speed.

Bras 1-2 VitesseV2 maxi. V2 Arms 1-2 montée UP - Max- speed.

Bras 1-2 VitesseV13 maxi. V3 Arms 1-2 montée UP - Ramp acceleration Bras 1-2 - Rampe accélération Arms 1-2 montée UP - Ramp deceleration Bras 1-2 - Rampe décélération Bras 1-2 - Vitesse Arms 1-2 descente DOWN - Max speed.maxi.

V1 V1 Bras 1-2 - Vitesse Arms 1-2 descente DOWN - Max speed.maxi.

V2 V2 Bras 1-2 - Vitesse Arms 1-2 descente DOWN - Max speed.maxi.

V3 V3 Bras 1-2 - Rampe accélération Arms 1-2 descente DOWN - Ramp acceleration Bras 1-2 - Rampe décélération Arms 1-2 descente DOWN - Ramp deceleration

58 64 70 14 7 42 46 50 16 7

TELESCOPE CONTROL GESTION TÉLESCOPE

0 1 2 3 4 5 6 7 8 9

Telescope - Max speed.

V1 Télescope extended sortie - Vitesse maxi. V1 Télescope extended sortie - Vitesse maxi. V2 Telescope - Max speed.

V2 Télescope extended sortie - Vitesse maxi. V3 Telescope - Max speed.

V3 Télescope extended sortie - Rampe Telescope - Rampaccélération acceleration Télescope extended sortie - Rampe Telescope - Rampdécélération deceleration Télescope retracted rentrée - Vitesse maxi. V1 V1 Telescope - Max speed.

Télescope retracted rentrée - Vitesse maxi. V2 V2 Telescope - Max speed.

Télescope retracted rentrée - Vitesse maxi. V3 V3 Telescope - Max speed.

Télescope retracted rentrée - Rampe Telescope - Ramp accélération acceleration Télescope retracted rentrée - Rampe Telescope - Ramp décélération deceleration

64 66 68 12 5 50 53 56 13 5

ARM 3 CONTROL GESTION BRAS 3

0 1 2 3 4 5 6 7 8 9

Arm 33UP - Max-speed.

Bras montée VitesseV1maxi. V1 Arm 33UP - Max-speed.

Bras montée VitesseV2maxi. V2 Bras montée VitesseV3maxi. V3 Arm 33UP - Max-speed.

Bras montée - Rampe accélération Arm 33UP - Ramp acceleration Bras 3 montée Rampe décélération Arm 3 UP - Ramp deceleration Bras descente - Vitesse Arm 33DOWN - Max speed.maxi.

V1 V1 Bras descente - Vitesse Arm 33DOWN - Max speed.maxi.

V2 V2 Bras descente - Vitesse Arm 33DOWN - Max speed.maxi.

V3 V3 Bras descente - Rampe accélération Arm 33DOWN - Ramp acceleration Bras descente - Rampe décélération Arm 33DOWN - Ramp deceleration

60 63 66 14 6 43 46 50 11 6

STEERINGDIRECTION CONTROL GESTION

0 1 2 3 4 5 6 7 8 9

Steering right speed.

V1 V1 Direction droite- Max - Vitesse maxi.

Steering right speed.

V2 V2 Direction droite- Max - Vitesse maxi.

Steering right speed.

V3 V3 Direction droite- Max - Vitesse maxi.

Direction droite- Ramp - Rampe accélération Steering right acceleration Direction droite- Ramp - Rampe décélération Steering right deceleration Direction gauche - Vitesse maxi. V1 Steering left - Max speed. V1 Direction gauche VitesseV2 maxi. V2 Steering left - Max- speed.

Direction gauche VitesseV3 maxi. V3 Steering left - Max- speed.

Direction gauche - Rampe accélération Steering left - Ramp acceleration Direction gauche - Rampe décélération Steering left - Ramp deceleration

100 100 100 0 4 100 100 100 0 4

80-04-07-M172EN

NNUMBER UMÉRO

DESCRIPTION DESCRIPTION

(04/2011)

SOU S-GROUPE SUB-GROUP TILT CONTROL GESTION INCLINAISON

NNUMBER UMÉRO

DESCRIPTION DESCRIPTION

VA LEUR VALUE

0 1 2 3 4 5 6 7 8 9

Tilt - Max speed.

V1- Vitesse maxi. V1 Inclinaison cavage Tilt - Max speed.

V2- Vitesse maxi. V2 Inclinaison cavage Tilt - Max speed.

V3- Vitesse maxi. V3 Inclinaison cavage Tilt - Ramp acceleration Inclinaison cavage - Rampe accélération Tilt - Ramp deceleration Inclinaison cavage - Rampe décélération Inclinaison - Vitesse maxi. V1 Tilt forward déversement - Max speed. V1 Inclinaison - Vitesse maxi. V2 Tilt forward déversement - Max speed. V2 Inclinaison - Vitesse maxi. V3 Tilt forward déversement - Max speed. V3 Inclinaison déversement - Rampe accélération Tilt forwardRamp acceleration Inclinaison déversement - Rampe décélération Tilt forwardRamp deceleration

57 57 57 6 2 15 15 15 10 4

PENDULAR ARM CONTROL GESTION PENDULAIRE

0 1 2 3 4 5 6 7 8 9

Pendular arm UP - Max speed.maxi.

V1 V1 Pendulaire montée - Vitesse Pendular arm UP - Max speed.maxi.

V2 V2 Pendulaire montée - Vitesse Pendular arm UP - Max speed.maxi.

V3 V3 Pendulaire montée - Vitesse Pendular arm UP - Ramp acceleration Pendulaire montée - Rampe accélération Pendular arm UP - Ramp deceleration Pendulaire montée - Rampe décélération Pendular arm DOWN - Max speed.

V1V1 Pendulaire descente Vitesse maxi.

Pendular arm DOWN - Max speed.

V2V2 Pendulaire descente Vitesse maxi.

Pendular arm DOWN - Max speed.

V3V3 Pendulaire descente Vitesse maxi.

Pendulaire descente Rampeacceleration accélération Pendular arm DOWN - Ramp Pendulaire descente Rampedeceleration décélération Pendular arm DOWN - Ramp

50 55 60 12 6 13 15 17 8 22

BASKET ROTATION CONTROL GESTION ROT PANIER

0 1 2 3 4 5 6 7 8 9

Basket rotation speed.

V1 V1 Rotation panier right droite- -Max Vitesse maxi.

Basket rotation speed.

V2 V2 Rotation panier right droite- -Max Vitesse maxi.

Rotation panier right droite- -Max Vitesse maxi.

Basket rotation speed.

V3 V3 Rotationrotation panier droite Rampe accélération acceleration Basket right --Ramp Rotationrotation panier droite décélération Basket right -- Rampe Ramp deceleration Rotation panier left gauche maxi. V1 Basket rotation - Max- Vitesse speed. V1 Rotation panier left gauche maxi. V2 Basket rotation - Max- Vitesse speed. V2 Rotation panier left gauche maxi. V3 Basket rotation - Max- Vitesse speed. V3

Rotation panierleft gauche - Rampe accélération Basket rotation - Ramp acceleration Rotation panier gauche Rampe décélération Basket rotation left - Ramp deceleration

8 8 8 0 0 8 8 8 0 0

GESTION ROTATION GESTION ROTATION TOURELLE TOURELLE

0 1 2 3 4 5 6 7 8 9

Turret rotation right - Max speed. maxi.

V1 V1 Rotation tourelle droite - Vitesse Turret rotation right - Max speed. maxi.

V2 V2 Rotation tourelle droite - Vitesse Turret rotation right - Max speed. maxi.

V3 V3 Rotation tourelle droite - Vitesse - Ramp acceleration Turret rotation Rotation tourelleright droite - Rampe accélération Rotation tourelleright droite - Rampe décélération Turret rotation - Ramp deceleration Rotation tourelle - Vitesse Turret rotation leftgauche - Max speed.

V1 maxi. V1 Rotation tourelle - Vitesse Turret rotation leftgauche - Max speed.

V2 maxi. V2 Rotation tourelle - Vitesse Turret rotation leftgauche - Max speed.

V3 maxi. V3 Rotation tourelleleft gauche - Rampe accélération - Ramp acceleration Turret rotation Rotation tourelle gauche Rampe décélération Turret rotation left - Ramp deceleration

17 17 18 80 4 17 17 18 80 4

ENGINE CONTROL GESTION MOTEUR

0 1 2 3 4 5 6

Time delay max engine speed stopping Tempo arrêtinrégime maximum Time delay in maxrégime enginemaximum speed activation Tempo activation Tempo sécurité démarrage moteur Time delay in engine start-up safety system Bypassof régime mouvement By-pass enginemoteur speed interdiction movement interdiction Seuil démarrage moteur Engine start-up threshold Tempo validation forçage forcing régime speed Time delay in confirming Tempo invalidation forçageforcing régimespeed Time delay in invalidating

1 4 20 1 600 1 0

ROTATING FLASHING LIGHT CONTROL GESTION GYROPHARE

0

Time delay in rotating flashing light stopping Tempo arrêt gyrophare

10

GENERATOR UNIT CONTROL GESTION. GÉNÉRATRICE

0

Time delay in generator unit activation Tempo activation génératrice

40

(04/2011)

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27

80

Electronic modules – Operational control

Electronic modules – Operational control

SUB-GROUP SOU S-GROUPE

NNUMBER UMÉRO

PRÉCHAUFFAGE PRE-HEATING

0

FAULT CONTROL GESTION DÉFAUTS

0 1 2 3 4 5 6 7 8 9 10 11 12

Tempo Bus CAN CAN busdéfaut fault time delay Tempo gestion générale General fault control timedéfauts delay Tempowater défauttemperature température eau moteur Engine fault time delay Tempo oil défaut pression Engine pressure faulthuile timemoteur delay Tempo défaut charge Battery charging fault batterie time delay Tempolevel défaut bas gasoil Diesel lowniveau fault time delay Tempo défaut Overload fault surcharge time delay Tempo devers Tilt faultdéfaut time delay Tempo ON buzzer ONtiltsur devers Buzzer under time delay Tempo OFF buzzer OFF devers Buzzer under tiltsur time delay Numéro klaxon base Base hornoption option number Tempo sur mouvement Horn ONklaxon underON movement time delay Tempo klaxon OFF sur mouvement Horn OFF under movement time delay

LANGUAGE LANGUE CONTROL GESTION

0

English Langue language Anglaise

INTERNAL DATA DONNEES INTERNES

0 1 2 3 4 5 6 7 8 9 10 11 12

Version: Version: Vx VxDate Date EEPROM reset reset EEPROM Process Processtimer timer Min proportional PVGPVG recovery Recouvrement mini. proportionnel Min proportional PVGPVG recovery Recouvrement maxi. proportionnel Current loop Pde gain GainP boucle courant Current loop Ide gain GainI boucle courant PWM Seuil error erreurthreshold Pwm PWM error cancellation delay Tempo annulation erreurtime Pwm PWM error detection time delay Tempo détection erreur Pwm PWM frequency Fréquence PWM PWM0 coefficient Coefficient PWM0 PWM1 coefficient Coefficient PWM1

80

28

80-04-07-M172EN

DESCRIPTION DESCRIPTION Pre-heating time delay Tempo préchauffage

VALUE VA LEUR

60 15 40 100 40 200 150 20 20 8 10 0 1 11 0 0 0 30 4300 5700 140 80 1000 100 20 3 1905 1905

(04/2011)

29

Electronic modules – Operational control

10 -Réglage Machine parameters - Level Nacelle: 160 ATJ FC Tableau Vitesses Réglage vitesses en Cdes panier, en V3, avec une personne dans le panier, huile machine chaude 40° à 60°.

Engine speed when warm: idling speed: 1350 rpm ±10, max speed: 2500 rpm ±25.

Main pressure 220b (±5 bars)

Pressure setting ±5 bars

parameters V3

Std

Time to be obtained in seconds and tolerance

Times Parameters obtained V3 obtained V3

V1 (less than V2)

Lower arms

UP Down

220 see Note 100

59 66

28±1 28±1

5 5

Arm 3 (pendular arm horizontal, telescope EXTENDED) Telescope (Arm 3 horizontal) Pendular arm

Up Down

220 see Note 110

76 58

35±1 33±1

3 3

Extended Retracted UP Down Cylinder extended Cylinder retracted R/L

120 180 200 80 200

67 53 78 35 57

18±1 16±1 23±2 23±2 35±2

3 3 3 0 0

100

15

27±2

0

160

42

27±1

3

R/L FRONT & BACK

160

16 37

10±1 46±12

0

Basket tilt

Turret rotation (Telescope EXTENDED) Basket rotation Translation in work mode (for 5m)

80

NB: Pressure restricted by main restrictor. To be set via the main restrictor.

(04/2011)

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Electronic modules – Operational control

D - PROGRAM W678600-002 How to use the computer 1 - Controls used on the base console

C1

68

53

68

2 - Engine start-up – User Level Actions on the base console controls

Screen display

Switching on

80

- Rearming the Emergency Stop

Screen off

Switching the computer on - Use of the ignition key

ENGINE PREHEATING pages

Engine start-up - Use of the starter button

PAGE(S) DÉFAUT(S)

WAIT screen Lifting speed / Counter machine timer / Control base / basket

80-04-07-M172EN

or

FAULT page See paragraph 3 – CHECKING FOR FAULTS (04/2011)

31

Electronic modules – Operational control

3 - Checking for faults – Operator level - Five types of Fault pages: THESE PAGES APPEAR DIRECTLY ON THE SCREEN

DIESEL LEVEL LOW fault

MAINTENANCE fault(s):

- Intermittent display of the fuel generator symbol.

- Intermittent display of the flat wrench symbol.

Fault(s) to be ACKNOWLEDGED (inadvertent) or to be DISPLAYED: - Intermittent display of the Hazard triangle.

TILT or OVERLOAD fault(s): - Intermittent display of the Hazard triangle.

Fault(s) to be ACKNOWLEDGED: - Display of the fault.

Description of the faults: Faults to be acknowledged (C1).

- Before displaying the Work page, compulsory acknowledgement of the faults by pressing key

Fault page BUS CAN

Fault page ENGINE WATER TEMPERATURE

Fault page ENGINE OIL PRESSURE

Fault page BATTERY CHARGE

Fault page LOW SUPPLY

Fault page INDUCTIVE SENSOR

Faults to be displayed - From the Fault(s) to be ACKNOWLEDGED (inadvertent) or to be DISPLAYED page. Access to the Faults pages by pressing key (C1).

- Scrolling of the pages or return to the Work page by pressing key

Fault page FORWARD MOTION JOYSTICK (04/2011)

Fault page ARMS 1/2 JOYSTICK

Fault page ARM 3 JOYSTICK

Fault page TELESCOPE JOYSTICK

Fault page TURRET JOYSTICK

(C1).

Fault page TILT

Fault page OVERLOAD

80-04-07-M172EN

80

- If an inadvertent fault occurs (appearance/disappearance of the fault during the work session), acknowledgement not requested again. Only the flashing Hazard triangle appears on the Work page.

View of the fault by pressing key (C1).

32

Electronic modules – Operational control

Maintenance faults - Display of the flat wrench symbol in the Work page by pressing the key the fault, scrolling of the pages or return to the Wait page by pressing key

or (C1), display of (C1).

- On demand from the maintenance pages, the Fault pages appear before the Maintenance pages: acknowledgement of the faults and then display of the Maintenance pages by pressing key (C1).

Fault page OIL FILTER MAINTENANCE

Fault page AIR FILTER MAINTENANCE

Fault page DIESEL FILTER MAINTENANCE

Fault page HYDRAULIC FILTER MAINTENANCE

Fault page HYDROSTATIC FILTER MAINTENANCE

Fault page LUBRICATION MAINTENANCE

Fault page MECHANICAL INSPECTION MAINTENANCE

80

Fault page OIL DRAINAGE MAINTENANCE

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Electronic modules – Operational control

33

4 - Screen settings – User Level

SCREEN SETTING AND ENTRY OF TE SECRET CODE pages (From the wait screen) - Display of the tabs:

MENU - Page selection (4 pages):

CONTRAST/ BRIGHTNESS pages

- I + (high) CONTRAST setting page

INITIALISATION Page

- Setting modification:

- I + (low) - Setting initialisation (default setting set at a median value):

and I + (low)

BRIGHTNESS setting page

INITIALISATION Page

TIME/DATE pages - Setting modification:

- I + (low) - Parameter change:

TIME/DATE Page

SECRET CODE pages - Display of the ENTER SECRET CODE page:

- I + (low) - Number selection:

- I + (low) - Number confirmation, changeover to the next number and confirmation of the entire code: SECRET CODE page

ENTRY OF SECRET CODE page

MENUS - Menu selection (3 menus):

- I + (high)

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80

IMAGINARY code

34

Electronic modules – Operational control

5 - Settings menu – Dealer / Lessor and Manufacturer’s Levels

SETTING menu -Sub-menu selection (2 sub-menus):

- I + (low) - Confirmation of selection:

CONTRAST setting page

BRIGHTNESS setting page

INITIALISATION page

TIME/DATE pages - Setting modification: - I + (low) - Parameter change:

TIME/DATE page IMAGINARY code

80

SCREEN SETTING submenu SECRET CODE pages - Access to ENTER SECRET CODE page: - I + (low) - Number selection: - I + (low) - Number confirmation, changeover to the next number and confirmation of the entire code: SECRET CODE page

ENTRY OF SECRET CODE page

SYSTEM PARAMETERS sub-menu - Parameter group selection: 3 Pages 16 Paramètres NIVEAU concessionnaire / loueur

- I + (low) NB: - 3 pages at DEALER/LESSOR level.

- 25 pages at MANUFACTURER’S level.

- Confirmation of selection:

ou 25 Pages 269 Paramètres NIVEAU constructeur

- Parameter selection:

- I + (high) NB: - 3 pages at DEALER/LESSOR level.

- 252 parameters at MANUFACTURER’S level.

- Setting modification - I + (low)

 § C 9 - PARAMETERS – DEALER/LESSOR LEVEL AND MANUFACTURER’S LEVEL 80-04-07-M172EN 80-04-07-M172FR

(04/2011)

Electronic modules – Operational control

35

6 - Maintenance menu - Dealer / Lessor and Manufacturer’s Levels

COUNTERS sub-menu - Counter selection (9 counters):

- I + (high and low) RAZ

RAZ

- Reinitialisation of the maintenance counters and reset of the hire counter to zero:

RAZ

(twice) P 1/3 - Maint.

- Oil change - Oil filter - Air filter

P 2/3 - Maint.

P 3/3 - Maint.

- Diesel filter - Hydraulic filter - Hydrostatic filter

- Lubrication .

- Mechanical check - Location.

dealer/lessor level

MAINTENANCE menu

COUNTERS sub-menu - Counter selection (10 counters): - I + (high and low) - Selection of the maintenance counter to modify:

- Sub-menu selection (2 or 3 sub-menus – depending on the secret code): - I + (low) - Confirmation of selection: P 3/3 - Maint.

- Diesel filter - Hydraulic filter - Hydrostatic filter

- Counter value modification: - I + (low) and

- Lubrication .

- Mechanical check - Location.

- Engine.

Manufacturer’s level

P 1/5 - Visu IN/OUT

P 2/5 - Visu IN/OUT

P 3/5 - Visu IN/OUT

P 4/5 - Visu IN/OUT

P 5/5 - Visu IN/OUT

- INTOR.

- OUTTOR.

- INANA.

- INHSCE.

- OUTANA. - OUTPWM.

(§ C8-1)

(§ C8-2)

(§ C8-3)

(§ C8-4)

(§ C8-5)

Sub-menu - Page selection (5 pages):

dealer/lessor and manufacturer’s level

14 CATEGORIES DE DEFAUTS 100 DEFAUTS MAXIMUM

FAULTS sub-menu - Page selection (up to 12 pages): manufacturer’s level

(04/2011)

80-04-07-M172EN 80-04-07-M172FR

80

P 2/3 - Maint.

P 1/3 - Maint.

- Oil change - Oil filter - Air filter

36

Electronic modules – Operational control

7 - Engine menu - Dealer / Lessor and Manufacturer’s Levels

Menu MOTEUR - Validation du choix:

DEALER/LESSOR AND MANUFACTURER’S LEVEL

8 - Inputs/outputs sub-menu - Dealer / Lessor and Manufacturer’s Levels 8-1 - Page 1/5 - INTOR

Intor 0 Intor 8

Intor 7 Intor 12

Intor 0 Intor 8 Intor 16

Intor 7 Intor 15 Intor 19

ClavMvt 7 ClavMvt 12 ClavFct 7

80

ClavMvt 0 ClavMvt 8 ClavFct 0

BASE UPC Bit Intor0 Intor1 Intor2 Intor3 Intor4 Intor5 Intor6 Intor7 Intor8 Intor9 Intor10 Intor11 Intor12

Description Base/basket selector Tilt sensor Low arm sensor 1 Telescope retracted sensor 1 Low arm sensor 2 Battery charge level Diesel level low Telescope retracted sensor 2 Engine water temperature high Engine oil pressure low Front axle sensor Rear axle sensor Forcing unit, max engine speed

Status 0

Status 1

Base position Basket position Under tilt Outside tilt range Work position Transport position Extended Retracted Work position Transport position Normal Low Low Normal Extended Retracted Abnormal Normal Abnormal Normal Misaligned Aligned Misaligned Aligned Normal Forced

INTOR = DIGITAL INPUT 80-04-07-M172EN

(04/2011)

Electronic modules – Operational control

37

BASE UPC Bit

Description

Status 0

Status 1

Intor0 Intor1 Intor2 Intor3 Intor4 Intor5 Intor6 Intor7 Intor8 Intor9 Intor10 Intor11 Intor12 Intor13 Intor14 Intor15 Intor16 Intor17 Intor18 Intor19

Steering control - Left Steering control - Right Tilt control - forward Tilt control - back Pendular arm control - UP Pendular arm control - DOWN Speed control - Slow Speed control - High Basket rotation control - Left Basket rotation control - Right Steering control - Crab Steering control – 4-wheel Joystick switch - arms 1/2 + Telescope Joystick switch - arm 3 + Turret rotation Joystick trigger - forward motion Push-button - Differential lock Overload safety Dead Man’s pedal Selector – Tilt unlocking Push-button – Horn

Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated / / Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated

Actuated Actuated Actuated Actuated Actuated Actuated Actuated Actuated Actuated Actuated Actuated Actuated / / Actuated Actuated Actuated Actuated Actuated Actuated

ON OFF

677719

BASE UPC Bit ClavMvt0 ClavMvt1 ClavMvt2 ClavMvt3 ClavMvt4 ClavMvt5 ClavMvt6 ClavMvt7 ClavMvt8 ClavMvt9 ClavMvt10 ClavMvt11 ClavFct0 ClavFct1 ClavFct2 ClavFct3 ClavFct4 ClavFct5 ClavFct6 ClavFct7 (04/2011)

Description Key - Pendular arm UP Key - Pendular arm DOWN Key - Telescope - Retraction Key - Telescope - Extension Key - Arm 3 - UP Key - Arm 3 - DOWN Key - Arms 1/2 - UP Key - Arms 1/2 - DOWN Key - Turret rotation Left Key - Turret rotation Right Key - Tilt forward Key - Tilt back Key - Right Key - PLUS Key - OK Key - Menu Key - Exit Key - Fault Key - MINUS Key - Left

Status 0

Status 1

Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated Not actuated

Actuated Actuated Actuated Actuated Actuated Actuated Actuated Actuated Actuated Actuated Actuated Actuated Actuated Actuated Actuated Actuated Actuated Actuated Actuated Actuated 80-04-07-M172EN

80

677718

38

Electronic modules – Operational control

8 - 2 - Page 2/5 - OUTTOR

Outtor 0 Outtor 8 Outtor 16 Outtor 24

Outtor Outtor Outtor Outtor

Outtor 0 Outtor 8

7 15 23 31

Outtor 7 Outtor 9

BASE UPC

80

Bit

A5 B5

B4 A4

A3 B3 A2 B2

B1

A1

Description

Outtor0 Proportional distributor supply - arms 1/2 UPC BASE Outtor1 Proportional distributor supply - arm 3 Outtor2 Proportional distributor supply- telescope BOuttor3 it DProportional escription distributor supply - N°4 Outtor0 proportionnel - Bras 1/2 Outtor4 Alimentation Max enginedistributeur revs Outtor1 distributeur proportionnel - Bras 3 Outtor5 Alimentation NOT ASSIGNED Outtor2 distributeur proportionnel - Telescope Outtor6 Alimentation NOT ASSIGNED Outtor3 distributeur proportionnel - N°4 Outtor7 Alimentation NOT ASSIGNED OOuttor8 uttor4 RHydraulic égime Maxsafety i Motesystem ur electro-valve OOuttor9 uttor5 NAnti-start ON AFFEC TÉE system security O uttor6 NRotating ON AFFEflCashing TÉE light Outtor10 O uttor7 NBuzzer ON AFFECTÉE Outtor11 Outtor8 Outtor12Electrovalve Preheating sécurité hydraulique O uttor9 Sé curité anti-dé-m arrage unit (option) Outtor13 Electro-valve Generator O uttor10 GElectro-valve yrophare Outtor14 - Crab steering O uttor11 AvElectro-valve ertisseur Son-o4WD re steering Outtor15 O uttor12 PrElectro-valve échauffage - Brake Outtor16 Outtor13 - Génératrice Outtor17Electrovalve Electro-valve - Differential(option) lock O uttor14 ElElectro-valve ectrovalve - D-iOscillation rection CrabN° e1 Outtor18 Outtor15 - Direction 4 Roues Outtor19Electrovalve Electro-valve - Oscillation N° 2 O uttor16 ElElectro-valve ectrovalve - F-rBasket ein Outtor20 rotation left Outtor17 - Blocage Outtor21Electrovalve Electro-valve - BasketDifférentiel rotation right O uttor18 ElElectro-valve ectrovalve - O- sTurret cillatiorotation n N°1 left Outtor22 O uttor19 ElElectro-valve ectrovalve - O- sTurret cillatiorotation n N°2 right Outtor23 Outtor20 - Rotation Gauche Outtor24Electrovalve Electro-valve - Steering left Panier Outtor21 - Rotation Droite Outtor25Electrovalve Electro-valve - Steering rightPanier Outtor22 - Rotation Gauche Tourelle Outtor26Electrovalve Electro-valve - Tilt forward Outtor23 - Rotation Droite Tourelle Outtor27Electrovalve Electro-valve - Tilt back Outtor24 - Direction Gauche Outtor28Electrovalve Electro-valve - Pendular arm UP O uttor25 ElElectro-valve ectrovalve - D-iPendular rection Drarm oite DOWN Outtor29 Outtor26 Outtor27 Outtor28 Outtor29

Electrovalve Electrovalve Electrovalve Electrovalve

-

Inclinaison Déversement Inclinaison Cavage Pendulaire Montée Pendulaire Descente

Status 0 Not actuated Not actuated Not actuated EtNot at 0actuated Non actionnée Not actuated Non actionnée / Non actionnée / Non actionnée / NoNot n acactuated tionnée / Not actuated / Not actuated / Not actuated Non actionnée Not actuated NoNot n acactuated tionnée NoNot n acactuated tionnée NoNot n acactuated tionnée NoNot n acactuated tionnée Non actionnée Not actuated NoNot n acactuated tionnée Non actionnée Not actuated NoNot n acactuated tionnée Non actionnée Not actuated NoNot n acactuated tionnée NoNot n acactuated tionnée Non actionnée Not actuated Non actionnée Not actuated Non actionnée Not actuated Non actionnée Not actuated Non actionnée Not actuated No n acactionnée tionnée Non Non Non Non Non

actionnée actionnée actionnée actionnée

Status 1 Actuated Actuated Actuated EtaActuated t1 Actionnée Actuated Actionnée / Actionnée / Actionnée / ActiActuated onnée / Actuated / Actuated / Actuated Actionnée Actuated ActiActuated onnée ActiActuated onnée ActiActuated onnée ActiActuated onnée Actionnée Actuated ActiActuated onnée Actionnée Actuated ActiActuated onnée Actionnée Actuated ActiActuated onnée ActiActuated onnée Actionnée Actuated Actionnée Actuated Actionnée Actuated Actionnée Actuated Actionnée Actuated ActiActuated onnée Actionnée Actionnée Actionnée Actionnée

OUTTOR = DIGITAL OUTPUT

OUTTOR = SORTIE NUMÉRIQUE 80-04-07-M172EN

(04/2011)

39

Electronic modules – Operational control

UPC PANIER BASKET UPC BitBit

Description Description

Status Etat 0 0

Status Etat 1 1

Outtor0 Outtor0 Outtor1 Outtor1 Outtor2 Outtor2 Outtor3 Outtor3 Outtor4 Outtor4 Outtor5 Outtor5 Outtor6 Outtor6 Outtor7 Outtor7 Outtor8 Outtor8 Outtor9 Outtor9

Vibreur Buzzer Sonore Indicator light - Front axle Témoin Pont Avant Indicator lightarrière - Rear axle Témoin Pont Indicator light -Moteur EngineThermique fault Témoin Défaut Indicator light -Devers Tilt fault Témoin Défaut Indicator light - Overload Témoin Surcharge Indicator light - Preheating Témoin Préchauffage Indicator light -Bas Diesel level low Témoin Niveau Gasoil NON AFFECTÉE AFFECTEE NON NON AFFECTÉE AFFECTEE NON

Nonactuated actionné Not Unlit Eteint Unlit Eteint Unlit Eteint Unlit Eteint Unlit Eteint Unlit Eteint Unlit Eteint / / / /

Actionné Actuated Lit Allumé Lit Allumé Lit Allumé Lit Allumé Lit Allumé Lit Allumé Lit Allumé / / / /

80

677718

(04/2011)

80-04-07-M172EN

40

Electronic modules – Operational control

8 - 3 - Page 3/5 - INANA

INANA = ANALOGIC INPUT INANA = ENTRÉE ANALOGIQUE

JOYSTICKS MANIPULATEURS Description 25% at 50%

Bit Inana0 Bit Inana1 Inana0 Inana2 Inana1 Inana3 Inana2 Inana4 Inana3

Joystick - arms 1/2 Description Joystick - telescope Manipulateur - Bras1/2 Joystick - arm 3 Manipulateur - Telescope Joystick - Turret Rotation Manipulateur - Bras 3 Joystick - Forward motion Manipulateur - Rotation tourelle

Inana4

Manipulateur - Avancement

Arm 3 Levage bras UP3

25% UP à 50% Retraction Levage UP Rentrée Rotation to the right Levage Reverse Rotation à droite Recul

50%

Neutre

Turret

80

Avance

Arms 1/2 Levage bras 1/2 UP Rotation rotation tourelle à to droite the right

Forward Avance

Telescope Rentrée télescope retracted

Sortie Telescope télescope extended

Rotation Turret tourelle à rotation gauche to the left

50% at 75%

Neutral 50% à Down 50% 75% Neutral Extension Neutre Descente Neutral Down Neutre Sortie Neutral Rotation to the left Neutre Descente Neutral Rotation àForward Neutre gauche

Recul Reverse 677719

Arms 1/2 Descente bras 1/2 Down

Descente Arms 3 bras 3

Down

ALIMENTATION UPC BASE BASE UPC SUPPLY DescriptionDescription

Nominal value Valeur nominal engine stopped moteur à l’arrêt

+APC Computer supply after contact (key) +APC Alimentation après contact (clé) calculateur +BAT Alimentation permanente calculateur +BAT Computer permanente supply UPC PANIER Alimentation après (key) contact (clé) UPC101 BASKET UPC Supply after contact UPC101 ECRAN Alimentation après contact (clé) SCREEN Supply after contact (key) CEK20 CEK20

~12,5V ~12,5V ~12,5V ~12,5V ~12,5V ~12,5V ~12,5V ~12,5V

Bit Bit

80-04-07-M172EN

Nominal value Valeur nominal engine started moteur démarré ~13,5V ~13,5V ~13,5V ~13,5V ~13,5V ~13,5V ~13,5V ~13,5V

(04/2011)

Electronic modules – Operational control

41

8-4 - Page 4/5 - INHSCE

INHSCE = HSCE INPUT

ENGINE speed Bit

Description Frequency signal coming from the alternator Engine speed (signal in HZ converted to rpm)

Idling

Forced

~202Hz ~398Hz ~1317rpm ~2590rpm

80

Raw Scale

(04/2011)

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Electronic modules – Operational control

8-5 - Page 5/5 - OUTPWM

PVG Bit Outana0 Outana1 Outana2 Outana3 Outana4 Outana5

Description Proportional distributor control - arms 1/2 Proportional distributor control - arm 3 Proportional distributor control - telescope Proportional distributor - N°4 NOT ASSIGNED NOT ASSIGNED

25% at 50%

50%

50% at 75%

Up Up Extension Supplied / /

Neutral Neutral Neutral Neutral / /

Down Down Retraction Tank return / /

POMPE AVCT Bit

Description

80

PWM0 Translation pump - Forward PWM1 Translation pump - Reverse

0 to 350 mA

350 to 1200mA

No movement No movement

Forward Reverse

OUTANA = ANALOGIC OUTPUT

80-04-07-M172EN

(04/2011)

Electronic modules – Operational control

9 - PARAMÈTRES NIVEAUX CONCESSIONNAIRE / LOUEUR 9 - Parameters - Dealer -/ Lessor and Manufacturer’s Levels CONSTRUCTEUR

43

ET

TheLes grey-coloured in the tables correspondaux to the zones griséesareas dans les tableaux correspondent onlyseuls parameters visible and modifiableavec with paramètres visibles et modifiables le the dealer/ lessor secret code. code secret concessionnaire / loueur.

GROUPE ÉCRAN ECRAN GROUPE

(04/2011)

NNUMERO UMÉRO

DESCRIPTION DESCRIPTION

VVALEUR ALEUR

0

Language Selection Selection Langue

0- 11

SECRETSECRET CODE CODES

0 1

Code Concession DealerSecret secret code --

0241 -

MAINTENANCE REGLAGES SETTINGS MAINTENANCES

0 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 31 32 33 34 35 36 37 38 39

Engine maintHuile init OK Init OKoil Maint Moteur Engine initHuile periodMoteur PeriodeoilInit Engine oil init alertMoteur Alerte Init Huile Engine period PeriodeoilHuile Moteur Engine oil alert Alerte Huile Moteur Oil OKHuile Initfilter OK maint Maint init Filtre Oil filter init Periode Initperiod Filtre Huile Oil filterInit initFiltre alert Huile Alerte Oil filter period Periode Filtre Huile Oil filterFiltre alert Huile Alerte Air OKAir Initfilter OK maint Maint init Filtre Air filter init Periode Initperiod Filtre Air Air filterInit initFiltre alert Air Alerte Air filter period Periode Filtre Air Air filterFiltre alert Air Alerte Diesel maint initGasoil OK Init OKfilter Maint Filtre Diesel filter period Periode Initinit Filtre Gasoil Diesel init alert Alertefilter Init Filtre Gasoil Diesel filter period Periode Filtre Gasoil Diesel Alertefilter Filtrealert Gasoil Hydraulic filter maint init OK Init OK Maint Filtre Hydraul Hydraulic filterFiltre init period Periode Init Hydraul Hydraulic initHydraul alert Alerte Initfilter Filtre Hydraulic filter period Periode Filtre Hydraul Hydraulic filterHydraul alert Alerte Filtre Hydrostatic filter maint init OK Init OK Maint Filtre Hydrost Hydrostatic initHydrost period Periode Initfilter Filtre Hydrostatic filter init alert Alerte Init Filtre Hydrost Hydrostatic filterHydrost period Periode Filtre Hydrostatic alert Alerte Filtrefilter Hydrost General maint init OK Init OK lubrication Maint Graiss General General period Periodelubrication Init Graissinit General General lubrication init alert Alerte Init Graiss General General period Periodelubrication Graiss General General lubrication alert Alerte Graiss General Mechanical inspection maint init OK Init OK Maint Contrôle Meca Mechanical inspection init period Periode Init Contrôle Meca Mechanical inspection init alert Alerte Init Contrôle Meca Mechanical inspection period Periode Contrôle Meca Mechanical inspection Alerte Contrôle Mecaalert

0 50 10 500 10 0 50 10 500 10 0 50 10 500 10 0 50 10 500 10 0 50 10 500 10 0 50 10 500 10 0 50 10 50 10 0 50 10 250 10 80-04-07-M172EN

80

SOSUB-GROUP US-GROUPE LANGUAGE LANGUE

44

Electronic modules – Operational control

MACHINE GROUP GROUPE MACHINE NNUMBER UMÉRO 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

DESCRIPTION DESCRIPTION Calcul coef engine speed Régime Moteur Coef Calcul Engine filerRetard delay Filtre Régimespeed Moteur Min recovery, joysticks Recouvrement Min Manips Max recovery, joysticks Recouvrement Max Manips Forward motion joystick switch activation Activation Switchs Manips Reversal direction arms 1/21-2 joystick InversionofSens Manip Bras Reversal direction telescope joystick InversionofSens Manip Telescope Reversal direction armBras 3 joystick InversionofSens Manip 3 InversionofSens Manip Tourelle Reversal direction turret joystick InversionofSens Manip Avancement Reversal direction forward motion joystick Filtr Manip Avct joystick Travail filter, Work Forward motion Filtr Manip Avct Transport Tortue transport Forward motion joystick filter, slow-speed Forward motion joystick filter, high-speed Filtr Manip Avct Transport Lievre transport Forward motion filter, ramp transport Filtr Manip Avctjoystick Transport Rampe Forward Tempomotion Detectjoystick NeutrNeutral Manipdetection Avct time delay

VA LEUR VALUE 567 15 4500 5500 0 1 0 1 1 0 10 14 40 18 5

INPUT CONTROL GESTION ENTREES

OUTPUT CONTROL GESTION SORTIES

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Inversion PVG arms Bras 1-2 Reversal ofSens direction 1/2 PVG Inversion PVG Telescope Reversal ofSens direction telescope PVG Inversion PVG arm Bras3PVG 3 Reversal ofSens direction Reversal ofSens direction 4 Inversion PVG PVG 4 Reversal ofSens direction Inversion PVG steering DirectionPVG Reversal ofSens direction PVG Inversion PVG tilt Inclinaison Reversal ofSens direction arm PVG Inversion PVG pendular Pendulaire Reversal ofSens direction rotation PVG Inversion PVG basket Rot Panier Reversal ofSens direction rotation PVG Inversion PVG turret Rot Tourelle Reversal ofSens direction RH forward motion pump Inversion Pompe Avct RH Reversal of direction SR forward motion pump Inversion Sens Pompe Avct SR Forward motion RH min current Marche Avant Courant Min RH ForwardAvant motion RH max current Marche Courant Max RH Reverse motion RH min current Marche Arrière Courant Min RH Reverse Arrière motionCourant RH max Max current Marche RH Forward motion SR min current Marche Avant Courant Min SR ForwardAvant motion SR maxMax current Marche Courant SR Reverse motion SR min current Marche Arrière Courant Min SR Reverse Arrière motionCourant SR max Max current Marche SR Hydraulic safety stop time Tempo Arrêt Secu Hydrau delay Authorised hydraulic mvt safety time delay Tempo Secu Mvt Hydrau Autorise Steering selection advance active Active Avance Select Direction SteeringArrêt select stop time delay Tempo Select Direction

1 1 1 0 0 0 0 0 1 0 0 350 1200 350 1200 230 1400 230 1400 0 1 0 10

FORWARD MOTION GESTION AVANCEMENT CONTROL

0 1 2 3 4 5

SAUER DANFOSS generator mode Mode Pompe SAUER DANFOSS Tempo Avct Après Arrêt Forward motion after stopping time delay Tempo Detection Arrêt Translation Translation stop detection time delay Tempo Detection Fdc Transport Transport end stop detection time delay Tempomode Detection Fdc detection Travail time delay Work end stop Blocage différentiel sur Devers+Arrêt Differential locking on Tilt+Stop

0 0 1 0 0 1

REXROTH FORWARD GESTION MOTION CONTROL AVANCEMENT REXROTH

0 1 2 3 4 5 6 7

Work - max Travailmode Vitesse Maxspeed Avt forwards Work - acceleration Travailmode Rampe Accel Avt ramp forwards Work - deceleration Travailmode Rampe Decel Avt ramp forwards Work mode - max Travail Vitesse Maxspeed Arr reverse Work mode - acceleration Travail Rampe Accel Arr ramp reverse Work mode - deceleration Travail Rampe Decel Arr ramp reverse Transport max slow speed forwards Transport -Tortue Vitesse Max Avt Transport slow acceleration ramp Transport -Tortue Rampe Accel Avt forwards

37 24 10 37 24 10 80 20

80

SO US-GROUPE SUB-GROUP

80-04-07-M172EN

(04/2011)

SOUSUB-GROUP S-GROUPE

NNUMBER UMÉRO

DESCRIPTION DESCRIPTION

VALUE VA LEUR

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Transport Rampe Decel Avtforwards Transport -Tortue slow deceleration ramp Transport Vitesse Arr Transport –Tortue max slow speedMax reverse Transport Rampe Accel Arrreverse Transport –Tortue slow acceleration ramp Transport Rampe Decel Arrreverse Transport -Tortue slow deceleration ramp Transport Vitesse Avt Transport –Lievre max high speedMax forwards Transport Rampe Accel Avtforwards Transport –Lievre high acceleration ramp Transport Rampe Decel Avtforwards Transport -Lievre high deceleration ramp Transport Vitesse Arr Transport –Lievre max high speedMax reverse Transport Rampe Accel Arrreverse Transport –Lievre high acceleration ramp Transport Rampe Decel Arrreverse Transport -Lievre high deceleration ramp Transport Vitesse Avt Transport –Rampe max ramp speedMax forwards Transport Rampe Accel Transport –Rampe ramp acceleration rampAvt forwards Transport Rampe Decel Transport -Rampe ramp deceleration rampAvt forwards Transport Vitesse Arr Transport –Rampe max ramp speedMax reverse Transport Rampe Accel Arrreverse Transport –Rampe ramp acceleration ramp Transport Rampe Decel Arrreverse Transport -Rampe ramp deceleration ramp Avancement Type motion Courbe Curve type forward Anticalage Anti-stallingActivation activation

4 80 20 4 100 15 10 100 15 10 40 26 15 40 26 15 0 0

SAUER-DANFOSS GESTION FORWARD MOTION AVANCEMENT SAUERCONTROL DANFOSS

0 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

Travail Vitesse Avt Work mode Forward motion Max max speed, Travail Rampe Avt Work mode Forward motion Accel accel ramp, Forward motion Decel decel ramp, Travail Rampe Avt Work mode Reverse motion max Travail Vitesse Maxspeed, Arr Work mode Reverse motion accel Travail Rampe Accelramp, Arr Work mode Reverse motion decel ramp, Travail Rampe Decel Arr Work mode Forward motion maxVitesse slow speed, Transport Transport Tortue Max Avt mode Forward motion accel ramp slow speed, Transport Tortue Rampe AccelTransport Avt mode Forward motion decel ramp slow speed, Transport Tortue Rampe DecelTransport Avt mode Reverse motion max slow speed, Transport Transport Tortue Vitesse Max Arr mode Reverse motion accel ramp slow speed, Transport Transport Tortue Rampe Accel Arr mode Reverse motion decel ramp slow speed, Transport Transport Tortue Rampe Decel Arr mode Forward motion maxVitesse high speed, Transport Transport Lievre Max Avt mode Forward motion accel ramp high speed, Transport Lievre Rampe AccelTransport Avt mode Forward motion decel ramp high speed, Transport Lievre Rampe DecelTransport Avt mode Reverse motion max Vitesse high speed, Transport Transport Lievre Max Arr mode Reverse motion accel ramp high speed, Transport Lievre Rampe AccelTransport Arr mode Reverse motion decel ramp high speed, Transport Transport Lievre Rampe Decel Arr mode Forward motion max ramp speed, Transport Transport Rampe Vitesse Max Avt mode Forward motion accel ramp ramp speed, Transport Transport Rampe Rampe Accel Avt mode Forward motion decel ramp ramp speed, Transport Transport Rampe Rampe Decel Avt mode Reverse motion max ramp speed, Transport Transport Rampe Vitesse Max Arr mode Reverse motion accel ramp ramp speed, Transport Transport Rampe Rampe Accel Arr mode Reverse motionRampe decel ramp ramp speed, Transport Transport Rampe Decel Arr mode Forward motion curve type Avancement Type Courbe Anti-stalling activation Anticalage Activation

37 24 10 37 24 10 80 20 4 80 20 4 100 15 10 100 15 10 40 26 15 40 26 15 0 0

ANTI-STALLING CONTROL GESTION

0 1 2 3 4 5

Idling speedRégime anti-stalling Anticalage Ralenti Max engine speed anti-stalling Anticalage Régime Maxi High P gain anti-stalling Anticalage GainP Haut High I gain anti-stalling Anticalage GainI Haut Low P gain anti-stalling Anticalage GainP Bas Low I gain anti-stalling Anticalage GainI Bas

1000 2000 800 800 300 300

ANTICALAGE

(04/2011)

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45

80

Electronic modules – Operational control

80

46

Electronic modules – Operational control

SUB-GROUP SOU S-GROUPE

NNUMBER UMÉRO

SPEED CONTROL GESTION VITESSES

0 1

Basket speed mode Mode movement Vitesse Mvts Panier Base movement speed mode Mode Vitesse Mvts Base

3 2

CONTROL OF ARMS1-2 1-2 GESTION BRAS

0 1 2 3 4 5 6 7

Arms speed raising V2-V1 Bras 1-2 1-2max Mont Vit. Max V2-V1 Arms 1-2 max speed raising V3-V2 Bras 1-2 Mont Vit. Max V3-V2 Arms raising Bras 1-2 1-2accel Montramp Rampe Accel Arms raising Bras 1-2 1-2decel Montramp Rampe Decel Arms speed V2-V1 Bras 1-2 1-2max Desc Vit. lowering Max V2-V1 Arms speed V3-V2 Bras 1-2 1-2max Desc Vit. lowering Max V3-V2 Arms 1-2 accel ramp lowering Bras 1-2 Desc Rampe Accel Arms lowering Bras 1-2 1-2decel Descramp Rampe Decel

5 5 14 7 5 5 16 7

TELESCOPE CONTROL GESTION TELESCOPE

0 1 2 3 4 5 6 7

Telescope speed extension V2-V1 Telescopemax Sort Vit. Max V2-V1 Telescope speed extension V3-V2 Telescopemax Sort Vit. Max V3-V2 Telescope accelAccel ramp Telescopeextension Sort Rampe Telescope decalDecel ramp Telescopeextension Sort Rampe Telescope speed retraction Telescopemax Rentr Vitesse Max V2-V1 V2-V1 Telescope max speed retraction V3-V2 Telescope Rentr Vit. Max V3-V2 Telescope accel ramp Telescoperetraction Rentr Rampe Accel Telescope decal ramp Telescoperetraction Rentr Rampe Decel

2 2 12 5 2 2 13 5

ARM 3 CONTROL GESTION BRAS 3

0 1 2 3 4 5 6 7

Arm max speed V2-V1 Bras3 3 Mont Vit.raising Max V2-V1 Arm max speed V3-V2 Bras3 3 Mont Vit.raising Max V3-V2 Arm accel ramp raising Bras3 3 Mont Rampe Accel Arm decel ramp raising Bras3 3 Mont Rampe Decel Arm 3 max speed lowering V2-V1 Bras 3 Desc Vit. Max V2-V1 Arm max speed V3-V2 Bras3 3 Desc Vit.lowering Max V3-V2 Arm accel ramp lowering Bras3 3 Desc Rampe Accel Arm decel ramp lowering Bras3 3 Desc Rampe Decel

3 3 14 6 3 3 11 6

STEERINGDIRECTION CONTROL GESTION

0 1 2 3 4 5 6 7 8 9

Max speedDroite steer right V2-V1V2-V1 Direction Vit. Max Max speedDroite steer right V3-V2V3-V2 Direction Vit. Max Max speedDroite steer right V3 Max V3 Direction Vitesse Accel ramp steer right Direction Droite Rampe Accel Decel rampDroite steer right Direction Rampe Decel Max speedGauche steer leftVit. V2-V1 Direction Max V2-V1 Max speed steer left V3-V2 Direction Gauche Vit. Max V3-V2 Max speedGauche steer leftVitesse V3 Direction Max V3 Accel rampGauche steer leftRampe Accel Direction Decel rampGauche steer leftRampe Decel Direction

0 0 100 0 4 0 0 100 0 4

TILT CONTROL GESTION INCLINAISON

0 1 2 3 4 5 6 7 8

Tilt back - Max speed V2-V1 Inclin Cavage Vit. Max V2-V1 Tilt back - Max speed V3-V2 Inclin Cavage Vit. Max V3-V2 Tilt back - Acceleration Inclin Cavage Ramperamp Accel Tilt backDeceleration Inclin Cavage Ramperamp Decel Tilt forward - MaxVit. speed Inclin Deverse MaxV2-V1 V2-V1 Tilt forward - MaxVit. speed Inclin Deverse MaxV3-V2 V3-V2 Tilt forward Acceleration ramp Inclin Deverse Rampe Accel Tilt forward - Deceleration Inclin Deverse Ramperamp Decel Tilt - TransportTransport Only Inclinaison Seul

0 0 6 2 0 0 10 4 0

80-04-07-M172EN

DESCRIPTION DESCRIPTION

VVALUE ALEUR

(04/2011)

Electronic modules – Operational control

NNUMBER UMÉRO 0 1 2 3 4 5 6 7

Max speed increase arm V2-V1 Pendulaire Mont Vit.pendular Max V2-V1 Max speed increase arm V3-V2 Pendulaire Mont Vit.pendular Max V3-V2 Accel ramp increase pendular Pendulaire Mont Rampe Accelarm Decel ramp Mont increase pendular Pendulaire Rampe Decelarm Max speed decrease pendular arm V2-V1 Pendulaire Desc Vit. Max V2-V1 Max speed decrease arm V3-V2 Pendulaire Desc Vit.pendular Max V3-V2 Accel ramp decrease pendular Pendulaire Desc Rampe Accelarm Decel ramp Desc decrease pendular Pendulaire Rampe Decelarm

2 2 12 6 2 2 8 22

BASKET ROTATION CONTROL GESTION ROT. PANIER

0 1 2 3 4 5 6 7

Max speed right rotation V2-V1 Rot Panier Dr Vit.basket Max V2-V1 Max speed right rotation V3-V2 Rot Panier Dr Vit.basket Max V3-V2

0 0 0 0 0 0 0 0

0 1 2 3 4 5 6 7

Max Rot speed Tourel right Dr Vit.turret Max rotation V2-V1 V2-V1 Max Rot speed Tourel right Dr Vit.turret Max rotation V3-V2 . V3-V2 Accel ramp right turret rotation Rot Tourel Dr Rampe Accel Decel ramp right turret rotation Rot Tourel Dr Rampe Decel Max turret rotation Rot speed Tourel left Gc Vit. Max V2-V1 V2-V1 Max turret rotation Rot speed Tourel left Gc Vit. Max V3-V2V3-V2 Accel ramp left rotation Rot Tourel Gcturret Rampe Accel Decel ramp left rotation Rot Tourel Gcturret Rampe Decel

1 1 80 4 1 1 80 4

ENGINE CONTROL GESTION MOTEUR

0 1 2 3 4 5 6

Max engine stop time delay Tempo Arrêtspeed Régime Maximum Max engine speed activation time delay Tempo Activation Régime Maximum Engine start-up safety time delay Tempo Securité Moteur Demarre Movement engine Bypass Regforbidden Mot Interdit Mvt reg by-pass Engine start-up threashold Seuil Moteur Demarre Engine Tempo speed Valide forcing Forcagevalidation Régime time delay Engine forcing devalidation Tempospeed Devalide Forcage Régimetime delay

1 4 20 1 600 1 0

FLASHING CONTROL GESTIONLIGHT GYROPHARE

0

Flashing lightGyrophare stop time delay Tempo Arrêt

10

GENERATOR CONTROL GEST. GÉNÉRATRICE

0

Generator activation time delay Tempo Activation Génératrice

40

FAULT CONTROL GESTION DEFAUTS

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

CAN busDefaut fault time Tempo Bus delay CAN General fault control time Defauts delay Tempo Gestion Générale Engine fault time delay Tempo water Defauttemperature Temp Eau Moteur Engine pressure Tempo oil Defaut Pres fault Huiletime Mot delay Battery charging fault time delay Tempo Defaut Charge Batterie Diesel lowNiveau fault time Tempolevel Defaut Basdelay Gasoil Overload fault time delay Tempo Defaut Surcharge Tilt faultDefaut time delay Tempo Devers Light ON underON tilt sur timeDevers delay Tempo Voyant Light OFF underOFF tilt time delay Tempo Voyant sur Devers Light ON underON overload time delay Tempo Voyant sur Surcharge Light OFF under overload time delay Tempo Voyant OFF sur Surcharge Buzzer under time delay Tempo ON Buzzer ONtiltsur Devers Buzzer under tiltsur time delay Tempo OFF Buzzer OFF Devers Buzzer under fault time delay Tempo ON Buzzer ONoil-water Defaut Eau-Huile Buzzer under oil-water fault time delay Tempo OFF Buzzer OFF Defaut Eau-Huile

15 40 100 40 200 150 20 20 6 4 6 4 8 10 6 10

TURRET ROTATION CONTROL GESTION ROT. TOUREL

(04/2011)

DESCRIPTION

Accel ramp right basket rotation Rot Panier Dr Rampe Accel Decel ramp right basket rotation Rot Panier Dr Rampe Decel Max speed left basket Rot Panier Gc Vit. Maxrotation V2-V1 V2-V1 Max speed left basket rotation Rot Panier Gc Vit. Max V3-V2 V3-V2 Accel ramp left rotation Rot Panier Gcbasket Rampe Accel Decel ramp left rotation Rot Panier Gcbasket Rampe Decel

VALUE VA LEUR

80-04-07-M172EN

80

SSUB-GROUP OUS-GROUPE PENDULAR ARM CONTROL GESTION PENDULAIRE

47

48

Electronic modules – Operational control

NNUMBER UMÉRO 16 17 18

DESCRIPTION Base hornOption option Klaxon numberBase Numéro Time delay - Horn ONsur under movement Tempo Klaxon ON Mouvement Time delay - Horn OFFsur under movement Tempo Klaxon OFF Mouvement

VVALUE ALEUR

MAX SPEED CONTROL GESTION VITESSE MAX

0 1 2 3 4 5 6 7 8 9 10 11 12 13

Arms max speedMax V3 V3 Bras 1-2 UP, Mont Vitesse Arms 1-2 DOWN, max speed V3 Bras Desc Vitesse Max V3 Telescope max speed Telescope extended, Sort Vitesse Max V3 V3 Telescope max Max speed Telescope retracted, Rentr Vitesse V3V3 Arm 3 UP, max speed V3 Bras 3 Mont Vitesse Max V3 Arm max speed Bras33DOWN, Desc Vitesse Max V3 V3 Tilt back, max speed V3Max V3 Inclin Cavage Vitesse Tilt forward, max speedMax V3 V3 Inclin Deverse Vitesse Pendular arm UP, Vitesse max speed Pendulaire Mont MaxV3 V3 Pendular arm DOWN, max speed Pendulaire Desc Vitesse Max V3 V3 Basket rotation right, max Rot Panier Dr Vitesse Maxspeed V3 V3 Basket rotation leftt, max speed Rot Panier Gc Vitesse Max V3 V3 Turret rotation right, max speed Rot Tourel Dr Vitesse Max V3 V3 Turret rotation left, maxMax speed Rot Tourel Gc Vitesse V3 V3

70 50 68 56 66 50 57 15 60 17 8 8 18 18

PRE-HEATING PRÉCHAUFFAGE

0

Preheating time delay Tempo Préchauffage

60

PARAMETER CONTROL GESTION PARAMETRES

0 1 2 3

Sauvegarde Réglage Save parameter setting Param.

Chargement Param. Defaut Load fault parameters Chargement Param.

Constructeur Load manufacturer’s parameters Initialisation totale Total initialisation

0 0 0 0

0 1 11

80

SOSUB-GROUP US-GROUPE

80-04-07-M172EN

(04/2011)

49

Electronic modules – Operational control

10 - Machine parameters - Level 4 Speed control table

Plateforme: 160 ATJ FC

Speed control in the basket controls in V3, with a person in the basket and the machine’s oil warm: 40 to 60°.

Engine speed when warm : idling speed: 1350 rpm ±10, max speed.: 2500 rpm ±25.

Main pressure 220b (±5bar)

Pressure Std setting ±5 bar Parameters V3

Time to be obtained in seconds and tolerance

Time obtened V3

parameters Obtened V3

V1 (less than V2)

Lower arms

Up Down

220 see note 100

59 66

28±1 28±1

5 5

Arm 3 (horizontal pendular arm, telescope EXTENDED) Telescope (Arm 3 horizontal) Pendular arm

Up Down

220 see note 110

76 58

35±1 33±1

3 3

Extension Retraction Up Down Cylinder ext.

Cylinder retract.

R/L

120 180 200 80 200 100 160

67 53 78 35 57 15 42

18±1 16±1 23±2 23±2 35±2 27±2 27±1

3 3 3 0 0 0 3

R/L FRONT & BACK

160

16 37

10±1 46±12

0

Basket tilt Turret rotation (Telescope EXTENDED) Basket Rotation Translation in work mode (for 5m)

80

Note: Pressure restricted by main restrictor. To be set via the main restrictor.

(04/2011)

80-04-07-M172EN

Modules électroniques - Contrôle fonctionnement

80

50

80-04-07-M172FR

(04/2011 )

SENSORS AND SETTINGS

Pages A - SENSORS - LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 2 B - TILT SENSOR - SETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 2 C - OVERLOAD SENSOR - SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 3 D - LOW ARM SENSORS - SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 4

80

E - TELESCOPE RETRACTED SENSORS – SETTING . . . . . . . . . . . . . . . . . . . . . . . P 5

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2

Sensors and settings

A - SENSORS : LOCATION - ................................................................................................ ................................................................................................ 80-03-M.172

B - TILT SENSOR - SETTING : REGLAGE The tilt sensors are preset by the manufacturer. The only parameter that you can adjust is sensor initialisation.

B1

FRONT

2 - Set the lifting platform on a level surface and leave it switched ON. - Open the right-hand turret cowl.

- Locate the tilt sensor (B1-1) under the base console casing.

Locate the emergency generator (B1-2) to the left of the base console casing.

1

- This setting must be made whenever a new tilt sensor (B2-1) is fitted on the machine.

B2

- Set the lifting platform on a level surface.

2

- Place a spirit level on the tilt sensor (B2-2).

1

- Level the sensor.

- Turn the tilt sensor’s “angle” screw (B3-1) to light up the red LED (B3-2).

Pin Broche A B C

Wire Fil Red Rouge Noir Black Blanc White

Connection Liaison + Supply Alimentation + -Alimentation Supply Retourreturn signal Signal

80

- The buzzer must sound for approx, two seconds after the red LED lights up.

- Start the engine.

- Instruct the lifting platform to move over a slope of at least 5° (so that it is under tilt) to check that the buzzer comes on (intermittent beep).

B3

- Instruct the lifting platform to move onto a horizontal surface to check that the buzzer stops.

- If it does not, repeat the setting operation.

1

80-04-81-M172EN

2

(04/2011)

3

Sensors and settings

C - OVERLOAD SENSOR : SETTING

C1 - Set the basket in the Low position.

1

- Switch off the engine but leave the lifting platform switched on.

Setting the pre-stress on the overload spring: - Place a 370kg load in the basket, distributing it evenly over the floor.

AV

A

NT

2

- Us a No. 14 hex wrench to tighten the socket head M16 bolt and a No. 24 socket wrench to tighten the nut.

- Access the bolt by passing the hex wrench between the hubs of the upper connecting rod (C1-1).

- Tighten the bolt so that it can still rotate freely with minimum play once the operation is complete.

C2 "7"/5 FRONT

Setting the overload sensor: - Remove the casing protecting the overload sensor (C1-2).

- Loosen the lock nut and then tighten the overload screw fully.

- Place a 420kg load in the basket, distributing it evenly.

- Loosen the overload screw until the alarm sounds (continuous beep).

Testing the overload circuit:

80

- Remove 20 Kg from the 420kg load in the basket and check that the alarm switches off.

- Return the 20kg load to the basket and check that the alarm sounds (continuous beep).

- Remove the load from the basket.

- Tighten the lock nut and apply a spot of paint to it to confirm that it has been set.

- Refit the overload sensor’s protective casing and fasten it tightly.

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Sensors and settings

D - LOW ARM SENSORS : SETTING - Set the arms in the Low position and hold down the Down control.

D1 1

- Switch off the engine but leave the lifting platform switched on.

- At the top of arm 3 (D1-1), locate the low arm sensors’ housing ........................................................................................................................... 80-03-M.172 - Remove the casing protecting the sensors (D1-2) and remove and retain the rubber gasket.

2

NNT

RAO

A VF

- Loosen the lock nuts (D2-3).

- Tighten or loosen the sensors (D2-3) until the LED next to their supply wire changes from red to green (the residual play between the support and the sensor is approx. 3mm).

D2

- Tighten the lock nuts.

4

- Refit the rubber gasket and the casing and fasten them tightly.

80

3

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Sensors and settings

E - TELESCOPE RETRACTED SENSORS : SETTING - Set the arms in the Low position, retract the telescope and hold down the control.

E1 F AV

NNT

RAO

1

- Switch off the engine but leave the lifting platform switched on.

- At the top of arm 3 (E1-1), locate the retracted telescope sensors’ housing ...................................................................... 80-03-M.172 - Remove the casing protecting the sensors.

- Loosen the lock nuts (E2-2).

E2

- Tighten or loosen the sensors (E2-3) until the LED next to their supply wire changes from red to green (the residual play between the support and the sensor is approx. 3mm).

3

- Tighten the lock nuts.

- Refit the casing and fasten it tightly.

80

2

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6

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Sensors and settings

80-04-81-M172EN

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JOYSTICKS - TESTING

Pages A - JOYSTICKS - TESTING FROM THE BASE CONSOLE . . . . . . . . . . . . . . . . . . P 2

80

B - JOYSTICKS - TESTING WITH A VOLTMETER . . . . . . . . . . . . . . . . . . . . . . . . P 3

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2

Joysticks - Testing

A - JOYSTICKS : TESTING FROM THE BASE CONSOLE Joysticks testing from the base console requires the presence of two operators.

A1 1 2 4

- Display the Input/Output sub-menu pages ........................80-04-07-M.172 80-04-07-M.172

5

- Switch on the lifting platform with the battery cut-out (pre-series production) and the ignition key; then start the engine.

6

- Climb into the basket, press the dead man’s pedal and then perform the following actions:

3

AV

A

NT

- Move the joystick (A1-1) forwards, backwards, to the left and to the right.

- Move the joystick (A1-2) forwards, backwards, to the left and to the right.

- Move the joystick lever (A1-3) forwards and backwards without pressing the trigger (A1-5).

- Press the top left-hand button and then the top right-hand button (A1-4) without pressing the trigger (A1-5).

- Press the trigger (A1-5) just by itself.

80

- For veach action check on the display screen the status of the inputs and outputs in Neutral and when the joysticks or contactors are engaged.

80-04-85-M172EN

(04/2011)

3

Joysticks - Testing

B - JOYSTICKS : TESTING WITH A VOLTMETER - Climb into the lifting platform’s basket with a voltmeter.

- Open the front of the basket console (A1-6) and then mark the wires connected to the joysticks: - Turret rotation & arm 3 control joystick (A1-1): see (B1).

B1 Y

GRIS GREY

(ALIMENTATION BPARM BRAS3)3) (SUPPLY - -BP

MARRON BROWN

(ALIMENTATION - POINT MILIEU) (SUPPLY TO MID-POINT)

JAUNE YELLOW

(ALIMENTATION BP TOURELLE) (SUPPLY –-TURRET BUTTON)

WHITE BLANC

(BATTERY + TERMINAL) (+ BATTERIE)

X

- Telescope & arms ½ control joystick (A1-2): see (B2).

B2 GREY GRIS

(SUPPLY - BP (ALIMENTATION - BPARMS BRAS 1/2) 1/2)

MARRON BROWN

(ALIMENTATION - POINT MILIEU) (SUPPLY TO MID-POINT)

YELLOW JAUNE

(SUPPLY - -TELESCOPE BUTTON) (ALIMENTATION BP TELESCOPE)

WHITE BLANC

(BATTERY + TERMINAL) (+ BATTERIE)

Y X

80

- Forward movement and steering control joystick (A1-3): see (B3).

B3 Y

BROWN MARRON GREY GRIS (Y) (Y)

(SUPPLY TO (AMID-POINT) LIMENTATION POINT MILIEU) (LONGITUDINAL (AXE LAXIS) ONGITUDINAL)

BROWN/GREY MARRON/GRIS GREEN/BLACK VERT/NOIR

(SUPPLY - TRIGGER) (ALIMENTATION - GACHETTE) (PUSH-BUTTON - TRIGGER) (BOUTON POUSSOIR - GACHETTE)

GREY/BLACK GRIS/NOIR

(STEER RIGHT (BPBUTTON) DIRECTION DROITE)

YELLOW/BLACK JAUNE/NOIR

(STEER LEFT BUTTON) (BP DIRECTION GAUCHE)

BLANC/NOIR WHITE/BLACK WHITE BLANC

(ALIMENTATION - BP DIRECTION) (SUPPLY TO STEERING BUTTON) (BATTERY +( + TERMINAL) BATTERIE)

- Take the voltage measurements with the voltmeter’s wands by placing them in contact with the clips crimped to each coloured wire at connector level.

(04/2011)

80-04-85-M172EN

4

Joysticks - Testing

Testing the analog outputs : - Turret rotation & arm 3 control joystick 3 (A1-1): Move the ball forwards and backwards, to the left and to the right and check the values displayed by the voltmeter (B4).

B4 3V 3V 0V 0V 12V 12V

GREY G (Y) GRIS (Y)(Y) BROWN M MARRON WHITE B BLANC

Joystick FORWARD Manipulateur versL'AVANT L’AVANT Manipulateur vers RAISING arm 3(3)3 LEVAGE du bras LEVAGE du bras 6V6V 6V6V 0V 0V 12V 12V

9V9V JAUNE YELLOW (X) J (X) (X) 0V BROWN 0V MARRON M 12V BLANC BLANC 12V B Joystick tovers the LEFT Manipulateur vers la GAUCHE Manipulateur la GAUCHE Turret rotation Rotation de tourelle à GAUCHE Rotation de tourelle LEFT à GAUCHE

YELLOW (X) JAUNE JAUNE(X) (X) GREY (Y) GRIS (Y) GRIS (Y) BROWN MARRON MARRON WHITE BLANC BLANC

3V3V JAUNE YELLOW (X) J (X) (X) 0V 0V 12V 12V

BROWN M MARRON WHITE BLANC B

Joystickvers to the RIGHT Manipulateur vers DROITE Manipulateur lalaDROITE Turret rotation RIGHT Rotation DROITE Rotation de de tourelle tourelle ààDROITE

NEUTRAL NEUTRE NEUTRE

9V 9V 0V 0V 12V 12V

GREY G (Y) GRIS (Y)(Y) BROWN M MARRON WHITE B BLANC

Joystick Manipulateur versBACK L’ARRIERE Manipulateur L'ARRIERE LOWERING 3(3)3 DESCENTE du bras DESCENTE duarm bras

- Telescope & arms ½ control joystick (A1-2): Move the ball forwards and backwards, to the left and to the right and check the values displayed by the voltmeter (B5).

80

B5 9V9V 0V 3V 0V 12V 12V

GYELLOW (Y) (X)(X) JAUNE MGREY (Y) MARRON BROWN B BLANC BLANC

Joystick FORWARD Manipulateur vers L’AVANT Manipulateur vers L'AVANT RAISING arms 1/2 LEVAGE du (1/2) LEVAGE dubras bras 1/2

0V 0V 9V 9V 12V 12V

6V6V 0V 0V 6V 6V 12V 12V

MBROWN MARRON J GREY (X) (Y)(Y) GRIS BWHITE BLANC

Joystick tovers the LEFT Manipulateur vers la GAUCHE Manipulateur la GAUCHE Telescope EXTENSION SORTIE télescope SORTIEdu du télescope

YELLOW GRIS (Y)(X)(X) JAUNE BROWN MARRON MARRON GREY(Y) (Y) GRIS JAUNE (X) WHITE BLANC BLANC

0V0V MARRON MBROWN 3V 3V GRIS J GREY (X) (Y)(Y) 12V BWHITE 12V BLANC

Joystick to thela RIGHT Manipulateur vers DROITE Manipulateur vers la DROITE Telescope du RETRACTION RENTREE dutélescope télescope RENTRÉE

NEUTRE NEUTRAL NEUTRE

3V3V (X)0V 0V 12V 12V

YELLOW G (Y) JAUNE (X) BROWN M MARRON WHITE

B BLANC

Joystick Manipulateur L'ARRIERE Manipulateur versBACK L’ARRIERE DESCENTE du bras (1/2) LOWERING arms 1/2 DESCENTE du bras 1/2 80-04-85-M172EN

(04/2011)

5

Joysticks - Testing - Forward movement and steering control joystick (A1-3): Move the lever forwards and backwards and check the values displayed by the voltmeter (B6).

B6

X

3V GREY (Y) 3V GRIS (Y) 0V BROWN 0V MARRON

Manipulateur Joystickvers L’ARRIERE - RECUL BACKWARDS -

X

6V GRIS (Y) 6V GREY (Y) 0V MARRON 0V BROWN

NEUTRE NEUTRAL

X

9V GRIS (Y)(Y) 6V GREY 0V MARRON 0V BROWN

Manipulateur Joystick vers L’AVANT FORWARDS- –AVANCE Forward

Reverse

movement

Testing the logic poutputs Forward movement and steering control joystick: Push the steering buttons (A1-4) on the joystick’s Dead Man’s trigger (A1-5) and check the values displayed by the voltmeter (B7 and B8).

B7

Direction Steer GAUCHE LEFT

GREY/BLACK GRIS/NOIR 12V YELLOW/BLACK 12V JAUNE/NOIR WHITE/BLACK BLANC/NOIR 12V WHITE 12V BLANC

VV VV

GRIS/NOIR (D) (R) GREY/BLACK YELLOW/BLACK JAUNE/NOIR (G) (L) WHITE/BLACK BLANC/NOIR 12V 12V WHITE BLANC

NEUTRE NEUTRAL

12V GRIS/NOIR (D) (R) 12V GREY/BLACK YELLOW/BLACK (L) JAUNE/NOIR(G)

WHITE/BLACK BLANC/NOIR Direction Steer RIGHT

12V WHITE 12V BLANC

DROITE

12V BROWN/GREY 12V MARRON/GRIS GREEN/BLACK VERT/NOIR 12V WHITE 12V BLANC

0V0V BROWN/GREY MARRON/GRIS GREEN/BLACK VERT/NOIR 12V 12V WHITE BLANC Gachettein Trigger NEUTRE NEUTRAL

80

B8

Trigger Gachette ACTIONNÉE ENGAGED

A “V” reading indicates that a random voltage is measurable on the indicated wire.

(04/2011)

80-04-85-M172EN

6

80

Joysticks - Testing

80-04-85-M172EN

(04/2011)

ELECTRICAL BUNDLES - REMOVAL

Pages

A1 - LOCATION OF THE BUNDLES IN THE LIFTING PLATFORM . . . . . . . . . . . P 3 A2 - BASKET CONSOLE BUNDLE - 1 : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 4 A3 - MISC. BUNDLES - No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 7 A4 - MISC. BUNDLES - No. 3, 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 8 A5 -MISC. BUNDLES - No. 4, 8, 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 9 A6 - MISC. BUNDLES - No. 7, 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p 10 A7 - MISC. BUNDLES - No. 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 11 A8 - CHASSIS BUNDLE - No. 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 12 A9 - MISC. BUNDLES BRC 301 - No. 10, 11, 26, 28, 45, 47 . . . . . . . . . . . . . . . . P 13 A10 - MISC. BUNDLES BRC 301 - No. 5, 25, 27, 43, 48 . . . . . . . . . . . . . . . . . . . P 14 A11 - MISC. BUNDLES BRC 301 - No. 9, 14, 44. . . . . . . . . . . . . . . . . . . . . . . . . . P 15 A12 - MISC. BUNDLES BRC 301 - No. 6, 12, 46. . . . . . . . . . . . . . . . . . . . . . . . . . P 16 A13 - MISC. BUNDLES BRC 301 - No. 30, 32, 34, 36, 38. . . . . . . . . . . . . . . . . . P 17 A14 - MISC. BUNDLES BRC 301 - No. 29, 31, 33, 35, 37, 41 . . . . . . . . . . . . . . P 18 A15 - MISC. BUNDLES BRC 301 - No. 39, 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 19 A16 - ENGINE BUNDLE - No. 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 20 A17 - MISC POWER CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 21 A18 - MISC POWER CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 22

(04/2011)

80-06-13-M172EN

80

A - Machines from No. 590 197

2

Electrical bundles - Removal - A1 - LOCATION OF THE BUNDLES IN THE LIFTING PLATFORM :

7

8

6

50

51

1 9 48 46 3 4

10

12

11

47

5

15

2

13

80

14

80-06-13-M172EN

Rep. No. 11 22 3 3 4 45 56 67 78 89 910 10 11 11 12 12 13 14 13 15 14 25 15 26 25 27 26 28 27 29 28 30 29 31 30 32 31 33 32 34 33 35 34 36 35 37 36 38 37 39 38 40 39 41 40 42 43 41 44 42 45 43 46 44 47 45 48 46 50 47 51 48 50 51

Désignation Designation PUPITRE PANIER COMPLETE BASKETCOMPLET CONSOLE CAPTEUR SURCHARGE OVERLOAD SENSOR FAISCEAU BUS CAN INTERMEDIAIRE CAN BUS INTERMEDIATE BUNDLE FAISCEAU CAPTEUR BRAS BAS/TELESCOPE TELESCOPE/LOW ARM SENSOR BUNDLE FAISCEAU SECURITE HYDRAULIQUE HYDRAULIC SAFETY BUNDLE FAISCEAU AVERTISSEUR SONORE BUZZER BUNDLE CAPTEUR BRAS BAS LOW ARM SENSOR CAPTEUR BRAS TELESCOPE TELESCOPE ARM SENSOR FAISCEAU GYROPHARE FLASHING BUNDLE FAISCEAU LIGHT DEVERS TILT BUNDLE FAISCEAU JAUGE CARBURANT FUEL GAUGE BUNDLE FAISCEAU COLLECTEUR COLLECTOR BUNDLE FAISCEAU CHASSIS FAISCEAU POMPE SECOURS CHASSIS BUNDLE FAISCEAU MOTEUR EMERGENCY PUMP BUNDLE FAISCEAU ELECTROVALVE PROPORTIONNELLE BRAS 1/2 ENGINE BUNDLE FAISCEAU ELECTROVALVEELECTROVALVE PROPORTIONNELLE TELESCOPE ARMS 1/2 PROPORTIONAL BUNDLE FAISCEAU ELECTROVALVE BRAS 3 TELESCOPE PROPORTIONAL PROPORTIONNELLE ELECTROVALVE BUNDLE FAISCEAU ELECTROVALVE PROPORTIONNELLE ARM 3 PROPORTIONAL ELECTROVALVE BUNDLE N°4 FAISCEAU ELECTROVALVE ROTATIONBUNDLE PANIER GAUCHE No. 4 PROPORTIONAL ELECTROVALVE FAISCEAU ELECTROVALVE ROTATION PANIER DROITE BASKET ROTATION LEFT ELECTROVALVE BUNDLE FAISCEAU ELECTROVALVE ROTATION TOURELLE GAUCHE BASKET ROTATION RIGHT ELECTROVALVE BUNDLE FAISCEAU ELECTROVALVE ROTATION TOURELLE DROITE TURRET ROTATION LEFT ELECTROVALVE BUNDLE FAISCEAU ELECTROVALVE DIRECTION GAUCHE TURRET ROTATION RIGHT ELECTROVALVE BUNDLE FAISCEAU ELECTROVALVE DIRECTION DROITE STEER LEFTELECTROVALVE ELECTROVALVE BUNDLE FAISCEAU LEVAGE PENDULAIRE STEER RIGHT ELECTROVALVEDESCENTE BUNDLE PENDULAIR FAISCEAU ELECTROVALVE PENDULAR ARM RAISING ELECTROVALVE FAISCEAU ELECTROVALVE INCLINAISONBUNDLE DEVERSEMENT PENDULAR ARM LOWERING INCLINAISON ELECTROVALVE BUNDLE FAISCEAU ELECTROVALVE CAVAGE TILTING ELECTROVALVE BUNDLE FAISCEAU CONNECTEUR AMP N°1 BOOSTER ELECTROVALVE FAISCEAUTILT CONNECTEUR AMPBUNDLE N°2 AMP No. 1 CONNECTOR BUNDLE FAISCEAU CAN BRC 301/UPC 301 AMP No. 2 CONNECTOR BUNDLE FAISCEAU CAN UPC 301/CEK 20 FAISCEAU ALIMENTATION ECRAN CEK 20 CAN BRC 301/UPC 301 BUNDLE FAISCEAU CLE CONTACT+COMMANDE CAN UPC 301/CEK 20 BUNDLE FAISCEAU BOUTON POUSSOIR CEK 20 SCREEN SUPPLY BUNDLEPOMPE SECOURS + BOUTON FAISCEAUCONTROL+ BUS CAN VERS PANIER IGNITION BUNDLE FAISCEAU ELECTROVALVE GENERATRICE EMERGENCY PUMP PUSH BUTTON + BUTTON BUNDLE FAISCEAU BRC 301/CAPTEURS CAN BUS TO BASKET BUNDLE BRAS BAS FAISCEAU BUS CAN 16 m GENERATOR ELECTROVALVE BUNDLE FAISCEAU RALLONGE CAPTEUR BRAS BAS TELESCOPE / ARM DOWN SENSORS BUNDLE CAN BUS 16m/18m (for 180ATJ) BUNDLE ARM DOWN SENSOR EXTENSION BUNDLE

(04/2011)

3

Electrical bundles - Removal - A1 - LOCALISATION DES FAISCEAUX DANS LA NACELLE :

39 40 41

42

43

44

45

25 26 27

34

28

32 30 38

29

36

31

35 37

(04/2011)

80-06-13-M172EN

80

33

4

Electrical bundles - Removal A2 - BASKET CONSOLE BUNDLE - 1 : No. A B C D E F G H I J K L M N O P Q R S T U V W

BASKET CONSOLE Plan: 831 694 No. 1

Designation Calculator UPC101 Buzzer Translation and steering joystick Hare / Tortoise switch Emergency Stop Telescope / arms 1/2 joystick Pendular arm switch Basket rotation switch Arm 3 / turrwet rotation joystick Pre-heating indicator light Start button Engine fault light Front axle alignment light Rear axle alignment light 4-wheel / crab steering selector switch Horn button Differential lock push-button DIESEL low level light Overlaod fault light Tilt fault light Tilt unlocking push-button Slope switch Emergency pump push-button C1

G H

L

29

42

15 1

28 14

J

0.1

2.1

C2

P

38.1

2.2

7.1

E D

C

K

1 2 3 6 5 4

F A

B

J

K

0.2

N M

B1

1 2 4 3

33.1

0.3

Wiring side view

0.2

34.1 N

0.4

0.3 M

O

A1 C

2.6

2

4.1

D

E

3.1

0.5

0.4

9.1

23.1

1

11.1

R

39.1

2.3

10.1

3

1

3

2

0.10

2.5

2.2

2.3

2.4

0.11

13.1

12.1

Q

35.1

2.4 0.6

2.5

P

0.5 L

80

UPC 101

A

B

Spare

32.1 F

45.1 44.1 43.1 42.1 41.1 22.1

D1

Wiring side view

3

G 1

2

9 5

6 1

F1

H

0.7 0.8

0.8

2

17.1

1

2.10 2.9

2.10

S 37.1

2.7

2.8

2.9

3

2.11

Welding side view

T

0.9 36.1

8.1

19.1 16.1

18.1

U

2.8

1 2 3 6 5 4

15.1

1

2

14.1 3

V

Spare Work headlight

I

1.1

0.12

W

40.1

E1

1.1

1.3 1 2 3 6 5 4

Wiring side view 80-06-13-M172EN

(04/2011)

Electrical bundles - Removal

Wire 1.2 32.1 33.1 34.1 35.1 36.1 37.1 38.1 39.1 43.1 44.1 27.1 45.1 12.2 / 29.1 28.1 31.1 30.1 23.1 8.1 21.1 20.1 9.1 26.1 41.1 42.1 0.11 / 25.1 24.1 14.1 15.1 18.1 19.1 10.1 16.1 17.1 12.1 13.1 11.1 0.14

Designation + Supply AMP 42 point connector - pin 1 and 14 point connector - pin F Buzzer / AMP connector 42 point connector-pin 2 LED - front axle alignment / AMP connector 42 Pts-pin 3 LED - rear axle / AMP connector 42 point connector-pin 4 LED - engine fault/ AMP connector 42 point connector-pin 5 LED - tilt fault/ AMP connector 42 point connector-pin 6 LED - overload fault/ AMP connector 42 point connector-pin 7 LED - preheating / AMP connector 42 point connector-pin 8 LED - Diesel level low / AMP connector 42 point connector-pin 9 Spare Spare Longitudinal joystick forward motion / AMP connector 42 point connector-pin 12 Spare + Supply joystick forward motion / AMP connector 42 point connector-pin 14 Spare Longitudinal joystick, arms 1-2 / AMP connector 42 point connector-pin 16 Lateral joystick, telescope / AMP connector 42 point connector-pin 17 Longitudinal joystick, arm 3 / AMP connector 42 point connector-pin 18 Lateral joystick, rotation turret / AMP connector 42 point connector-pin 19 Horn button / AMP connector 42 point connector-pin 20 Tilt unlocking button / AMP connector 42 point connector-pin 21 AMP 14 point connector - pin P / 42 point connector - pin 22 AMP 14 point connector - pin P / 42 point connector - pin 23 Differential locking button / AMP 42 point connector - pin 24 Joystick forward motion trigger / AMP connector 42 point connector-pin 25 Spare Spare Buzzer Earth / AMP connector 42 point connector-pin 28 Spare Joystick, forward motion left / AMP connector 42 point connector-pin 30 Joystick, forward motion right / AMP connector 42 point connector-pin 31 Switch, tilt forward / AMP connector 42 point connector-pin 32 Switch, tilt back / AMP connector 42 point connector-pin 33 Switch, pendular arm UP / AMP connector 42 point connector-pin 34 ISwitch, pendular arm DOWN / AMP connector 42 point connector-pin 35 Switch, Slow speed/ AMP connector 42 point connector-pin 36 Switch, rotation left / AMP connector 42 point connector-pin 37 Switch, rotation right / AMP connector 42 point connector-pin 38 Switch, Crab steering switch / AMP connector 42 point connector-pin 39 Switch, 4-wheel steering switch / AMP connector 42 point connector-pin 40 Switch, Fast speed / AMP connector 42 point connector-pin 41 Earth AMP 42 point connectors - pin 42 / 14 point connector - pin L

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

Wire 40.1 7.1 3.1 6.1 20.1 1.2 5.1 1.3 22.1 0.12 0.13 0.14 4.1 2.3 21.1

Designation Emergency generator button / AMP 14 point connector - pin A Starter button / AMP 14 point connector - pin B Emergency Stop / AMP 14 point connector - pin C Sub-D 9 POINT - pin 2 / AMP 14 point connector - pin D AMP 14 point connector - pin E / 42 point connector- pin 23 + Supply to AMP 42 point connectors - pin 1 / 14 point connector - pin F 9 point sub-D - pin 7 / AMP 14 point connector - pin G + Supply to emergency generator button / AMP 14 point connector - pin H Spare Working light Earth / AMP 14 point connector - pin K Forward motion joystick Earth / AMP 14 point connector - pin L 42 point connector Earth - pin 42 / 14 point connector - pin L Emergency Stop connection / AMP 14 point connector - pin M + Supply to 4-wheel / crab steering switch / differential locking button AMP 14 point connector - pin P / 42 point connector- pin 22

Pin 1 2 3 4 5 6

Wire 27.1 / 25.1 24.1 / 26.1

Designation Longitudinal joystick, forward motion / AMP 42 point connector - pin 12 Spare Joystick, forward motion left / AMP 42 point connector - pin 30 Joystick, forward motion right / AMP 42 point connector- pin 31 Spare Forward motion joystick trigger / AMP 42 point connector- pin 25

Pin 1

Wire 2.1 2.12 2.1 2.12 2.1 2.12 0.1 0.13

2 3 4

(04/2011)

Designation

Type

Representation

Connector AMP 42 point connector No. A1

Type

Representation

Connector Deutsch female 14 point connector No. B1

Type

80

Pin 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 31 32 33 34 35 36 37 38 39 40 41 42

Representation

Connector Deutsch male 6 point connector No. C1 Type

Representation

+ Supply to forward motion joystick + Supply to forward motion joystick + Supply to forward motion joystick

5

Connector Deutsch male 4 point connector No. C2

Forward motion joystick Earth

80-06-13-M172EN

6

Electrical bundles - Removal

Pin 1 2 3 4 5 6

Pin 1 2 3 4 5 6

Wire 2.11 2.13 30.1 / / 31.1 0.9 0.10 Wire 27.1 / 25.1 24.1 / 26.1

Designation

Type

Representation

+ Supply to telescope joystick - arms 1/2 Lateral joystick, telescope retraction/extension / AMP 42 point connector- pin 17 Spare Spare Longitudinal joystick, arms 1/2 UP/DOWN / AMP 42 point connector- pin 16

Connector Deutsch male 6 point connector No. D1

Telescope joystick Earth - arms 1/2 Designation

Type

Representation

+ Supply to turret joystick - arm 3 Lateral joystick, turret rotation / AMP 42 point connector- pin 19 Spare Spare Longitudinal joystick, arm 3 UP/DOWN / AMP 42 point connector - pin 18

Connector Deutsch male 6 point connector No. E1

Turret joystick Earth - arm 3 Designation Longitudinal joystick, forward motion / AMP 42 point connector- pin 12 Spare Joystick, forward motion left / AMP 42 point connector- pin 30 Joystick, forward motion right / AMP connector 42 point connector-pin 31 Spare Forward motion joystick trigger / AMP 42 point connector- pin 25

Type

Representation

Connector Sub-D female 9 point connector No. F1

80

Pin 1 2 3 4 5 6

Wire 2.6 2.7 28.1 / / 29.1 0.6 0.7

80-06-13-M172EN

(04/2011)

Electrical bundles - Removal

7

A3 - MISC. BUNDLES 2 : 676845 OVERLOAD SENSOR BUNDLE No 2 To Can Bus bundle 160 ATJ FC: 768 872 180 ATJ: 768 873

1 2

No. 50 Pin 1 2

Wire Black White/Black

679256 - Version A FORWARD MOTION JOYSTICK BUNDLE Pin 1 2 3 4 5 6

DTM

Wire White Yellow Green (not used) NC (not used) Grey Brown

1 2 3

80

6 5 4

679253 - Version A FORWARD MOTION JOYSTICK BUNDLE No X1

No

DTM

X2

Pin 1 2 3 4

Wire White White/Black Brown/White Brown

Pin 1 2 3 4 5 6

Wire Grey NC (not used) Yellow/Black Grey/Black Green (not used) Green/Black

X1 1 2

4 3

1 2 3

6 5 4

X2 (04/2011)

80-06-13-M172EN

8

Electrical bundles - Removal - A4 - MISC. BUNDLES 3, 42 :

To Can Bus bundle 160 ATJ FC: 180 ATJ:

768 872 768 873

No. 50

12 11 10 1 2 3

9 4

8 5

7 6

5 4 3 2 1 9 8 7 6

80

1 2 3 4 5 6 7 8 9

Pin 1 2 3 4 5 6 7 8 9

Wire Connection Spare White BUS CAN low Spare Spare Spare Spare Brown BUS CAN High Spare Spare

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

CAN BUS TO BASKET

BUS CAN UPC 301 / CEK 20

R120

676 884 CAN BUS BUNDLE No. 42

Wire

Connection

Grey/Pink Black Red/Blue White Pink Brown Violet Yellow Grey Green Blue Red

Basket emergency pump button Basket engine starter button Basket Emergency Stop CAN low basket + BAT (+12Vcc) basket CAN high basket + BAT (+12Vcc) basket Spare Basket earth Basket earth Basket Emergency Stop + APC (+12Vcc) basket

676 846 INTERMEDIATE BUS BUNDLE Version A No. 3

1 2 3 12 11 10

4 9

5 8

6 7

To Can bus bundle to basket 676 888

UPC 301

80-06-13-M172EN

Rep. 46

(04/2011)

9

Electrical bundles - Removal - A5 - MISC. BUNDLES 4, 8, 51 :

Wire Blue Green Yellow Grey Brown White

Connection INTOR 4 / low arm 2 sensor INTOR 2 / low arm 1 sensor INTOR 3 / telescope sensor 1 +12Vcc / low arm sensors INTOR 7 / telescope sensor 2 +12Vcc / telescope sensors

1

6

2

5

3

4

677 795 INTERMEDIATE BUNDLE INDUCTIVE SENSOR Version A Rep. 4

LOW ARM/TELESCOPE SENSORS

Pin 1 2 3 4 5 6

C AB

Pin A B C

Wire

Connection

Blue INTOR 4 / arm low sensor 2 Grey +12Vcc / arm low sensor Green INTOR 2 / arm low sensor 1

 To low arm sensor extension bundle

2

Pin 1 2

Wire

1

Connection

White +12Vcc / telescope sensor Yellow INTOR 3 / telescope sensor 1

2

1

1

2

Pin 1 2

Pin 1 2

Wire

Wire

Connection

Common White Brown

+12Vcc / telescope sensor INTOR 7 / telescope sensor 2

2

Black Black

1

Pin 1 2

Wire Black Black

677 797

(04/2011)

676 851 TELESCOPE SENSOR BUNDLE Version A Rep. 8

TELESCOPE ARM SENSOR

TELESCOPE ARM SENSOR

80

Version B No. 51

80-06-13-M172EN

10

Electrical bundles - Removal - A6 - MISC. BUNDLES 7, 51 :

To inductive sensors intermediate bundle 677 795

Version B No. 4  Pin A B C

Wire Connection Brown INTOR 4 / low arm sensor 2 White +12Vcc / telescope sensors Green INTOR 2 / low arm sensor 1

AB C

677 797 ARM DOWN SENSOR EXTENSION BUNDLE Version B No. 51

Wire Common White Green

Pin Wire

Liaison

1

2

1

White +12Vcc / Arm down sensor Brown INTOR 4 / Arm down sensor 1 Wire Black Black

2

1

2

ARM DOWN SENSOR

80

Pin 1 2

80-06-13-M172EN

1

1

2

677 796 ARM DOWN SENSOR No. 7

Pin 1 2

Connection +12Vcc / Arm down sensors INTOR 2 / Arm down sensor 2

Wire Black Black

ARM DOWN SENSOR

Pin 1 2

2

(04/2011)

Electrical bundles - Removal

11

- A7 - MISC. BUNDLES 50 :

Wire Wire 1 Wire 2 Wire 3 Wire 4 Green (3x0.75) Wire 5 Wire 6 Wire 7 Wire 8 Wire 9 Wire 10 Wire 11 Wire 12 + Brown (3x0.75) White (3x0.75)

Liaison Basket emergency pump button Basket engine starter button Basket Emergency Stop CAN low basket + BAT (+12Vcc) basket CAN high basket + BAT (+12Vcc) basket +BAT (+12Vcc) panier Spare Basket earth Basket earth Basket Emergency Stop +APC (+12Vcc) basket +APC (12Vcc) basket INTOR 17/ dead man pedal

N M

P D

C L

E F

A

G

B K

J

H

2

1

Pin A B C D E F G H J K L M N O P

80

Connection Alim +12Vcc capteur surcharge INTOR 16 / capteur surcharge

BASKET/CONTROLLER CAN BUS

Wire Marron (3x0.75) Vert (3x0.75)

DEAD MAN PEDAL

OVERLOAD SENSORS

1 2

Pin 1 2

768 872 CAN BUS BUNDLE Version B No. 50

2 1

Pin 1 2

Wire Common red White (3x0.75)

Connection +12Vcc pedal INTOR 17 / dead man pedal

12 11 10 9 1 2 3 4

8 5

Pin

Wire

1

Wire 1

2 3 4 5 6 7 8 9 10 11 12

Wire 2 Wire 3 Wire 4 Wire 5 Wire 6 Wire 7 Wire 8 Wire 9 Wire 10 Wire 11 Wire 12

Connection Basket emergency pump button Basket engine starter button Basket Emergency Stop CAN low basket + BAT (+12Vcc) basket CAN high basket + BAT (+12Vcc) basket Spare Basket earth Basket earth Basket Emergency Stop +APC (+12Vcc) basket

7 6

To intermediate CAN BUS bundle 676 846

No. 3 (04/2011)

80-06-13-M172EN

12

Electrical bundles - Removal A8 - CHASSIS BUNDLE 13:

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

Wire

Connection

Grey/Pink Black Red/Blue White Pink Brown Violet Yellow Grey Green Blue Red

F / R axle sensors + 12 V DC supply F / R axle sensors Earth INTOR 11 / REAR axle sensor INTOR 10 / FRONT axle sensor OUTTOR 17 / Differential lock (electro-valve) OUTTOR 16 / Brake electro-valve Brake & differential lock electro-valve Earth OUTTOR 14 / Crab steering electro-valve OUTTOR 15 / 4-wheel steering electro-valve Crab / 4-wheel steering electro-valve Earth OUTTOR 18 - OUTTOR 19 / Oscillation 1 & 2 electro-valve Oscillation 1 & 2 electro-valve Earth

12 1

11 2

10 3

9 4

8 65

7

XP41 676 856 CHASSIS BUNDLE Version E No. 13

EP2 EP1

XS42 RE

AR

L AX

ES

E

O NS

EP5 EP6

FR

R

C

ES

1

SO

G

E

RIN

BR

Pin 1

Wire

Connection

Brown

2

Common Red

OUTTOR 16 / Brake electro-valve Brake & differential lock electrovalve Earth

Yellow

2

Common Black

Grey/Pink 3 Black

+F / R axle sensors + 12 V DC supply F / R axle sensors Earth

XS43

1

2

XS47

Connection OUTTOR 14 / Crab steering electro-valve Crab /2- 4-wheel steering electrovalve Earth

1 2

Wire

Connection

Common black Red 3

OUTTOR 18/19 - Oscillation 1 & 2 EV Oscillation 1 & 2 electro-valve Earth

2

XS49

2

XS48

2

XS46 Wire

B C

1

1

1

Pin

4-WHEEL

BS 2

Pin 1

Connection FRONT axle sensor

N2

K

AK

XS44 XS45

White

TIO ILLA

LOC

2

1

R

Wire

A

OSC

AL

OSCILLATION 1

FE DIF

TI REN

STEERING

Connection REAR axle sensor F / R axle sensors Earth

TEE

Wire Pink Common Red

EN

Pin

BA C

CRA

80

XL

Wire Connection Red/Blue REAR axle sensor Grey/pink 2 +12Vcc F / R axle sensors Black 2 F / R axle sensors Earth

Pin A B C

Pin 1 2

80-06-13-M172EN

TA

EP3 EP4

B A

Pin 1 2

ON

Pin 1 2

Wire

Connection

Common black OUTTOR 18/19 - Oscillation 1 & 2 EV Red 2 Oscillation 1 & 2 electro-valve Earth

Wire

Connection

Grey Common Black

OUTTOR 15 / 4-wheel steering EV Crab /4-wheel steering electrovalve Earth

(04/2011)

13

Electrical bundles - Removal

DIESEL GAUGE

ELECTRIC GENERATOR

TELESCOPE PROPORTIONAL E-V

- A9 - MISC. BUNDLES BRC 301 - No. 10, 11, 26, 28, 45, 47 :

Connection OUTANA 2: Telescope control PVG OUTTOR 2: +Supply to telescope PVG Telescope PVG Earth

Pin 1 2

Wire Brown Green

Connection OUTANA 13/ + Electric generator supply Generator electro-valve Earth

676 889 ELECTRIC GENERATOR BUNDLE No. 47

676 868 EMERGENCY PUMP BUTTON BUNDLE Version A No. 26

Connection Emergency pump button Emergency pump button

676 887 EMERGENCY PUMP BUTTON BUNDLE Version A No. 45

(04/2011)

Wire

Connection

1 2

Brown White

Earth/Diesel level Inana 8/Diesel level

684 407 PROPORTIONAL DIESEL GAUGE BUNDLE No. 11

1 2 3

1 2 3 4

Wire Brown White

Pin

Pin 1 2 3

Wire White Brown Green

Connection OUTANA 3: PVG No. 4 control OUTTOR 3: +PVG No. 4 supply PVG No. 4 Earth

676 870 PROPORTIONAL ELECTRO-VALVE BUNDLE No. 28

A C B

Pin A B C

Wire Brown Green White

Connection +Tilt indicator +12V supply Tilt indicator Earth INTOR 1 / Tilt indicator

832 136 TILT BUNDLE No. 10

80-06-13-M172EN

80

Wire White Brown Green

EV PRO N°4

Pin 1 2 3

2 1

2 1

1 2 3 4

TILT BOX

EMERGENCY PUMP

1 2 3

14

Electrical bundles - Removal

ARM 3 SENSOR

EV PRO ARM 3

SUPPLY CEK 20

- A10 - MISC. BUNDLES BRC 301 - No. 5, 25, 27, 43, 48 :

Pin 1 2 3

Wire Connection White OUTANA 1: Arm 3 PVG control Brown OUTTOR 1: +Arm 3 PVG supply Green Arm 3 PVG Earth

3 4

80

676 869 ARM 3 PROPORTIONAL ELECTRO-VALVE BUNDLE No. 27

1 2 3

676 867 ARMS PROPORTIONAL ELECTRO-VALVE BUNDLE No. 25

80-06-13-M172EN

A1

Wire Connection Brown BAT+ screen supply (+12 V DC) Green Screen supply Earth White APC+ screen supply (+ 12 V DC)

676 885 CEK20 SCREEN SUPPLY BUNDLE No. 43

1 6

Pin 1 2 3 4 5 6

Wire Blue Green Yellow Grey Brown White

Connection INTOR 4/arm down sensor 2 INTOR 2/arm down sensor 1 INTOR 3/telescope sensor 1 +12Vcc/arm down sensor INTOR 7/telescope sensor 2 +12Vcc/telescope sensor

677 819 TELESCOPE SENSOR BUNDLE No. 48 2

Wire Connection White OUTANA 0: Arms 1/2 PVG control Brown OUTTOR 0: +Arms 1/2 PVG supply Green Arms 1/2 PVG Earth

A2

2 5

1 2 3 4

Pin 1 2 3

A3

Pin A1 A2 A3

1 2 3 4

HYDRAULIC SAFETY

EV PRO ARMS 1/2

1 2 3

3

1

diresction of assembly to be respected (Pin 3 to cable entry)

Pin 1 2

Wire Connection Brown OUTTOR 8/ Hydraulic safety EV Green Hydraulic safety electro-valve Earth

676 848 SAFETY ELECTRO-VALVE BUNDLE Version B No. 5

677 795 To inductive sensors intermediate bundle No. 4

(04/2011)

Electrical bundles - Removal

15

IGNITION KEY

EMERGENCY PUMP

FLASHING LIGHT

- A11 - MISC. BUNDLES BRC 301 - No. 9, 14, 44 :

SPARE

Wire

Connection OUTTOR 10: +flashing Brown light Blue Flashing light earth

Wire Connection Blue Earth Brown +12Vcc

676 857 EMERGENCY PUMP 676 852 BUNDLE FLASHING LIGHT BUNDLE No. 14 Version A No. 9

(04/2011)

Wire Connection Yellow Ignition key Brown Start-up key + (+12VDc) Key Green BAT

Connection + (+12VDc) forcing supply INTOR 12: engine speed forcing

Wire Pink Violet White

Connection INTOR 0: Basket selector + (+12VDc) selector BAT Base selector

Wire Red/Blue Grey/pink

Connection Emergency Stop Emergency Stop

80

Wire Grey White

676 886 IGNITION KEY BUNDLE Version B No. 44

80-06-13-M172EN

16

Electrical bundles - Removal

2

80

1 12

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

2 11

Wire Grey/Pink Black Red/Blue White Pink Brown Violet Yellow Grey Green Blue Rouge

3 10

COLLECTOR BUNDLE

BUZZER

BASKET CAN BUS

- A12 - MISC. BUNDLES BRC 301 - No. 6, 12, 46 :

4 9

5 8

6 7

Connection Basket emergency pump button Basket engine starter button Basket Emergency Stop CAN low basket +BAT (+12VDc) basket CAN high basket +BAT (+12VDc) basket Spare Basket earth Basket earth Emergency Stop +APC (+12VDc) basket

676 888 CAN BUS BUNDLE TO BASKET Version A No. 46

Pin 1 2

Wire Blue Brown

1

Connection Buzzer earth OUTTOR 11: Buzzer

676 849 BUZZER BUNDLE No. 6

1 12

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

Wire Grey/Pink Black Red/Blue White Pink Brown Violet Yellow Grey Green Blue Red

2 11

3 10

4 9

5 8

6 7

Connection +12VDc axles sensors axles sensors earth INTOR 11/R axle sensor INTOR 10/F axle sensor OUTTOR 17/Differential locking EV OUTTOR 16/Electric brake EV Electric brake and diffl locking EV Earth OUTTOR 14/ Crab steering EV OUTTOR 15/ 4-wheel steering EV Crab / 4-wheel steering EV earth OUTTOR 18/Oscillation EV 1 and 2 Oscillation electro-valve 1 and 2 Earth

676 855 COLLECTOR BUNDLE No. 12

676 846 To CAN BUS intermediate bundle Version A No. 3

80-06-13-M172EN

(04/2011)

Electrical bundles - Removal

17

1

1

FAISCEAU ELECTROVALVE 676 880 INCLINAISON CAVAGE BOOST TILT 676880 ELECTRO-VALVE BUNDLE INDICE # No. 38 Rep.38

Broche Fil Pin Wire Liaison Connection Marron 29 / EV descente pendulaire 11 BrownOUTTOR OUTTOR 29 / Pendular arm lowering EV 2 Vert Masse EV descente pendulaire 2 Green Pendular arm lowering EV Earth

FAISCEAU ELECTROVALVE 831 702 DESCENTE PENDULAIRE PENDULAR 831702 ARM LOWERING ELECTRO-VALVE INDICE # BUNDLE Rep.36 No. 36

(04/2011)

1

Broche Fil Pin Wire Liaison Connection 1 1 Marron 23/ /Turret EV rotation Brown OUTTOR OUTTOR 23 rotationtourelle right EV droite 2 2 Vert rotation droiteEarth Green Masse Turret EV rotation righttourelle electro-valve

FAISCEAU676 ELECTROVALVE 874 ROTATION TOURELLE DROITE TURRET ROTATION RIGHT 676874 ELECTRO-VALVE INDICE # BUNDLE No. 32 Rep.32

Pin Wire Liaison Connection Broche Fil Marron 27/27EV inclinaison cavage 11 Brown OUTTOR OUTTOR /Boost tilt electro-valve Vert EVtilt inclinaison cavage 22 Green Masse Boost electro-valve Earth

2

BASKET ROTATION RIGHT ROTATION PANIER DROITE

2

2

1 2

Broche Fil Liaison Pin Wire Connection 1 Marron OUTTOR 25/ EV direction droite 1 Brown OUTTOR 25 / Steering right EV 2 Vert Masse EV direction droite 2

Green

Steering right electro-valve Earth

FAISCEAU ELECTROVALVE 676 876 DIRECTION DROITE FAISCEAU ELECTROVALVE 676876 DIRECTION DROITE INDICE # No. 34 Rep.34

1

Pin Wire Connection Broche Fil Liaison Marron 2121/ /EV rotation panier 11 Brown OUTTOR OUTTOR Basket rotation rightdroite EV 2 Vert Masse EV rotation panier droite 2

Green

Basket rotation right electro-valve Earth

FAISCEAU ELECTROVALVE 676 872 ROTATION PANIER DROITE BASKET ROTATION RIGHT 676872 ELECTRO-VALVE INDICE #BUNDLE Rep.30 No. 30

80-06-13-M172EN

80

2

STEERING RIGHT DIRECTION DROITE

PENDULAR LOWERING DESCENTEARM PENDULAIRE

BOOST TILT CAVAGE INCLINAISON

TURRET ROTATION RIGHT ROTATION TOURELLE DROITE

- A13 - DIVERS FAISCEAUX BRC 301 - REP. 30, 32, 34, 36, 38 :

18

Electrical bundles - Removal

Pin Connection Broche FilWire Liaison 2 1 Blanc Low White BUS BUSCAN CAN low 2 Green BUS CAN High High 7 Marron BUS CAN

676 883 FAISCEAU BRC CAN 301-UPC 301 BRC 301 UPC 301 BUNDLE 676883 No. 41 INDICE # Rep.41

2

Pin Wire Fil Connection Broche Liaison 1 Marron OUTTOR 26 angle / EV 26 / Tilting 1 Brown OUTTOR electro-valve inclinaison déversement 2 Green Tilting angle electro-valve Earth 2 Vert Masse EV inclinaison déversement

1

80

2

Pin Wire Broche Fil Liaison Connection 1 1 Marron EV levage pendulaire Brown OUTTOR OUTTOR 2828/ / Pendular arm raising EV Green Masse Pendular arm raisingpendulaire EV Earth 2 2 Vert EV levage

676 880 FAISCEAU ELECTROVALVE PENDULAR ARM RAISING LEVAGE PENDULAIRE 676877 BUNDLE ELECTRO-VALVE INDICE No. 35 # Rep.35

80-06-13-M172EN

Pin

Wire

1

Connection

Broche Fil Liaison OUTTOR 22 / Turret rotation left 11 Brown Marron OUTTOR 22/ EV rotation electro-valve tourelle Turret rotationgauche left electro-valve 2 Green 2 VertEarthMasse EV rotation tourelle gauche

831 703 FAISCEAU ELECTROVALVE TILTING ANGLE ELECTROINCLINAISON DEVERSEMENT VALVE BUNDLE 831703 No. 37 INDICE # Rep.37

UPC 301

TURRET ROTATION LEFT GAUCHE ROTATION TOURELLE

1

2

CAN

BASKET ROTATION LEFT ROTATION PANIER GAUCHE

1 2 3 4 5 6 7 8 9

STEERING LEFT DIRECTION GAUCHE

PENDULAR ARM RAISING LEVAGE PENDULAIRE

BUS 301 BUSCAN CANUPC UPC 301

TILTING ANGLEDEVERSEMENT INCLINAISON

- A14 - MISC. BUNDLES BRC 301 - No. 29, 31, 33, 35, 37, 41 :

831 700

TURRET ROTATION LEFT FAISCEAU ELECTROVALVE ELECTRO-VALVE BUNDLE ROTATION TOURELLE GAUCHE 831700 No. 31 INDICE # Broche Liaison Pin Wire Fil Connection Rep.31 24/ 1 1BrownMarron OUTTOROUTTOR 24 / Steering leftEV EV 2

Green

2

2

1

Steeringdirection left electro-valve Earth gauche

Vert

Masse EV direction gauche

831 701 STEERING LEFT ELECTROFAISCEAU VALVEELECTROVALVE BUNDLE DIRECTION GAUCHE No. 33 831701 INDICE # Rep.33

2

1

Broche Liaison Pin WireFil Connection 1 Marron OUTTOR 20/ rotation EV rotation OUTTOR 20 / Basket left 1 Brown electro-valve panier gauche 22 Green Basket rotation left EV Earth Vert Masse EV rotation panier gauche

831 699 FAISCEAU ELECTROVALVE BASKET ROTATION LEFT ROTATION TOURELLE GAUCHE ELECTRO-VALVE BUNDLE 831699 No. 29 INDICE # Rep.29

(04/2011)

Electrical bundles - Removal

19

- A15 - MISC. BUNDLES BRC 301 - No. 39, 40 :

676 882 FAISCEAU

676 881 FAISCEAU

CONNECTOR CONNECTEUR AMP N°2 BUNDLE 676882 AMP N°2 INDICE A Version Rep.40A Rep. 40

CONNECTOR CONNECTEUR AMP N°1 BUNDLE 676881 AMP N°1 INDICE A Version Rep.39 A Rep. 39

UPC 301

(04/2011)

Connection

Liaison

+BAT (+12Vcc) + BAT (+12 Vcc) OUTTOR 0: PVG supply, arms 1/2 OUTTOR 0: Alim PVG bras 1/2 OUTTOR 1: PVG supply, arms 3 OUTTOR 1: Alim PVG bras 3 OUTTOR telescope OUTTOR 2: 2: PVG Alim supply PVG télescope OUTTOR OUTTOR 3: 3: PVG Alim supply PVG N°N°4 4 OUTTOR safety system OUTTOR 8: 8: Hydraulic Sécurité hydraulique OUTTOR security system OUTTOR 9: 9: Anti-start Sécurité anti-démarrage OUTTOR flashing light OUTTOR 10: 10: Rotating Gyrophare OUTTOR OUTTOR 11: 11: Buzzer Avertisseur sonore OUTTOR OUTTOR 12: 12: Preheating Préchauffage OUTTOR OUTTOR 13: 13: Generator Electro-génératrice PWMO -: (-) Generator, forward avant motion Pompe avancement PWMO +: +: (+) (+) Pompe Generator, forwardavant motion avancement + APC (+12Vcc) ( +12 Vcc) +BAT + BAT(+12Vcc) (+12 Vcc) NOT USED NON UTILISEE NOT USED NON UTILISEE NOT USED NON UTILISEE NOT USED NON UTILISEE INHSCE0: INHSCE0: Engine Régimerevs moteur INHSCE1 (INTOR12): max engine revs INHSCE1(INTOR 12):Forcing Forcageunit, régime maxi moteur OUTANA 0: commande PVG control, arms 1/2 PVG bras 1/2 OUTANA 1: commande PVG control, arms 33 PVG bras OUTANA 2: commande PVG controlPVG télescope télescope OUTANA 3: commande PVG controlPVG N°4N°4 PWM 1-: (-) Generator, reverse arrière Pompe avancement PWM 1+: 1+: (+) (+) Pompe Generator, reverse arrière avancement Earth Masse +BAT + BAT(+12Vcc) (+12 Vcc) INTOR 0: control 0: Selector, Sélecteurbasket commande panier INTOR 1: indicator 1: Tilt Indicateur dévers INTOR 2: 2: Sensor CapteurN°1, N°1low brasarm bas Sensor N°1, telescope retractedrentré INTOR 3: Capteur N°1 télescope INTOR 4: 4: Sensor CapteurN°2 N°2low brasarm bas INTOR 5: chargebatterie level 5: Battery Retour charge INTOR 6: 6: Diesel Niveaulevel bas low gasoil INTOR 8: waterhaute temperature high 8: Engine Température eau moteur 9: Engine Pressionoilbasse huilelow moteur INTOR 9: pressure 10: Sensor, Détecteur pontaxle avant INTOR 10: front INTOR 11: 11: Sensor, Détecteur pont arrière INTOR rear axle INTOR 7: 7: Sensor CapteurN°2, N°2telescope télescope rentré INTOR retracted Masse Earth

Pin 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 31 32 33 34 35 36 37 38 39 40 41 42

Broche Liaison Connection 1

+ BAT (+12 Vcc)

+BAT 2 (+12Vcc) OUTTOR 14: Direction crabe OUTTOR 14: Crab steering 3 OUTTOR 15: Direction 4 roues OUTTOR 15: 4-wheel16: steering 4 OUTTOR Electro-frein OUTTOR 16: Brake electro-valve 5 OUTTOR 17: Blocage différentiel OUTTOR 17: Diff erential lock oscillation N°1 6 OUTTOR 18: Electro OUTTOR 18: Oscillation electro-valve N°1N°2 7 OUTTOR 19: Electro oscillation OUTTOR 19: Oscillation electro-valve N°2 8 OUTTOR 20: Rotation gauche panier OUTTOR 20: Basket rotation left droite panier 9 OUTTOR 21: Rotation OUTTOR Basket rotation rightgauche tourelle 10 21: OUTTOR 22: Rotation 11 22: OUTTOR 23: Rotation OUTTOR Turret rotation left droite tourelle 12 23: OUTTOR 24: Electro direction gauche OUTTOR Turret rotation right 13 24: OUTTOR direction droite OUTTOR Steering25: leftElectro electro-valve 14 25: + APC ( +12right Vcc)electro-valve OUTTOR Steering 15 (+12Vcc) + BAT (+12 Vcc) + APC 16(+12Vcc) OUTTOR 26: Inclinaison déversement +BAT 17 26: OUTTOR 27: Inclinaison cavage OUTTOR Tilting angle 18 27: OUTTOR 28: Pendulaire montée OUTTOR Boost tilt 19 28: OUTTOR 29:arm Pendulaire OUTTOR Pendular raising descente 20 29: NON UTILISEE OUTTOR Pendular arm lowering NOT21USED NON UTILISEE NOT22USED OUTANA 4: Libre OUTANA 4:OUTANA Spare 5: Libre 23 OUTANA 5:NON Spare 24 UTILISEE NOT25USED NON UTILISEE NOT26USED NON UTILISEE NOT27USED NON UTILISEE NOT28USED Masse 29 + BAT (+12 Vcc) Earth 30(+12Vcc) NON UTILISEE +BAT NOT31USED NON UTILISEE NOT32USED NON UTILISEE NOT33USED NON UTILISEE NOT34USED NON UTILISEE NOT35USED NON UTILISEE NOT36USED OUTTOR 4: Régime maxi moteur 37 4:OUTTOR 5: Libre OUTTOR Max engine speed 38 5:OUTTOR OUTTOR Spare 6: Libre 39 6:OUTTOR OUTTOR Spare 7: Libre 40 7:NON OUTTOR SpareUTILISEE NOT41USED NON UTILISEE NOT42USED Masse Earth 80-06-13-M172EN

80

Pin

Broche 1 1 2 2 3 3 44 55 66 77 88 99 10 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23 24 24 25 25 26 26 27 27 28 28 29 29 30 30 31 31 32 32 33 33 34 34 35 35 36 36 37 37 38 38 39 39 40 40 41 41 42 42

20

Electrical bundles - Removal - A16 - ENGINE BUNDLE - No. 15 :

FFUUSE SIB S LE

LHE ERLT UAR

+Bat atte rie F1 F1

S

OE ETT

+1 +12V

2VBR BRCCF1 F

1

RE

SRS MTUA

++BBat

atte teririe e

PPré réch

F2F

2

chau auffff..F2 F2

W hite Bla

nc

IE RRY TEE TTT BAA ++B

Preheating Sortie relais relay exit e préchauffag

PREEH CE

HATUIN FFGAGE

1

Broche Liaison Pin Wire Fil Connection Blanc / Violet PWM0-PWMO-/ / Forward pompe motion pump 1 1 White/violet avancement avant 2 Blue PWM0+ / Forward motion pump 2 Bleu PWMO+ / pompe avancement avant

BrocheWire Pin

Fil

Liaison Connection

pompepump Black NoirPWM1- /PWM1-/ Reverse motion arrière White/Black PWM1+avancement / Reverse motion pump

OR

AL TE RN AT EU R

Blanc / Noir

AT

PWM1+ / pompe avancement arrière

N ER

T AL

80

+D Borne terminal D+ (battery (chargelading) batterie)

Rouge Red White Blanc

ALTERNATOR SUPPLY ALIMENTATION (+Bat) ALTERNATEUR (+Bat)

ENGINE SPEED EV EV REGIME MOTEUR

ST

AR

TE

R

BNla ocikr

+Bat VERS ALTERNATEUR +Bat TO ALTERNATOR STARTER SUPPLY ALIMENTATION DEMARREUR

Terminal BORNE WW

ILE

elec accelerator accélérateur élec elec accelerator Masse accélérateurearth élec

/viool letet

2

Bl Nac oirk/vi

1

1

R EU RR MA DE

1 2

FAISCEAU MOTEUR THERMIQUE ENGINE BUNDLE 831697 831697 INDICE No.15 # Rep.15

WATER TEMPERATURE TEMPERATURE EAU

2

EVPROP PROPFORWARD MARCHE AVANT EV MOTION N TIO RO EAM E S RH VREC REA PM O PR EV

NBola irck

2

HU

RE

N

SU

PR E 2

ENGINE INJECTION INJECTION MOTEUR

SS IO

ES

L OI

PR

2

1

Pin Wire Connection Broche Fil Liaison Gris température eau moteur 11 Grey Masse Engine water temperature earth Vert INTOR8 moteur 22 Green INTOR8température Engine water eau temperature

1

PinBroche Wire 1 2

Fil Liaison Connection 1 Brown Marron Masse / pression Earth/engine oil pressure huile oil moteur White/Blue INTOR9/engine pressure 2 Blanc / Bleu INTOR9 / pression huile moteur

2

1

Broche Liaison Pin WireFil Connection Jaune Earth/engine MASSE/STOP MOTEUR 11 Yellow stop Blanc / Rouge +BAT/+EV STOP 22 White/Red +BAT/+ engine stop EV MOTEUR

80-06-13-M172EN

(04/2011)

Electrical bundles - Removal

21

- A17 - MISC POWER CABLES :

80 +BATTERY

FUSE

TURRET EARTH (04/2011)

FUSE

677 733

CABLE +BATTERY EMERGENCY PUMP FUSE

EMERGENCY PUMP

676 864

35MM² CABLE FUSE / EMERGENCY PUMP

EMERGENCY PUMP EARTH

676 866

35MM² CABLE TURRET EARTH / EMERGENCY PUMP

80-06-13-M172EN

22

Electrical bundles - Removal - A18 - MISC POWER CABLES :

50MM² CABLE ENGINE / TURRET EARTH

50MM² CABLE -BATTERIE/MASSE TOURELLE

CABLE +BATTERY/ STARTER

+BATTERY

-BATTERY

ENGINE EARTH

80

STARTER

677 813

TURRET EARTH

679 080

TURRET EARTH

676 859 (Indice B)

TO BE FITTED ON THE BATTERY - TERMINAL

80-06-13-M172EN

(04/2011)

HYDRAULICS

- HYDRAULIC COMPONENTS - LOCATION - HYDRAULIC PRESSURE - HYDRAULIC LAYOUT - DISTRIBUTOR COMPONENTS - REMOVAL

70

- CYLINDERS - REMOVAL

HYDRAULIC COMPONENTS - LOCATION

Pages A - Chassis hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 3 B - Turret hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 4

70

C - Arm hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 5

(04/2011)

70-03-M172EN

Hydraulic components - Location

70

2

70-03-M172EN

(04/2011)

3

Hydraulic components - Location

T NNT O A FR AV

Rear steering Vérin de cylinder direction arrière

Oscillation locking Vérin de blocage cylinder right oscillation droit

Axle brake Frein de pont

Differential Blocage lock differentiel

Front steering Vérin de cylinder direction avant Braking block Bloc frein

Translation hydrostatic Moteur hydrostatique motor de translation

E R R E

A

A REI R R

(09/2010)

70-07-M172EN

70

Oscillation locking Vérin de blocage cylindergauche left oscillation

4

Hydraulic components - Location

Radiator Radiateur

NNTT

O FRA V A

Oilàtank Bac huile Hydrostatic pump Pompe hydrostatique Turret rotation Moteur deengine rotation tourelle

Suction filter Filtre aspiration Auxiliary pump Pompe auxiliaire

Distributor Bloc block distributeur

70

Emergency Pompe de secours pump

Rotary joint Joint tournant 2-tracks 2 pistes 160 ATJ FC

Proportional Distributeur distributor proportionnel Pressure filter Filtre pression

Rotary joint Joint tournant 6-tracks 6 pistes 160 ATJ FC RC

R IARE

E

RE

R AR 70-07-M172EN

(09/2010)

5

Hydraulic components - Location

NTT N O A FR AV

Compensation Vérin de cylinder compensation

Telescoping Vérin de cylinder télescopage

70

TiltVérin cylinder d'inclinaison

LeftVérin arm 3 raising cylinder d'élévation bras 3 Pendular arm Vérin de cylinder pendulaire

ArmsVérin 1/2 raising cylinder d'élévation bras 1/2

Basket Vérinrotation de cylinder rotation panier

AR (09/2010)

ARE REI

RE

R

70-07-M172EN

6

70

Hydraulic components - Location

70-07-M172EN

(09/2010)

HYDRAULIC PRESSURE

Pages A - Proportional distributor - Taring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 2

B - Distributor block - Taring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 6

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C - Compensation / tilt circuit - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . P 11

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Hydraulic pressure

Before making the tare settings described in this section, you must necessarily have two hydraulic manometers to hand: - 1 manometer 0 - 400 bar.

- 1 manometer 0 - 100 bar.

A1

FRONT AV ANT

1

- Lift the turret cowl (A1-1) and fit the stand.

4

- Locate the proportional distributor (A1-2) and the distributor block (A1-3).

- Switch on the platform.

- Start the engine.

3

2 A - PROPORTIONAL DISTRIBUTOR TARING 1 - INLET PLATE PRESSURE RESTRICTOR - TARING - Connect the manometer 400 bar to the pressure take-off (A2-1) marked as (A2-2).

M on the upper block (A2-2)

2

A2

4

0 400

1

5

- Install the manual lever on the last element of the Distributor (A2-3).

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- While holding the button of the (A2-4) VS.push the manual control lever (A2-3) and check thatthe pressure gauge shows a pressure of 180 bar.

3

N TT A ON AFVR

- If the value is different, rthe pressure restrictor’s protective stopper (A2-5) on the upper block (A2-2) and set the pressure reducer to obtain 220 bars.

Re-insert the stopper.

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Hydraulic pressure

2 - ARMS 1/2 RAISING CYLINDER BLOCK VALVE - TARING - Connect the manometer to the pressure take-off (A3-1) marked as M on the upper block (A3-2) (A3-2).

- From the base console (A1-4), instruct the arms 1/2 raising cylinder to extend/retract, hold down the control and when it is at the stop check that the manometer displays a pressure of:

2

A3

1

4

- 240 bars on cylinder extension - 100 bars on cylinder retraction - If the values displayed are different, remove the stoppers:

3 N TT AON V R AF

- (A3-3) from the arms 1/2 raising cylinder extension valve - (A3-4) from the arms 1/2 raising cylinder retraction valve - From the base console (A1-4), instruct the arms 1/2 raising cylinder to extend/retract (hold down the control) and adjust the tare setting for the valves to: - 240 bars on cylinder extension - 100 bars on cylinder retraction

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- Re-insert the stopper.

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Hydraulic pressure

3 - TELESCOPE CYLINDER BLOCK VALVE - TARING - Connect the manometer to the pressure take-off (A4-1) marked as M on the upper block (A4-2) (A4-2).

- From the base console (A1-4), instruct the telescope cylinder to extend/ retract, hold down the control and when it is at the stop check that the manometer displays a pressure of:

2

A4

1

- 120 bars on cylinder extension

4

- 180 bars on cylinder retraction - If the values displayed are different, remove the stoppers:

3

NT A NT O V A R

F

- (A4-3) from the telescope cylinder extension valve.

- (A4-4) from the telescope cylinder retraction valve.

- From the base console (A1-4), instruct the telescope cylinder to extend/ retract (hold down the control) and adjust the tare setting for the valves to: - 120 bars on cylinder extension - 180 bars on cylinder retraction

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- Re-insert the stoppers.

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Hydraulic pressure

4 - ARM 3 RAISING CYLINDER BLOCK VALVE - TARING - Connect the manometer to the pressure take-off (A5-1) marked as M on the upper block (A5-2) (A5-2).

- From the base console (A1-4), instruct the arm 3 raising cylinder to extend/ retract, hold down the control and when it is at the stop check that the manometer displays a pressure of:

A5

2 1

- 240 bars on cylinder extension (160 ATJ FC / 160 ATJ FC RC).

RC)

4

- 110 bars on cylinder retraction - If the values displayed are different, remove the stoppers:

3

NTT AN O V R AF

- (A5-3) ) from the arm 3 raising cylinder extension valve.

- (A5-4) from the arm 3 raising cylinder retraction valve - From the base console (A1-4), instruct the telescope cylinder to extend/ retract (hold down the control) and adjust the tare setting for the valves to: RC) - 240 bars on cylinder extension (160 ATJ FC / 160 ATJ FC RC).

- 110 bars on cylinder retraction

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- Re-insert the stoppers.

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Hydraulic pressure B - DISTRIBUTOR BLOCK TARING 1 - PENDULAR ARM SUPPLY CIRCUIT VALVES - TARING

B1

NT ANT

- Connect the manometer to the pressure take-off (A5-1) marked as M on the distributor block.

AFVRO

A5 M1

B5 B4

A4

A3

- From the base console (A1-4), instruct the pendular arm to deploy/retract, hold down the control when it is at the stop and check that the manometer displays a pressure of:

B3 M A2

B2 B1

- 200 bars when the pendular arm is deployed.

- 80 bars when the pendular arm is retracted.

A1

FARVO

A N

- If the values displayed are different, remove the stoppers:

N TT

M1

1

B2

B5

B4

A5

- (B1-1) from the cylinder raising valve A4

- (B2-1) from the cylinder lowering valve

B3

A3

A2

- From the base console (A1-4), instruct the telescope cylinder to deploy/retract (hold down the control) and adjust the tare setting for the valves to:

B2

B1

2

A1

- 200 bars when the pendular arm is deployed.

- 80 bars when the pendular arm is retracted.

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- Re-insert the stoppers.

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Hydraulic pressure

2 - COMPENSATION / TILT CIRCUIT SUPPLY VALVES - TARING - Release the pressure in the compensation/tilt cylinder supply hoses, proceeding as follows (B3) :

B3

2

1 - From the base console (A1-4), instruct arm 3 to rise midway.

1

2 - Instruct the tilt cylinder to deploy fully.

4

3 - Lower arm 3 to the low position.

3

4 - Instruct arm 3 to rise 1cm.

- Remove the hoses at distributor block level (B4-1).

- Insert T connectors between the distributor block and the hoses (B4-2).

B4

Take a straight connector (B4-3), fit it to one of the T connectors and connect the manometer to it.

A5 M1

B5 B4

A4

A3

B3

- Take a stopper (B4-4) and place it over the remaining connector.

M A2

B2 B1

- Remember:

B1

6

A1

A1

- Output (B4-5) A1: Tilt (tilt cylinder extension).

3 4

2

1

70

- Output (B4-6) B1: Boost (tilt cylinder retraction).

5

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Hydraulic pressure

Adjusting the tilt cylinder output valve - From the base console, instruct arm 3 to rise midway (B5-black arrow).

- From the base console, instruct the basket (B5-white arrow) to tilt until the cylinder is at the stop.

B5

- Instruct arm 3 (B6) to lower and simulltaneously check that the manometer connected to the output (B4-5) displays a pressure of 180 bars.

B6

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- If the value displayed is different, remove the stopper (B7-1) from the tilt cylinder output valve.

- From the base console, instruct arm 3 (B6) to lower and simultaneously adjust the valve’s tare setting to 200 bar

B7

T N NT

A O AFVR

A5 M1

B5 B4

A4

A3

B3 M A2

B2 B1

A1

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Hydraulic pressure

Adjusting the tilt cylinder retraction valve

B8

- From the base console, instruct the basket to be boosted until the retracted cylinder is at the stop (B8) (B8).

AV ANT FRONT

- Instruct arm 3 (B9) to rise and simultaneously check that the manometer connected to the output (B4-6) displays a pressure of 100 bars.

B9

FRONT AV ANT

- From the base console, instruct arm 3 (B9) to rise and simultaneously adjust the valve’s tare setting to 100 bars.

- Release the pressure in the hoses (see the beginning of the paragraph).

70

- If the value displayed is different, remove the stopper (B10-1) from the tilt cylinder retraction valve.

B10

T NNT

A O

AFVR

A5 M1

- Refit the hydraulic hoses in their original configuration.

B5 B4

A4

- Close the right-hand turret cowl.

A3

B3 M

- Instruct raising, telescoping, tilting and boosting movements.

A2

B2

- Check the hydraulic oil level and top up, if necessary.

B1

A1

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Hydraulic pressure

C - COMPENSATION / TILT CIRCUIT Troubleshooting

C1

2

- If the basket does not remain in position and falls under gravity when the lifting platform is not being used, conduct the following testing procedure.

1

AV ANT FRONT

Testing procedure

4

- Release the pressure in the compensation/tilt cylinder supply hoses by proceeding as follows (C1) :

3

1 - From the base console (A1-4), instruct arm 3 to rise midway.

2 - Instruct the tilt cylinder to deploy fully.

3 - Lower arm 3 to the low position.

C2

4 - Instruct arm 3 to rise 1cm.

1 - Take a receptacle and place it under the compensation cylinder.

- Mark the hoses connected to the compensation cylinder in the lower chamber (C2-1) and remove them.

2

- Take a straight connector MA 8S/MA 8S (Ref. 201746) and connect it to the lower chamber’s hoses (C2-1).

(C2-2).

- Proceed in the same way with upper chamber’s hoses (C2-2)

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- Remove the hoses at distributor block level (C3-1).

N TT N

A O

- Insert T connectors between the distributor block and the hoses (C3-2) (C3-2).

AFVR

C3 A5 M1

3

B5 B4

A4

0 200

A3

B3 M

- Take a manometer 0 - 400 bar (C3-3) and fit it to the left T connector: output A1.

A2

B2 B1

A1

- Take a manometer 0 - 100 bar (C3-4) ) and fit it to the right T connector: output B1.

0 100

4

B1 A1

2

1 - From the base console (A1-4), instruct several tilt/boost movements up to the stop (C4) so as to put the hydraulic circuit under pressure.

N TT

C4

A ON AFVR

- Set the basket in a horizontal position.

- Switch off the engine.

- Note the pressure values displayed by both manometers.

- Check that the basket does not drop.

NB - This procedure may take some time (several hours).

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Hydraulic pressure

Results analysis - The basket remains in position and the hydraulic pressure does not fall: the cylinder or the compensation cylinder seals are defective.

- Remove the compensation cylinder

 70-06-80-M.172

- Remove the cylinder and check the condition of the seals: change them, if necessary  547406 - Check the condition of the cylinder body: if there are scratches, pollution or traces of rust... replace the cylinder  547406 - The basket remains in position and the hydraulic pressure has dropped in one or both hydraulic lines: one or both distributor block valves show sealing and adjustment problems.

- Release the pressure in the compensation/tilt circuit supply hoses. §C - Remove the valves (C5-1) and check the seals’ appearance: change the valves if the seals are defective  547406 - Re-insert the valves and then check their §B-2

settings

- The basket descends, the pressure tends to balance out (+/- 10 bar) in both manometers or the pressure is constant in line A1 and has reduced in line B1.

- Remove the tilt cylinder

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- Release the pressure in the compensation/tilt circuit supply hoses  § C.  70-06-80-M.172

- Remove the cylinder and check the condition of the seals: change them if necessary  547406 - Check the condition of the cylinder body: if there are scratches, pollution or traces of rust... replace the cylinder  547406

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Hydraulic pressure

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HYDRAULIC LAYOUT

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Hydraulic layout

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Block diagram - Hydraulic

BASKET ROTATION

FUNCTIONS

STEERING

2 3 4 5 6

OSCILLATION LOCKING

PENDULAR ARM

TURRET ROTATION

1

COMPENSATION / TILT

7

9 R

L

EMERGENCY ELECTRICAL PUMP 1300 W, DS1 motor S2: 6,2min at 100 b S3: 10,3% at 100 b

STEERING - 2-WHEELS - 4-WHEELS - CRAB

FRONT

8

10 11

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DR DIFFERENTIAL LOCK

BRAKE

TELESCOPE

Booster pump MAX Auxiliary pump MAX Auxiliary pump MINI Brake Differential lock 2 / 4 / crab steering Low arm Raising Low arm Lowering Telescope extended Telescope retracted Upper arm raising Upper arm Lowering Function block proportional valve Pendular arm raising Pendular arm lowering Steer Left / Right Turret Basket rotation Cylinder extension Cylinder retraction

Pres. bars

112 40

/ 320

21 47,5 30,40 0 0 10,00 15,00 8,00 18,00 12,00 9,00 5,00

26 220 220 26 26 180 220 100 120 180 220 110

/

/

4 1,5 10,00 1,95 1,00 / /

200 80 180 160 160 220 100

UPPER CYLINDER

GA

Engine Idling speed 1400 rpm Max: 2500 rpm

LOWER CYLINDER

12 13 14 15 15

Hydrostatic pump - Max speed - Max power

Flow l/min

HYDRAULIC COMPONENTS A: Oil tank B: 6-track rotary joint C: 100μm intake strainer D: DANFOSS proportional distributor E: Variable cubic capacity pump F: Bent axis motor G: Distributor block H: Braking block I: 10μm abs. pressure filter J: 10μm nom. pressure filter K: Cooler L: Emergency electric pump M: Radiator block N: Valve block

D-HY-634 70-05-M172EN

70

PLAN: 831 156 Index#

4

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Block diagram - Hydraulic

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4 Stop Left Right Left 4-wheels Right Left Crab Right

Work Position

Transport Position

2-wheels Steering only Translation

Left Right Translation + Left 4-wheels Steering Right Left Crab Right Stop Left 2-wheels Right Steering Left 4-wheels only Right Left Crab Right Translation Left 2-wheels Right Left 4-wheels Translation + Right Steering Left Crab Right Raising Arms 1/2 Lowering Raising Raising Arm 3 Lowering Extension Telescope Retraction Raising Pendular arm Lowering Right Basket rotation Left Right Turret rotation Left Boost Tilt Tilt 2-wheels

E E E E E E E E E E E E E E -

6

7

5 6a 6b 7a 7b - - - - - - - E - - - E - - - - E - - - E - E/- - - - - E/- E/E/- E - - E/- E - - E/- - E - E/- - E - - - - - - - - E - - - E - - - - E - - - E - E/- - - - - E/- E/E/- E - - E/- E - - E/- - E - E/- - E - - - - E - - - - E - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Electro-valves - : Rest E : Excited 8 9 10 11 12 13 14 15 Electro 8a 8b 9a 9b 10a 10b 11a 11b 12a 12b 13a 13b 14a 14b 15a 15b generat.* E - - - - - - - - - - - - - - - - - - - E - - - E - - - - - - - - - - E - - - - E - - - - - - - - - E - - - E - - - - - - - - - - E - - - - E - - - - - - - - - E - - - E - - - - - - - - - - E - - - - E - - - - - - - - - - - - - - - - - - - - - - - - E - - - E - - - - - - - - - - E - - - - E - - - - - - - - - E - - - E - - - - - - - - - - E - - - - E - - - - - - - - - E - - - E - - - - - - - - - - E - - - - E - - - - - - - - - - - - - - - - - - - - E - - - - E - - - E - - - - - - - - - - E - - - - E - - - - - - - - - E - - - E - - - - - - - - - - E - - - - E - - - - - - - - - E - - - E - - - - - - - - - - E - - - - E - - - - - - - - - - - - - - - - - - - - - - - - E - - - E - - - - - - - - - - E - - - - E - - - - - - - - - E - - - E - - - - - - - - - - E - - - - E - - - - - - - - - E - - - E - - - - - - - - - - E - - - - E - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E - - - - - - - - - - - - - - - E - - - - - - - - - - - E - - - - - - - - - - - - - - - E - - - - - - - - - - - - - - - - E - E - - - - - - - - - - - - E - - E - - - - - - - - - - - E - - - - - - - E - - - - - - E - - - - - - - - E - - - - - E - - - - - E - - - - - - - - E - - - - - - E - - - - - - - E - - - - - - - - - E - - - - E - - - - - - - - - - E -

* The generator set’s electro-valve is disengaged after 5 seconds without any movement.

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5

Hydraulic layout

6

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Hydraulic layout

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DISTRIBUTOR COMPONENTS – REMOVAL

Pages A - Proportional distributor components - Removal . . . . . . . . . . . . . . . . . . . . P 2

70

B - Distributor block components - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . P 4

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Distributor components – Removal

A - Proportional distributor components Removal - Switch off the lifting platform.

A1

AV ANT FRONT

1

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

- Locate the proportional distributor (A1-2).

- Release the pressure in all the hoses connected to the distributor  70-06-80-M.172 - Mark and remove all the hoses.

2

- Locate the electrical bundles connected to the control units (A21) and disconnect them.

2

A2

- Remove the fixing screws (A2-2) and remove the proportional distributor unit.

- Remove the component(s) to be changed (using various flat and hex wrenches).

70

547406  547406

10 10 DA 409

N TT A ON AFVR

1

RE-INSTALLATION - Perform the above operations in reverse order.

Before switching the machine on again, check the calibration values  70-04-M.172

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Distributor components – Removal

B - Distributor block components Removal - Switch off the lifting platform.

- Open the right-hand turret cover (B1-1) and fit the stand.

- Locate the distributor block (B1-2).

- Release the pressure in all the hoses connected to the distributor  70-06-80-M.172

AV ANT FRONT

B1 1

- Mark and remove all the hoses.

- Locate the electrical bundles connected to the solenoids (B2-1) and disconnect them.

2

- Remove the fixing screws (B2-2) and remove the distributor block.

- Remove the component(s) to be changed (using various flat and hex wrenches).

547406  547406

10 10 DA 410

T NT AON

B2

A FVR

2 1

70

RE-INSTALLATION - Perform the above operations in reverse order.

Before switching the machine on again, check the calibration values  70-04-M.172

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Distributor components – Removal

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CYLINDERS – REMOVAL

Pages A - Lifting platform - Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 2 B - Releasing the pressure in the hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 3 C - Cylinders - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 4

E - Valves and valve blocks – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 7

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D - Cylinders - Re-installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 6

2

Cylinder - Removal

A - LIFTING PLATFORM - PREPARATION

A1 FRONT

Set the lifting platform on a horizontal surface.

Depending on the cylinder to be removed, use the base console to instruct arms 1/2 or arm 3 to rise, the telescope to extend or the pendular arm to deploy. Depending n the cylinder, hold it by chocking it or with a sling connected to a hoist.

For the pendular arm, tilt, compensation and telescope cylinders: – Chock the basket (A1-1) to remove the pendular arm (A1-2), tilt (A1-3) and compensation (A2-1) cylinders:

3 2

1

D-VE-016

A2

FRONT

WARNING! In the case of the tilt and compensation cylinders, the basket should be immobilised AFTER releasing the pressure in the hoses ..................................................§ B

1

70

D-VE-017

For arms 1/2 and arm 3 cylinders:

A3

T ON

FR

– Use the base console to instruct arms 1/2 to rise up to the upper articulation point (A3-1), i.e. one metre above the counterweight.

1

D-BS-75

– Climb on to the chassis, remove the locking pin, raise the maintenance arms vertical manually (A4-1) and fit the retaining stand (A4-2).

– Use the base console to instruct arms 1-2 to lower to the upper articulation point (A3-1), coming in contact with the maintenance arms: then, release the controls.

– To remove the lifting cylinders for arm 3 (A4-3) and arms 1/2 (A4-4).

A4 C4 FRONT

2

3 4

Switch off the engine and switch off the lifting platform.

1

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Cylinder - Removal

B - RELEASING THE PRESSURE IN THE HOSES

B5

FRONT

Releasing the pressure in the hoses: lifting and telescope cylinders Open the right-hand turret cover.

Locate the proportional distributor (B1-1).

– Take the lever (B1-2) set on a support to the left of the distributor (B1-3) and place it as required.

– Pull and then push the lever (B1-3) to balance the pressure in the hoses connected to the cylinder concerned (B1-3):

2 3

1 D-HY-629

D-DH-105

B2 1

2

3

4

D-DH-106

– On the lifting cylinder distributor control (B2-1) for arms 1/2.

– On the cylinder distributor control (B2-2) for the telescope.

– On the lifting cylinder distributor control (B2-3) for arm 3.

Releasing the pressure in the pendular arm cylinder’s hoses Open the right-hand turret cover.

Locate the distributor block (B3-1).

– Take hold of the manual control for one of the pendular arm’s two valves (B3-2) and operate it manually, screwing it in up to the stop.

– Take the lever (B1-2) and set it on the pendular arm distributor control (B2-4).

– Pull and then push the lever (B1-3).

FRONT

1

2

– Return the manual valve control to its initial position.

– Perform the same operation with the other valve.

Releasing the pressure in the compensation/tilt circuit hoses Use the base console to instruct arm 3 to rise 10° with respect to its Low position (B4-1).

Instruct the tilt cylinder to extend completely (B4-2).

Lower arm 3 to the Low position.

Instruct arm 3 to rise: extend the cylinder rod 1cm.

To put the lifting platform in Safe mode ............................  § A-1

D-HY-630

D-DH-107

B4 1

2

D-BS-309

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Hold the lever in each position for around ten seconds.

B3

FRONT

Hold the lever in each position for around ten seconds.

4

Cylinder - Removal

C - CYLINDERS: Removal 1 - All the cylinders except basket rotation - Mark, remove and plug the hydraulic hoses connected to the cylinder to be removed. Proceed as follows: - Place a receptacle under the hoses to be removed.

- Loosen the hoses slowly, a quarter turn at a time to release any residual pressure.

- When the pressure has fallen, completely remove the hoses and plug them with male plugs: - 12S Arms (1/2) UP, arm (3) UP, telescoping.

- 8S Compensation, tilt, pendular arm.

- Provide yourself with the necessary tools and remove the desired cylinder: Compensation cylinder 24kg Tilt cylinder 29kg Arms (1/2) UP cylinder 60kg Arm (3) UP cylinder 50kg Pendular arm cylinder 26kg Telescoping cylinder 52kg

§E

70

- Before any work to dismantle the removed cylinder

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Cylinder - Removal

2 - REMOVING THE BASKET ROTATION CYLINDER - Set the lifting platform in Transport position.

- Switch off the engine.

NT T OAN

C1

V AFR

- Switch off the lifting platform.

- Hook a sling connected to a winch at several points on the basket or place a lift truck’s forks under the basket.

1

- Locate the basket rotation cylinder (C1-1) between the head of the pendular arm and the basket’s articulation point under its protective casing.

C2

- Remove the fixing screws (C2-1) (C2-1).

3

1

- Remove the basket rotation shaft: (C2-2).

- Remove the nut (C2-2) - Remove the shaft (C2-3) taking care to hold the basket.

4 2

C3

- Place a receptacle under the cylinder valve block (C3-1) (C3-1).

- Remove the elbow connectors (C3-2), plug them with the MA8S plugs and let the oil flow from the cylinder.

2

NTT

OAN

AFVR

NTT OAN V R AF

- Remove the straight connectors (C3-3) (C3-3).

3

- Remove the rotation cylinder..

1 RE-INSTALLATION - Perform the removal operations in reverse order.

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- Release the basket rotation cylinder overload rotation support clevis (C24) by moving the basket sideways (C2-black arrow) fifteen centimetres: WARNING! Do not pull on the electrical bundles in the casing wound with black plastic.

6

Cylinder - Removal

D - CYLINDERS: Re-installation - Perform the removal operations in reverse order.

- Switch the machine ON, start the engine and perform a complete test of all the machine’s movements.

- Drain the compensation/tilt circuit: after conducting any technical work on the compensation/tilt hydraulic circuit, you must necessarily drain the circuit as described below: A - Perform steps 1 and 2 several times, up to the stop.

1

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Raise arm 3 up to the High stop; step 3.

2 BAS

3

B - Perform steps 4 and 5 up to the stop.

4

5

Lower arm 3 down to the Low stop; step 6.

6 C - Repeat the steps described above, several times.

D - Set the basket horizontal.

E - Check that the basket stays in the horizontal position throughout the raising of arm 3.

F - Check the above point while completely lowering arm 3.

- Switch off the engine, check the hydraulic oil level in the reservoir and top it up if necessary.

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7

Cylinder - Removal

E - VALVES AND VALVE BLOCKS: Removal A cylinder equipped with valves may still have its chambers under very high pressure (in excess of 100 bars, particularly in the tilt compensation circuit) even after it has been removed.

It is advisable to release the pressure in the chambers before proceeding to remove the cylinder.

Removing an equipped valve block To avoid spurts of high-pressure oil, the operator should position the cylinder with the contact face (E1-1) between the valve block and the cylinder vertical.

E1

HAUT

1

- Hold the body of the cylinder firmly in a vice.

- Loosen the block’s fixing bolts (E1-2) one after another: MAXIMUM a quarter turn for each screw.

BAS

- Unscrew the bolts a quarter turn with a wrench until the pressure has escaped

2 Removing a valve

D-HY-293

- Hold the body of the cylinder firmly in a vice.

E2

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To avoid spurts of high-pressure oil, the operator should position protections (E2-1) around the valve seat after positioning the wrench.

1

- Loosen the valves (E1-2) one after another: MAXIMUM a quarter turn for each valve.

- Unscrew the bolts a quarter turn with a wrench until the pressure has escaped.

2

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D-HY-294

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Cylinder - Removal

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ARMS - LIFTING PLATFORM

55

- SKIDS - REMOVAL

SKIDS - REMOVAL

Pages A - Telescoping cylinder skids - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 2

C - Mobile tube skids – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 4

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55-06-21-M172EN

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B - Arm skids (3) – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P 3

2

Skids - Removal

A - TELESCOPING CYLINDER SKIDS Removal - Remove the telescoping cylinder  70-06-80-M.172 - Remove the skids (A1-1) (A1-1).

T

NT ON RA A FV

A1

1

RE-INSTALLATION

55

- Perform the above operations in the reverse order.

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3

Skids - Removal

B - ARM SKIDS (3) Removal - Remove the shaft from the head of the telescoping cylinder.

- Raise the basket with a hoist to relieve the skids.

- Remove the fasteners fixing the skids to the head of the jib (B11).

1)

NTT AON R V AF

B1

- Pay attention to the number and the position of the adjusting plates (B1-2) (B1-2).

- Remove the skids.

1 2

RE-INSTALLATION - Perform the above operations in the reverse order.

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- If necessary, fit adjusting plates:  547406 - Plates (B1-2) The maximum play to be left between the mobile tube and the skids on arm 3 is 0.5mm.

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Skids - Removal

C - MOBILE TUBE SKIDS Removal - Instruct the telescope to extend until the shaft in the head of the telescoping cylinder is accessible.

- Remove the telescoping cylinder

 70-06-80-M.172

- Remove the hose guide fasteners on the mobile tube (C1-1) (C1-1).

- Strap the basket/pendular arm/joint assembly (C1-2) (C1-2).

T NNT RAO V F A

C1

1

3

- Remove the shaft from the base of the tilt cylinder.

4 - Instruct the basket to tilt back so that the tilt cylinder has its rod retracted; remove the shaft from the head of the tilt cylinder (C1-3) and then remove the tilt cylinder, while leaving it still connected to its hoses.

2

- Remove the shaft (C1-4) and then remove the basket/pendular arm/joint assembly: leave it nearby so as not to damage the hydraulic hoses and the electrical bundles.

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- Raise the basket with a hoist to relieve the skids.

- Remove the fasteners fixing the skids to the head of the jib (C21) 1).

NTT AON R V AF

C2

- Pay attention to the number and the position of the adjusting plates (C2-2) for each of the skids.

- Remove the skids.

1

- Remove the mobile tube.

(C3-1).

- Remove the skids from the bottom of the jib (C3-1)

2

NTT A ON FR AV

C3 1

- Pay attention to the position of the adjusting plates (C3-2) (C3-2).

RE-INSTALLATION - Perform the above operations in reverse order: the jib base skids (C3-1) should be forcibly fitted with a hammer.

2

- If necessary, fit adjusting plates: - Plates (C3-2)  547406 The maximum play to be left between the mobile tube skids and arm 3 is 0.5mm.

55-06-21-M172EN

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