Manitou Work Platforms 120AE Repair Manual 547313 - PDF DOWNLOAD

®

BP 249 Z. I. 44 158 ANCENIS CEDEX FRANCE TEL : 02 40 09 10 11

YOUR DEALER

REF : 547313 EN (01/00)

PLATFORMS 120 AE

REPAIR MANUAL

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

DATE D'EDITION DATE PUBLICATION

01 / 2000

09 / 10 / 97 OBSERVATION OBSERVATION

- ADDING : 80-8-85-M.13 EN 80-8-86-M.13 EN - UP DATING : 0-1-M.13 EN 70-6-M.13 EN 80-6-M.13 EN 100-M.13 EN

TABLE OF CONTENTS Groups

0 0-1-M.13 EN

55 55-8-M.13 EN

70

Chapters

General points Technical characteristics

Arm - Platform Adjusting the platform overload springs

Hydraulics

70-5-M.13 EN

Hydraulic Pressure

70-6-M.13 EN

Hydraulic diagram

80 80-6-M.13 EN

Electricity Electrical diagrams

80-8-11-M.10 EN

Inspecting the SEVCON variator operation

80-8-11-M.13 EN

Variator adjustment values

80-8-81-M.13 EN

Adjusting the switches

80-8-85-M.13 EN

Manipulator assembly procedure

80-8-86-M.13 EN

Position of sensors

100

Trouble shooting

100-M.13 EN

Tracing electrical failures

GROUPS 0

GENERAL POINTS

TECHNICAL CHARACTERISTICS 120 AE 0-1-M.13 EN

01 / 2000

1

CHARACTERISTICS ELECTROPOMPE - Type

5,5 RQL 3000 - 24 - A201 BOSCH (1st assembly) 8 RQL 3000 - 24 - A201 BOSCH (2nd assembly) 24 V 3 KW 5,5 cm3 (1st assembly) 8 cm3 (2nd assembly)

- Supply - Power - Capacity

- Pressure

230 bar

WHEEL HYDRAULIC MOTORS - Type

OMSS 250 DANFOSS (1st assembly) OMTFX 250 DANFOSS (2nd assembly)

BRAKE - Type

(1st assembly) OMSS DANFOSS Hydraulic brake applied on the front wheels by loss of pressure.

(2nd assembly) OMTFX 250 INTEGRATED

ELECTRIC

CIRCUIT

- Battery - Charger - Variable speed (Type)

BOARD

24 V - 300 Ah 40 Ah REGHEL (1st assembly) TEM 10 668 24-48 SEVCON (2nd assembly)

FUSES

- General - Input - Output

10A 1A 8A

2

SPECIFICATIONS (up to machine N° 500292 excepting N° 500278) - Use

Interior and exterior

- capacity

265 Kg including 2 people

- Control system

Electro - hydraulic

- Travel speed of the access platform . Forward . Reverse

0 à 6 km/h 0 à 6 km/h

- Working height - Plateform height - Offset maxi

12200 mm 10200 mm 4900 mm

- Access platform weight . Unladen . Rated load

2300 Kg 2565 Kg

- Number of speed

3

- Maximum slope

15%

- Maximum authorized wind speed

45 km/h

- Admissible maximum tipping

5% or 3°

FRONT

AND REAR TYRES

DIMENSIONS

PRESSURE

TYRE LOAD UNLADEN

EN CHARGE MAXI

23 x 8,50

Foam

568 Kg

1700 kg

3

SPECIFICATIONS

(N°500278 and from machine N°500293)

- Use

Interior and exterior

- capacity

250 Kg including 2 people

- Weight of on-board fittings allwed: . With one person in the basket . With two persons in the basket

170 Kg 90 Kg

- Control system

Electro - hydraulic

- Travel speed of the access platform . Forward . Reverse

0 à 5 km/h 0 à 5 km/h

- Working height - Plateform height - Offset maxi

12200 mm 10200 mm 4900 mm

- Access platform weight . Unladen . Rated load

2825 Kg 3075 Kg

- Number of speed

2

- Maximum slope

25%

- Maximum authorized wind speed

45 km/h

- Admissible maximum tipping

5% or 3°

- Maximum allowed horizontal manual force

40 daN

- 1 daN = 1kg

FRONT

AND REAR TYRES

DIMENSIONS

TYRE LOAD UNLADEN

UNDER MAX.LOAD

PPS 27,10x12

1800 Kg

2500 kg

4

5

DIMENSIONS

up to N°500292 excepting N°500278

N°500278 and from N°500293

A

4800 mm

A

4800 mm

B

1870 mm

B

1870 mm

C

1800 mm

C

1800 mm

D

840 mm

D

840 mm

E

1950 mm

E

1950 mm

F

185 mm

F

150 mm

G

1750 mm

G

1750 mm

H

10200 mm

H

10200 mm

I

330 mm

I

330 mm

6

3

2

1

0

1

2

3

4

5 12

11

10

9

8

7

6

5

4

3

2

1

3

2

1

0

1

2

3

4

5

MAX. 5% or 3 7

FILTER CARTRIDGE

1

DESIGNATION 1 - Hydraulic return oil filter cartridge

PART NUMBER

CHANGE

20 507

900 H

LUBRICANTS

ORGANS TO BE LUBRICATED HYDRAULIC OIL TANK

CAPACITY

RECOMMENDATION

PACKAGING

REFERENCE

18 L

Oil MANITOU HYDRAULIQUE ISO 46

25 L.

161 588

Cartridge 400 Gr.

161 589

GENERAL GREASING

Grease SHELL RETINAX HD

GREASING OF BALL RACES

Grease SHELL ALVANIA EP LF 2

1 Kg

545 836

LUBRIFICATION OF TEETH

Oil SHELL MALLEUS GL 205

Cartridge 400 Gr.

545 834

8

GROUPS 55

ARMS - PLATFORM

ADJUSTING THE PLATFORM OVERLOAD SPRINGS 55-8-M.13 EN

10 / 1997

ADJUSTING THE PLATFORM OVERLOAD SPRINGS

This operation must be carried out when one or several springs have been dismantled.

- Adjust each spring in accordance with the dimensions stated below.

- PLATFORM 120 AE

A

B

1

GROUPS 70

HYDRAULICS

HYDRAULIC PRESSURE 120 AE 70-5-M.13 EN

10 / 1997

PRESSURE PORT 120 AE

A

BALANCING VALVE PRESSURE REDUCER

PRESSURE REDUCER (from N°500339)

BALANCING VALVE

PRESSURE RELIEF VALVE

TRAVELLING CIRCUIT (230 BAR) (Lower arm switch on) - Required tooling • 1 pressure gauge (0 - 400 bar) ...... 549885 • 1 1/4 connection .............................. 58182 • 1 test plug ........................................ 58181 • 1 test hose ..................................... 549887 - The platform must be in transport position (arms completely folded).

B

- Remove the Distributor cowl.

- Connect the pressure gauge 1 ( Fig. B) onto the distributor.

Note : For the distributors with no port A (Fig. B) connect the pressure gauge under the body of the distributor into the port B (Fig. B).

1

- Wedge the travelling (block the wheels with wedges).

- Activate and hold the travelling control as long as possible A

- Read the pressure on the pressure gauge.

M1

- Travelling circuit pressure = 230 bar

B

- If necessary, act upon the pressure relief valve (Fig. A) with the aid of a 17 mm wrench (lock nut) and a 5 mm hexagonal wrench (adjusting screw).

1

LIFTING / STEERING / ROTATION CIRCUIT (150 BAR) C : up to N° 500338 Required tooling • 1 pressure gauge (0 - 400 bar) ...............549885 • 1 connection ..........................................211689 • 1 test plug .................................................58181 • 1 test hose ..............................................549887

2

1

- Lift the lower arm. up to the machine N° 500338 - Fit the pressure gauge 1 (Fig. C) between the connection and the feed hose of the valve 2 (Fig. C) of the lower arm cylinder. from machine N° 500339 - Fit the pressure gauge 1 (Fig. C) onto the distributor.

- Bring the lower arm cylinder to a stop and read the pressure on the pressure gauge.

- Lifting/ steering / rotation circuit pressure = 150 bar

C1 : from N° 500339 1

- If necessary, act upon the pressure relief valve (Fig. A) with the aid of a 19 mm wrench (lock nut) and a 6 mm hexagonal wrench (adjusting screw).

M

BRAKE CIRCUIT 120 AE (up to the machine N° 500338) (25 BAR) - These machines are equipped with specific wheel engine / brake. A pressure relief valve is mounted on the brake feed circuit.

Required tooling • 1 pressure gauge (0-40 bar) .................549883 • 1 connection .............................................211689 • 1 test plug ......................................................58181 • 1 test hose ..................................................549887

D 1

- Lift the lower arm.

- Remove the cover from the steering cylinder.

- Lift the platform so as to release the drive wheels.

- Wedge under the chassis.

- Fit the pressure gauge 1 (Fig. D) onto the REG plug of the valve 2 (Fig D.).

2

- Activate the travelling and read the pressure on the pressure gauge.

3

- Brake circuit pressure = 25 bar.

- If necessary, act upon the adjusting screw 3 (Fig. D) of the valve 2 (Fig. D) with the aid of a 17 mm wrench (lock nut) and a 3/16 " hexagonal wrench (adjusting screw).

2

BRAKE CIRCUIT (from machine N° 500339) (25 BAR)

E

Required tooling • 1 pressure gauge (0-40 bar) .................549883 • 1 connection .............................................211689 • 1 test plug ......................................................58181 • 1 test hose ..................................................549887 - Lift the platform so as to release the drive wheels.

F1

- Wedge under the chassis.

- Open the Distributor cowl.

- Dismantle the brake hose 1 (Fig. E) at level F1 of the distributor - Fit the connection on F1 and the brake hose onto the connection.

- Fit the pressure gauge onto the connection - Activate the travelling and read the pressure on the pressure gauge.

- Break circuit pressure = 25 bar - If necessary, act upon the adjusting screw of the valve with the aid of a 17 mm wrench (lock nut) and a 3/16 mm hexagonal wrench (adjusting screw).

BALANCING VALVE ADJUSTMENT - The distributor is fitted with two balancing valves (one on each side) (See fig. A).

- The adjustment is to be carried out when one or two of the valves are changed.

- Loosen the lock nut.

- Tightly screw on the adjusting screw.

- Unscrew by three and a half times.

- Retighten the lock nut.

3

1

HYDRAULIC DIAGRAMC DIAGRAM 120 AE 70-6-M.13 EN

01 / 2000

ABBREVIATION

BC :

Pilot operated valve box

CM :

Manual control

EBD :

Differential locking element

ED :

Steering element

EF :

Brake Element

ER :

Rotating element

ET :

Travelling element

LP :

Pressure relief valve

M:

Motor

MC :

Pressure switch

MF :

Engine / Brake

MR :

Rotation motor

P:

Pump

PM :

Manual pump

R:

Valve

RD :

Flow rate regulator

RF :

Breaking Reducer

RH :

Hydraulic tank

RP :

Pressure reducer

RT :

Turning Valve

S:

Selector

V:

Valve

VB :

By-pass Valve

VD :

Steering cylinder

VDM :

Manual lowering valve

VE :

Balancing valve

VL :

Lifting valve

1

2

ROTATION STEERING

TRAVELLING LIFTING

HYDRAULIC DIAGRAM OF PLATFORM 120 AE (up to the machine N° 500113)

3

LIFTING

RH

TRAVELLING

STEERING

ROTATION

SHYDRAULIC DIAGRAM OF PLATFORM 120 AE (from N° 500114 to N°500338)

GROUPS 80

ELECTRICITY

ELECTRIC DIAGRAMS 120 AE 80-6-M.13 EN

01 / 2000

INDEX

– 120 AE (REGHEL Variator) ..................................................................................

2

Up to n° 500164

– 120 AE (SEVCON Variator) ..................................................................................

3

From n° 500167 up to n° 500458

– 120 AE (SEVCON Variator) ..................................................................................

From n° 500459

1

4

INSPECTING THE SEVCON VARIATOR OPERATION 80-8-11-M.10 EN

01 / 2000

INDEX

DESCRIPTION OF SPEED VARIATOR SEVCON MOS90......................................

3

TECHNICAL SPECIFICATIONS ..............................................................................

6

INSTALLATION.........................................................................................................

7

CONNECTION .........................................................................................................

8

CALIBRATOR ........................................................................................................... 10 1 - PRESENTATION ................................................................................................. 11 2 - ADJUSTING SETTINGS WITH THE CALIBRATOR ........................................... 11 3 - THE CALIBRATOR AS AN OPERATION CONTROL APPLIANCE .................... 12 4 - THE CALIBRATOR AS A MEASURING APPLIANCE......................................... 13 5 - DIAGNOSES ....................................................................................................... 14

1

2

DESCRIPTION OF THE SEVCON MOS90 SPEED VARIATOR

The new range of SEVCON MOS90 speed variators for direct current motors combines the latest MOSFET and MICROPROCESSOR technologies.

The MOSFET system provides a whole compact range of high efficiency variators of reduced dimensions.

In addition to the safety features that come with its operation and the simplification of the different wiring, the MICROPROCESSOR offers a number of settings which are extremely easy to adjust.

The combination of the MOSFET and the MICROPROCESSOR enables SEVCON to present a variator with outstanding reliability at the cutting edge of the technology and at the most competitive price.

The variators in the MOS90 range are available in 4 versions of different current capacities.

Each "current" version comes in a variety of presentations such as voltage, variators mounted on panels with switches etc.

The version defined in this way will have different functions adapted to the utilization of the electric vehicle via the microprocessor.

The MOS90 range comes in a compact form fully protected against all types of external aggression.

3

4

MOS90 PUMP VARIATOR

Current Product family

Option 24/48V

Type

MOS90C

Notes (1)

Mechanics

L

H

Dropout

Power connections

W

2mm

(2) CC 1 Hr

(3)

400

175

800

5 (25mm2)

140

283

62

Note

Steering switches + choice of 2 switches or CC/ FW/ PS

Notes : (1) : The limit current is measured for a maximum 60 % ON (ON = transistor conductor times, OFF = variator idle.

(2) : Single hour current whatever the ON %, provided that the variator is correctly mounted onto the chassis (Single hour current - maximum continuous current over one hour).

(3) : This is the maximum value, this current is usually adjusted to 1.5 times the limit current. Care must be taken with the permitted power for the switches and motor.

5

TECHNICAL SPECIFICATIONS

1 - SAFETY DEVICE A threefold safety system lets you check the power and thin wire operation. In the event of any anomaly, this system operates at very high speed (microprocessor).

2 - ACCELERATOR In the event of faulty wiring of the accelerator wires or an accelerator fault, the information is given in the form of a "green light flash".

3 - ACCELERATION CURVE There is no linear relationship between the position of the accelerator and the motor voltage, so as to obtain very fine control of speed at low RPM.

4 - MAXIMUM SPEED You can make an adjustment to set the maximum speed to the desired value.

5 - FLAT BATTERY PROTECTION The variator stops operating if the battery drops below 13 volts. You will then need to recycle in the neutral position.

6 - PROTECTION ON VARIATOR CONNECTIONS All variator inputs are protected from the battery + and -.

7 - TEMPERATURE PROTECTION When the variator temperature rises to 80°C, the limit current drops, to reach zero at 90°C.

9 - LED DIAGNOSIS See section on diagnosis.

6

INSTALLATION

1 - MOUNTING THE VARIATOR The variator must be screwed either onto a flat, unpainted steel sheet, or directly onto the vehicle frame, and where possible applying a thin film of grease for improved heat exchange.

2 - CABLE The power cables must be flexible and of sufficient section to take the current. The terminal connections must be either welded or crimped.

3 - SWITCHES The switches used are of the Albright brand and their type depends on the required power input.

4 - FUSE It is recommended that you fit a power fuse in series with the battery +, likewise the thin fuse fitted onto the "ignition key" line must not exceed 10 Amp.

7

POWER CIRCUIT CONNECTION

INPUTS

8

MOS 90 CONNECTION - CONTROL CIRCUIT

CONNECTOR (WIRING SIDE VIEW)

NOT USED NORMALLY OPEN

IGNITION KEY

SW8 ROTATION (Base control) FUSE 10 MAX

NOT USED SW4 LIFTING (basket control) SW2 STEERING + BATTERY SW5 TRAVELLING (arms lifted) SW1 TRAVELLING (arms lowered)

NOT USED SW4 LIFTING (base control) SW3 ROTATION (basket control) 0 - 5V LINEAR ACCELERATOR

NOT USED NOT USED NOT USED NOT USED

9

CALIBRATOR Réf. MANITOU BF : 551810

Fig. A

CALIBRATOR

(Green LED) VARIATOR

10

1 - PRESENTATION

The calibrator is connected to the variator connection 1 (Fig. A) known as the adjustment connection.

The calibrator enables the various parameters to be set numerically. The value of these parameters may be read off on the calibrator's digital display.

Thanks to the microprocessor all these parameters are entered into the variator memory.

Each parameter to be set is selected with the "SELECT" button 2 (Fig. A). The setting is adjusted upwards by pressing + 3 (Fig. A) and downwards by pressing - 4 (Fig. A).

The calibrator also enables a diagnosis to be carried out on the truck's wiring, and provides assistance with tracing faults.

No adjustment apparatus such as shunt, ammeter etc. is required.

2 - ADJUSTING SETTINGS WITH THE CALIBRATOR

- Connect the calibrator to the variator.

NOTE : The first indication on the calibrator shows the number of minutes of operation of the variator. By pressing - 4 (Fig. A) you get the time in hundreds of hours and by pressing + 3 (Fig. A) you get the time in thousands of hours.

- Select the various parameters to be set using the "SELECT" button 2 (Fig. A).

- Adjust the parameter settings by pressing + 3 (Fig. A) to increase and - 4 (Fig. A) to decrease.

ADJUSTMENT TABLE

PARAMETERS SPEED 1 SPEED 2 SPEED 3 SPEED 4 SPEED 5 SPEED 6 SPEED 7 SPEED 8

CREEP RAMP EXTRA MAX. I

DESCRIPTION

VALUE

Travelling arms lowered Steering Rotation (basket control) Lifting (basket control) Travelling arms lifted Not used Lifting (base control) Rotation (base control

100 40 25 60 30 100 40 25

Micro-speed Acceleration curve Not used Max. allowable current

0 1.00 0 400

11

3 - THE CALIBRATOR AS AN OPERATION CONTROL APPLIANCE With the calibrator connected to the variator, switch off the ignition key, use the "SELECT" button 2 (Fig. A) to move into the "TEST" position 5 (Fig. A).

SAFETY SYSTEM When the test position is displayed, the platform operates normally.

The first control is the accelerator, the display varies between 0 and 100 % when the accelerator varies from the min. to the max. position.

To select the other tests, use the + and - buttons 3 - 4 (Fig. A).

Number of tests : 10.

TEST – 1 2 3 4 5 6 7 8 9 10

FUNCTION Potentiometer Travelling arms lowered Steering Rotation (basket control) Lifting (basket control) Travelling arms lifted Not used Lifting (base control) Rotation (base control) Not used Not used

OP = OPEN CL = CLOSED

12

INDICATION 0 to 100 % OP / CL OP / CL OP / CL OP / CL OP / CL OP / CL OP / CL

4 - THE CALIBRATOR AS A MEASURING APPLIANCE

The last 5 positions on the calibrator enable it to be used as a measuring appliance.

Batt........................

Motor V..................

Motor Amp.............

Temp .....................

Test .......................

Indicates the battery voltage (by pressing + 3 (Fig. A) you get the maximum battery voltage at which the variator has been powered) Indicates the motor voltage Indicates the motor current Indicates the temperature inside the variator (by pressing + 3 (Fig. A) you get the maximum temperature at which the variator has operated) Controls the platform control function.

The battery voltage measurement can be made at any time at all, including when the truck is in operation, which means that battery voltage variations can be analysed if required.

The measurement of motor voltage during operation enables the voltage to be applied at the motor terminals to be determined for a given speed 1 or 2.

The value of this voltage, calculated as a percentage of the battery voltage, determines the setting value for speed 1 or 2.

The measurement of the truck motor current e.g. when loaded or on a ramp, can help to determine the value of the limit current to which the variator is to be set.

The temperature measurement enables the conditions in which the variator is heated - and hence the operating conditions of the truck - to be measured.

13

5 - DIAGNOSES Through utilization of the microprocessor, the variator comes equipped with a diagnostic system. This extremely straightforward system uses a green LED 6 (Fig. A) located near the calibrator connection.

- On closing the ignition key the LED should come on, and remain lit.

This means that the variator is functioning correctly.

- If the green LED 6 (Fig. A) is off, this means that : - The variator is not in a state to operate.

- The safety circuit on the variator is damaged.

- The noise suppression devices on the switches are damaged, etc.

- The fuses are damaged.

- The green LED 6 (Fig. A) may also flash on and off a certain number of times and this can happen as soon as the ignition key is closed.

2 flashes...........

Not used.

3 flashes...........

Variator power short circuited or the power circuit of the engine is open.

4 flashes...........

Not used.

5 flashes...........

Not used.

6 flashes...........

Not used.

7 flashes...........

Battery voltage lower than 13 v.

8 flashes...........

Thermal safety 80 °.

14

3 FLASHES

- Point A < 7 volts in neutral position or < 7 volts for 15 ms or switch coil short circuited.

- No driving allowed.

- Recycle in neutral position to stop the flashing.

NOTE : If this is not enough, the fault being due to the short circuit switch coil, recycle with the ignition key.

Check the power cables, look for a short circuit

Change the switches

Replace the variator

7 FLASHES

- Battery flat < 13 volts - No driving allowed.

- Recycle in neutral position to stop the flashing.

Check the battery voltage

Charge the battery

Check the power connections, fuses etc.

Repair

Check the earths Check the battery for leaks

Repair

Replace the variator

15

8 FLASHES

- Temperature safety system operation - Main radiator > 80°C cut-out at 80°C - To stop the flashing leave the variator to cool

Check the limit current

Adjust to the correct setting

Ensure that the variator is mounted onto the frame correctly

Perform correct mounting

Check that the application is correct

Use a more powerful variator

Replace the variator

GREEN LED LAMP OUT - No battery voltage - Faulty variator - Faulty LED

Check that the battery is connected and that the ignition key is closed

Correct the fault

Check that all fuses are OK

Correct the fault

Check the power supply cables

Correct the fault

Replace the variator

16

VARIATOR ADJUSTMENT VALUES 80-8-11-M.13 EN

10 / 1997

VARIATOR ADJUSTMENT VALUES : MOS 90 SEVCON

120 AE Micro MAN 4.3 SPEED : BOX Lifting

Speed 7

40%

8,5 volts

Rotation

Speed 8

35%

8 volts

Lifting

Speed 4

60%

13 volts

Rotation

Speed 3

35%

8 volts

Lifted arm traveling

Speed 5

35%

8 volts

Arm at rest traveling

Speed 1

100%

23 volts

Steering

Speed 2

50%

12 volts

Not used

Speed 6

100%

SPEED : CONSOLE

1

ADJUSTING THE SWITCHES 120 AE 80-8-81-M.13 EN

10 / 1997

INDEX

A – ADJUSTING PLATFORM OVERLOAD SWITCH .............................................

2

B – ADJUSTING THE ARM END OF TRAVEL SWITCH .......................................

2

C – ADJUSTING THE SLOPE DETECTOR .............................................................

3

1

A - ADJUSTING PLATFORM OVERLOAD SWITCH

- Turn on the platform.

Up to N° 500292 except N° 500278 - Load the platform with nominal load : 265 kg and add 10 %.

N° 500278 and from N° 500293 - Load the platform with nominal load : 250 kg and add 10 %.

- The sound alarm must operate and no platform movement is authorized.

- If necessary, act upon the adjustment screw until the sound alarm is activated.

- Do not forget to retighten the lock nut.

B - ADJUSTING THE ARM END OF TRAVEL SWITCH

B1 1

- The switch must turn on when the upper arm tilts against the pad 1 (Fig. B1).

- The adjustment consists in allowing at least 1 mm of travel between the upper part of the small wheel 2 (Fig. B2) when the latter is completely pushed in and the upper edge of the pad 3 (Fig. B2) to avoid the breaking of the switch.

- Check that the switch is operating correctly by simulating the lowered arm.

B2 2

2

3

C - ADJUSTING THE SLOPE DETECTOR

- This adjustment must be carried out when a new slope detector 1 (Fig. C1) is mounted onto the machine.

C1

- Place the platform on even ground.

1

- Lift the lower arm.

- Position a spirit level 2 adjusted at 3 ° on the front of the chassis (Fig. C2).

C2

2

- Position a jack on the front of the chassis.

- Lift the platform so as to tilt it with a 3° angle, check with the aid of a spirit level 2 (Fig. C2).

C3

- Act upon the "angle" screw 3 (Fig. C3) of the slope detector in order to turn on the red LED 4 (Fig. C3).

- The sound alarm must ring for approximately 2 seconds after turning on the red LED.

3

3

4

MANIPULATOR ASSEMBLY PROCEDURE 80-8-85-M.13 EN

01 / 2000

PROPORTIONAL MANIPULATOR

1 - Overview :

2 - Schematic diagram : 120 AE

83 73 13 23 84 74 14 24 12 17

9

8

6

5

3

2

1

Deadman pedal

3 - Potentiometer configuration :

potentiometer

Balance point

Cursor of potentiometer

potentiometer

1

4 - Manipulator internal electrical connection :

Lateral potentiometer analog output

“-” manipulator

Longitudinal potentiometer analog output

54

53

64

63

13 23

33 43 93 94

14 24

34 44

74

73

84

83

“+” manipulator

Longitudinal movement detector switch FWD or REV

Right or leftward movement detector switch

2

5 - Main connection : 120 AE

54

53

64

63

13 23

~

+

-

~

33 43

Manipulator analog signal

93 94 14 24

34 44

74

73

84

83

“+” manipulator

Rotation / Steering to right

Rotation / Steering to left

“+” to position switch

“+” after deadman pedal

Lowering / Reverse arm

Lifting / Forward arm

6 - Procedure for changing a potentiometer : A - Fit the corresponding small gear shipped on the new potentiometer.

B - Important : Carry out cursor adjustment on the balance point : place an ohmmeter between the cursor and the balance point. Turn the potentiometer rod so as to obtain 0 ohm on the ohmmeter. Mark the rod's position in relation to the potentiometer.

C - Mark the old potentiometer wiring and disassemble it (3 mounting screws).

D - Position the new potentiometer. When the manipulator is in the idle position, the potentiometer should be facing its "balance point" mark (see paragraph 3). If necessary, use the ohmmeter to recheck..

E - Wire the new potentiometer in the same way as the old one. If necessary, check the electrical diagram in this chapter..

F - You are advised to do a check with the calibrator, on the SEVCON variable speed unit (see SEVCON variable speed unit chapter). In idle position, the reading should be 0% and 100% in max. position in both directions.

3

7 - Procedure for changing the switch block A - Mark the switch block wiring and disconnect.

B - Remove the faulty switch block (4 screws at the ends). Fit the new block and wire it as before. If necessary, check the electrical diagram in this chapter.

C - This manipulation may alter the idle balance point on the potentiometers. In which case, repeat the procedure for changing a potentiometer (starting at point B).

D - Check that all 4 directions (2 axles) are being detected via the LED on the switch box main board. (see electrical diagram chapter).

4

POSITION OF THE SENSORS 120 AE 80-8-86-M.13 EN

01 / 2000

POSITION OF THE SENSORS

Foot switch : Deadman pedal

Basket overload detector switch

Slope sensor

Arm 2 folded detection switch

1

GROUPS 100

TROUBLE SHOOTING

TRACING ELECTRICAL FAULTS 120 AE 100-M.13 EN

01 / 2000

TRACING ELECTRICAL FAULTS

PROBLEM

No movement possible

POSSIBLE CAUSES

_ Is the battery disconnector activated ? _ Is the main cut-out activated ? _ Are the three fuses on the printed circuit open (make a visual check that the LEDs are on). _ Is the battery charger connection connected? _ Is the base or basket selector key control in position in the control station? _ Are the emergency stops unlocked? (make a visual check that the RAU LED is on). _ Is the RUN LED flashing ?

The siren goes on and off

_ The machine is on a slope

The siren goes on all the time

_ The platform basket is overloaded.

Certain movements are not performed

_ See table of relevant movements.

The Arm 1 does not lift in lower arm

_ Lift the arm 2 for 2 undisrupted seconds

No possible rotation

_ Lift the arm 2 for 2 undisrupted seconds

1

120 AE

TABLE OF LED STATUS BY POSSIBLE MOVEMENT (Part no. Micro MAN 4,3)

CI input

120 AE

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

Base control Lifting arm 1

1

0

0

0

0

0

0

0

0

0

0

1

1

1

1

x

x

x

x

x

Basket control Lifting arm 1

1

0

0

0

0

0

0

0

0

0

1

1

1

1

1

x

x

x

x

x

Movement

CI input R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Movement Base control Lifting arm 1

x

0

1

0

0

0

0

0

0

0

0

0

x

0

0

1

0

0

0

0

Basket control Lifting arm 1

x

0

0

0

0

0

0

0

0

0

0

0

x

0

0

1

0

0

0

1

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

0

1

0

0

0

0

0

0

0

0

x

1

x

x

x

x

x

x

x

x

CI input Movement Lowering arm 1

CI input R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Movement Lowering arm 1

0

0

0

0

0

1

0

0

0 = Platinum LED off to have movement 1 = Lit LED off to have movement X = No account taken of status 0 - 1 to have movement

2

0

0

0

0

x

0

0

1

0

0

0

0

TABLE OF LED STATUS BY POSSIBLE MOVEMENT (Part no. Micro MAN 4,3)

CI input

120 AE

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

Base control Lifting arm 2

1

0

1

0

0

0

0

0

0

0

0

1

1

x

1

x

x

x

x

x

Basket control Lifting arm 2

1

0

1

0

0

0

0

0

0

0

1

1

1

x

1

x

x

x

x

x

Movement

CI input R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Movement Base control Lifting arm 2

x

0

1

0

0

0

0

0

0

0

0

0

x

0

1

0

0

0

0

0

Basket control Lifting arm 2

x

0

0

0

0

0

0

0

0

0

0

0

x

0

1

0

0

0

0

1

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

0

1

1

0

0

0

0

0

0

0

x

1

x

x

x

x

x

x

x

x

CI input Movement Lowering arm 2

CI input R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Movement Lowering arm 2

0

0

0

0

0

1

0

0

0 = Platinum LED off to have movement 1 = Lit LED off to have movement X = No account taken of status 0 - 1 to have movement

3

0

0

0

0

x

0

1

0

0

0

0

0

TABLE OF LED STATUS BY POSSIBLE MOVEMENT (Part no. Micro MAN 4,3)

CI input

120 AE

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

x

x

x

0

1

1

0

0

0

x

1

1

x

x

x

x

x

x

x

x

Movement Left Direction

CI input R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Movement Left Direction

CI input

0

0

0

1

0

0

0

0

0

1

0

0

x

0

0

0

0

0

0

0

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

x

x

x

1

0

1

0

0

0

x

1

1

x

x

x

x

x

x

x

x

Movement Right Direction

CI input R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Movement Right Direction

0

0

0

1

0

0

0

0

0 = Platinum LED off to have movement 1 = Lit LED off to have movement X = No account taken of status 0 - 1 to have movement

4

1

0

0

x

0

0

0

0

0

0

0

0

TABLE OF LED STATUS BY POSSIBLE MOVEMENT (Part no. Micro MAN 4,3)

120 AE

CI input

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

Lowered arm extension Lowered arm extension with differential Lifted arm extension

1

0

x

x

x

1

0

0

0

0

1

1

x

1

x

x

x

x

x

x

1

0

x

x

x

1

0

0

0

1

1

1

x

1

x

x

x

x

x

x

1

0

x

x

x

1

0

0

0

x

1

1

x

0

1

x

x

x

x

x

Movement

CI input R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Movement Lowered arm extension Lowered arm extension with differential Lifted arm extension

x

0

0

0

0

0

1

0

0

0

0

0

0

0

0

0

1

0

0

0

x

0

0

0

1

0

1

0

0

0

0

0

0

0

0

0

1

0

0

0

x

0

0

0

0

0

1

0

0

0

0

0

0

0

0

0

0

1

0

0

CI input

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

Lowered arm retraction Lowered arm retraction with differential Lifted arm retraction

0

1

x

x

x

1

0

0

0

0

1

1

x

1

x

x

x

x

x

x

0

1

x

x

x

1

0

x

0

1

1

1

x

1

x

x

x

x

x

x

0

1

x

x

x

1

0

0

0

x

1

1

x

0

1

x

x

x

x

x

Movement

CI input R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Movement Lowered arm retraction Lowered arm retraction with differential Lifted arm retraction

x

0

0

0

0

0

0

1

0

0

0

0

0

0

0

0

1

0

0

0

x

0

0

0

1

0

0

1

0

0

0

0

0

0

0

0

1

0

0

0

x

0

0

0

0

0

0

1

0

0

0

0

0

0

0

0

0

1

0

0

0 = Platinum LED off to have movement 1 = Lit LED off to have movement X = No account taken of status 0 - 1 to have movement

5

TABLE OF LED STATUS BY POSSIBLE MOVEMENT (Part no. Micro MAN 4,3)

CI input

120 AE

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

Base control Left Rotation

0

0

x

0

1

0

0

0

0

0

x

1

x

0

1

x

0

x

x

x

Basket control Left Rotation

0

0

x

0

1

0

0

0

0

0

1

1

x

0

1

x

0

x

x

x

Movement

CI input R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Movement Base control Left Rotation

x

1

0

0

0

0

0

0

0

0

0

1

x

0

0

0

0

0

0

0

Basket control Left Rotation

x

0

0

0

0

0

0

0

0

0

0

1

x

0

0

0

0

0

1

0

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

Base control Right Rotation

0

0

x

1

0

0

0

0

0

0

x

1

x

0

1

x

0

x

x

x

Basket control Right Rotation

0

0

x

1

0

0

0

0

0

0

1

1

x

0

1

x

0

x

x

x

CI input Movement

CI input R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Movement Base control Right Rotation

x

1

0

0

0

0

0

0

0

0

1

0

x

0

0

0

0

0

0

0

Basket control Right Rotation

x

0

0

0

0

0

0

0

0

0

1

0

x

0

0

0

0

0

1

0

0 = Platinum LED off to have movement 1 = Lit LED off to have movement X = No account taken of status 0 - 1 to have movement

6

TRACING ELECTRICAL FAULTS

PROBLEM

No movement possible

POSSIBLE CAUSES

_ Is the battery disconnector activated ? _ Is the main cut-out activated ? _ Are the three fuses on the printed circuit open (make a visual check that the LEDs are on). _ Is the battery charger connection connected? _ Is the base or basket selector key control in position in the control station? _ Are the emergency stops unlocked? (make a visual check that the RAU LED is on). _ Is the RUN LED flashing ?

The siren goes on and off

_ The machine is on a slope

The siren goes on all the time

_ The platform basket is overloaded.

Certain movements are not performed

_ See table of relevant movements.

The Arm 1 does not lift in lower arm

_ Lift the arm 2 for 2 undisrupted seconds

No possible rotation

_ Lift the arm 2 for 2 undisrupted seconds

1

120 AE

TABLE OF LED STATUS BY POSSIBLE MOVEMENT (Part no. Micro MAN 4,4)

CI input

120 AE

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

Base control Lifting arm 1

1

0

0

0

0

0

0

0

0

0

0

1

1

1

1

x

x

x

x

x

Basket control Lifting arm 1

1

0

0

0

0

0

0

0

0

0

1

1

1

1

1

x

x

x

x

x

Movement

CI input R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Movement Base control Lifting arm 1

x

0

1

0

0

0

0

0

0

0

0

0

x

0

0

1

0

0

0

0

Basket control Lifting arm 1

x

0

0

0

0

0

0

0

0

0

0

0

x

0

0

1

0

0

0

1

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

0

1

0

0

0

0

0

0

0

0

x

1

x

x

x

x

x

x

x

x

CI input Movement Lowering arm 1

CI input R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Movement Lowering arm 1

0

0

0

0

0

1

0

0

0 = Platinum LED off to have movement 1 = Lit LED off to have movement X = No account taken of status 0 - 1 to have movement

2

0

0

0

0

x

0

0

1

0

0

0

0

TABLE OF LED STATUS BY POSSIBLE MOVEMENT (Part no. Micro MAN 4,4)

CI input

120 AE

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

Base control Lifting arm 2

1

0

1

0

0

0

0

0

0

0

0

1

1

x

1

x

x

x

x

x

Basket control Lifting arm 2

1

0

1

0

0

0

0

0

0

0

1

1

1

x

1

x

x

x

x

x

Movement

CI input R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Movement Base control Lifting arm 2

x

0

1

0

0

0

0

0

0

0

0

0

x

0

1

0

0

0

0

0

Basket control Lifting arm 2

x

0

0

0

0

0

0

0

0

0

0

0

x

0

1

0

0

0

0

1

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

0

1

1

0

0

0

0

0

0

0

x

1

x

x

x

x

x

x

x

x

CI input Movement Lowering arm 2

CI input R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Movement Lowering arm 2

0

0

0

0

0

1

0

0

0 = Platinum LED off to have movement 1 = Lit LED off to have movement X = No account taken of status 0 - 1 to have movement

3

0

0

0

0

x

0

1

0

0

0

0

0

TABLE OF LED STATUS BY POSSIBLE MOVEMENT (Part no. Micro MAN 4,4)

CI input

120 AE

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

x

x

x

0

1

1

0

0

0

x

1

1

x

x

x

x

x

x

x

x

Movement Left Direction

CI input R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Movement Left Direction

CI input

0

0

0

1

0

0

0

0

0

1

0

0

x

0

0

0

0

0

0

0

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

x

x

x

1

0

1

0

0

0

x

1

1

x

x

x

x

x

x

x

x

Movement Right Direction

CI input R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Movement Right Direction

0

0

0

1

0

0

0

0

0 = Platinum LED off to have movement 1 = Lit LED off to have movement X = No account taken of status 0 - 1 to have movement

4

1

0

0

x

0

0

0

0

0

0

0

0

TABLE OF LED STATUS BY POSSIBLE MOVEMENT (Part no. Micro MAN 4,4)

120 AE

CI input

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

Lowered arm extension Lowered arm extension with differential Lifted arm extension

1

0

x

x

x

1

0

0

0

0

1

1

x

1

x

x

x

x

x

x

1

0

x

x

x

1

0

0

0

1

1

1

x

1

x

x

x

x

x

x

1

0

x

x

x

1

0

0

0

x

1

1

x

0

1

x

x

x

x

x

Movement

CI input R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Movement Lowered arm extension Lowered arm extension with differential Lifted arm extension

x

0

0

0

0

0

1

0

0

0

0

0

0

0

0

0

1

0

0

0

x

0

0

0

1

0

1

0

0

0

0

0

0

0

0

0

1

0

0

0

x

0

0

0

0

0

1

0

0

0

0

0

0

0

0

0

0

1

0

0

CI input

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

Lowered arm retraction Lowered arm retraction with differential Lifted arm retraction

0

1

x

x

x

1

0

0

0

0

1

1

x

1

x

x

x

x

x

x

0

1

x

x

x

1

0

x

0

1

1

1

x

1

x

x

x

x

x

x

0

1

x

x

x

1

0

0

0

x

1

1

x

0

1

x

x

x

x

x

Movement

CI input R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Movement Lowered arm retraction Lowered arm retraction with differential Lifted arm retraction

x

0

0

0

0

0

0

1

0

0

0

0

0

0

0

0

1

0

0

0

x

0

0

0

1

0

0

1

0

0

0

0

0

0

0

0

1

0

0

0

x

0

0

0

0

0

0

1

0

0

0

0

0

0

0

0

0

1

0

0

0 = Platinum LED off to have movement 1 = Lit LED off to have movement X = No account taken of status 0 - 1 to have movement

5

TABLE OF LED STATUS BY POSSIBLE MOVEMENT (Part no. Micro MAN 4,4)

CI input

120 AE

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

Base control Left Rotation

0

0

x

0

1

0

0

0

0

0

x

1

x

0

1

x

0

x

x

x

Basket control Left Rotation

0

0

x

0

1

0

0

0

0

0

1

1

x

0

1

x

0

x

x

x

Movement

CI input R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Movement Base control Left Rotation

x

1

0

0

0

0

0

0

0

0

0

1

x

0

0

0

0

0

0

0

Basket control Left Rotation

x

0

0

0

0

0

0

0

0

0

0

1

x

0

0

0

0

0

1

0

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

Base control Right Rotation

0

0

x

1

0

0

0

0

0

0

x

1

x

0

1

x

0

x

x

x

Basket control Right Rotation

0

0

x

1

0

0

0

0

0

0

1

1

x

0

1

x

0

x

x

x

CI input Movement

CI input R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 Movement Base control Right Rotation

x

1

0

0

0

0

0

0

0

0

1

0

x

0

0

0

0

0

0

0

Basket control Right Rotation

x

0

0

0

0

0

0

0

0

0

1

0

x

0

0

0

0

0

1

0

0 = Platinum LED off to have movement 1 = Lit LED off to have movement X = No account taken of status 0 - 1 to have movement

6