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REPAIR MANUAL MANUEL DE RÉPARATION REPARATURANLEITUNG MANUAL DE REPARACIÓN MANUALE RIPARAZIONE This document has been printed from my e doc

MANITOU BF

Head office: 430, Rue de l’Aubinière 44150 Ancenis - FRANCE Share capital: 39,548,949 euros 857 802 508 RCS Nantes Tel: +33 (0)2 40 09 10 11 www.manitou.com

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GENERAL INSTRUCTIONS AND SAFETY NOTICE REPAIR MANUAL - CHARACTERISTICS - MRT 1540 TURBO MOT 1004 4T

1-1

ENGINE REPAIR MANUAL - ENGINE DISASSEMBLY 1004.4 /1004.4 t

2-1

TRANSMISSION REPAIR MANUAL - REAR AXLE DISASSEMBLY

3-1

AXLE ASSEMBLY - AXLE REPAIR MANUAL - REAR AXLE DISASSEMBLY

4-1

BRAKE REPAIR MANUAL - BRAKE - MRT 1540 TURBO MOT 1004 4T

5-1

TELESCOPIC BOOM REPAIR MANUAL - ARM - MRT 1540 TURBO MOT 1004 4T

6-1

HYDRAULIC REPAIR MANUAL - HYDRAULIC - MRT 1540 TURBO MOT 1004 4T

7-1

ELECTRICITY REPAIR MANUAL - ELECTRICITY - MRT 1540 TURBO MOT 1004 4T

8-1

CHARACTERISTICS 10-1-6 EN

CHARACTERISTICS CONTENTS CHAPTER PAGE CHARACTERISTICS

FROM 1 TO 44

- Instructions for the fork-lift truck operator

- Introduction

- Characteristics

- Specifications

- Control instruments (PAT DS 100)

- Capacity tables (PAT DS 100)

- Control instruments (PAT DS 100 Comfort Line)

- Capacity tables (PAT DS 100 Comfort Line)

- Control instruments (PAT DS 50 Comfort Line)

- Capacity tables (PAT DS 50 Comfort Line)

- Scheduled maintenance

● Filtering elements and belts ● Operation frequency ● Maintenance and lubrication table

● Oils - Grease - Liquids - Fuel

- Hydraulic system

29 31 31 32 33

Page 1

CHARACTERISTICS INSTRUCTIONS FOR THE FORK-LIFT TRUCK OPERATOR

REMEMBER THAT THIS SYMBOL MEANS :

WARNING: BE CAREFUL ! YOUR SAFETY IS INVOLVED OR THAT OF YOUR TRUCK

- Become familiar with the telescopic fork-lift truck on the ground where it will be used. - Transport the load in a lowered position and the telescopic arms fully retracted. - Position the arms of the forks perpendicular to the load to be lifted. - Guide the truck at a speed that is suitable for the ground conditions. - Never travel too fast nor brake suddenly while carrying a load. - When picking up a load, check that the ground is as uniform as possible. - When the load is lifted, make sure that no one can obstruct the operation and do not perform incorrect operations. - Do not try to complete operations that exceed the capacity of the fork-lift truck. - Do not lift a load that is greater than the capacity of the fork-lift truck and do not increase the size of the counterweight. - Move around obstacles. - Watch out for electric cables, trenches, recently excavated soil or backfill. - Never leave the engine running and unattended. - Use the parking brake when placing a difficult load or on sloping ground. - Never park the truck with the load lifted. - Do not allow anyone to approach or pass under a load. - Always think about safety and transport only well balanced loads. - Never lift a load using only one arm of the fork. - Drive carefully and with quick reflexes. - When the fork-lift truck is not being used, lower the fork arms to the ground and engage the parking brake. - Never leave the ignition key in the truck without a driver - Do not leave the truck loaded with the parking brake engaged on a slope that exceeds 15% . - Comply with the data indicated on the load diagrams. - Never transport another person on the fork-lift truck.

Page 2

CHARACTERISTICS INTRODUCTION Our telescopic fork-lift trucks have been designed for the sole purpose of offering the operator very simple operations and providing the mechanic with the easiest possible maintenance. However, before starting the fork-lift truck for the first time, the operator must carefully read and understand the various subjects discussed in this manual which has been prepared to help solve any operating and maintenance problem. By following these instructions, the operator will be able to take advantage of the entire potential of his telescopic fork-lift truck. The references to “right” and “left”, “forward” and “backward” are defined for a person who is sitting in the truck driver’s seat and looking straight ahead. When ordering spare parts or for all technical information, always specify the following:

MANUFACTURER’S RATING PLATE (FIG.A)

- Model - Series - Serial number - Chassis number - Year built

Fig. A ON THE COMBUSTION ENGINE (FIG.B)

- Engine number

☞ Fig. B ON THE HYDROSTATIC TRANSMISSION (FIG.C)

- MANITOU reference number - Serial number

☞ Fig. C

Page 3

CHARACTERISTICS ON THE FRONT AND REAR AXLE (FIG.D)

- Axle type and model - Serial number of the front axle - Serial number of the rear axle Fig. D

1 Axle type and model 2 Serial number

3 Lubricant

ON THE CAB (FIG.E)

Cab number

☞ Fig. E

To make it easier to indicate all these numbers, it is recommended to write them down immediately in the empty spaces shown above. Since it is MANITOU’s policy to constantly improve our products, our line of telescopic fork-lift trucks may be subjected to changes without any obligation on our behalf to provide our customers with prior notice.

Page 4

CHARACTERISTICS CARACTERISTICS ENGINE

Type Number of cylinders Number of strokes Injection system Ignition order Rocker arm clearance (cold) - Intake - Exhaust Engine displacement Bore Stroke Volume ratio Rated operating speed Idle speed Max. speed under no-load conditions Power DIN 70.020 Maximum torque

Perkins 1004-4 T 4 4 direct 1.3.4.2. 0,20 mm 0,45 mm 3990 cm3 100 mm 127 mm 16.0:1 2300 rpm 775 rpm 2475 rpm 114 CV-84 KW at 2600 rpm 349 Nm at 1800 rpm

COOLING CIRCUIT

Type Two-speed suction fan - Number of blades - Diameter Thermostat - Start opening - End opening

Water 2000 rpm < 85°C 3200 rpm ≥ 85°C 8 500 mm 75°C / 85°C 92°C / 98°C

ELECTRIC SYSTEM

Ground Battery Alternator Voltage regulator Starter

negative 12 V - 120 Ah 12 V - 55 A built into the alternator 12 V

TRANSMISSION

Type

RexRoth hydrostatic, variable displacement pump and engine

Gearbox - Number of forward gears - Number of reverse gears Gear reverser

Mechanical with hydraulic control 2 2 Electromagnetic

Page 5

CHARACTERISTICS BRAKES

Type Service brake Parking brake

disc in oil bath servo-assisted pedal, acts on the front and rear wheels hydraulic with negative drive, acts on the front axle

FRONT AXLE

Type Wheel hub reducer

steering epicycloid

REAR AXLE

Type Wheel hub reducer

steering epicycloid

FRONT AND REAR TYRES

Dimensions Inflation pressure

18 x 22,5 T35 16PR Tubeless Dunlop 5 BARS

HYDRAULIC SYSTEM

Movement circuit: Pump type Capacity at 2300 rpm Pressure Displacement

gears 120 l/min 270 bar 27+27 cm3

Lifting circuit

100 l. controlled by Danfoss distributor

I-II-III extension circuit

100 l. controlled by Danfoss distributor

Rotation circuit

65 l. controlled by Danfoss distributor

Optional circuit

65 l. controlled by Danfoss distributor

Tilting circuit

100 l. controlled by Danfoss distributor

Steering circuit Type Pressure

load-sensing 175 bar

Brake circuit Servo-assisted by the hydrostatic transmission Pressure

40 bar

Page 6

CHARACTERISTICS SPECIFICATIONS Truck maximum running speed: Forward, unladen with rated load Backward, unladen with rated load

28 Km/h 10 Km/h 28 Km/h 10 Km/h

Standard lifting height

15000 mm

Rated capacity with STD equipment:Forks

4000 Kg

Distance from the centre of gravity

500 mm

Weight of the truck with STD equipment:Forks

13040 Kg

Distribution of the weights and axle with STD equipment: Forks front axle 5900 rear axle 7140 Dimensions of the standard forks (length x width x thickness) 1200 x 125 x 50 mm Maximum gradient unladen laden

105 % 66 %

Rotation

360° continuous

Suspensions Oscillating rear axle with automatic hydraulic lock during rotation Stabilizers Type No. With individual or simultaneous control Tank capacity hydraulic and transmission oil fuel

telescopic 4

140 l. 108 l.

Page 7

CHARACTERISTICS

DIMENSIONS IN mm

Page 8

1200

290

5170

4630

1155

2320

1155

460

2410

2945

2040

1930

2400

4100

4500

200

4000

3410

4100

CHARACTERISTICS

PAT DS 100

CONTROL INSTRUMENTS

35 14 8 4

B 2

15 A

☞

☞ A

10 9

Page 9

CHARACTERISTICS

PAT DS 100

20 21 22

31 29

Page 10

CHARACTERISTICS

PAT DS 100

DESCRIPTION

1 - Driver’s seat 2 - Instrument panel 3 - Top switch console 4 - Light switch 5 - Ignition key 6 - Accelerator pedal 7 - Service brake pedal 8 - Reverser lever 9 - Hydraulic parking brake 10 - Gear lever (Slow-fast) 11 - Heater switch (OPTIONAL) 12 - Seat left arm control lever 13 - Rotation lock pin control lever 14 - Spirit level 15 - Electro-hydraulic servo-controls 16 - III Extension/optional control selector 17 - Stabilizer selection buttons 18 - Extension-return/stabilizer down-up selector 19 - Extension-return/stabilizer down-up control lever 20 - Steering type selector 21 - Rear wheel alignment - yellow lamp 22 - Front wheel alignment - green lamp 23 - Position lights - green lamp 24 - Tower alignment - green lamp 25 - Rotation lock - red lamp 26 - Stabilizers retracted - green lamp 27 - Red emergency button 28 - Rear window wiper switch 29 - Window washer liquid reservoir 30 - Ceiling lamp 31 - Rear window opening lever 32 - Ventilation outlets 33 - Cab door handle 34 - Top door locking handle 35 - Safety device control panel (OPTIONAL) 36 - Safety device exclusion key (OPTIONAL) 37 - “RESET TRANSMISSION” illuminated push-button 38 - Yellow lamp 39 - Tower rotation - yellow lamp 40 - Stabilizers extended and lowered - blue lamp 41 - Cab roof window wiper switch

Page 11

PAT DS 100

CHARACTERISTICS

CAPACITY TABLES

LOAD TABLE THE CAPACITIES REFER TO THE POSITION AND THE EXTENSION OF THE THREE SECTIONS OF THE TELESCOPIC ARM IN ORDER:

Page 12

I° - LARGE SECTION II° - INTERMEDIATE SECTION III° - SMALL SECTION

CHARACTERISTICS

PAT DS 100 PAT POSITION 1

N.B. THE CAPACITY TABLES ARE VALID ONLY IF THE SAFETY SYSTEM IS INSTALLED

Page 13

PAT DS 100

CHARACTERISTICS

PAT POSITION 1

N.B. THE CAPACITY TABLES ARE VALID ONLY IF THE SAFETY SYSTEM IS INSTALLED

Page 14

CHARACTERISTICS

PAT DS 100 PAT POSITION 1

N.B. THE CAPACITY TABLES ARE VALID ONLY IF THE SAFETY SYSTEM IS INSTALLED

Page 15

PAT DS 100 Comfort Line C H A R A C T E R I S T I C S INSTRUMENTS AND CONTROLS

2 8

4 3

23-29

37 5

16 9 12

Page 16

☞

13 30

22 21 15 A

C H A R A C T E R I S T I C S PAT DS 100 Comfort Line

11 14

Page 17

PAT DS 100 Comfort Line C H A R A C T E R I S T I C S DESCRIPTION 1 - Driver’s seat 2 - Instrument panel 3 - Upper switch console 4 - Light switch 5 - Starter key 6 - Accelerator pedal 7 - Brake pedal 8 - Reversing lever 9 - Hydraulic parking brake 10- Gearshift lever (slow-fast) 11- Heater switch 12- Left seat armrest control lever 13- Slewing lock pin control lever 14- Bubble level 15- Electro-hydraulic servo-controls 16- 3rd extension selector/optional 17- Outriggers 18- Outrigger descent-ascent/extension-retraction selector 19- Outrigger descent-ascent/extension-retraction lever 20- Steering selector 21- Rear wheel alignment warning light (yellow) 22- Front wheel alignment warning light (green) 23- Parking light warning light (green) 24- Turret alignment warning light (green) 25- Slewing lock warning light (green) 26- Outriggers retracted warning light (green) 27- Light (blue) 28- Tower rotation light (yellow) 29- Extender and lowered outriggers light (green) 30- Red emergency button 31- Window washing fluid reservoir 32- Ceiling light 33- Rear window opening lever 34- Air vents 35- Door lock 36- Top half-door lock 37- Steering wheel adjustment lock lever 38- Control panel of the safety device 39- Key to inhibit the safety device 40- Illuminated "TRANSMISSION RESET" button RECCOMENDATIONS However experienced the driver may be in this field, he must become fully familiar with the location and function of all instruments and controls before operating the lift truck. Check all instruments immediately after having started the truck when the engine has warmed up and at regular intervals during use. This will enable the driver to immediately identify any faults and to proceed with prompt remedies. If an instrument fails to give the right indication, switch off the engine and take the necessary measures in order to restore correct operation. WARNING : Use of the truck without due regard of these recommendations could be dangerous. Page 18

C H A R A C T E R I S T I C S PAT DS 100 Comfort Line LOAD CHARTS PAT POSITION 1

MRT 1540 LOAD CHART WITH FORKS

Radius in mm

LOAD CURVE THE CAPACITY VALUES REFER TO THE POSITION AND EXTENSION OF THREE TELESCOPIC BOOM SECTIONS. IN THE FOLLOWING ORDER : I LARGE SECTION II INTERMEDIATE SECTION III SMALL SECTION Page 19

PAT DS 100 Comfort Line C H A R A C T E R I S T I C S

PAT POSITION 1

MRT 1540 LOAD CHART WITH FORKS WORK AREA : FRONTAL ON TYRES

N.B. THIS LOAD CHART IS AVAILABLE ONLY WITH THE SECURITY SYSTEM INSTALLED

Page 20

C H A R A C T E R I S T I C S PAT DS 100 Comfort Line

PAT POSITION 1

MRT 1540 LOAD CHART WITH FORKS WORK AREA : THROUGH 360° ON TYRES

N.B. THIS LOAD CHART IS AVAILABLE ONLY WITH THE SECURITY SYSTEM INSTALLED

Page 21

PAT DS 100 Comfort Line C H A R A C T E R I S T I C S

PAT POSITION 1

MRT 1540 LOAD CHART WITH FORKS

WORK AREA : THROUGH 360° ON OUTRIGGERS

N.B. THIS LOAD CHART IS AVAILABLE ONLY WITH THE SECURITY SYSTEM INSTALLED

Page 22

CHARACTERISTICS

PAT DS 50 Comfort Line

INSTRUMENTS AND CONTROLS

23-29

3 15 37

22 21 15 A

16 9 12

☞

13 10

Page 23

PAT DS 50 Comfort Line

CHARACTERISTICS

11 14

Page 24

CHARACTERISTICS

PAT DS 50 Comfort Line

DESCRIPTION 1 - Driver’s seat 2 - Instrument panel 3 - Upper switch console 4 - Light switch 5 - Starter key 6 - Accelerator pedal 7 - Brake pedal 8 - Reversing lever 9 - Hydraulic parking brake 10- Gearshift lever (slow-fast) 11- Heater switch 12- Left seat armrest control lever 13- Slewing lock pin control lever 14- Bubble level 15- Electro-hydraulic servo-controls 16- 3rd extension selector/optional 17- Outriggers 18- Outrigger descent-ascent/extension-retraction selector 19- Outrigger descent-ascent/extension-retraction lever 20- Steering selector 21- Rear wheel alignment warning light (yellow) 22- Front wheel alignment warning light (green) 23- Parking light warning light (green) 24- Turret alignment warning light (green) 25- Slewing lock warning light (green) 26- Outriggers retracted warning light (green) 27- Light (blue) 28- Tower rotation light (yellow) 29- Extender and lowered outriggers light (green) 30- Red emergency button 31- Window washing fluid reservoir 32- Ceiling light 33- Rear window opening lever 34- Air vents 35- Door lock 36- Top half-door lock 37- Steering wheel adjustment lock lever 38- Control panel of the safety device 39- Key to inhibit the safety device 40- Illuminated "TRANSMISSION RESET" button RECCOMENDATIONS However experienced the driver may be in this field, he must become fully familiar with the location and function of all instruments and controls before operating the lift truck. Check all instruments immediately after having started the truck when the engine has warmed up and at regular intervals during use. This will enable the driver to immediately identify any faults and to proceed with prompt remedies. If an instrument fails to give the right indication, switch off the engine and take the necessary measures in order to restore correct operation. WARNING : Use of the truck without due regard of these recommendations could be dangerous. Page 25

PAT DS 50 Comfort Line

CHARACTERISTICS

LOAD CHARTS PAT POSITION 1

MRT 1540 LOAD CHART WITH FORKS WORK AREA : FRONTAL ON TYRES

16 15 14 13 12 11 10 9

3000 kg

2500 kg

1000 kg 1500 kg 2000 kg

800 kg

2 1 0m

0 kg

500 kg

50 kg

5 4

200 kg

4000 kg

8 7 6

14 13 12 11 10 9 8 7 6 12,50 13,1 11,50

9,50

5 4 3

2 1

4,25 6,50 5,25 7,50

N.B. THIS LOAD CHART IS AVAILABLE ONLY WITH THE SECURITY SYSTEM INSTALLED

Page 26

CHARACTERISTICS

PAT DS 50 Comfort Line

PAT POSITION 1

MRT 1540 LOAD CHART WITH FORKS WORK AREA : THROUGH 360° ON TYRES

16 15 14 13 12 11 10 9 8 2500 kg

7 6 1000 kg 1500 kg 2000 kg

500 kg

250 kg

100 kg

0 kg

2 1 0m 14 13 12 11 10 9 8 8,50 13,1

6 5 4 3 4,5 4,25

2 1

N.B. THIS LOAD CHART IS AVAILABLE ONLY WITH THE SECURITY SYSTEM INSTALLED

Page 27

CHARACTERISTICS

PAT DS 50 Comfort Line

PAT POSITION 1

MRT 1540 LOAD CHART WITH FORKS

WORK AREA : THROUGH 360° ON OUTRIGGERS

16 15 14 13 12 11 10 9 8

6 3000 kg

2250 kg

1500 kg

1000 kg

800 kg

4000 kg

2 1 0m 14 13 12 11 10 9 13,1 11,5

6 5 4 3 5,5 4,25 4,5

N.B. THIS LOAD CHART IS AVAILABLE ONLY WITH THE SECURITY SYSTEM INSTALLED

Page 28

CHARACTERISTICS SCHEDULED MAINTENANCE FILTERING ELEMENTS AND BELTS

2 1 3 4

MANITOU REFERENCE

50 H (1ST COUPON)

300 H (2ND COUPON)

PERIODIC REPLACEMENTS

1 Engine oil filter

476954

REPLACE

Every 300 H

2 Air filter cartridge £

504507

CLEAN

REPLACE

Every 450 H

3 Transmission oil filter

485 695

REPLACE

Every 450 H

4 Fuel filter cartridge

477758

REPLACE

Every 450 H

5 Hydraulic oil filter cartridge (exhaust)

485 696

REPLACE

Every 450 H

6 Hydraulic oil filter cartridge (intake)

448 273

7 Engine belt

503965

8 Hydraulic oil tank breather

448269

DESCRIPTION

Every 900 H

CHECK

Every 900 H Every 450 H

£ : In a very dusty atmosphere reduce the maintenance time interval and replace parts earlier Page 29

CHARACTERISTICS OPERATION FREQUENCY

A Every day or every 10 hours of operation

A1 - Combustion engine oil level A2 - Coolant level A3 - Clean fuel pre-filter A4 - Bleed the fuel supply circuit (if necessary)

B Every 50 hours of operation

B1 - Air filter cartridge £ B2 - Hydraulic oil and transmission level B3 - Tyre pressure and wheel lug torque setting B4 - Radiator grill B5 - Wear blocks on the telescopic arm

C Every 150 hours of operation

C1 - Alternator/crankshaft belt tension C2 - Front and rear axle differential oil level C3 - Front and rear wheel reducer oil level C4 - 2-speed reducer oil on front axle C5 - Battery C6 - Grease the telescopic arm articulation pin C7 - Grease the rapid connector articulation pin C8 - Grease the fork tilting jack head and foot pins C9 - Grease the lifting jack head and foot pins C10 - Grease the compensation jack head and foot pins C11 - Grease the cab door C12 - Grease the articulated pins (PIVOTS) on the front and rear wheels C13 - Grease the rear axle oscillation bushings C14 - Grease the transmission shaft cross and cardan C15 - Grease the front and rear stabilizer tilting jack head and foot pins + front and rear stabilizer unit pins C16 - Grease the rotation fifth wheel

D Every 300 hours of operation

D1 - Combustion engine oil D2 - Combustion engine oil filter D3 - Rotation reducer oil D4 - Fifth wheel fastening screw torque setting

E Every 450 hours of operation (See note)

E1 - Air filter cartridge E2 - Fuel filter cartridge E3 - Transmission oil filter E4 - Hydraulic oil filter cartridge (exhaust) E5 - Hydraulic oil and transmission breather E6 - Fuel supply pump

Page 30

X X X X

EMPTY

ADJUST

REPLACE

GREASE

CLEAN

ORGANI INTERESSATI

CHECK

FREQUENCY

OPERATION NO.

CHAPTER

MAINTENANCE AND LUBRICATION TABLE

X X X X X

X X X X X X X X X X

X X X X X

X X X X X X X X X X

F Every 900 hours of operation (See note)

Every 1800 hours of operation

F1 - Hydraulic and transmission oil F2 - Hydraulic oil filter cartridge (suction “rose”) F3 - Front and rear axle differential oil F4 - Front and rear wheel reducer oil F5 - 2-speed reducer oil on axle F6 - Rotation reducer oil F7 - Fuel tank F8 - Alternator/crankshaft belt - Engine valve clearance - Injectors - Alternator and starter motor - Turbocharger FOR THESE OPERATIONS CONSULT YOUR AGENT OR DEALER

EMPTY

ADJUST

REPLACE

GREASE

CLEAN

PARTS INVOLVED

CHECK

FREQUENCY

OPERATION NO.

CHAPTER

CHARACTERISTICS

X X X X X X

X X X X

X X X X X X

NOTE : To be performed once a year if the truck has not yet reached these work hours. £ : In a very dusty atmosphere reduce the maintenance time interval and replace parts earlier.

Page 31

CHARACTERISTICS SUPPLY TABLE

PARTS TO BE LUBRICATED

CAPACITY

RECOMMENDED PRODUCT oil

- COMBUSTION ENGINE

7,5L

- HYDRAULIC OIL AND TRANSMISSION TANK

140 L

- ROTATION REDUCER - FRONT AND REAR AXLE DIFFERENTIAL

3.6 L

- FRONT AXLE REDUCER - FRONT AND REAR WHEEL REDUCERS

2,8 L

11 L

1,6 L each

RIMULA X OIL 15W/40

oil SHELL TELLUS T46 oil SHELL DONAX TD

oil SHELL SPIRAX HD 80W/90

Grease - GENERAL GREASING

SHELL EP2

Grease

- TELESCOPIC ARM GREASING - ARTICULATIONS

SHELL BARBATIA GREASE4

- COOLING CIRCUIT

25 L

SHELL ANTIFREEZE

- FUEL TANK

108 L

Diesel oil

Page 32

CHARACTERISTICS HYDRAULIC SYSTEM LEGEND FOR THE MRT 1540 MOVEMENT HYDRAULIC SYSTEM 1ST VERSION M.R.T. V.B.B. V.A. C.R. L.P. P D.F. D S F.A. F.S. A A.A. P.A.A. C.S. C.S.I. C.S.II. C.S.III. C.B. C.C. V.S.P. V.S.P.D. E.S. E M.V. V.L.G.V.

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

Tower rotation motor Balancing and block valve Shock control valve Rotating hydraulic collector Pressure limiter valve Triple gear pump Flow splitter Danfoss Distributor Oil tank Intake filter Exhaust filter Winch Arm hose-winder winch Arm hose-winder winch control pump Lifting cylinder First extension cylinder Second extension cylinder Third extension cylinder Tilting cylinder Compensation cylinder Driven safety valve Double driven safety valve Selector solenoid valve Hydraulic system exclusion solenoid valve Fan hydraulic motor Fan revolution limiter valve

Page 33

MOVEMENT HYDRAULIC SYSTEM 1ST VERSION

CHARACTERISTICS

Page 34

STABILIZER SYSTEM

STEERING SYSTEM

CHARACTERISTICS

LEGEND FOR THE MRT 1540 MOVEMENT HYDRAULIC SYSTEM 2ND VERSION M.R.T. V.B.B. V.A. C.R. L.P. P D.F. D S F.A. F.R. V.A. V.L. V.T.I. V.T.II. V.T.III. V.I. V.C. C.S.P. C.S.P.D. E.S. E M.V. V.L.G.V.

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

Tower rotation motor Balancing and block valve Shock control valve Rotating hydraulic collector Pressure limiter valve Triple gear pump Flow splitter Danfoss Distributor Oil tank Intake filter Exhaust filter Attachment cylinder Lifting cylinder First extension cylinder Second extension cylinder Third extension cylinder Tilting cylinder Compensation cylinder Driven safety valve Double driven safety valve Selector solenoid valve Hydraulic system exclusion solenoid valve Fan hydraulic motor Fan revolution limiter valve

Page 35

MOVEMENT HYDRAULIC SYSTEM 2ND VERSION

CHARACTERISTICS

Page 36

STABILIZER SYSTEM

STEERING SYSTEM

CHARACTERISTICS LEGEND FOR THE STABILIZER HYDRAULIC SYSTEM C.1 C.2 C.3 C.4 C.5 C.6 C.7 C.8 S F.A. F.R. P G.E.S. L.P. C.I.R. E.S.

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

Lifting cylinder - Right front stabilizer descent Left front stabilizer extension cylinder Right front stabilizer extension cylinder Lifting cylinder - Left front stabilizer descent Lifting cylinder - Right rear stabilizer descent Left rear stabilizer extension cylinder Right rear stabilizer extension cylinder Lifting cylinder - Left rear stabilizer descent Oil tank Intake filter Exhaust filter Pump Stabilizer solenoid valve unit Pressure limiter valve Hydraulic rotation collector Stabilizer selector solenoid valve

Page 37

STABILIZER HYDRAULIC SYSTEM

CHARACTERISTICS

Page 38

CHARACTERISTICS LEGEND FOR THE STEERING HYDRAULIC SYSTEM P = F.A. = F.R. = V = E = C.R. = V.D. = P.D. =

Triple gear pump Intake filter Exhaust filter Valve Solenoid valve Hydraulic rotation collector Steering cylinders Steering pump

STEERING HYDRAULIC SYSTEM

Page 39

CHARACTERISTICS LEGEND FOR THE 17m / 23m BASKET HYDRAULIC SYSTEM C.R. P. L.P. E. E.S. S. F.A. F.R. P.S. M.R.T. V.A. V.B.B. D. C.P.D. V.R. C.P.B. C.S.P.D. V.N. V.I.

Page 40

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

Hydraulic rotation collector Triple gear pump Pressure limiter valve Hydraulic system exclusion solenoid valve Selector solenoid valve for stabilizers Oil tank Intake filter Exhaust filter Safety pump Tower rotation motor Rotation motor valve Balanced block valve Danfoss Distributor Double driven valve Basket rotation cylinder Driven block valve Double driven safety valve Basket cylinder Basket tilting cylinder

17m / 23m BASKET HYDRAULIC SYSTEM

CHARACTERISTICS

SCHEMA NUOVO

STABILIZER SYSTEM

Page 41

CHARACTERISTICS LEGEND FOR THE BRAKE/ ACCELERATOR / REAR AXLE BLOCK AND GEARBOX CONTROL HYDRAULIC SYSTEM V.B.P. V.B.P.A. F.D.A.V. F.D.A.R. M. V.C.A. P.H. C.R. V.C.L.R. V.F.P. P.F. P.C.A. P.A. R. M.C. V.S.L.R. R.C.F.P.

Page 42

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

Rear axle block valve Rear axle block cylinder Rear disc brakes Front disc brakes Combustion engine Accelerator control cylinder Hydrostatic pump Hydraulic rotation collector Slow - fast control cylinder Parking brake control cylinder Brake pedal Accelerator control pedal Accelerator pump Brake fluid reservoir Brake pump Slow - fast selector valve Parking brake control valve

BRAKE / ACCELERATOR / REAR AXLE BLOCK AND GEARBOX CONTROL HYDRAULIC SYSTEM

CHARACTERISTICS

Page 43

TRANSMISSION HYDRAULIC SYSTEM

CHARACTERISTICS

Page 44

INCHING VALVE VARIABLE DISPLACEMENT PUMP A 4 VG 71 DA VARIABLE DISPLACEMENT ENGINE A 6 VM 107 DA COOLING HYDRAULIC RESERVOIR

ENGINE DISASSEMBLY 1004.4 /1004.4 t 10-3-5/6 EN

IMPORTANT

The MRT 1540 machine is equipped with a 1004.4 T engine with a rated operating speed of 2300 rpm and a maximum of 2475 rpm. Letter code AB “Four cylinders, supercharged”. ★

★

It must be considered for all the adjustments indicated in the Manual.

REAR AXLE DISASSEMBLY 30-2-5 EN

R E PA I R M A N U A L REAR AXLE DISASSEMBLY Before mounting the rear wheels, it is possible to disassemble the rear axle while the machine remains raised using the lowered stabilizers.

- Unscrew the tightening screws of the cardan shaft flange, (Detail 1 - Photo B2/10).

B2/10

☞

- Disconnect the hydraulic hoses, right and left side, on the steering cylinder, (Detail 1 - Photo B2/11).

☞

B2/11

1 B2/12

D 17

☞

2 D 18

- Disconnect the hydraulic hose of the service brake control, (Detail 2 - Photo B2/11) and the stop bulb wiring, (Detail 1 - Photo B2/12) and the rear wheel alignment, (Detail 2 - Photo B2/12).

- Position a transpallet at the base of the differential. B2/13 - Secure the differential on a bridge crane or a hoist, placing the chains under tension.

- Unscrew the axle fastening screws, at the front and rear of the rear axle, (Detail 1 - Photo B2/13).

☞

- Remove the rear differential.

Page 1

REAR AXLE DISASSEMBLY 30-2-5 EN

R E PA I R M A N U A L REAR AXLE DISASSEMBLY Before mounting the rear wheels, it is possible to disassemble the rear axle while the machine remains raised using the lowered stabilizers.

- Unscrew the tightening screws of the cardan shaft flange, (Detail 1 - Photo B2/10).

B2/10

☞

- Disconnect the hydraulic hoses, right and left side, on the steering cylinder, (Detail 1 - Photo B2/11).

☞

B2/11

1 B2/12

D 17

☞

2 D 18

- Disconnect the hydraulic hose of the service brake control, (Detail 2 - Photo B2/11) and the stop bulb wiring, (Detail 1 - Photo B2/12) and the rear wheel alignment, (Detail 2 - Photo B2/12).

- Position a transpallet at the base of the differential. B2/13 - Secure the differential on a bridge crane or a hoist, placing the chains under tension.

- Unscrew the axle fastening screws, at the front and rear of the rear axle, (Detail 1 - Photo B2/13).

☞

- Remove the rear differential.

Page 1

UNIT 40

BRAKE

BRAKE DISASSEMBLY 40-3-M9 EN

BRAKE

NEGATIVE BRAKE NEGATIVE BRAKE CYLINDER DISASSEMBLY (Dwg. 1) Position the machine on flat surface with the combustion engine on. 1) Loosen the nut and counternut (A) 2) Pull out the screw (B) from the eyebolt (C) 3) Turn off the combustion engine 4) Disconnect the hydraulic hose (D) (Photo 2) 5) Unscrew the screw (E) 6) Remove the negative brake cylinder from the front axle 7) Lock the cylinder on the bottom side (F) in a clamp 8) Loosen the counternut (G) keeping the stem stationary (H) using a wrench 9) Unscrew the eyebolt (C) keeping the stem stationary (H) 10) Unscrew the head (I) of the cylinder 11) Pull out the spring (L) and the stem (H) 12) Replace the set of gaskets B

Dwg. 1

I C

L A

C 74

LOCTITE 270 - H F

Page 1

BRAKE NEGATIVE BRAKE CYLINDER RE-ASSEMBLY (Dwg. 1) Re-assemble the negative brake cylinder after completing repairs. 1) Lubricate the interior of the liner of the bottom side of the cylinder (F) to avoid damaging the piston gasket (M) and lock it with a clamp 2) Screw the stem (H) to the piston (M) using LOCTITE 270 3) Insert the stem (H) and the spring (L) into the bottom side of the cylinder (F) 4) Screw in the head (I) of the cylinder 5) Screw in the eyebolt (C) into the previous position keeping the stem (H) stationary 6) Connect the hydraulic hose (D) (Photo 2) and turn on the combustion engine 7) Replace the negative brake cylinder on the front axle as shown in figure 2 8) Tighten the screw (E) 9) Insert the screw (B) into the eyebolt (C) 10) Tighten the nut and lock it with the counternut (A) 11) Adjust the negative brake cylinder placing the axis of the eyebolt (C) about 72.5 mm from striker of the head (I) (see Photo 3) making sure that the two levers are resting on the limit switch screws 12) Tighten the counternut with loctite 242

Photo 2

Photo 3

☞

C 72

D 15

72,5

Page 2

BRAKE BLEEDING 40-4-M9 EN

BRAKE

BRAKE BLEEDING PROCEDURE - Connect the brake bleeder (Photo B) on the reservoir R (Detail 1 - Fig. C), located on the instrument panel; (fitting dimension = 1/4 GAS) - Disconnect the hydraulic manifold return pipes at the cabin and plug them. - Loosen the 2 bleeder screws located on the rear axle and attach the transparent hoses (Detail 1 - Photo A). - Place the brake bleeder under pressure and wait until all the air has left the transparent hoses. Re-tighten the 2 bleeder screws on the rear axle. - Repeat the same procedure the front axle. - In addition, make sure that the brake pump stroke is normal. If not, adjust the brakes for both axles (see the procedure on page 11, the AXLE DISASSEMBLY chapter).

Photo B

Photo A

☞

C 76

Page 1

BRAKE

BRAKE BLEEDING PROCEDURE Fig. C

BRAKE BLEEDER

✷ BLEED BRAKES ON HURTH AXLES

✷

C 77

Page 2

UNIT 50

ARM

TELESCOPIC ARM MACHINE DISASSEMBLY AND RE-ASSEMBLY 50-2-M9 EN

SUMMARY Removing and reinstalling the machine telescopic arm page 1-10 up to machine serial no. 112842/5701 including machine serial no. 114274/5706

Removing and reinstalling the machine telescopic arm page 13/20 starting with machine serial no. 114275/5708 including machine serial no. 114456/5705

Removing and reinstalling the machine telescopic arm page 1-10 up to machine serial no. 112842/5701 including machine serial no. 114274/5706

TELESCOPIC ARM

TELESCOPIC ARM DISASSEMBLY - Position the machine on a flat surface (do not turn off the combustion engine) and disassemble the tower rear closing plate.

- Activate the arm lifting control until it is possible to work on the pivot pin of the lifting jack on the stem-arm side, without interfering with the cab.

- Secure the arm, in the special eyebolts, with a bridge crane or a hoist.

☞

- Secure the lifting cylinder with a stand. - Unscrew the stop screws (Detail 1 - Photo A1) and remove the pin. - Rest the lifting jack on the tower and retract the stem using the control in the cab.

- Unscrew the stop screw and pull out the compensation cylinder pin (Detail 1 - Photo A2) using a puller if necessary. - Retract the stem of the tilting compensation jack using the control in the cab.

☞

- Stop the combustion engine. - Turn on the ignition key without turning on the combustion engine and perform all the control movements (Photo A3) to release the pressure in the hydraulic hoses.

A3 LEFT MANIPULATOR

E X

1 ST EX

OP T S

N E SI LE O C N TO N S IO R N O P TI O N A L

TO R W O E TA R TI O N

RIGHT MANIPULATOR N SIO N E XT ND E 2

Page 1

TELESCOPIC ARM - Turn off the ignition key and disconnect the battery terminals.

- Disassemble the clamp collar of the 1st extension jack hydraulic supply hoses (Detail 1 - Photo A4).

☞

- Remove the 0.8 metre signal proximity switch (Detail 1 A5 Photo A5). - Disassemble the clamp collar of the hydraulic hoses for the hoist supply and discharge, located in the back of the tower (Detail 2 - Photo A5).

☞

- Remove the arm return signal proximity switch (Detail 1 A6 - Photo A6). - Lower the telescopic arm to the horizontal position using the bridge crane or a hoist.

Page 2

☞

TELESCOPIC ARM - Remove the telescopic arm up limit switch signal microswitch (Detail 1 - Photo A7).

- Disconnect the arm supply hydraulic hoses from the wall entries 1-2-3-4-5-6-7-8 (Photo A8) marking them to ensure correct re-assembly (the side to start the disassembly is at the discretion of the operator).

8 642 7531

- Disconnect the hydraulic hoses 1-2 (Photo A9) from the 1st extension valve (they should be marked).

1 2

Page 3

TELESCOPIC ARM - Disassemble the clamp collar of the hoist supply and discharge hydraulic hoses (Detail 1 - Photo A8).

☞ ☞

- Disconnect the hoist supply and discharge hydraulic hoses (Detail 1 and 2 - Photo A9).

☞

Page 4

TELESCOPIC ARM - Open the box, disconnect the internal connections with A10 a special tool and pull out the electric wiring (only for the machine with a basket), (Detail 1 - Photo A10).

☞

- Disassemble the PAT winder cover, disconnect the A11 electric cable and pull it out for the entire length of the arm (Detail 1 - Photo A11).

☞

☞ - Unscrew the stop screw and pull out the pivot pin of the arm on the tower (Detail 1 - Photo A12).

A12

- Using a bridge crane or a hoist remove the arm from the seat in the tower.

☞

Page 5

TELESCOPIC ARM

TELESCOPIC ARM RE-ASSEMBLY - Using a bridge crane or a hoist, hook the arm in the special eyebolts and position it on the machine in the special tower seat.

☞

- Insert the pivot pin of the arm on the tower (Detail 1 Photo B1) and tighten the pin stop screw.

- Connect the electric cable of the PAT winder and repla- B2 ce the cover (Detail 1 - Photo B2).

☞

☞ - Insert the electric wiring into the box and re-establish all the connections with a special tool (they should be B3 marked), (Detail 1 - Photo B3).

☞

Page 6

TELESCOPIC ARM B4

☞ ☞

- Re-connect the hoist supply and discharge hydraulic hoses (Detail 1 and 2 - Photo B4).

- Replace the clamp collar for the hoist supply and discharge hydraulic hoses (Detail 1 - Photo B5). B5

- Correctly re-connect the hydraulic hoses to the 1st extension valve (Detail 1 and 2 - Photo B6).

☞

1 2

Page 7

TELESCOPIC ARM - Correctly re-connect the arm hydraulic supply hoses to B7 the wall entries 1-2-3-4-5-6-7-8 (Photo B7, the side to start the re-assembly is at the discretion of the operator).

8 642 7531

- Replace the telescopic arm up limit switch signal microswitch (Detail 1 - Photo B8).

B9 - Replace the arm return signal proximity switch (Detail 1 - Photo B9).

☞

Page 8

TELESCOPIC ARM - Lift the arm using a bridge crane or a hoist in order to B10 replace the 0.8 metre signal proximity switch (Detail 1 Photo B10). - Replace the clamp collar of the hoist supply and discharge hydraulic hoses, located in the back of the tower (Detail 2 - Photo B10).

☞ ☞

- Replace the clamp collar of the 1st extension jack hydraulic supply hoses (Detail 1 - Photo B11).

B11

- Re-connect the battery terminals and start the combustion engine. - Using the control in the cab, tilt to pull out the compensation jack stem.

B12

☞

- Insert the pivot pin in the arm (Detail 1 - Photo B12). Tighten the stop screw.

☞

Page 9

TELESCOPIC ARM - Place the lifting jack on a wooden support (Detail 1 Photo B13).

B13

- Lower the telescopic arm, using a bridge crane or a hoist, to insert the stem eyebolt into the special seat (Detail 2 - Photo B13).

- Tighten the pin stop screw (Detail 1 - Photo B14).

- Adjust the microswitches and the proximity switches that had been disassembled, following the instructions in the ELECTRICITY chapter, “PROXIMITY SWITCHES AND MICROSWITCHES” section. B14

☞

- Replace the tower rear closing plate.

Page 10

Removing and reinstalling the machine telescopic arm page 13/20 starting with machine serial no. 114275/5708 including machine serial no. 114456/5705

TELESCOPIC ARM

TELESCOPIC ARM DISASSEMBLY - Position the machine on a flat surface (do not turn off the combustion engine) and disassemble the tower rear closing plate.

- Activate the arm lifting control until it is possible to work on the pivot pin of the lifting jack on the stem-arm side, without interfering with the cab.

- Secure the arm, in the special eyebolts, with a bridge crane or a hoist.

☞

- Secure the lifting cylinder with a stand. - Unscrew the stop screws (Detail 1 - Photo A1) and remove the pin. - Rest the lifting jack on the tower and retract the stem using the control in the cab.

☞

- Stop the combustion engine. - Turn on the ignition key without turning on the combustion engine and perform all the control movements (Photo A3) to release the pressure in the hydraulic hoses.

A3 LEFT MANIPULATOR

E X

1 ST EX

OP T S

N E SI LE O C N TO N S IO R N O P TI O N A L

TO R W O E TA R TI O N

RIGHT MANIPULATOR N SIO N E XT ND E 2

Page 13

TELESCOPIC ARM - Turn off the ignition key and disconnect the battery terminals.

- Disassemble the clamp collar of the 1st extension jack hydraulic supply hoses (Detail 1 - Photo A4).

- Remove the 0.8 metre signal proximity switch (Detail 1 Photo A5).

☞

A6 - Remove the arm return signal proximity switch (Detail 1 - Photo A6). - Lower the telescopic arm to the horizontal position using the bridge crane or a hoist.

Page 14

☞

TELESCOPIC ARM A7 - Remove the telescopic arm up limit switch signal microswitch (Detail 1 - Photo A7).

A8 - Disconnect the arm supply hydraulic hoses from the wall entries 1-2-3-4-5-6-7-8 (Photo A8) marking them to ensure correct re-assembly (the side to start the disassembly is at the discretion of the operator).

8 6 4 2 7 5 3 1

A9 - Disconnect the hydraulic hoses 1-2 (Photo A9) from the 1st extension valve (they should be marked).

1 2

Page 15

TELESCOPIC ARM A10 - Open the box, disconnect the internal connections with a special tool and pull out the electric wiring (only for the machine with a basket), (Detail 1 - Photo A10).

☞

A11

- Disassemble the PAT winder cover, disconnect the electric cable and pull it out for the entire length of the arm (Detail 1 - Photo A11).

☞

☞ A12

- Unscrew the stop screw and pull out the pivot pin of the arm on the tower (Detail 1 - Photo A12). - Using a bridge crane or a hoist remove the arm from the seat in the tower.

Page 16

☞

TELESCOPIC ARM

TELESCOPIC ARM RE-ASSEMBLY - Using a bridge crane or a hoist, hook the arm in the special eyebolts and position it on the machine in the special tower seat.

☞

- Insert the pivot pin of the arm on the tower (Detail 1 Photo B1) and tighten the pin stop screw.

- Connect the electric cable of the PAT winder and repla- B2 ce the cover (Detail 1 - Photo B2).

☞

☞ - Insert the electric wiring into the box and re-establish all the connections with a special tool (they should be B3 marked), (Detail 1 - Photo B3).

☞

C 10

Page 17

TELESCOPIC ARM B4 - Correctly re-connect the hydraulic hoses to the 1st extension valve (Detail 1 and 2 - Photo B4).

1 2

B5 - Correctly re-connect the arm hydraulic supply hoses to the wall entries 1-2-3-4-5-6-7-8 (Photo B5, the side to start the re-assembly is at the discretion of the operator).

8 6 4 2 7 5 3 1

B6 - Replace the telescopic arm up limit switch signal microswitch (Detail 1 - Photo B6).

Page 18

TELESCOPIC ARM B7 - Replace the arm return signal proximity switch (Detail 1 - Photo B7).

☞

B8 - Lift the arm using a bridge crane or a hoist in order to replace the 0.8 metre signal proximity switch (Detail 1 Photo B8). - Replace the clamp collar of the hoist supply and discharge hydraulic hoses, located in the back of the tower (Detail 2 - Photo B8).

☞ ☞

B9 - Replace the clamp collar of the 1st extension jack hydraulic supply hoses (Detail 1 - Photo B9). - Re-connect the battery terminals and start the combustion engine. - Using the control in the cab, tilt to pull out the compensation jack stem.

☞

Page 19

TELESCOPIC ARM B10 - Insert the pivot pin in the arm (Detail 1 - Photo B10). Tighten the stop screw.

☞

B11 - Place the lifting jack on a wooden support (Detail 1 Photo B11). - Lower the telescopic arm, using a bridge crane or a hoist, to insert the stem eyebolt into the special seat (Detail 2 - Photo B11).

2 1

- Adjust the microswitches and the proximity switches that had been disassembled, following the instructions in the ELECTRICITY chapter, “PROXIMITY SWITCHES AND MICROSWITCHES” section.

- Replace the tower rear closing plate.

Page 20

B12

☞

- Tighten the pin stop screw (Detail 1 - Photo B12).

COMPLETE TELESCOPIC ARM DISASSEMBLY AND RE-ASSEMBLY 50-3-M9 EN

SUMMARY Removing and reinstalling the complete telescopic arm on page 1-17 up to machine serial no. 112842/5701 including machine serial no. 114274/5706

Removing and reinstalling the complete telescopic arm page 21/42 starting with machine serial no. 114275/5708 including machine serial no. 114456/5705 up to machine serial no.

124814/6535

Removing and reinstalling the complete telescopic arm page 45/68 starting with machine serial no. 124822/6536

Removing and reinstalling the complete telescopic arm on page 1-17 up to machine serial no. 112842/5701 including machine serial no. 114274/5706

TELESCOPIC ARM COMPLETE TELESCOPIC ARM DISASSEMBLY - After placing the telescopic arm on two stands, disassemble the hydraulic hose guard plate on the side of the arm.

2 - Disconnect the hydraulic hoses from the tilting jack valve at the head of the telescopic arm (Detail 1 Photo C1).

☞ ☞

- Disconnect the hydraulic hoses from the fittings of the optional at the head of the telescopic arm (Detail 2 and 3 - Photo C1).

C3 - Unscrew the valve from the 3rd extension jack at the head of the arm and disconnect the hydraulic hoses (Detail 1 - Photo C2). - Disconnect the plate wires from the wiring inside the electric box with the help of the special tool [at the head (Detail 2 - Photo C2) and in the back of the arm (Detail 1 - Photo C3)]. It is recommended to mark the wires.

☞

2 1

Page 1

TELESCOPIC ARM C4

☞

- Disassemble the hydraulic hose containing plates at the guide rollers (Detail 1 - Photo C4). - Disassemble the hydraulic hose locking plate and electric plate at the head of the arm (Detail 2 - Photo C4).

- Disassemble the guide plate of the hydraulic hoses (Detail 1 - Photo C5). - Unscrew the hydraulic hoses from the metal tubes (Detail 2 - Photo C5).

☞

2 1

☞

- Pull out the hydraulic hoses from the roller passages. - Disassemble the collars from the hose locking plate at the end of the external arm Detail 3 Photo C5).

☞

2 3

- Disconnect the hydraulic hoses located on the raceway from the metal tubes. C6 - Disassemble the brackets of the hoses located in the middle and at the end of the raceway. - Cut the clamp holding the electric plate to the hydraulic hoses (Detail 2 - Photo C6) and pull out the electric plate from the guide rollers. - Disassemble the hydraulic hose containment plate located at the end of the telescopic arm (Detail 1 - Photo C6).

Page 2

☞

2 C 38

TELESCOPIC ARM C7 - Disconnect the hydraulic hoses at the wall entries 1-23-4-5-6-7-8 (Photo C7) starting from the 1st one also disassembling the wall entries, each time, of the single hoses.

87654 3 2 1

- Remove the hydraulic hoses.

C8 - Disconnect the hydraulic hoses 1 and 2 (Photo C8) of the 2nd extension under the arm and remove them.

1 2

- Disassemble the collar clamping the hydraulic hoses of the 2nd extension under the arm (Detail 3 - Photo C8).

☞

C9 - Disconnect the hydraulic hoses 1 and 2 (Photo C9) from the valve of the 2nd extension at the end of the arm and remove them.

C 41

1 2

Page 3

TELESCOPIC ARM C 10

☞

☞ ☞

5 C 42

☞

- Make sure to mark all the blocks and any spacers that are disassembled from the telescopic arm so that they will be replaced in the correct position. 1) Disassembling the 2nd and 3rd extension

C 11

- Unscrew the six plate fastening screws (Detail 1 - Photo C11) and the lock ring (Detail 2 - Photo C11) that locks the 2nd extension jack stem. - Using a bridge crane or a hoist pull out the 2nd and the 3rd extension from the telescopic arm, placing them on two stands.

Page 4

☞

- Unscrew all the block lock screws of the 2nd extension, rear side (Detail 2 - Fig. C10). Remove the blocks of the 2nd extension, rear side.

☞

- Unscrew all the block lock screws of the 1st extension, front side (Detail 1 - Fig. C10). Remove the blocks of the 1st extension, front side.

C 43

TELESCOPIC ARM 2°) Extracting the 1st extension

C 12

☞

- Unscrew all the block lock screws of the 1st extension, rear side (Detail 4 - Fig. C10). Remove the blocks of the 1st extension, rear side.

☞

- Unscrew all the block lock screws of the external arm, front side (Detail 3 - Fig. C10). Remove the blocks of the support arm, front side.

- Disassemble the 1st extension jack guard at the head of the support arm (Detail 1 - Photo C12). - Secure the 1st extension jack to a bridge crane or a hoist. - Disassemble the Seegers (Detail 2 - Photo C12) using the special pliers and pull out the 1st extension jack pivot pins (Detail 6 and 7 - Fig. C13). Remove the 1st extension jack from the telescopic arm seat. - Using a bridge crane or a hoist pull out the 1st extension from the telescopic arm, placing in on two stands. 3) Separating the 2nd and 3rd extension - Unscrew the lock screws of the 2nd extension jack pivot pins located at the end (Detail 1 Fig. C13). Pull out the two jack pivot pins (Detail 1 - Fig. C13) using a puller if necessary. - Unscrew the lock screw of the 3rd extension jack pivot pin located at the end of the 2nd extension. Pull out the 3rd extension jack pivot pin with the 2nd extension arm (Detail 2 - Fig. C13).

C 13

6 5 7

C 45

3 1

Page 5

TELESCOPIC ARM - Unscrew all the block lock screws of the 2nd extension, front side (Detail 5 - Fig. C10). Remove the blocks of the 2nd extension, front side. - Unscrew all the block lock screws of the 3rd extension, rear side (Detail 6 - Fig. C10). Remove the blocks of the 3rd extension, rear side. - Using a bridge crane or a hoist remove the 3rd extension from the 2nd extension and place it on two stands. 4) Disassembling the jacks of the 2nd and 3rd extensions - Using the access hole to the 3rd extension arm (Detail 9 - Fig. C10) remove the 3rd extension jack pivot pin lock screw. - Pull out the pin. - Using a bridge crane or a hoist pull out the jacks of the 2nd and 3rd extension from their seat in the telescopic arm, placing them on two stands. 5) Rapid connector disassembly - Unscrew the lock screw. - Pull out the pin. - Secure the rapid connector to a bridge crane or a hoist. - Unscrew the lock screw of the rapid connector pivot pin attached to the telescopic arm. - Pull out the pin (Detail 7 - Fig. C10). - Place the rapid connector on a support. 6) Tilting jack disassembly - Using a bridge crane or a hoist, turn the 3rd extension arm 180° on the stands. - Secure the tilting jack to the bridge crane or a hoist. - Unscrew the lock screw and pull out the tilting jack pivot pin attached to the telescopic arm (Detail 5 - Fig. C13). - Pull out the jack from its seat and place it on a support.

Page 6

TELESCOPIC ARM COMPLETE TELESCOPIC ARM RE-ASSEMBLY

1 WARNING: Each time the block must be attached to the arm structure it is recommended to follow the assembly instructions described below (Fig. D1): A) insert the block (1) into the work seat. B) tighten the fastening screw (2) leaving a distance of about 4-5 mm from the work surface of the block. C) lock the screw with a self-locking nut (3).

2 C 50

4-5mm 3

arm surface

1) 3rd extension re-assembly D2

The clearance between the blocks and the elements of the arm is about 1 mm. After the adjustment, it is important to check that there is no clearance or a subsequent lock at the time the extensions return or extend.

- Rest the 3rd extension of the telescopic arm on two stands with the connector “TS” towards the top.

C 45

- Using a bridge crane or a hoist insert the tilting jack into the seat of the telescopic arm. - Insert the tilting jack pivot pin into the telescopic arm (Detail 1 - Fig. D2). - Tighten the pin lock screw. - Using a bridge crane or a hoist, turn the 3rd extension arm 180°, with the connector “TS” toward the bottom. - Mount the blocks in the top part of the 3rd extension arm, rear side (Detail 1 - Fig. D3). - Mount the blocks in the bottom part of the 2nd extension arm, front side (Detail 2 - Fig. D3) and grease the internal surfaces where the 3rd extension blocks operate.

D3 REAR

FRONT

3 2

C 46

- Using a bridge crane or a hoist insert the 3rd extension D 4 arm into the 2nd extension allowing it to project by about FRONT 0.5 metres. - Make sure that the bottom part of the 2nd extension (Detail 2 - Fig. D5) is perfectly parallel to the “TS” articulation pin (Detail 1 - Fig. D5). - Makes sure that the two rear top blocks of the 3rd extension closely adhere to the top surface of the 2nd extension.

21 34

REAR

C 46

Page 7

TELESCOPIC ARM - If necessary, shim the blocks in the bottom part of the 2nd extension arm, front side (Detail 2 - Fig. D3).

D6 REAR

FRONT

- Lock the blocks with the fastening screws.

- Center the top part of the 3rd extension in relation to the 2nd extension. Insert side blocks 1 and 2 in the top front part of the 2nd extension, shimming them if necessary and lock them (Fig. D4). Insert blocks 3 and 4, shimming them if necessary and locking them. N.B. The spacers of blocks 1, 2, 3, 4 may be different.

C 46

2 3 1

- Completely insert the 3rd extension into the 2nd extension. - Clamp the top part of the telescopic arm, rear side (Detail A - Fig. D6) to mount the bottom blocks (Detail 1 - Fig. D6), shimming if necessary.

- Lock the blocks with the fastening screws. - Loosen the clamp and, if necessary, shim the top blocks (Detail 2 - Fig. D6).

3 1

- Lock the blocks with the fastening screws. - Mount the side block shimming it, if necessary (Detail 3 - Fig. D6). D5

C 42

1 Page 8

TELESCOPIC ARM - Using a bridge crane insert the 2nd and 3rd D 8 extension jacks; WARNING: because of the cross stand (Detail 4 - Fig. D7) the cylinder must be turned slightly to make it pass through. - Grease the 3rd extension jack pivot pin (Detail 1 - Fig. D7) and insert it into the special hole in the 2nd extension arm.

FRONT

REAR

- Tighten the 3rd extension jack pivot pin lock screw. - Grease the 2nd extension jack pivot pins (Detail 2 - Fig. D7) and insert them into the special holes. - Tighten the 2nd extension jack pivot pin lock screw. - Grease the 3rd extension jack pivot pin (Detail 3 - Fig. D7) and insert it into the special hole - Tighten the 3rd extension jack pivot pin lock screw. 2) Mounting the 1st extension in the external arm - Place the blocks in the top part of the 1st extension arm, rear side (Detail 1 - Fig. D8). - Place the blocks in the lower part of the telescopic arm, front side (Detail 2 - Fig. D8) and grease the internal surfaces where the 1st extension blocks will operate. - Using a bridge crane or a hoist insert the 1st extension arm into the telescopic arm allowing it to project by about 0.5 metres. - The lower part of the 1st extension (Detail 2 - Fig. D9) must be parallel to the pivot pin of the arm to the tower (Detail 1 - Fig. D9). D9

C 42

Page 9

TELESCOPIC ARM D 9.1

Make sure that the two blocks in the top rear part of the 1st extension adhere closely to the top surFRONT face of the external arm. - Add spacers to the blocks in the front lower part of the external arm (Detail 2 - Fig. D8). Lock the blocks with the lock screws.

REAR

2 1 4 3

- Insert the blocks with interference in the top base of the telescopic arm (Detail 3 - Fig. D8). D 10

- Lock the blocks with the lock screws. - Center the top part of the 1st extension in relation to the external arm. Insert the top side blocks 1 and 2 (Fig. D9.1). Shim them if necessary and lock them. Insert blocks 3 and 4, shim them, if necessary and lock them. N.B. The spacers of blocks 1, 2, 3, 4 may be different. - Completely insert the 1st extension into the external arm.

D 11

- Clamp the top rear part of the telescopic arm (Photo D10) to mount the bottom blocks (Detail 5 - Fig. D9.1), shimming if necessary. Lock the blocks with the fastening screws.

- Using a bridge crane or a hoist insert the 1st extension jack into the special seat on the telescopic arm.

D 12

- Using a special tool mount the seegers in the seats of the pins (Detail 1 - Photo D12). - Mount the 1st extension jack guard at the head of the telescopic arm (Detail 2 - Photo D12).

Page 10

☞

- Grease the 1st extension jack pivot pins (Detail 1 and 2 - Fig. D11) and insert them into the special holes.

☞

- Mount the side block shimming it, if necessary (Detail 6 - Fig. D9.1). Lock the blocks with the lock screws.

TELESCOPIC ARM 3) Mounting the 2nd and 3rd extension into the 1st extension and external arm assembly FRONT - Place the blocks in the top part of the 2nd extension arm rear side (Detail 1 - Fig. D13). - Place the blocks in the lower part of the 1st extension arm front side (Detail 2 - Fig. D13) and grease the internal surfaces where the 2nd extension blocks will operate.

D 13 REAR

- Using a bridge crane or a hoist, insert the arm consisting of the 2nd and 3rd extension into the assembly consisting of the 1st extension and the telescopic arm.

D 15

FRONT

- Make sure that the 1st and 2nd extensions are parallel: To do so the arm pivot pin external to the tower (Detail 2 - Fig. D14) must be parallel to the 3rd extension pivot pin with “TS” (Detail 1 - Fig. D14).

REAR

2 1

- Make sure that the two blocks in the top part of the 3rd extension adhere closely to the top part of the 2nd extension. D 14

C 42

1 Page 11

TELESCOPIC ARM D 16 - Shim, if necessary, the blocks in the bottom part of the 1st extension arm, front side (Detail 1 - Fig. D15). Lock the blocks with the fastening screws. - Insert the blocks with interference in the top base of the telescopic arm (Detail 2 - Fig. D15). Lock the blocks with the fastening screws.

FRONT

21 43

REAR

6 5

- Center the 2nd extension in the 1st extension. Insert the top side blocks 1 and 2 (Fig. D16), shim them if necessary and lock them. Insert blocks 3 and 4 (Fig. D16), shim them if necessary and lock them. N.B. The spacers of blocks 1, 2, 3, 4 may be different.

D 17

D 18

- Tighten the fastening lock ring to the stem, locking it with a safety dowel. - Using the control unit make the jack stem return up to the mechanical stop between the fastening plate and the telescopic arm brackets. - Tighten the six plate fastening screws to the telescopic arm brackets (Photo D18). Page 12

C 51

TELESCOPIC ARM D 19 - Using a bridge crane insert the rapid connector in its seat on the 3rd extension. - Grease the rapid connector pivot pin with the 3rd extension (Detail 1 - Fig. D19). Tighten the jack pivot pin lock screw.

C 42

- Grease the tilting jack stem side pivot pin with rapid connector and insert it into the special hole (Detail 1 Fig. D20). Tighten the jack pivot pin lock screw.

D 20

C 45

- It is recommended to wrap the end of the hydraulic hoses of the 2nd extension jack with adhesive tape hooking also a piece of iron wire. - Insert the end of the hydraulic hoses, prepared as described above, into the rear side lower cavity between the 1st extension and the telescopic arm, until it sticks out of the opposite window located in the lower part front side in the direction of the rapid connector (Detail 1 - Photo D21).

D 21

C 43

☞ 1

Page 13

TELESCOPIC ARM - Connect the hydraulic hoses 1 and 2 (Photo D22) to the 2nd extension jack valve.

D 22

C 41

1 2

- Connect the hydraulic hoses of the 2nd extension with D 23 those that run on the raceway (Detail 2 and 3 - Photo D23). - Mount the lock clamp for the hydraulic hoses of the 2nd extension under the telescopic arm (Detail 1 Photo D23).

3 2

☞

- Connect the hydraulic hoses of the 2nd extension to wall entry 1 and 2 (Photo D24). - Mount the hydraulic hoses of the 3rd extension jack on the raceway and connect them to wall entries 3 and 4 (Photo D24). - Mount the hydraulic hoses of the tilting jack on the raceway and connect them to wall entries 5 and 6 (Photo D24): 5 directly on the stem and 6 to the bottom side. - Mount the hydraulic hoses of the optional on the raceway and connect them to wall entries 7 and 8 (Photo D24).

Page 14

D 24

1 2 3 45678 C 39

TELESCOPIC ARM - Connect the hydraulic hoses to the metal tubes making sure they remain face up: keep the metal tubes longer in the 3rd and 4th mounting position starting from the telescopic arm (Detail 1 - Photo D25).

D 25

- Lock the metal tubes to the fastening plate with the collars; keep the tubes longer above the plate (Detail 2 - Photo D25).

☞ 1

- Insert the hydraulic hoses in the guide rollers along the arm and connect them to the metal tubes.

- Mount the guide plate of the hydraulic hoses (Detail 3 - Photo D25) with the electric plate take-up roller (Detail 4 - Photo D25): it is recommended to keep the hoses pushed forward to position them correctly in their seat. Once the guide plate is attached, push the hoses until the plate (Detail 2 - Photo D25) is aligned with the hose protection raceway. - Insert the electric plate in the guide rollers along the telescopic arm.

☞

D 26

- Correctly connect the wires of the wiring plate inside the electric box located on the telescopic arm rear side with the help of the special tool (Detail 1 - Photo D26).

☞

D 27 - Mount the fastening plates of the hydraulic hoses located in the middle and at the end of the raceway, locking the electric plate (Detail 1 Photo D27). - Attach the electric plate to two hydraulic hoses with a plastic tie-wrap (Detail 2 - Photo D27).

☞

Page 15

TELESCOPIC ARM - Mount the hydraulic hose containment plate positioned on the telescopic arm rear side (Detail 1 - Photo D28).

D 28

- Attach the electric plate to two hydraulic hoses with a plastic tie-wrap (Detail 2 - Photo D28).

☞

2 C 38

- Mount the hose locking plate and electric plate on the D 29 front side of the arm keeping the hoses taut (Detail 1 Photo D29).

☞

- Replace the hydraulic hoses containment plate on the guide rollers (Detail 2 - Photo D29).

☞ 1 2

- Connect the 3rd extension jack control hydraulic hoses to the valve (Detail 1 - Photo D30): to make it easier to re-assemble the valve, the hydraulic hoses should be connected with a torque setting of 1/4 of a turn in the clockwise direction. This allows the hoses, in a bend, to move in a position that makes it easier to fasten the valve.

D 30 - Run the tilting jack and optional control hydraulic hoses above the same cylinder (Detail 3 Photo D30).

Page 16

☞

TELESCOPIC ARM - Connect the tilting jack control hydraulic hoses to the valve at the head of the telescopic arm (Detail 1 Photo D31). - Connect the hydraulic hoses to the fittings of the optional on the telescopic arm front side (Detail 2 and 3 Photo D31). - Correctly re-connect the wires of the wiring plate inside the electric box located on the telescopic arm front left side with the help of the special tool (Detail 2 Photo D30).

D 31

☞ ☞

1 3

- Wrap all the hydraulic hoses that run through the access hole of the telescopic arm front side with at least 10 cm of plastic to protect against rubbing. - Mount the hydraulic hose guard plate. WARNING Before using the machine, grease the blocks on the telescopic arm as follows: - completely extend the telescopic arm - using a brush, apply a coat of grease (see the “FILLING TABLE” in the Use and Maintenance manual) on the 4 sides of the telescopic arm (Fig. D32) - activate the telescopic arm several times to distribute the grease in a uniform manner - remove any excess grease

D 32

C 54

Page 17

Removing and reinstalling the complete telescopic arm page 21-42 starting with machine serial no. 114275/5708 including machine serial no. 114456/5705 up to machine serial no.

124814/6535

TELESCOPIC ARM COMPLETE TELESCOPIC ARM DISASSEMBLY C1 - After placing the telescopic arm on two stands, disassemble the hydraulic hose guard plate on the side of the arm.

☞ ☞

- Disconnect the hydraulic hoses from the tilting jack valve at the head of the telescopic arm (Detail 1 Photo C1).

- Disconnect the hydraulic hoses from the fittings of the optional at the head of the telescopic arm (Detail 2 and 3 - Photo C1).

C2 - Unscrew the valve from the 3rd extension jack at the head of the arm and disconnect the hydraulic hoses (Detail 1 - Photo C2).

1 1

☞

C3 - Disconnect the plate wires from the wiring inside the electric box with the help of the special tool [at the head (Detail 2 - Photo C2) and in the back of the arm (Detail 1 - Photo C3)]. It is recommended to mark the wires.

☞

Page 21

TELESCOPIC ARM C4 - Remove the collar locking the hydraulic pipes (Detail 1-Photo C4).

☞

C5 - Unscrew the chain from the support (Detail 1Photo C5).

☞ 1

- Withdraw the hydraulic pipes and electric cables from the chain support for the 3rd extension from the back (Photo C5).

- Disconnect the hydraulic pipes located in the metal pipe duct (Detail 3-Photo C6). - Remove the chain from the duct at the front (Detail 4-Photo C6).

Page 22

☞ 1

☞

- Remove the metal pipe locking collar from the securing plate (Detail 2-Photo C6).

☞

- Withdraw the electrical wires from the chain (Detail 1-Photo C6).

☞

TELESCOPIC ARM C7 - Unscrew the chain from the support at the back (Detail 1-Photo C7).

☞ 1

- Withdraw the hydraulic pipes and electric cables from the chain support for the 2nd extension from the back (Photo C7).

C8 - Remove the chain support from the 2nd extension (Detail 1-Photo C8).

☞

- Withdraw the electrical wires from the chain (Detail 1-Photo C9).

- Remove the metal pipe locking collar from the securing plate (Detail 2-Photo C9).

☞

- Disconnect the hydraulic pipes located in the metal pipe duct (Detail 3-Photo C9). - Remove the chain from the duct at the front (Detail 4-Photo C9).

☞

Page 23

TELESCOPIC ARM C 10 - Unscrew the chain from the support at the back (Detail 1-Photo C10).

☞

- Withdraw the hydraulic pipes and electric cables from the chain support for the 1st extension from the back (Photo C10).

- Withdraw the chain electric wire (Detail 1-Photo C11).

- Disconnect the hydraulic pipes located in the metal pipe duct (Detail 3-Photo C11).

☞

- Remove the chain from the duct at the front (Detail 1-Photo C12).

☞

C 11

☞

- Remove the metal pipe locking collar from the securing plate (Detail 2-Photo C11).

- Remove the hydraulic pipe securing plate located C 12 at the back of the telescopic arm (Detail 1-Photo C13).

C 13

☞

Page 24

TELESCOPIC ARM C 14 - Disconnect the hydraulic hoses at the wall entries 1-23-4-5-6-7-8 (Photo C14) starting from the 1st one also disassembling the wall entries, each time, of the single hoses.

1 2 3 45678

- Remove the hydraulic hoses.

C 15

- Disassemble the collar clamping the hydraulic hoses of the 2nd extension under the arm (Detail 3 - Photo C15).

☞

- Disconnect the hydraulic hoses 1 and 2 (Photo C15) of the 2nd extension under the arm and remove them.

12 3

C 16 - Disconnect the hydraulic hoses 1 and 2 (Photo C16) from the valve of the 2nd extension at the end of the arm and remove them.

1 2

Page 25

TELESCOPIC ARM C 17

☞

☞ ☞

☞

- Make sure to mark all the blocks and any spacers that are disassembled from the telescopic arm so that they will be replaced in the correct position. 1) Disassembling the 2nd and 3rd extension

C 18

- Unscrew the six plate fastening screws (Detail 1 - Photo C18) and the lock ring (Detail 2 - Photo C18) that locks the 2nd extension jack stem. - Using a bridge crane or a hoist pull out the 2nd and the 3rd extension from the telescopic arm, placing them on two stands.

Page 26

☞

- Unscrew all the block lock screws of the 2nd extension, rear side (Detail 2 - Fig. C17). Remove the blocks of the 2nd extension, rear side.

☞

- Unscrew all the block lock screws of the 1st extension, front side (Detail 1 - Fig. C17). Remove the blocks of the 1st extension, front side.

TELESCOPIC ARM 2°) Extracting the 1st extension

C 19

☞

- Unscrew all the block lock screws of the 1st extension, rear side (Detail 4 - Fig. C17). Remove the blocks of the 1st extension, rear side.

☞

- Unscrew all the block lock screws of the external arm, front side (Detail 3 - Fig. C17). Remove the blocks of the support arm, front side.

- Disassemble the 1st extension jack guard at the head of the support arm (Detail 1 - Photo C19). - Secure the 1st extension jack to a bridge crane or a hoist. - Disassemble the Seegers (Detail 2 - Photo C19) using the special pliers and pull out the 1st extension jack pivot pins (Detail 6 and 7 - Fig. C20). Remove the 1st extension jack from the telescopic arm seat. - Using a bridge crane or a hoist pull out the 1st extension from the telescopic arm, placing in on two stands. 3) Separating the 2nd and 3rd extension - Unscrew the lock screws of the 2nd extension jack pivot pins located at the end (Detail 1 Fig. C20). Pull out the two jack pivot pins (Detail 1 - Fig. C20) using a puller if necessary. - Unscrew the lock screw of the 3rd extension jack pivot pin located at the end of the 2nd extension. Pull out the 3rd extension jack pivot pin with the 2nd extension arm (Detail 2 - Fig. C20).

C 20

6 5 7

3 1

Page 27

TELESCOPIC ARM - Unscrew all the block lock screws of the 2nd extension, front side (Detail 5 - Fig. C17). Remove the blocks of the 2nd extension, front side. - Unscrew all the block lock screws of the 3rd extension, rear side (Detail 6 - Fig. C17). Remove the blocks of the 3rd extension, rear side. - Using a bridge crane or a hoist remove the 3rd extension from the 2nd extension and place it on two stands. 4) Disassembling the jacks of the 2nd and 3rd extensions - Using the access hole to the 3rd extension arm (Detail 9 - Fig. C17) remove the 3rd extension jack pivot pin lock screw. - Pull out the pin (Detail 3 - Fig. C20). - Using a bridge crane or a hoist pull out the jacks of the 2nd and 3rd extension from their seat in the telescopic arm, placing them on two stands. 5) Rapid connector disassembly - Unscrew the lock screw (Detail 4 - Fig. C20). - Pull out the pin (Detail 4 - Fig. C20). - Secure the rapid connector to a bridge crane or a hoist. - Unscrew the lock screw of the rapid connector pivot pin attached to the telescopic arm. - Pull out the pin (Detail 7 - Fig. C17). - Place the rapid connector on a support. 6) Tilting jack disassembly - Using a bridge crane or a hoist, turn the 3rd extension arm 180° on the stands. - Secure the tilting jack to the bridge crane or a hoist. - Unscrew the lock screw and pull out the tilting jack pivot pin attached to the telescopic arm (Detail 5 - Fig. C20). - Pull out the jack from its seat and place it on a support.

Page 28

TELESCOPIC ARM COMPLETE TELESCOPIC ARM RE-ASSEMBLY

2 4-5mm 3

arm surface

1) 3rd extension re-assembly D2

- Rest the 3rd extension of the telescopic arm on two stands with the connector “TS” towards the top. - Using a bridge crane or a hoist insert the tilting jack into the seat of the telescopic arm. - Insert the tilting jack pivot pin into the telescopic arm (Detail 1 - Fig. D2). - Tighten the pin lock screw. - Using a bridge crane or a hoist, turn the 3rd extension arm 180°, with the connector “TS” toward the bottom. - Mount the blocks in the top part of the 3rd extension arm, rear side (Detail 1 - Fig. D3). - Mount the blocks in the bottom part of the 2nd extension arm, front side (Detail 2 - Fig. D3) and grease the internal surfaces where the 3rd extension blocks operate.

D3 FRONT

REAR

3 2

REAR

21 34

Page 29

TELESCOPIC ARM - If necessary, shim the blocks in the bottom part of the 2nd extension arm, front side (Detail 2 - Fig. D3).

D6 FRONT

REAR

- Lock the blocks with the fastening screws. - Center the top part of the 3rd extension in relation to the 2nd extension. Insert side blocks 1 and 2 in the top front part of the 2nd extension, shimming them if necessary and lock them (Fig. D4). Insert blocks 3 and 4, shimming them if necessary and locking them. N.B. The spacers of blocks 1, 2, 3, 4 may be different.

- Lock the blocks with the fastening screws. - Loosen the clamp and, if necessary, shim the top blocks (Detail 2 - Fig. D6).

3 1

2 - Lock the blocks with the fastening screws. - Mount the side block shimming it, if necessary (Detail 3 - Fig. D6). D5

1 Page 30

FRONT

REAR

Page 31

TELESCOPIC ARM D 9.1

REAR

2 1 4 3

- Insert the blocks with interference in the top base of the telescopic arm (Detail 3 - Fig. D8). D 10

D 11

- Clamp the top rear part of the telescopic arm (Photo D10) to mount the bottom blocks (Detail 5 - Fig. D9.1), shimming if necessary. Lock the blocks with the fastening screws.

- Using a bridge crane or a hoist insert the 1st extension jack into the special seat on the telescopic arm.

D 12

- Using a special tool mount the seegers in the seats of the pins (Detail 1 - Photo D12). - Mount the 1st extension jack guard at the head of the telescopic arm (Detail 2 - Photo D12).

Page 32

☞

- Grease the 1st extension jack pivot pins (Detail 1 and 2 - Fig. D11) and insert them into the special holes.

☞

- Mount the side block shimming it, if necessary (Detail 6 - Fig. D9.1). Lock the blocks with the lock screws.

D 13 REAR

- Using a bridge crane or a hoist, insert the arm consisting of the 2nd and 3rd extension into the assembly consisting of the 1st extension and the telescopic arm. - Make sure that the 1st and 2nd extensions are parallel: To do so the arm pivot pin external to the tower (Detail 2 - Fig. D14) must be parallel to the 3rd extension pivot pin with “TS” (Detail 1 - Fig. D14).

D 15

FRONT

REAR

2 1

- Make sure that the two blocks in the top part of the 3rd extension adhere closely to the top part of the 2nd extension. D 14

1 Page 33

FRONT

21 43

REAR

6 5

D 17

- Using a fork-lift truck (Photo D17) lift the top part of the telescopic arm rear side to mount the bottom blocks, shimming if necessary (Detail 5 - Fig. D16). Lock the blocks with the fastening screws. - Mount the side block, shimming it if necessary (Detail 6 - Fig. D16). Lock the blocks with the fastening screws. - Connect a special electro-hydraulic control unit to the 2nd extension jack valve with two hydraulic hoses. - Using the control unit pull out the stem of the jack until it is possible to mount the fastening plate with the 21st extension arm. - Tighten the fastening lock ring to the stem, locking it with a safety dowel. - Using the control unit make the jack stem return up to the mechanical stop between the fastening plate and the telescopic arm brackets. - Tighten the six plate fastening screws to the telescopic arm brackets (Photo D18). - Using a bridge crane insert the rapid connector in its Page 34

D 18

TELESCOPIC ARM D 19

seat on the 3rd extension. - Grease the rapid connector pivot pin with the 3rd extension (Detail 1 - Fig. D19). Tighten the jack pivot pin lock screw. - Grease the tilting jack stem side pivot pin with rapid connector and insert it into the special hole (Detail 1 Fig. D20). Tighten the jack pivot pin lock screw. - Install the hydraulic pipe duct on the outer arm (Detail 1Fig D21).

D 22

D 20

D 21

☞ 1

Page 35

TELESCOPIC ARM D 23 - Connect the hydraulic hoses 1 and 2 (Photo D23) to the 2nd extension jack valve.

1 2

D 24

☞

- Connect the hydraulic hoses of the 2nd extension with those that run on the raceway (Detail 2 and 3 - Photo D24). - Mount the lock clamp for the hydraulic hoses of the 2nd extension under the telescopic arm (Detail 1 Photo D24).

23 1

D 25 - Connect the hydraulic hoses of the 2nd extension to wall entry 1 and 2 (Photo D25). - Insert the hydraulic pipes for the 3rd extension jack into the duct and hook them up to wall entry 3 and 4 (Photo D25). - Insert the hydraulic pipes for the swing cylinder into the duct and hook them up to wall entry 5 and 6 (Photo D25): 5 runs directly to the rod, 6 to the bottom. - Insert the electric wire into the duct. - Insert the hydraulic pipes for the optional into the duct and hook them up to wall entry 7 and 8 (Photo D25). Page 36

1 2 3 45678

TELESCOPIC ARM D 26 - At the bench, insert the hydraulic pipes into the chain (Photo D26).

D 27 - Install the chain on the duct and lock it at the front (Detail 1-Photo D27).

☞

D 28

☞ ☞

- Hook up the hydraulic pipes in the duct to the metal pipes and run them upward alternating the upper ones with the lower ones (Detail 1-Photo D28).

- Hook up the hydraulic pipes inside the chain to the metal pipes (Photo D28). - Lock the metal pipes to the securing plate using the collars (Detail 2-Photo D28).

☞

- Insert the electric wire into the chain (Photo D28). - Bind the electric wire to the metal pipe (Detail 3-Photo D28).

Page 37

TELESCOPIC ARM D 29 - Insert the hydraulic pipes and electric cables into the chain support for the 1st extension from the back (Photo D29).

☞ 1

- Screw down the chain to the support (Detail 1Photo D29).

D 30 - At the bench, insert the hydraulic pipes into the chain (Photo D30).

- Hook up the hydraulic pipes inside the chain to the metal pipes (Photo D31). - Lock the metal pipes to the securing plate using the collars (Detail 3-Photo D31). - Insert the electric wire into the chain (Photo D31). - Bind the electric wire to the metal pipe (Detail 4-Photo D31). Page 38

☞ ☞

☞

- Install the chain on the support, locking it at the front (Detail 1-Photo D31). D 31 - Hook up the hydraulic pipes in the support to the 1 metal pipes and run them upward alternating the upper ones with the lower ones (Detail 2-Photo D31).

☞

TELESCOPIC ARM D 32 - Install the chain support on the 2nd extension (Detail 1-Photo D32).

☞ D 33 - Insert the hydraulic pipes and electric cables into the chain support for the 2nd extension from the back (Photo D33).

☞ 1

- Screw down the chain to the support (Detail 1Photo D33).

D 34 - At the bench, insert the hydraulic pipes into the chain (Photo D34).

Page 39

TELESCOPIC ARM D 35 - Install the chain in the duct, locking it at the front (Detail 1-Photo D35).

☞

- Hook up the hydraulic pipes in the duct to the metal pipes and run them upward alternating the upper ones with the lower ones (Detail 2-Photo D35).

1 3

☞

- Hook up the hydraulic pipes inside the chain to the metal pipes (Photo D35). - Lock the first two metal pipes to the securing plate using the collars (Detail 3-Photo D35). - Insert the electric wire into the chain (Photo D35). D 36

☞

- Insert the hydraulic pipes and electric cables into the chain support for the 3rd extension from the back (Photo D36).

- Screw down the chain to the support (Detail 1Photo D36). - Install the hydraulic pipe securing collar without tightening the screws (Detail 1-Photo D37). - Hook up the hydraulic pipes controlling the 3rd extension jack to the valve (Detail 1-Photo D38): to facilitate valve installation the hydraulic pipes should be connected by turning 1/4 revolution clockwiD 37 se; in this manner the curve in the pipes facilitates securing the valve.

☞

D 38

☞

Page 40

TELESCOPIC ARM D 39 - Mount the hydraulic hose containment plate positioned on the telescopic arm rear side (Detail 1 Photo D39).

- Run the tilting jack and optional control hydraulic hoses above the same cylinder (Detail 1 - Photo D40). - Correctly re-connect the wires of the wiring plate D 40 inside the electric box located on the telescopic arm front left side with the help of the special tool (Detail 2 - Photo D40).

- Correctly re-connect the wires of the wiring plate inside the electric box located on the telescopic arm rear side with the help of the special tool (Detail 1-Photo D41).

☞

- Connect the tilting jack control hydraulic hoses to the valve at the head of the telescopic arm (Detail 1 - Photo D42). - Connect the hydraulic hoses to the fittings of the optional on the telescopic arm front side (Detail 2 and D 41 3 - Photo D42).

D 42

☞

☞ ☞

1 3

Page 41

TELESCOPIC ARM D 43

☞ ☞ ☞

- Wrap all the hydraulic hoses that run through the access hole of the telescopic arm front side with at least 10 cm of plastic to protect against rubbing.

- Tighten the hydraulic pipe securing collar (Detail 1-Photo D43). - Lock the metal pipes to the securing plate using the collars (Detail 2-Photo D43).

☞ 3

- Bind the electric wire to the metal pipe (Detail 3Photo D43).

WARNING Before using the machine, grease the blocks on the telescopic arm as follows: - completely extend the telescopic arm - using a brush, apply a coat of grease (see the “FILLING TABLE” in the Use and Maintenance manual) on the 4 sides of the telescopic arm (Fig. D44) - activate the telescopic arm several times to distribute the grease in a uniform manner - remove any excess grease

D 44

Page 42

Removing and reinstalling the complete telescopic arm page 45-68 starting with machine serial no. 124822/6536

TELESCOPIC ARM COMPLETE TELESCOPIC ARM DISASSEMBLY C1 - After placing the telescopic arm on two stands, disassemble the hydraulic hose guard plate on the side of the arm.

☞ ☞

- Disconnect the hydraulic hoses from the tilting jack valve at the head of the telescopic arm (Detail 1 Photo C1).

- Disconnect the hydraulic hoses from the fittings of the optional at the head of the telescopic arm (Detail 2 and 3 - Photo C1).

C2 - Unscrew the valve from the 3rd extension jack at the head of the arm and disconnect the hydraulic hoses (Detail 1 - Photo C2).

1 1

☞

Page 45

TELESCOPIC ARM C4 - Remove the collar locking the hydraulic pipes (Detail 1-Photo C4).

☞

C5 - Unscrew the chain from the support (Detail 1Photo C5).

☞ 1

- Withdraw the hydraulic pipes and electric cables from the chain support for the 3rd extension from the back (Photo C5).

C6 - Remove the chain support from the 3rd extension (Detail 1-Photo C6).

☞

Page 46

TELESCOPIC ARM C7 - Withdraw the electrical wires from the chain (Detail 1-Photo C7).

- Disconnect the hydraulic pipes located in the metal pipe duct (Detail 3-Photo C7).

☞ 1

☞

- Remove the metal pipe locking collar from the securing plate (Detail 2-Photo C7).

4 2

☞

- Remove the chain from the duct at the front (Detail 4-Photo C7).

C8 - Unscrew the chain from the support at the back (Detail 1-Photo C8).

☞ 1

- Withdraw the hydraulic pipes and electric cables from the chain support for the 2nd extension from the back (Photo C8).

C9 - Remove the chain support from the 2nd extension (Detail 1-Photo C9).

☞

Page 47

TELESCOPIC ARM C 10

☞

- Remove the metal pipe locking collar from the securing plate (Detail 2-Photo C10).

☞

- Withdraw the electrical wires from the chain (Detail 1-Photo C10).

☞

- Disconnect the hydraulic pipes located in the metal pipe duct (Detail 3-Photo C10). - Remove the chain from the duct at the front (Detail 4-Photo C10).

C 11 - Unscrew the chain from the support at the back (Detail 1-Photo C11).

☞

- Withdraw the hydraulic pipes and electric cables from the chain support for the 1st extension from the back (Photo C11).

C 12 - Remove the chain support from the 1st extension (Detail 1-Photo C12).

☞ 1

Page 48

TELESCOPIC ARM C 13

- Remove the metal pipe locking collar from the securing plate (Detail 2-Photo C13).

☞

- Withdraw the chain electric wire (Detail 1-Photo C13).

☞

- Disconnect the hydraulic pipes located in the metal pipe duct (Detail 3-Photo C13).

C 14 - Remove the chain from the duct at the front (Detail 1-Photo C14).

☞

C 15 - Remove the hydraulic pipe securing plate located at the back of the telescopic arm (Detail 1Photo C15).

Page 49

TELESCOPIC ARM C 16 - Disconnect the hydraulic hoses at the wall entries 1-23-4-5-6-7-8 (Photo C16) starting from the 1st one also disassembling the wall entries, each time, of the single hoses.

1 2 3 45678

- Remove the hydraulic hoses.

C 17 - Disconnect the hydraulic hoses 1 and 2 (Photo C17) of the 2nd extension under the arm and remove them.

☞

- Disassemble the collar clamping the hydraulic hoses of the 2nd extension under the arm (Detail 3 - Photo C17).

12 3

C 18 - Disconnect the hydraulic hoses 1 and 2 (Photo C18) from the valve of the 2nd extension at the end of the arm and remove them.

1 2

Page 50

TELESCOPIC ARM C 19

☞

☞ ☞

☞

- Make sure to mark all the blocks and any spacers that are disassembled from the telescopic arm so that they will be replaced in the correct position. 1) Disassembling the 2nd and 3rd extension

C 20

☞

- Unscrew all the block lock screws of the 2nd extension, rear side (Detail 2 - Fig. C17). Remove the blocks of the 2nd extension, rear side.

☞

- Unscrew all the block lock screws of the 1st extension, front side (Detail 1 - Fig. C17). Remove the blocks of the 1st extension, front side.

Page 51

TELESCOPIC ARM 2°) Extracting the 1st extension

C 21

☞

- Unscrew all the block lock screws of the 1st extension, rear side (Detail 4 - Fig. C17). Remove the blocks of the 1st extension, rear side.

☞

- Unscrew all the block lock screws of the external arm, front side (Detail 3 - Fig. C17). Remove the blocks of the support arm, front side.

C 22

6 5 7

3 1

Page 52

Page 53

TELESCOPIC ARM COMPLETE TELESCOPIC ARM RE-ASSEMBLY

2 4-5mm 3

superficie del braccio

1) 3rd extension re-assembly D2

- Using a bridge crane or a hoist, turn the 3rd extension arm 180°, with the connector “TS” toward the bottom.

ANTERIORE

POSTERIORE

3 2

- Mount the blocks in the top part of the 3rd extension arm, rear side (Detail 1 - Fig. D3). - Mount the blocks in the bottom part of the 2nd extension arm, front side (Detail 2 - Fig. D3) and grease the internal surfaces where the 3rd extension blocks operate.

- Using a bridge crane or a hoist insert the 3rd extension D 4 arm into the 2nd extension allowing it to project by about ANTERIORE 0.5 metres. - Make sure that the bottom part of the 2nd extension (Detail 2 - Fig. D5) is perfectly parallel to the “TS” articulation pin (Detail 1 - Fig. D5). - Makes sure that the two rear top blocks of the 3rd extension closely adhere to the top surface of the 2nd extension. Page 54

21 34

POSTERIORE

TELESCOPIC ARM - If necessary, shim the blocks in the bottom part of the 2nd extension arm, front side (Detail 2 - Fig. D3).

D6 ANTERIORE

POSTERIORE

- Lock the blocks with the fastening screws. - Loosen the clamp and, if necessary, shim the top blocks (Detail 2 - Fig. D6).

3 1

2 - Lock the blocks with the fastening screws. - Mount the side block shimming it, if necessary (Detail 3 - Fig. D6). D5

1 Page 55

TELESCOPIC ARM - Using a bridge crane insert the 2nd and 3rd D 8 extension jacks; ANTERIORE WARNING: because of the cross stand (Detail 4 - Fig. D7) the cylinder must be turned slightly to make it pass through. - Grease the 3rd extension jack pivot pin (Detail 1 - Fig. D7) and insert it into the special hole in the 2nd extension arm.

POSTERIORE

Page 56

TELESCOPIC ARM D 9.1

Make sure that the two blocks in the top rear part of the 1st extension adhere closely to the top surANTERIORE face of the external arm. - Add spacers to the blocks in the front lower part of the external arm (Detail 2 - Fig. D8). Lock the blocks with the lock screws.

POSTERIORE

2 1 4 3

- Insert the blocks with interference in the top base of the telescopic arm (Detail 3 - Fig. D8). D 10

D 11

- Clamp the top rear part of the telescopic arm (Photo D10) to mount the bottom blocks (Detail 5 - Fig. D9.1), shimming if necessary. Lock the blocks with the fastening screws.

- Using a bridge crane or a hoist insert the 1st extension jack into the special seat on the telescopic arm.

D 12

- Using a special tool mount the seegers in the seats of the pins (Detail 1 - Photo D12).

☞

- Grease the 1st extension jack pivot pins (Detail 1 and 2 - Fig. D11) and insert them into the special holes.

☞

- Mount the side block shimming it, if necessary (Detail 6 - Fig. D9.1). Lock the blocks with the lock screws.

- Mount the 1st extension jack guard at the head of the telescopic arm (Detail 2 - Photo D12).

Page 57

TELESCOPIC ARM 3) Mounting the 2nd and 3rd extension into the 1st extension and external arm assembly ANTERIORE - Place the blocks in the top part of the 2nd extension arm rear side (Detail 1 - Fig. D13). - Place the blocks in the lower part of the 1st extension arm front side (Detail 2 - Fig. D13) and grease the internal surfaces where the 2nd extension blocks will operate.

D 15

ANTERIORE

POSTERIORE

2 1

- Make sure that the two blocks in the top part of the 3rd extension adhere closely to the top part of the 2nd extension. D 14

1 Page 58

POSTERIORE

D 13

ANTERIORE

21 43

POSTERIORE

6 5

D 17

D 18

TELESCOPIC ARM D 19

D 22

D 20

D 21

☞ 1

Page 60

TELESCOPIC ARM D 23 - Connect the hydraulic hoses 1 and 2 (Photo D23) to the 2nd extension jack valve.

1 2

D 24

☞

23 1

1 2 3 45678

- Insert the hydraulic pipes for the swing cylinder into the duct and hook them up to wall entry 5 and 6 (Photo D25): 5 runs directly to the rod, 6 to the bottom. - Insert the electric wire into the duct. - Insert the hydraulic pipes for the optional into the duct and hook them up to wall entry 7 and 8 (Photo D25). Page 61

TELESCOPIC ARM D 26 - At the bench, insert the hydraulic pipes into the chain (Photo D26).

D 27 - Install the chain on the duct and lock it at the front (Detail 1-Photo D27).

☞

D 28

☞ ☞

- Hook up the hydraulic pipes in the duct to the metal pipes and run them upward alternating the upper ones with the lower ones (Detail 1-Photo D28).

- Hook up the hydraulic pipes inside the chain to the metal pipes (Photo D28). - Lock the metal pipes to the securing plate using the collars (Detail 2-Photo D28). - Insert the electric wire into the chain (Photo D28). - Bind the electric wire to the metal pipe (Detail 3-Photo D28).

Page 62

☞

TELESCOPIC ARM D 29 - Install the chain support on the 1st extension (Detail 1-Photo D29).

☞ 1

D 30 - Insert the hydraulic pipes and electric cables into the chain support for the 1st extension from the back (Photo D30).

☞

- Screw down the chain to the support (Detail 1Photo D30).

- At the bench, insert the hydraulic pipes into the chain (Photo D31).

D 31

Page 63

TELESCOPIC ARM D 32 - Install the chain on the support, locking it at the front (Detail 1-Photo D32).

☞ ☞

☞

- Hook up the hydraulic pipes in the support to the metal pipes and run them upward alternating the upper ones with the lower ones (Detail 2-Photo D32).

1 3

☞

- Hook up the hydraulic pipes inside the chain to the metal pipes (Photo D32). - Lock the metal pipes to the securing plate using the collars (Detail 3-Photo D32). - Insert the electric wire into the chain (Photo D32). - Bind the electric wire to the metal pipe (Detail 4Photo D32).

D 33

- Install the chain support on the 2nd extension (Detail 1-Photo D33).

☞ D 34

☞

- Insert the hydraulic pipes and electric cables into the chain support for the 2nd extension from the back (Photo D34).

- Screw down the chain to the support (Detail 1Photo D34).

Page 64

TELESCOPIC ARM D 35 - At the bench, insert the hydraulic pipes into the chain (Photo D35).

D 36

☞

- Hook up the hydraulic pipes in the duct to the metal pipes and run them upward alternating the upper ones with the lower ones (Detail 2-Photo D36).

☞

- Install the chain in the duct, locking it at the front (Detail 1-Photo D36).

☞

- Hook up the hydraulic pipes inside the chain to the metal pipes (Photo D36). - Lock the first two metal pipes to the securing plate using the collars (Detail 3-Photo D36). - Insert the electric wire into the chain (Photo D36). D 37 - Install the chain support on the 3rd extension (Detail 1-Photo D37).

☞

Page 65

TELESCOPIC ARM D 38 - Insert the hydraulic pipes and electric cables into the chain support for the 3rd extension from the back (Photo D38).

☞ 1

- Screw down the chain to the support (Detail 1Photo D38).

D 39 - Install the hydraulic pipe securing collar without tightening the screws (Detail 1-Photo D39).

☞

D 40

Page 66

☞

- Hook up the hydraulic pipes controlling the 3rd extension jack to the valve (Detail 1-Photo D40): to facilitate valve installation the hydraulic pipes should be connected by turning 1/4 revolution clockwise; in this manner the curve in the pipes facilitates securing the valve.

TELESCOPIC ARM D 41 - Mount the hydraulic hose containment plate positioned on the telescopic arm rear side (Detail 1 Photo D41).

☞ - Run the tilting jack and optional control hydraulic hoses above the same cylinder (Detail 1 - Photo D42). - Correctly re-connect the wires of the wiring plate D 42 inside the electric box located on the telescopic arm front left side with the help of the special tool (Detail 2 - Photo D42).

- Correctly re-connect the wires of the wiring plate inside the electric box located on the telescopic arm rear side with the help of the special tool (Detail 1-Photo D43).

☞

- Connect the tilting jack control hydraulic hoses to the valve at the head of the telescopic arm (Detail 1 - Photo D44). - Connect the hydraulic hoses to the fittings of the optional on the telescopic arm front side (Detail 2 and D 43 3 - Photo D44).

D 44

☞

☞ ☞

1 3

Page 67

TELESCOPIC ARM D 45

☞ ☞ ☞

- Wrap all the hydraulic hoses that run through the access hole of the telescopic arm front side with at least 10 cm of plastic to protect against rubbing.

- Tighten the hydraulic pipe securing collar (Detail 1-Photo D45). - Lock the metal pipes to the securing plate using the collars (Detail 2-Photo D45).

☞ 3

- Bind the electric wire to the metal pipe (Detail 3Photo D45).

D 46

Page 68

UNIT 70

HYDRAULIC

TANK DISASSEMBLY 70-2-41-M9 EN

R E PA I R M A N U A L TANK DISASSEMBLY HYDRAULIC OIL AND FUEL TANK DISASSEMBLY

I10/1

- Position the machine on a flat surface, turn the tower 180°, and turn off the combustion engine. - Empty the tank based on the description in the use and maintenance manual (only if necessary).

- Disassemble the cover, (Detail 1 - Photo I10/1).

I10/2 - Disassemble the hand accelerator control attached to the access step, (Detail 1 - Photo I10/2).

1 D 19 1

☞ ☞ I10/3 - Unscrew the oil return collector mounted on the drain filter, (Detail 1 - Photo I10/3).

- Unscrew the relay box screws, (Detail 2 - Photo I10/3).

☞

1 2 D 20

☞

Page 1

R E PA I R M A N U A L I10/4 - Unscrew the screws that attach the collector to the chassis, (Detail 1 - Photo I10/4).

☞

- Disconnect the intake hoses of the hydraulic motor mounted on the tank, 1-2-3-4 (Photo I10/5). - Disconnect the hydraulic intake hoses on the transmission oil filter, (Detail 5 - Photo I10/5).

I10/5

☞

- Disconnect the hydraulic hose for the radiator oil return, (Detail 8 6 - Photo I10/5).

7 6 5

- Disconnect the hydraulic hose to drain the rotation motor, (Detail 7 - Photo I10/5). - Disconnect the hydraulic hose for the hydrostatic pump oil return, (Detail 8 - Photo I10/5).

1 2 3 4

I10/6 - Disconnect the fuel intake and return hoses mounted on the level indicator, (Detail 1 - Photo I10/6). - Disconnect the electrical connection of the fuel level indicator, (Detail 2 - Photo I10/6). - Unscrew the oil vent filter, (Detail 3 - Photo I10/6) and screw in an eyebolt to secure the tank to the bridge crane or a hoist.

Page 2

☞ ☞

R E PA I R M A N U A L I10/7 - Disassemble the step ladder, unscrewing the screws on the top of the tank, (Detail 1 - Photo I10/7) and the screw at the bottom of the tank, (Detail 1 - Photo I10/8). D 24 I10/8

D 25

☞

I10/9 - Unscrew the screw on the inside of the tank to the chassis, (Detail 1 - Photo I10/9).

☞

- Remove the tank.

Page 3

HYDRAULIC ROTATION COLLECTOR DISASSEMBLY AND RE-ASSEMBLY 70-2-43-M9 EN

HYDRAULIC HYDRAULIC ROTATION COLLECTOR DISASSEMBLY F1

- Position the machine on a flat surface and completely lift the telescopic arm. - Turn off the combustion engine and disconnect the battery terminals. - Disassemble the cover (Detail 1 - Photo F1).

- Disassemble the rubber clamps (Detail 1 - Photo F2).

C 64 1

☞

C 71

- Cut the string clamps (Detail 1 - Photo F3). - Disconnect the electric wiring (Detail 2 - Photo F3) from the cab. - Disassemble the hydraulic rotation collector towing lugs (Detail 3 - Photo F3).

C 69

☞ ☞

Page 1

HYDRAULIC - Disconnect the electric wiring (Detail 2 - Photo F4) from the control distribution box.

- Disconnect all the hoses from the hydraulic rotation collector.

☞1 C 70

40-PIN ROTATING FITTING CONNECTION BOARD

BROWN CABLE GROUP

N° 01 02 03 04 05 06 07 08 09 10

COLOUR Brown-white Green-blue Grey-blue Orange-blue Yellow-blue Light blue-yellow Orange-black Yellow-red Orange-red Orange

DESCRIPTION Stabilizer retracted lamp Stabilizer extended micro-pressure switches Right front stabilizers Return solenoid valve Left rear beam Right rear beam Right front beam Right rear stabilizer Left rear stabilizer Left front beam

GREY CABLE GROUP

N° 01 02 03 04 05 06 07 08 09 10

COLOUR Blue-red Pink Red-black Grey no. 4 Yellow-green Violet-black Grey-white Yellow-brown White-green White-red

Page 2

DESCRIPTION Left front stabilizer Fuel level indicator Fuel reserve lamp Stabilizer general solenoid valve Slow/fast enabling signal Rear axle alignment Hydraulic circuit exclusion solenoid valve Reverse Start enabling signal Emergency pump key

FINO ALLA MACCHINA JUSQ'A LA MACHINE UP TO MACHINE BIS DER MASCHINE

➞ N°121778-6352

HYDRAULIC

BLACK CABLE GROUP

N° 01 02 03 04 05 06 07 08 09 10

COLOUR White Grey-green Violet-white Green-white Green-white Blue Blue-black Yellow-grey Black d. 6 Red d. 6

DESCRIPTION Position lights Air filter clogged Front axle alignment Crab turned Concentric turned Right direction lights Left direction lights Forward gear Negative power supply Positive power supply

WHITE CABLE GROUP

N° 01 02 03 04 05 06 07 08 09 10

COLOUR Green-black Grey-black White no. 3 White no. 4 Yellow-violet Grey-red Grey Brown Green White-black

DESCRIPTION High-beam headlights Low-beam headlights Thermal starter Ignition key current Starter Battery charger lamp Low engine oil pressure lamp Engine off Active rear suspensions Engine water temperature indicator

Page 3

HYDRAULIC A PARTIRE DALLA MACCHINA A PARTIR DE LA MACHINE FROM MACHINE AB DER MASCHINE

CONNECTION CARD FOR TINSLEY 44-POLE ROTATING TAP

➞ N°121779-6356 Nº 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030 031 032 033 034 035 036 037 038 039 040 041 042 043 044

Page 4

CORRISP. COLORE Brown-white Green-blue sec.0,5 Grey-blue Orange-blue Yellow-blue Pale blue-yellow Orange-black Yellow-red Orange-red Orange Blue-red Pink sec. 0,5 Pink-black sec. 0,5 Grey n.4 Yellow-green Violet-black sec. 0,5 Grey-white Yellow-brown White-green sec. 0,5 Violet n.7 White Grey-green sec. 0,5 Violet-white sec. 0,5 Green-white Green-white Blue Blue-black Yellow-grey Green-black sec. 0,5 Grey-black sec. 0,5 White n.3 Black-red n.2 Yellow-violet Grey-red sec. 0,5 Grey sec. 0,5 Brown Green White-black sec. 0,5 --------------------------------------------Green-black sec. 2,5 Yellow sec. 2,5 Black sec. 10,0 Brown sec. 10,0

DESCRIZIONE Outriggers retracted light Outrig. exten. pressure switch micro Right front outrigger solenoid valve Outriggers retraction solenoid valve Left rear outrigger arm solenoid valve Right rear outrigger arm solenoid valve Right front outrigger arm solenoid valve Right rear outrigger solenoid valve Left rear outrigger solenoid valve Left front outrigger arm solenoid valve Left front outrigger solenoid valve Fuel level instrument Fuel reserve light General outrigger solenoid valve Slow-fast enabling signal Rear axle alignment light Hydr. circuit inhibiting solenoid valve Reverse running solenoid valve Start enabling Proximity 55° Parking lights Air filter clogged light Front axle alignment light Crabwise steering solenoid valve Concentric steering solenoid valve Right turn signals Left turn signals Forward running solenoid valve Relay control high beams Relay control low beams Relay control thermo-starter Relay control services Relay control starting Battery charge light Low engine oil pressure light Engine stop Rear suspensions active Engine water temperature light --------------------------------------------------------------------------------Negative power supply for logic and pat Positive power supply for logic and pat Negative power supply Positive power supply

RIF. POSIZIONE 10/9 6/5 9/4 8/14 9/7 9/11 9/3 9/12 9/8 8/15 8/17 5/7 5/6 8/12 2/6 2/11 6/14 2/6 1/11 14/12 3/3 5/9 2/15 4/17 4/17 3/15 3/16 2/4 3/9 3/7 1/16 2/18 1/10 1/4 5/11 7/14 6/8 5/13 ------12/12 12/10 ---1/11

HYDRAULIC HYDRAULIC ROTATING COLLECTOR

▲

▼

▲

A 1 2 3 4 5 6 7 8

10 11

3 12

10 17

A 5

14 6

8 2 13

12 11

14 10

B 15 9 16 17

Page 5

HYDRAULIC HYDRAULIC ROTATING COLLECTOR

1) - Drain 2) - Drain 3) - (slow/fast) gearbox supply 4) - Accelerator supply 5) - (slow/fast) gearbox supply 6) - Front axle service brake supply 7) - Parking brake supply 8) - Rear axle service brake supply 9) - (slow/fast) gearbox solenoid valve supply - parking brake valve - service brake pump 10) - Inching supply 11) - Arm extender hoist supply 12) - Steering type solenoid valve supply 13) - Front steering cylinder supply 14) - Tower rotation supply 15) - Tower rotation supply 16) - Movement - stabilizer distributor supply 17) - Power steering - distributor movement supply

Page 6

HYDRAULIC HYDRAULIC ROTATION COLLECTION RE-ASSEMBLY G1

- Using a bridge crane or a hoist, mount the hydraulic rotation collector (Detail 1 - Photo G1) in the special housing on the machine chassis. - Tighten the fastening screws.

☞

C 65 1

- Mount the electric rotating collector towing support (Detail 1 - Photo G2). - Mount the electric rotating collector towing flange (Detail 2 - Photo G2).

- Match the holes of the support to the electric rotating collector fastening screws (Detail 2 - Photo G3).

☞

- Insert the electric wiring (Detail 1 - Photo G3) from the top to the bottom in the bushing of the hydraulic rotating collector (Detail 3 - Photo G2).

2 C 68

- Match the electric collector towing coupling (Detail 3 Photo G3) with the special flange; turn the electric element (Detail 1 - Photo G4) to insert the towing coupling correctly. G4

C 67

☞

2 C 66

☞

☞ Page 7

HYDRAULIC G5

- Tighten the fastening screws of the electric rotating collector with the towing support in a criss-cross pattern to prevent them from being locked incorrectly. - Mount the side guard plate of the electric rotating collector.

- Mount the hydraulic rotation collector towing lugs (Detail 1 - Photo G5).

☞

- Carefully re-connect the hydraulic hoses to the rotation collector.

C 69

☞

- Re-connect the electric wiring from the electric rotation collector to the cab (Detail 2 - Photo G5) and to the control distribution box (Detail 1 - Photo G6). - Lock the hydraulic hoses and the electric wiring with the string clamps (Detail 3 - Photo G5). - Lock the electric strip to the machine chassis with rubber clamps (Detail 1 - Photo G7).

☞1 C 70

- Mount the cover (Detail 1 - Photo G8). - Re-connect the battery terminals.

☞

☞1 C 64 1

Page 8

C 71

STABILIZER EXTENSION JACK DISASSEMBLY AND RE-ASSEMBLY 70-2-65-M9 EN

HYDRAULIC STABILIZER EXTENSION JACK DISASSEMBLY 1) To disassemble the extension jack the following conditions are required: A- Lower the stabilizers until it is possible to work on the pin (A - Fig. 1) B- Using the special controls, extend the stabilizer extension arm until it is possible Fig. 2 work on the pin (B - Fig. 1) C- If it is impossible to extend the arm, unscrew the F set screw, pull out the pin (C - Fig. 1) and remove the foot (D - Fig. 1) 2) Disassemble the valve protection plate (E - Fig. 2) 3) If necessary, disassemble the valve on the bottom of the jack and disconnect the two hydraulic feed hoses

4) As a precaution, detach the arm return signal proximity switch (F - Fig. 2) 5) Unscrew the set screw and remove the pin (B - Fig. 1) 6) Unscrew the set screw and remove the pin (A - Fig. 1) 7) Pull out the stabilizer extension jack from the side of the bottom RE-ASSEMBLY: Carry out the same disassembly operations (in the reverse order) from point n° 7 to n° 1. Fig. 1

C 55

Page 1

STABILIZER TILTING JACK DISASSEMBLY AND RE-ASSEMBLY 70-2-66-M9 EN

HYDRAULIC STABILIZER UP AND DOWN JACK DISASSEMBLY 1) To disassemble the tilting jack, disassemble the front and rear light support to prevent it from breaking accidentally 2) Use a bridge crane or an elevator to hook the foot side stabilizer arm 3) Disassemble the hydraulic hoses connected to the stabilizer tilting jack valve 4) Loosen the fixing screw and pull out the pin (A-Fig. 1) 5) Place the foot side stabilizer arm on the ground 6) Secure the jack to a bridge crane or an elevator using a special chain on the jack bottom side 7) Loosen the fixing screw and pull out the pin (B-Fig. 1) 8) Extract the jack from the seat RE-ASSEMBLY: Follow the disassembly operations (in reverse order) from point n° 8 to point n° 1.

Fig. 1

C 55

Page 1

ELECTRO-PROPORTIONAL CONTROL DISTRIBUTOR 70-3-51-M9 EN

HYDRAULIC

DANFOSS DISTRIBUTOR TYPE PVG32 The system is driven with an "electro-proportional" process. This system moves the distributor cursor gradually and precisely, using the manipulator in the cab. Power supply: - general power supply: - control signal :

12 volt neutral position 6 volt If an operation is carried out by using a manipulator, the signal will vary toward 9 volts to deliver the flow to hole A or towards 3 volts to deliver the flow to hole B.

There is a special design feature on all the elements of the distributor in the lower part that, by moving a lever, allows the operation to be carried out manually (Ref. 22 lever X). Distributor legend 1 - Inlet element 2 - Pressure reducer valve (12 b) 3 - Main pressure limiter 4 - Two-stage lifting element 5 - Cursor (two-stage lifting element) 6 - Two-stage element 1st extension 7 - Cursor (Two-stage element 1st extension, 2nd extension, 3rd extension, tilting) 8 - Check valve 9 - Shock and cavitation control valve of extension no. 1 (230 bar) 10 - Two-stage element (2nd extension) 11 - Shock and cavitation control valve of extensions no. 2 and 3 (175 bar) 12 - Two-stage element (rotation) 13 - Cursor (Rotation two-stage element) 14 - Two-stage element (tilting) 15 - Tilting and compensation plant shock and cavitation control valve (280 bar) 16 - Two-stage element (3rd extension) 17 - Two-stage element (optional) 18 - Cursor (Two-stage element optional) 19 - Closing element 20 - Proportional solenoid valve type PVEM 21 - Rotation proportional solenoid valve TYPE PVEH 22 - Manual control 23 - “load sensing” pressure selector valve 24 - Pressure balancing valve

Page 1

Page 2

23 24

C 17 23

23 24

HYDRAULIC

C 78

Page 3

HYDRAULIC

INTEGRATED FUNCTIONS OF THE PROPORTIONAL DISTRIBUTOR 1 - The distributor cursor is used to select the feed section and to adjust the flow directed to the receiver (speed adjustment). 2 - Pressure balancing is used to compensate for the pressure variations caused by load variations on the other receivers that are controlled simultaneously. It guarantees a flow adjustment (speed) that depends on the stroke of the distribution cursor. 3-4 - The valve controlled by the inlet plate evacuates the excess flow, using the cursor (4), to the reservoir at a pressure that is slightly greater than that of the receiver with the greatest load, for the case involving a fixed displacement pump. It also protects the pump and distribution assembly. The maximum pressure of the circuit is controlled by the valve in the inlet plate. 5 - The return header is common to all the distribution elements. 6 - The pressure header is common to all the distribution elements (parallel distribution). 5'-6' - The oil flow to the receiver is controlled on the feed (circuit 6'). The return to the reservoir is performed freely by using circuit 5. 7 - 8 - To control the speed of a receiver when it is the auto-motor type, a balancing valve must be placed on the return circuit (8). Depending on the technology utilised, this valve is internal (8) or external (flanged on each cylinder for the machines with a variable flow rate). The shock control valves (9) are used to protect the receivers and the piping of these receivers against accidental pressure peaks due to limit switch shock or overloads resulting from violent stops of the movements. 10 - The re-feed valves are used to avoid cavitation in the receivers when they tend to consume a flow that is greater than what is supplied to them (for example auto-motor receiver). 11 - In addition to different sizes of cursors, there are two separate families of cursors ●

those closed in the central position,

●

those "semi-open" in the central position. The latter are used to decompress the lines An and B.

(Decompression of lines A and B is useful when the controlled valves must keep the receiver in position.)

Page 4

HYDRAULIC TECHNOLOGY OF THE INTEGRATED FUNCTIONS OF PVG 32 1

Max. control pressure valve

Pressure reducer for controlling the electro-hydraulic commands

Pressure gauge fitting

Plug (for an open centre inlet plate, fixed displacement pump).

Choker (for a closed centre inlet plate, variable displacement pump).

By-pass cursor of the main inlet limiter valve

Choker (for a closed centre inlet plate).

LS external connection

LS (Load-Sensing) internal ducts

Selection valves for the highest LS pressure

Distributor and flow adjustment cursor

LS pressure limiter

Shock and cavitation control valves

Pressure balancing (pressure variation compensation)

LS individual connection, outlet A

LS individual connection, outlet B

Re-feed valve (cavitation control)

Check/drop control valve

Internal control ducts of electro-hydraulic commands

Page 5

HYDRAULIC

PVG 32 SECTION

C 79

Page 6

HYDRAULIC

PVG 32 PRESSURE ADJUSTMENT

C 80

GENERAL LIMITER OF THE PVP INLET PLATE : The limiter is installed under a plastic cap located close to hole T. One turn in the clockwise direction using a 6 mm Allen wrench increases the pressure by 100 bar. (Pressure fittings installed on the pumps).

Page 7

HYDRAULIC

FLOW RATE ADJUSTMENT The flow rate is proportional to the tilt angle of the manual control lever. The maximum outlet flow rate from holes A or B can be adjusted separately by means of a stop screw (with locking nut-counternut) located in the casing of the manual control. WARNING It is not possible to adjust the limit switch when the electric controls are energised. (The threads may be stripped). The limit switches must be adjusted with the manual control.

C 81

Page 8

HYDRAULIC WARNING : Pages A, B, C, D, E and F illustrate the different possible versions of the PVG 32 distributor. Some components are not used in the MANITOU version. (see microfilm 47949 M - MLT 626 for details about items common to MRT 1540).

Page 9

HYDRAULIC

PVP (Pump part module)

C 82

Page 10

HYDRAULIC

PVB (Base module) PVLA (Cavitation control valve) PVLP (Cavitation and shock control valve)

C 83

Page 11

HYDRAULIC

PVAS (Complete Kit)

C 84

Page 12

HYDRAULIC

PVBS (Main element)

C 85

Page 13

HYDRAULIC

PVM (Mechanical control module) PVMD (Mechanical control for cover)

C 86

Page 14

HYDRAULIC

F PVEH (Electric control module, proportional high performances) PVEM (Electric control module, proportional medium performances) PVEO (Electric control module, ON - OFF)

C 87

Page 15

HYDRAULIC PRINCIPLE OF THE PROPORTIONAL ELECTRO-HYDRAULIC CONTROL The control signal is issued by a manipulator (potentiometer). This is a low-level, voltage control signal (0.5 mA for 12V). A given voltage value corresponds to one and only one element position, therefore a well-defined flow rate. The voltage U/2 (or 12/2 = 6V for example) corresponds to the neutral position of the element. 0.75U corresponds to the maximum stroke of the cursor from part B (maximum flow toward B). 0.25U corresponds to the maximum stroke of the cursor from part A (maximum flow toward A). The control voltage corresponds to the stroke of the element - and therefore the flow rate - as follows: the cursor is hydraulically controlled by four small solenoid valves. For example, solenoid valves 3 and 4 are excited to move the cursor to the right. Cursor movement is controlled by a sensor C. The sensor C converts the movement into an electric parameter / each position corresponds to a voltage: measured voltage. The control built-in electronics compares the control voltage to the measured (position) voltage. If there is a different, the electronic circuitry orders a correction by excitation of solenoid valves 3.

Proportional, high performances

When the cursor obtains the desired position (control voltage = measured voltage), solenoid valves 2 and 4 are excited to lock the cursor in that position. The control system checks the position of the cursor adjusting the flow in proportion to a voltage control signal.

Proportional, medium performances

Page 16

HYDRAULIC MANIPULATOR

C 90

Page 17

HYDRAULIC PVRE

Remote electric controls

Signal amplification It is not necessary to mount a signal amplifier between electric remote control manipulators and the PVG proportional distributor.

C 91

PVRE

General

In addition to its robust construction that allows it to withstand bad weather, it also offers the following advantages: • easier to control • ergonomic design

Three functions

The PVRE proportional electric remote-control manipulator can include a maximum of three potentiometers. Thus, it can simultaneously adjust three proportional functions, the movement for each main stroke of the manipulator and a third one controlled by pressing the button located at the end of the lever.

Characteristic curve

DANFOSS 155B5413

(24 V) (12 V)

C 92

18°

(12 V) (24 V)

0.55 daN

Page 18

0.48 daN

0.4 daN

0.48 daN

0.55 daN

LIFTING JACK DISASSEMBLY 70-3-60-M9 EN

HYDRAULIC

LIFTING JACK DISASSEMBLY (MRT 1540) Tools required: - 1 hook wrench (for lock rings) - 1 4 mm Allen wrench

FINO ALLA MACCHINA JUSQ’A LA MACHINE UP TO MACHINE BIS DER MASCHINE

➞

N° 6214 - 120767

DISASSEMBLY - Unscrew the head Ref. 10 using a hook wrench. - Remove the stem + piston assembly from the jack liner. - Disassemble the socket screw (4 mm Allen wrench) of the piston Ref. 16. - WARNING the screw is locked with loctite. - Unscrew the jack piston using the hook wrench. - Remove the jack piston. - Disassemble the gaskets Ref. 12 and the waterproof gasket Ref. 13 of the piston. - Disassemble the 2 gaskets Ref. 18 and 11, the anti-extrusion gasket Ref. 9 and the 2 waterproof gaskets Ref. 7 and 8 on the head. - Check the condition of the valve, the valve seat and the spring. - Change the gaskets and parts if necessary. - WARNING check the re-assembly direction. RE-ASSEMBLY Reverse the disassembly operation. Note: - The socket screw must be mounted using thread lock loctite. - Grease the gaskets with hydraulic oil. - When mounting the set of waterproof gaskets Ref. 13 “Do not match the cuts of the anti-extrusion gaskets” (Move over by a third of a circumference) Page 1

HYDRAULIC

LIFTING JACK DISASSEMBLY (MRT 1540) Tools required: - 1 hook wrench (for lock rings) - 1 4 mm Allen wrench

A PARTIRE DALLA MACCHINA A PARTIR DE LA MACHINE FROM MACHINE AB DER MASCHINE

➞

N° 6241 - 120844

DISASSEMBLY - Unscrew the head Ref. 10 using a hook wrench. - Remove the stem + piston assembly from the jack liner. - Disassemble the socket screw (4 mm Allen wrench) of the piston Ref. 16. - WARNING the screw is locked with loctite. - Unscrew the jack piston using the hook wrench. - Remove the jack piston. - Disassemble the gaskets Ref. 12 and the waterproof gasket Ref. 13 of the piston. - Remove gasket Ref. 11, the antiextrusion seal Ref. 9 and the 2 watertight seals Ref. 7 and 8 at the head. - Check the condition of the valve, the valve seat and the spring. - Change the gaskets and parts if necessary. - WARNING check the re-assembly direction. RE-ASSEMBLY Reverse the disassembly operation. Note: - The socket screw must be mounted using thread lock loctite. - Grease the gaskets with hydraulic oil. - When mounting the set of waterproof gaskets Ref. 13 “Do not match the cuts of the anti-extrusion gaskets” (Move over by a third of a circumference) Page 2

TILTING JACK DISASSEMBLY 70-3-61-M9 EN

HYDRAULIC

TILTING JACK DISASSEMBLY (MRT 1540) Tools required: - 1 hook wrench (for lock rings) - 1 4 mm Allen wrench

C 26

DISASSEMBLY - Unscrew the head Ref. 20 using a hook wrench. - Remove the stem + piston assembly from the jack liner. - Disassemble the socket screw Ref. 6 (4 mm Allen wrench) of the piston. - WARNING the screw is locked with loctite. - Unscrew the jack piston using the hook wrench. - Remove the jack piston. - Disassemble the gaskets Ref. 11 and the waterproof gasket Ref. 10 of the piston. - Disassemble the 2 gaskets Ref. 12 and 15, the anti-extrusion gasket Ref. 13 and the waterproof gasket Ref. 14 on the head. - Check the condition of the valve, the valve seat and the spring. - Change the gaskets and parts if necessary. - WARNING check the re-assembly direction. RE-ASSEMBLY Reverse the disassembly operation. Note: - The socket screw must be mounted using thread lock loctite. - Grease the gaskets with hydraulic oil. - When mounting the set of waterproof gaskets Ref. 10 “Do not match the cuts of the anti-extrusion gaskets” (Move over by a third of a circumference) Page 1

COMPENSATION JACK DISASSEMBLY 70-3-64-M9 EN

HYDRAULIC

COMPENSATION JACK DISASSEMBLY (MRT 1540) Tools required: - 1 hook wrench (for lock rings) - 1 4 mm Allen wrench

FINO ALLA MACCHINA JUSQ’A LA MACHINE UP TO MACHINE BIS DER MASCHINE

➞

N° 6145 - 120426

DISASSEMBLY - Unscrew the head Ref. 19 using a hook wrench. - Remove the stem + piston assembly from the jack liner. - Disassemble the socket screw Ref. 18 (4 mm Allen wrench) of the piston. - WARNING the screw is locked with loctite. - Unscrew the jack piston Ref. 5-6 using the hook wrench. - Remove the jack piston. - Disassemble the gaskets Ref. 8 and the waterproof gasket Ref. 7 of the piston. - Disassemble the 2 gaskets Ref. 10 and 13, the anti-extrusion gasket Ref. 11 and the waterproof gasket Ref. 12 on the head Ref. 19. - Change the gaskets and parts if necessary. - WARNING check the re-assembly direction. RE-ASSEMBLY Reverse the disassembly operation. Note: - The socket screw must be mounted using thread lock loctite. - Grease the gaskets with hydraulic oil. - When mounting the set of waterproof gaskets Ref. 7 “Do not match the cuts of the anti-extrusion gaskets” (Move over by a third of a circumference) Page 1

HYDRAULIC

COMPENSATION JACK DISASSEMBLY (MRT 1540) Tools required: - 1 hook wrench (for lock rings) - 1 4 mm Allen wrench

A PARTIRE DALLA MACCHINA A PARTIR DE LA MACHINE FROM MACHINE AB DER MASCHINE

➞

N° 6146 - 120747

DISASSEMBLY - Unscrew the head Ref. 13 using a hook wrench. - Remove the stem + piston assembly from the jack liner. - Disassemble the socket screw Ref. 18 (4 mm Allen wrench) of the piston. - WARNING the screw is locked with loctite. - Unscrew the jack piston Ref. 5-6 using the hook wrench. - Remove the jack piston. - Disassemble the gaskets Ref. 8 and the waterproof gasket Ref. 7 of the piston. - Disassemble the 2 gaskets Ref. 10, the anti-extrusion gasket Ref. 11 and the waterproof gasket Ref. 12 on the head Ref. 13. - Change the gaskets and parts if necessary. - WARNING check the re-assembly direction. RE-ASSEMBLY Reverse the disassembly operation. Note: - The socket screw must be mounted using thread lock loctite. - Grease the gaskets with hydraulic oil. - When mounting the set of waterproof gaskets Ref. 7 “Do not match the cuts of the anti-extrusion gaskets” (Move over by a third of a circumference) Page 2

STABILIZER TELESCOPIC JACK DISASSEMBLY 70-3-65-M9 EN

HYDRAULIC

STABILIZER TELESCOPIC JACK DISASSEMBLY (MRT 1540) Tools required: - 1 hook wrench (for lock rings)

FINO ALLA MACCHINA JUSQ’A LA MACHINE UP TO MACHINE BIS DER MASCHINE

➞

N° 6144 - 120425

DISASSEMBLY - Unscrew the head Ref. 11 using a hook wrench. - Remove the stem + piston assembly from the jack liner. - Unscrew the jack piston Ref. 3 using the hook wrench. - Remove the jack piston. - Disassemble the gasket Ref. 6 and the waterproof gasket Ref. 5 of the piston. - Disassemble the 2 gaskets Ref. 7 and 10, the anti-extrusion gasket Ref. 8 and the waterproof gasket Ref. 9 on the head. - Check the condition of the valve, the valve seat and the spring. - Change the gaskets and parts if necessary. - WARNING check the re-assembly direction. RE-ASSEMBLY Reverse the disassembly operation. Note: - Grease the gaskets with hydraulic oil. - When mounting the set of waterproof gaskets Ref. 7 “Do not match the cuts of the anti-extrusion gaskets” (Move over by a third of a circumference)

Page 1

HYDRAULIC

STABILIZER TELESCOPIC JACK DISASSEMBLY (MRT 1540) Tools required: - 1 hook wrench (for lock rings)

A PARTIRE DALLA MACCHINA A PARTIR DE LA MACHINE FROM MACHINE AB DER MASCHINE

➞

N° 6145 - 120426

DISASSEMBLY - Unscrew the head Ref. 11 using a hook wrench. - Remove the stem + piston assembly from the jack liner. - Using an Allen wrench, unscrew nut Ref. 14. - Remove the jack piston Ref. 3-10. - Disassemble the gasket Ref. 6 and the waterproof gasket Ref. 5 of the piston. - Remove gasket Ref. 7, the antiextrusion seal Ref. 8 and the watertight seal Ref. 9 at the head. - Check the condition of the valve, the valve seat and the spring. - Change the gaskets and parts if necessary. - WARNING check the re-assembly direction. RE-ASSEMBLY Reverse the disassembly operation. Note: - Grease the gaskets with hydraulic oil. - When mounting the set of waterproof gaskets Ref. 7 “Do not match the cuts of the anti-extrusion gaskets” (Move over by a third of a circumference)

Page 2

STABILIZER TILTING JACK DISASSEMBLY 70-3-66-M9 EN

HYDRAULIC

STABILIZER TILTING JACK DISASSEMBLY (MRT 1540) Tools required: - 1 hook wrench (for lock rings)

FINO ALLA MACCHINA JUSQ’A LA MACHINE UP TO MACHINE BIS DER MASCHINE

➞

N° 6145 - 120426

DISASSEMBLY - Unscrew the head Ref. 11 using a hook wrench. - Remove the stem + piston assembly from the jack liner. - Unscrew the jack piston Ref. 6 using the hook wrench. - Remove the jack piston. - Disassemble the gasket Ref. 7 and the waterproof gasket Ref. 8 of the piston. - Disassemble the 2 gaskets Ref. 9 and 10, the anti-extrusion gasket Ref. 12 and the waterproof gasket Ref. 13 on the head. - Check the condition of the valve, the valve seat and the spring. - Change the gaskets and parts if necessary. - WARNING check the re-assembly direction. RE-ASSEMBLY Reverse the disassembly operation. Note: - Grease the gaskets with hydraulic oil. - When mounting the set of waterproof gaskets Ref. 8 “Do not match the cuts of the anti-extrusion gaskets” (Move over by a third of a circumference)

Page 1

HYDRAULIC

STABILIZER TILTING JACK DISASSEMBLY (MRT 1540) Tools required: - 1 hook wrench (for lock rings)

A PARTIRE DALLA MACCHINA A PARTIR DE LA MACHINE FROM MACHINE AB DER MASCHINE

➞

N° 6146 - 120747

DISASSEMBLY - Unscrew the head Ref. 11 using a hook wrench. - Remove the stem + piston assembly from the jack liner. - Unscrew the jack piston Ref. 6 using the hook wrench. - Remove the jack piston. - Disassemble the gasket Ref. 7 and the waterproof gasket Ref. 8 of the piston. - Remove gasket Ref. 9, the antiextrusion seal Ref. 12 and the watertight seal Ref. 13 at the head. - Check the condition of the valve, the valve seat and the spring. - Change the gaskets and parts if necessary. - WARNING check the re-assembly direction. RE-ASSEMBLY Reverse the disassembly operation. Note: - Grease the gaskets with hydraulic oil. - When mounting the set of waterproof gaskets Ref. 8 “Do not match the cuts of the anti-extrusion gaskets” (Move over by a third of a circumference)

Page 2

JACK DISASSEMBLY 1ST EXTENSION 70-3-67-M9 EN

HYDRAULIC

JACK DISASSEMBLY 1ST EXTENSION (MRT 1540) Tools required: - 1 hook wrench (for lock rings) - 1 Socket wrench FINO ALLA MACCHINA JUSQ’A LA MACHINE UP TO MACHINE BIS DER MASCHINE

➞

N° 6146 - 120747

DISASSEMBLY - Unscrew the head Ref. 9 using a hook wrench. - Remove the stem + piston assembly from the jack liner. - Unscrew the nut Ref. 2 using the socket wrench. - Remove the jack piston Ref. 5. - Disassemble the gasket Ref. 6 and the 2 waterproof gaskets Ref. 3 and 4 of the piston. - Disassemble the gaskets Ref. 16 and 17, the anti-extrusion gasket Ref. 8 and the 2 waterproof gaskets Ref. 10 and 11 on the head. - Check the condition of the valve, the valve seat and the spring. - Change the gaskets and parts if necessary. - WARNING check the re-assembly direction. RE-ASSEMBLY Reverse the disassembly operation. Note: - Grease the gaskets with hydraulic oil. - When mounting the set of waterproof gaskets Ref. 3 “Do not match the cuts of the anti-extrusion gaskets” (Move over by a third of a circumference)

Page 1

HYDRAULIC

JACK DISASSEMBLY 1ST EXTENSION (MRT 1540) Tools required: - 1 hook wrench (for lock rings) - 1 Socket wrench A PARTIRE DALLA MACCHINA A PARTIR DE LA MACHINE FROM MACHINE AB DER MASCHINE

➞

N° 6150 - 120748

DISASSEMBLY - Unscrew the head Ref. 9 using a hook wrench. - Remove the stem + piston assembly from the jack liner. - Unscrew the nut Ref. 2 using the socket wrench. - Remove the jack piston Ref. 5. - Disassemble the gasket Ref. 6 and the 2 waterproof gaskets Ref. 3 and 4 of the piston. - Disassemble the gaskets Ref. 16 and 17, the anti-extrusion gasket Ref. 8 and the 2 waterproof gaskets Ref. 10, 11 and 12 on the head. - Check the condition of the valve, the valve seat and the spring. - Change the gaskets and parts if necessary. - WARNING check the re-assembly direction. RE-ASSEMBLY Reverse the disassembly operation. Note: - Grease the gaskets with hydraulic oil. - When mounting the set of waterproof gaskets Ref. 3 “Do not match the cuts of the anti-extrusion gaskets” (Move over by a third of a circumference)

Page 2

JACK DISASSEMBLY 2ND EXTENSION 70-3-68-M9 EN

HYDRAULIC

JACK DISASSEMBLY 2ND EXTENSION (MRT 1540) Tools required: - 1 hook wrench (for lock rings) - 1 4 mm Allen wrench

DISASSEMBLY - Unscrew the head Ref. 7 using a hook wrench. - Remove the stem + piston assembly from the jack liner. - Disassemble the socket screw Ref. 12 (4 mm Allen wrench) of the piston. - WARNING the screw is locked with loctite. - Unscrew the jack piston Ref. 11 using a hook wrench. - Remove the jack piston. - Disassemble the gaskets Ref. 10, 26, 24, 25 and the waterproof gaskets Ref. 13 and 14 of the piston. - Disassemble the 2 gaskets Ref. 9 and 8, the anti-extrusion gasket Ref. 6 and the waterproof gaskets Ref. 2-3-4 and 5 on the head. - Remove the Allen screw Ref. 23 (using a 4 mm Allen wrench) from the piston. - CAUTION the screw is locked in place with loctite. - Remove the rod Ref. 1 from the securing terminal Ref. 22. - Remove the seals Ref. 18. - Check the condition of the valve, the valve seat and the spring. - Change the gaskets and parts if necessary. - WARNING check the re-assembly direction. RE-ASSEMBLY Reverse the disassembly operation. Note: - The socket screw must be mounted using thread lock loctite - Grease the gaskets with hydraulic oil. - When mounting the set of waterproof gaskets Ref. 6 “Do not match the cuts of the anti-extrusion gaskets” (Move over by a third of a circumference) Page 1

JACK DISASSEMBLY 3RD EXTENSION 70-3-69-M9 EN

HYDRAULIC

JACK DISASSEMBLY 3RD EXTENSION (MRT 1540) Tools required: - 1 hook wrench (for lock rings) - 1 4 mm Allen wrench

DISASSEMBLY - Unscrew the head Ref. 7 using a hook wrench. - Remove the stem + piston assembly from the jack liner. - Disassemble the socket screw Ref. 12 (4 mm Allen wrench) of the piston. - WARNING the screw is locked with loctite. - Unscrew the jack piston Ref. 11 using a hook wrench. - Remove the jack piston. - Remove gasket Ref. 10, 26, 24, 25 and the antiextrusion seals Ref. 13-14 for the piston. - Disassemble the 2 gaskets Ref. 6 and 17, the anti-extrusion gasket Ref. 7 and the waterproof gaskets Ref. 9-10-11 and 12 on the head. - Remove the Allen screw Ref. 23 (using a 4 mm Allen wrench) from the piston. - CAUTION the screw is locked in place with loctite. - Remove the rod Ref. 1 from the securing terminal Ref. 22. - Remove the seals Ref. 18. - Check the condition of the valve, the valve seat and the spring. - Change the gaskets and parts if necessary. - WARNING check the re-assembly direction. RE-ASSEMBLY Reverse the disassembly operation. Note: - The socket screw must be mounted using thread lock loctite - Grease the gaskets with hydraulic oil. - When mounting the set of waterproof gaskets Ref. 6 “Do not match the cuts of the anti-extrusion gaskets” (Move over by a third of a circumference) Page 1

REAR AXLE LOCKING JACK DISASSEMBLY 70-3-70-M9 EN

HYDRAULIC

REAR AXLE LOCKING JACK DISASSEMBLY (MRT 1540) Attrezzi necessari: - 1 chiave ad uncino (per ghiere)

FINO ALLA MACCHINA JUSQ’A LA MACHINE UP TO MACHINE BIS DER MASCHINE

➞

N° 6146 - 120747

DISASSEMBLY - Unscrew the head Ref. 9 using a hook wrench. - Remove the stem + piston assembly from the jack liner. - Unscrew the jack piston Ref. 3 using a hook wrench. - Remove the jack piston. - Disassemble the waterproof gaskets Ref. 4 of the piston. - Disassemble the gasket Ref. 5, the anti-extrusion gasket Ref. 6 and the 2 waterproof gaskets Ref. 7 and 8 on the head. - Change the gaskets and parts if necessary. RE-ASSEMBLY Reverse the disassembly operation. Note: - Grease the gaskets with hydraulic oil. - When mounting the set of waterproof gaskets Ref. 4 “Do not match the cuts of the anti-extrusion gaskets” (Move over by a third of a circumference)

Page 1

HYDRAULIC

REAR AXLE LOCKING JACK DISASSEMBLY (MRT 1540) Attrezzi necessari: - 1 chiave ad uncino (per ghiere)

A PARTIRE DALLA MACCHINA A PARTIR DE LA MACHINE FROM MACHINE AB DER MASCHINE

➞

N° 6150 - 120748

DISASSEMBLY - Unscrew the head Ref. 9 using a hook wrench. - Withdraw the rod from the cylinder liner. - Disassemble the waterproof gaskets Ref. 4-6 of the piston. - Disassemble the gaskets Ref. 3-5, the anti-extrusion gasket Ref. 8 and the waterproof gasket Ref. 7 on the head. - Change the gaskets and parts if necessary. RE-ASSEMBLY Reverse the disassembly operation. Note: - Grease the gaskets with hydraulic oil. - When mounting the set of waterproof gaskets Ref. 4-6 “Do not match the cuts of the anti-extrusion gaskets” (Move over by a third of a circumference)

Page 2

ACCELERATOR CONTROL JACK AIR BLEED PROCEDURE 70-4-71-M9 EN

HYDRAULIC ACCELERATOR CONTROL JACK AIR BLEED PROCEDURE - Engine off. - Keep the accelerator control jack with the bleeder screw facing up (Detail 1- Photo 1). - Press the accelerator pedal several times, keep it pressed and loosen the bleeder screw to release the air, tighten the screw and repeat the same operation until oil flows out without air bubbles. - Make sure that the jack stem sticks out completely up to the mechanical striker, which can also be heard by the mechanical noise. - IMPORTANT: Adjust the two limit switches (idle - maximum rpm) using the fork screwed onto the accelerator control jack stem.

Photo 1

☞

1 C 18

Page 1

PRESSURE CONTROL 70-5-M9 EN

HYDRAULIC

PRESSURE CONTROL To control the pressure values, use an appropriate pressure gauge. The oil must have a temperature of about 60°. The combustion engine must be at the maximum rpm.

FIG. A

4 90 60

150

90 60

120

120 0

bar

180

150

bar

180

3 P1 P3

P2 P4

300 200

500

100

DANFOSS DISTRIBUTOR PVG 32

L I F T.

E X T. 1

E X T. 2

R O T A T.

T I L T.

E X T. 3

400

bar

FIG. B O P T I O N.

230 bar

LP 260 1

230 bar 175 bar Page 2

280 bar

600

175 bar

HYDRAULIC Pressure control A) Pump P1 : main circuit supply. Pressure fitting (Ref. 1-Fig. A).

PRESSURE CONTROLS - Danfoss main distributor pressure - Extension no. 1 piston side 3 - Extension no. 2 piston side 4 - Tilting and compensation stem side 5 - Extension no. 3 6 - Tower rotation (2) 1 2

- Direction

VALUE

ADJUSTMENT

260b 230b 175b 230b 175b 100b

Danfoss distributor main limiter pre-adjusted shock control valve pre-adjusted shock control valve pre-adjusted shock control valve pre-adjusted shock control valve pressure limiter on the engine supply block pressure limiter in the Danfoss power steering casing

175b

B) Pompa P2 : alimentazione circuito stabilizzatori e circuito principale. Presa di pressione (Rif. 2-Fig. A). CONTROLLI PRESSIONI

VALORE

REGOLAZIONE

- circuito stabilizzatori

220b

limitatore situato sul blocco elettrovalvola 3 vie, parte anteriore del telaio (Rif. 1-Fig. C).

Photo C

☞ 1

Page 3

HYDRAULIC C) Pump P4 : Fan circuit supply. Pressure fitting (Ref. 1 - Photo C). PRESSURE CONTROL

VALUE

ADJUSTMENT

Speed 3200 rpm Speed 2000 rpm

120b approx. 50b approx.

limiter located on pump P4 limiter located on the block mounted on the engine side of the fan and 2000 rpm speed reducer solenoid valve (Ref. 2 - Photo D). The detailed procedure is described in the chapter “COOLING FAN OPERATION”.

Photo D

☞ ☞ 1

Page 4

HYDRAULIC CIRCUIT PRESSURE ADJUSTMENT - The speed of 3200 rpm is obtained at the time in E1 which the pressure of the fan hydraulic circuit is about 120 bar. The pressure is adjusted at the level of the limiter located on the pump (Detail 2 - Fig. E3). - The speed of 2000 rpm is obtained at the time in which the pressure of the circuit is about 50 bar. The adjustment is performed at the level of the limiter (Detail 4 - Fig. E3).

- The fan speeds must be measured with the combustion engine turning at maximum speed and using a revolution counter. - This is a suction fan. Note : To make the speed adjustment easier (3200 rpm) it is recommended during the adjustment to place a bridge on one of the two temperature sensors (Detail 1- Fig. E1 and E2).

C 23

☞

1 4 3 2

C 24

Page 5

HYDRAULIC D) Pump P1 : check compensation pressure at the bottom. Pressure outlet (Ref. 1Photo F). Photo F

Per effettare il controllo della pressione di compensazione lato fondello (Rif. 1-Foto F), è necessario di sovratarare il limitatore principale a 285b. Dopo l’operazione ritarare il limitatore principale a 260b. 7

- A second method, which avoids having to over-calibrate the main limiter, involves the following: - Connect to a pressure gauge (Ref. 1 - Photo F) - Completely lift the arm - Completely extend the swinging jack - Rev up the combustion engine to approximately 1000 rpm and lower the unit. While lowering, detect the pressure at the second manometer 280b on the pre-set impact resistant valve 300 on the Danfoss distributor 200

☞

400

500

100

bar

600

E) Supercharger pump on hydrostatic transmission. Pressure fitting (Ref. 3 - Fig. A). PRESSURE CONTROL

VALUE

ADJUSTMENT

- Parking brake

40b

- Power brake - Speed change control (slow and fast)

40b 40b

on the supercharger pressure limiter (see hydrostatic transmission chapter).

F) Pump P3 : engine supply hose tension. Pressure fitting (Ref. 4 - Fig. A). PRESSURE CONTROL

VALUE

ADJUSTMENT

- Engine pressure

85b

pressure limiter located on the block flanged on the engine hose tension

Page 6

POSITION OF THE HYDRAULIC COMPONENTS 70-7-M9 EN

➞

EXCLUSION E. SOLENOID VALVE FOR HYDRAULIC PLANTS LOCATED ON THE CHASSIS IN FRONT OF THE HYDRAULIC RESERVOIR

N° 6716 - 127718

FINO ALLA MACCHINA JUSQ’A LA MACHINE UP TO MACHINE BIS DER MASCHINE

STABILIZER PRESSURE LIMITER

FAN MOTOR FEED PUMP PRESSURE LIMITER

POSITION OF THE HYDRAULIC COMPONENTS

E.S. SOLENOID VALVE FOR STABILIZERS

HYDRAULIC

Page 1

Page 2

➞

EXCLUSION E. SOLENOID VALVE FOR HYDRAULIC PLANTS LOCATED ON THE CHASSIS IN FRONT OF THE HYDRAULIC RESERVOIR

N° 6717 - 128414

A PARTIRE DALLA MACCHINA A PARTIR DE LA MACHINE FROM MACHINE AB DER MASCHINE

STABILIZER PRESSURE LIMITER

FAN MOTOR FEED PUMP PRESSURE LIMITER

POSITION OF THE HYDRAULIC COMPONENTS

E.S. SOLENOID VALVE FOR STABILIZERS

HYDRAULIC

HYDRAULIC MOTOR

FAN HYDRAULIC MOTOR PRESSURE LIMITER

POSITION OF THE HYDRAULIC COMPONENTS

HYDRAULIC

Page 3

COMPENSATION JACK LIFTING JACK

Page 4 DANFOSS PVG32 MAIN DISTRIBUTOR

DANFOSS OLS80 FLOW SPLITTER

POSITION OF THE HYDRAULIC COMPONENTS

HYDRAULIC

STABILIZER EXTENSION JACK

STABILIZER UP/DOWN JACK

ELECTRO-DISTRIBUTOR FOR STABILIZERS LOCATED ON THE FRONT RIGHT SIDE OF THE CHASSIS

E.S. SOLENOID VALVE FOR STABILIZERS LOCATED ON THE CHASSIS IN FRONT OF THE CAB

POSITION OF THE HYDRAULIC COMPONENTS

HYDRAULIC

Page 5

Page 6

HYDROSTATIC MOTOR A 6 VM 107 DA

TRANSMISSION PUMP A 4 VG 71 DA

HYDROSTATIC PLANT COOLING BY-PASS

TRANSMISSION SUPERCHARGER PUMP INTAKE FILTER

REAR AXLE OSCILLATION LOCKING JACK

REAR AXLE OSCILLATION LOCKING SOLENOID VALVES

POSITION OF THE HYDRAULIC COMPONENTS

HYDRAULIC

DANFOSS POWER STEERING

ROTARY HYDRAULIC HEADER

SELECTION SOLENOID FOR TYPE OF STEERING LOCATED ON THE REAR PART OF THE CHASSIS

POSITION OF THE HYDRAULIC COMPONENTS

HYDRAULIC

Page 7

Page 8

ACCELERATOR AND BRAKE FLUID RESERVOIR

ENGINE ACCELERATOR CONTROL JACK

POWER BRAKE

ACCELERATOR SERVOCONTROL

POSITION OF THE HYDRAULIC COMPONENTS

HYDRAULIC

EXTERNAL ARM

K-

K JAC

SIO

EN EXT

NSI

E EXT

- 2N

- 3R

K JAC

JAC

XT TE

ENS

ION

POSITION OF THE HYDRAULIC COMPONENTS

N° 5706 - 114274 ECCETTO PER - SAUF POUR EXCEPT FOR - NICHT FUR N° 5705 - 114456

➞

FINO ALLA MACCHINA JUSQ’A LA MACHINE UP TO MACHINE BIS DER MASCHINE

FORK TILTING JACK

HYDRAULIC

Page 9

Page 10

N° 5706 - 114274

ECCETTO PER - SAUF POUR EXCEPT FOR - NICHT FUR N° 5705 - 114456

➞

FINO ALLA MACCHINA JUSQ’A LA MACHINE UP TO MACHINE BIS DER MASCHINE

HYDRAULIC MOTOR HOSE TENSION

POSITION OF THE HYDRAULIC COMPONENTS

HYDRAULIC

N° 5708 - 114275

E PER - ET POUR AND FOR - UND FUR N° 5705 - 114456

➞

A PARTIRE DALLA MACCHINA A PARTIR DE LA MACHINE FROM MACHINE AB DER MASCHINE

EXTERNAL ARM

K JAC

JAC

K JAC

EN-

XT DE

- 3R

XT DE

EN-

EXT

- 2N

T - 1S

POSITION OF THE HYDRAULIC COMPONENTS

HYDRAULIC

Page 11

Page 12

N° 5708 - 114275

E PER - ET POUR AND FOR - UND FUR N° 5705 - 114456

➞

A PARTIRE DALLA MACCHINA A PARTIR DE LA MACHINE FROM MACHINE AB DER MASCHINE

POSITION OF THE HYDRAULIC COMPONENTS

FORK TILTING JACK

HYDRAULIC

ECCETTO PER - SAUF POUR EXCEPT FOR - NICHT FUR N° 5889 - 116696 N° 5948 - 117101 N° 5980 - 116661 N° 6090 - 116662

➞

N° 6094 - 120144

FINO ALLA MACCHINA JUSQ’A LA MACHINE UP TO MACHINE BIS DER MASCHINE

AUXILIARY PLANT SUPPLY DELIVERY

ROTATION PRESSURE LIMITERS BALANCING VALVES

ROTATION REDUCER WITH BRAKE

POSITION OF THE HYDRAULIC COMPONENTS

INCHING VALVE

ROTATION MOTOR

HYDRAULIC

Page 13

Page 14

N° 6132 - 120739

AUXILIARY PLANT SUPPLY DELIVERY

E PER - ET POUR AND FOR - UND FUR N° 5889 - 116696 N° 5948 - 117101 N° 5980 - 116661 N° 6090 - 116662

➞

A PARTIRE DALLA MACCHINA A PARTIR DE LA MACHINE FROM MACHINE AB DER MASCHINE

ROTATION PRESSURE LIMITERS BALANCING VALVES

ROTATION REDUCER WITH BRAKE

POSITION OF THE HYDRAULIC COMPONENTS

INCHING VALVE

ROTATION MOTOR

HYDRAULIC

COOLING FAN OPERATION 70-8-42-M9 EN

HYDRAULIC

COOLING FAN HYDRAULIC CIRCUIT To reduce the noise level of the machine, the fan is equipped with a device that allows it to rotate at two E 1 different speeds according to need. This is possible thanks to 2 thermal switches that detect the temperature of the water (Detail 1 - Photo E1) and the hydrostatic transmission oil (Detail 1 Photo E2) allowing the fan to turn at a speed of 3200 rpm if the temperature is greater than 85° and limiting it to 2000 rpm if the temperature is less than 85°.

The detailed procedure can be found in the chapter entitled “CHECKING PRESSURE”

☞

Page 1

ROTATION ADJUSTMENT PROCEDURE 70-8-44-M9 EN

HYDRAULIC ROTATION ADJUSTMENT PROCEDURE Rotation adjustment With 1000 KG on the forks, 1st 2nd 3rd arms extended to the limit of the C.E.C. Engine on, gradually close the flow regulator so that the reducer brake remains unlocked. Perform the rotation and loosen the lever. The stop must be completed within about one metre. Use the VBB valves. Loosening the stop will take longer. Then loosen the brake progression tap 3 turns. The brake must take effect 10 cm before the hydraulic stop (listen for the noise of the brake). The valves are adjusted to 100 bar with the tower locked by the special pin and at a combustion engine speed of about 1000 rpm. Rotation rate : cage model = 0.7 mt/sec

FINO ALLA MACCHINA JUSQ'A LA MACHINE UP TO MACHINE BIS DER MASCHINE

➞ N°120144-6094 ECCETTO PER - SAUF POUR EXCEPT FOR - NICHT FUR

N°116696-5889 N°117101-5948 N°116661-5980 N°116662-6090

Flow regulator

Pressure limiters

VBB balancing valve

Pressure limiters

VBB balancing valve

Page 1

HYDRAULIC REGULATION PROCEDURE OF THE TOWER ROTATION REDUCER Rotation regulating procedure REF. "A" This block has two valves used to regulate rotation braking. It is regulated while the combustion engine is running at maximum r.p.m.: - extend the arm to full horizontal extension - rotate clockwise and make certain that when the knob is released, braking is not too abrupt : the braking space must not be more than 1 mt (if necessary regulate “A1”) - repeat the operation counter-clockwise and make certain that the braking space is the same (if necessary regulate “A2”) Loosening up makes braking softer. - if necessary, as a further check, leave the manometer in the main pump pressure outlet and check that, during the above maneuver, the pressure is the same in both directions of rotation REF. "B" There are two shock-absorbing valves at the inlet; 100 bar with combustion engine idling. - install a manometer (250 bar scale) in the pressure outlet on the main pump - lock the cabin with the pin - rotate clockwise all the way(if necessary regulate “B1”) - repeat the operation counter-clockwise (if necessary regulate “B2”) A PARTIRE DALLA MACCHINA A PARTIR DE LA MACHINE FROM MACHINE AB DER MASCHINE

➞ N°120739-6132 E PER - ET POUR AND FOR - UND FUR

N°116696-5889 N°117101-5948 N°116661-5980 N°116662-6090

"A1" RIF. "A" "A2" RIF. "B"

"B1"

"B2"

Page 2

HYDRAULIC ROTATION REGULATING PROCEDURE WITH CAGE INSTALLED Rotation regulating procedure The electronic logic control box located behind the cabin holds the “Danfoss” flow regulator controlling cage rotation rate (this is the horizontally installed regulator Ref. 2). Regulation is performed with the combustion engine running at 1000 min-1 (accelerate to maximum using the hand lever Ref. 1) : - raise the arm approximately 45° - extend the 1st and 2nd extensions approximately half of their full course - rotate the cage 1 - rotate the tower clockwise and make certain that the rotation rate is approximately 0.7 mt/sec (if necessary regulate “A2”) - repeat the operation counter-clockwise and make certain that the rotation rate is approximately 0.7 mt/sec (if necessary regulate “B2”)

☞

☞ ☞

Ref. 2

Page 3

UNIT 80

ELECTRICITY

LOCATION OF PROXIMITY SENSORS MICROSWITCHES 80-7-81-M9 EN

ELECTRICITY

PROXIMITY SWITCHES AND MICROSWITCHES

A) Operation enabling microswitch: To obtain the enabling signal for all operations make sure that the left arm rest is lowered until it compresses the microswitch (Detail 1 - Photo E1) which issues the electric enabling signal. In the left arm rest there is a hand brake control lever which includes a microswitch (Detail 1 - Photo E2) and which is designed to cut off the enabling signal for machine translation and to turn on the red “parking brake” light on the instrument panel.

☞

Page 1

ELECTRICITY B) Stabilizer beam microswitch (Detail 1 - Photo E3): FUNCTIONS = To signal that the stabilizers are completely extended and E3 lowered. ADJUSTMENT = To be performed so that the reference on the beam presses the microswitch to close the contact, only when the stabilizers rest on the ground.

C) Retracted stabilizer proximity switch (Detail 2 - Photo E3): FUNCTIONS = Exclusively that of signalling, through the electronic board and lighting the cab lamp, that the stabilizers have retracted; it has no lock effect on the operations. ADJUSTMENT = It is positioned at a distance of about 2-3 mm from the reference component.

☞

Warning: 1) check that when extending the beam, in case of oscillations, that there is no interference with the proximity switch and thus leading to possible damage. 2) maximum reading distance = 5 mm N.B. When the proximity switch is active and transmits a signal, the built-in red lamp also turns on to make it easier to check that it is operating correctly.

D) 5° Proximity switch (Detail 1 - Photo E4): FUNCTIONS

ADJUSTMENT

= This proximity switch, located on the rear of the chassis, signals that the tower is turned more than 5° to the right or to the left of the front longitudinal axis, locking the rear axle oscillation. = It is positioned about 2-3 mm from the measurement bracket.

Warning: maximum reading distance = 5 mm N.B. When the proximity switch is active and transmits a signal, the built-in red lamp also turns on to make it easier to check that it is operating correctly. Page 2

☞

ELECTRICITY E) Cab blocked - cab aligned microswitch (Photo E5): FUNCTIONS

ADJUSTMENT

E5 = (Detail 1) The microswitch signals to the operator the longitudinal alignment of the tower frame by lighting the green lamp on the instrument panel. (Detail 2) The microswitch signals to the operator that the tower lock pin has been inserted by lighting the red lamp on the instrument panel. = (Detail 1) The green lamp should turn on only when the tower is aligned so that its rotation can be locked. (Detail 2) The red lamp should turn on only when the tower rotation lock pin is inserted in the approE6 priate seat. Warning: The two microswitches, connected in series, can also be used to vary the capacity diagram with FRONT ON WHEELS (4 T) to 360° ON WHEELS (2,5 T).

☞ ☞

☞

F) Danfoss distribution microswitch

(Detail 1- Photo E6): FUNCTIONS = To signal the arm up operation to the safety system. ADJUSTMENT = The microswitch must be pushed only when the arm up operation is activated; (check with the display DS100).

G) Arm up limit switch microswitch (Detail 1 - Photo E7): FUNCTIONS = To interrupt the contact before the limit switch pressure peak occurs supplying erroneous data to the safety system display. ADJUSTMENT = Put the arm at the up limit switch, position the microswitch so that is pressed 1 mm before the mechanical stop, leaving an overstroke clearance to avoid mechanical breakage.

☞

Page 3

ELECTRICITY H) Retracted arm proximity switch

(Detail 1 - Photo E8): FUNCTIONS = To allow the stabilizers to be lifted only when the arm is retracted. ADJUSTMENT = Set the proximity switch to a distance of about 2-3 mm from the pin.

I) Arm angle proximity switch (Detail 1 - Photo E9): FUNCTIONS = To allow the stabilizers to be lifted (basket above 1 metre of height). ADJUSTMENT = Adjust the proximity switch to about 2-3 mm from the arm.

Page 4

☞ 1

☞

ELECTRICITY

Proximity switches and Microswitches (Basket version) L) Proximity switch on rapid connector

E10

(Detail 1 - Photo E10): ADDITIONAL FUNCTIONS FOR BASKET = Activate safety devices. ADJUSTMENT = Adjust the special screw (Detail 1 Photo E11), to 2-3 mm from the sensor. Warning: maximum reading distance = 5 mm N.B. It’s possible to check the correct function of the proximity thanks to the built-in red lamp (the built-in red lamp has not to turn on when the basket is connected to the quick connection).

☞

E11

☞

E12

M) Proximity switch on the arm saddle (Detail 1 - Photo E12) with 23m basket: FUNCTIONS

ADJUSTMENT

= To raise and lower the stabilizers with the arm lowered below 0.8 m and with the basket arm in the road traffic position. = It must be adjusted so that with the basket arm in the road traffic position (resting on the fork on the arm), the sensor is 2-3 mm away.

☞

ELECTRICITY

N) Microswitch on door (Detail 1 - Photo E13) and platform (Detail 1 - Photo E14) with basket extendible up to 17m: FUNCTIONS ADJUSTMENT

E14

= Used to enable the operations from the basket. = They must be adjusted so that, with the door closed and with the basket open or closed, the microswitches are pressed and the red lamp on the console is off.

☞

E13

☞

O) Microswitch on 17 m basket (Detail 1 - Photo E15 E15) (France version): FUNCTIONS ADJUSTMENT

Page 6

= It blocks the movements of the basket under overload conditions. = It must be adjusted so that the sensor is 5-6 mm from the set screw.

☞

WIRING DIAGRAMS 80-6-M9 EN

INDEX Electric system 1st Version page 1-41 until the truck n° included the truck n°

Electric system 2nd Version page 45-88 from the truck n° included the trucks n°

117101/5948 118104/5989

117102/5983 116122/5857 116123/5858 116678/5931 117099/5933 117100/5982

until the truck n°

120379/6132

Electric system 2nd Version page 91-134 from the truck n°

120425/6144

until the truck n°

121778/6352

Electric system 2nd Version page 137-180 from the truck n°

121779/6356

Electric system 1st Version page1-41 until the truck n° included the truck n°

117101/5948 118104/5989

ELECTRICITY

1st Version

FUSES

The electric circuit is protected by fuses located : in the instrument panel under the cover 1 (fig. B), in the fuse holder box located in the cab (fig. C) and in the electric box under the driver’s cab (Fig. D Page 3). To change a fuse, remove it and replace it with a new one of the same type and rating. When replacing a fuse, it is important to comply with the original specifications: “Quality and Amperage”. If a power outage occurs, check all the fuses and verify if a short-circuit was generated. Do not try to repair a fuse which has burned. Always replace it with a new one with an equal rating.

INSTRUMENT PANEL FUSES

7,5

10 11 12

➠

☞

7,5

Fig. B

FUNCTION DESCRIPTION 1) Fuse 7.5 A direction indicator power supply 2) Fuse 7.5 A buzzer and engine stop power supply. 3) Fuse 7.5 A right position lights power supply. 4) Fuse 7.5 A left position lights power supply. 5) Fuse 7.5 A low-beam lights power supply. 6) Fuse 7.5 A red emergency button, seat left arm microswitch, electronic pendulum power supply. 7) Fuse 7.5 A alignment and tower lock microswitch power supply. 8) Fuse 7.5 A electro-hydraulic servocontrol power supply. 9) Fuse 7.5 A steering type selector and stabilizer selection button lighting power supply. 10) Fuse 7.5 A electric gearbox power supply. 11) Fuse 7.5 A chassis electric system services relay power supply. 12) Fuse 7,5 A high-beam lights power supply.

Page 1

ELECTRICITY

1st Version CAB FUSE HOLDER BOX Fig. C

➠

FUNCTION DESCRIPTION 1) Fuse 25 A available or heater glow plug power supply (if present). 2) Fuse 15 A “DANFOSS” distributor power supply. 3) Fuse 15 A cab beacon power supply. 4) Fuse 15 A heater control unit (if present), emergency lights and ceiling lamp. 5) Fuse 15 A logic board power supply (software and relays) (behind the cab). 6) Fuse 15 A logic board power supply (basket commands and proximity). 7) Fuse 10 A stabilizer panel power supply (extension-return/down-up selector). 8) Fuse 10 A safety system selector. 9) Fuse 10 A cab window wipers power supply. 10) Fuse 10 A front work lights pre-setting. 11) Fuse 10 A available. 12) Fuse 10 A rear work lights pre-setting.

Page 2

ELECTRICITY

1st Version

ELECTRIC BOX UNDER CAB

Fig. D

FUNCTION DESCRIPTION 1) Starter relay. 2) Engine glow plug relay. 3) Low-beam lights relay. 4) High-beam lights relay. 5) Relay for ignition key current and fuse power supply. 6) Stabilizer general solenoid valve relay. 7) Tilting block cylinder relay. 8) Radiator fan relay. 9) General fuse. 10+11) Fuses F1 and F2 10 A right and light position lights. 12) Fuse F3 10 A low-beam lights. 13) Fuse F4 10 A high-beam lights. 14) Fuse F5 10 A stabilizer general solenoid valve protection E6 15) Fuse F6 10 A rear suspension solenoid valve protection E4-E5, solenoid valve for radiator fan 2nd speed E26. 16) Fuse F7 10 A electric safety pump relay protection R11+PNP axle + tower alignment + line N11. 17) Fuse F8 10 A forward and reverse solenoid valve protection E1 and E2 and electronic board C5 (retracted stabilizers). 18) Stabilizer return electronics board.

Page 3

1st Version

ELECTRICITY

LEGEND FOR MRT1540 ELECTRIC PLANT USERS WITH SOFTWARE A1 . Buzzer (Tab. 3) A2 . Reverse buzzer on (Tab. 2) A3 . Active pendulum with basket buzzer (Tab. 11) B1 . Battery no. 1 (12volt - Tab. 1) C1 . Turn signal unit connection (Tab. 3) C2 . Instrument panel white 21-pin connection (Tab. 4) C3 . Cab connection (Tab. 4) C4 . Instrument panel green 21-pin connection(Tab. 5) C5 . Stabilizers return electronic circuit (Tab. 10) E1 . Forward solenoid valve (Tab. 2) E2 . Reverse solenoid valve (Tab. 2) E3 . Engine stop solenoid valve (Tab. 4) E4 . Left rear suspension solenoid valve (Tab. 6) E5 . Right rear suspension solenoid valve (Tab. 6) E6 . Stabilizer general solenoid valve (Tab. 6) E7 . Crab turned solenoid valve (Tab. 6) E8 . Concentric turned solenoid valve (Tab. 6) E9 . Hydraulic circuit exclusion solenoid valve (Tab. 6) E10 . Danfoss tilting solenoid valve (Tab. 7) E11 . Danfoss lifting solenoid valve (Tab. 7) E12 . Danfoss optional solenoid valve (Tab. 7) E13 . Danfoss second extension solenoid valve (Tab. 7) E14 . Danfoss rotation solenoid valve (Tab. 7) E15 . Danfoss third extension solenoid valve (Tab. 7) E16 . Danfoss first extension solenoid valve (Tab. 7) E17 . Stabilizer return solenoid valve (Tab. 8) E18 . Left front beam solenoid valve (Tab. 8) E19 . Left front stabilizer solenoid valve (Tab. 8) E20 . Right front beam solenoid valve (Tab. 9) E21 . Right front stabilizer solenoid valve (Tab. 9) E22 . Left rear beam solenoid valve (Tab. 9) E23 . Left rear stabilizer solenoid valve (Tab. 9) E24 . Right rear beam solenoid valve (Tab. 9) E25 . Right rear stabilizer solenoid valve (Tab. 9) E26 . Sound-proofing solenoid valve (Tab. 9) E27 . Rotation speed reduction solenoid valve (Tab. 9) E28 . 23 metres basket movement solenoid valve (Tab. 9) F1 . Fuse 10A left position lights (Tab. 5) F2 . Fuse 10A right position lights (Tab. 5) F3 . Fuse 10A low-beam lights (Tab. 5) F4 . Fuse 10A high-beam lights (Tab. 5) F5 . Fuse 10A stabilizer general solenoid valve.(Tab. 6) F6 . Fuse 10A suspension solenoid valve. + sound-proofing solenoid valve (Tab. 6) F7 . Fuse 10A rear truck key current (Tab. 2) F8 . Fuse 10A rear truck key current. (Tab. 2) F9 . Fuse link 80A (Tab. 1) F10 . Fuse 15A Danfoss solenoid valves (Tab. 7)

Page 4

ELECTRICITY

1st Version

F11 . Fuse 15A stabilizers (Tab. 8) F12 . Fuse 10A extension up proximity (Tab. 10) F13 . Fuse 10A software circuit power supply (Tab. 11) F14 . Fuse 10A basket power supply (Tab. 11) F15 . Fuse 10A tilting control system (Tab. 12) G1 . Alternator (Tab. 1) I1 . Parking brake microswitch (Tab. 2) I2 . Gearbox manipulator (Tab. 2) I3 . Slow-fast speed microswitch (Tab. 2) I4 . Gearbox reset button (Tab. 2) I5 . Stop lights pressure switch (Tab. 2) I6 . Rear axle alignment proximity PNP (Tab. 2) I7 . Tower alignment proximity PNP (Tab. 2) I8 . Front axle alignment proximity PNP (Tab. 2) I9 . Emergency electric pump key (Tab. 3) I10 . Cab emergency key (Tab. 4) I11 . Fuel reserve contact (Tab. 5) I12 . Air filter clogged pressure switch (Tab. 5) I13 . Pressure switch for low engine oil pressure (Tab. 5) I14 . Cab locked microswitch (Tab. 6) I15 . Cab aligned microswitch (Tab. 6) I16 . Extended right rear stabilizer microswitch (Tab. 6) I17 . Extended left rear stabilizer microswitch (Tab. 6) I18 . Extended left front stabilizer microswitch (Tab. 6) I19 . Extended right front stabilizer microswitch (Tab. 6) I20 . Hydraulic oil temp. thermal contact (Tab. 6) I21 . Engine water temperature thermal contact (Tab. 6) I22 . Hydraulic circuit exclusion button (Tab. 6) I23 . Arm-rest microswitch (Tab. 6) I24 . Steering selector (Tab. 6) I25 . Optional selector-third extension (Tab. 8) I26 . Stabilizer extended-return manipulator (Tab. 8) I27 . Beam-stabilizer selector (Tab. 8) I28 . Left front stabilizer button (Tab. 8) I29 . Right front stabilizer button (Tab. 9) I30 . Left rear stabilizer button (Tab. 9) I31 . Right rear stabilizer button (Tab. 9) I32 . Retracted left rear stabilizer proximity PNP (Tab. 10) I33 . Retracted right rear stabilizer proximity PNP (Tab. 10) I34 . Retracted left front stabilizer proximity PNP (Tab. 10) I35 . Retracted right front stabilizer proximity PNP (Tab. 10) I36 . Arm extension proximity PNP (Tab. 10) I37 . 0.8 mt arm up proximity PNP (Tab. 10) I38 . Electronic levelling pendulum (Tab. 10) I39 . 23 mt basket saddle proximity PNP (Tab. 11) I40 . Basket sensor proximity PNP (N.C.) (Tab. 11) I41 . Lifting exclusion microswitch (Tab. 11) I42 . Basket motor stop button (Tab. 11) I43 . Basket buzzer button (Tab. 11)

Page 5

1st Version I44 . Active contact with 23 mt basket on (Tab. 11) I45 . Basket overload microswitch (Tab. 11) I46 . Basket door microswitch (Tab. 11) I47 . Basket start-up button (Tab. 12) I48 . Basket operating enabling button (Tab. 12) I49 . Basket operation selector (Tab. 12) I50 . Arm up microswitch (Tab. 12) I51 . Tilting control system safety key. (Tab. 12) L1 . Rear axle alignment optical indicator (Tab. 2) L2 . Front axle alignment optical indicator (Tab. 2) L3 . Blocked rear axle optical indicator (Tab. 4) L4 . Position lights optical indicator (Tab. 4) L5 . Locked cab optical indicator (Tab. 6) L6 . Aligned cab optical indicator (Tab. 6) L7 . Extended stabilizer optical indicator (Tab. 6) L8 . Retracted stabilizer optical indicator (Tab. 10) L9 . Active pendulum optical indicator (Tab. 10) L10 . (Basket) defect optical indicator (Tab. 11) L11 . (Basket) active pendulum optical indicator (Tab. 11) M1 . Starter motor (Tab. 1) M2 . Emergency electric pump (Tab. 1) M3 . Cab left Danfoss manipulator (Tab. 8) M4 . Cab right Danfoss manipulator (Tab. 8) M5 . Basket operation manipulator (Tab. 12) P1 . Left rear stop light (Tab. 2) P2 . Right rear stop light (Tab. 2) P3 . Left front direction light (Tab. 3) P4 . Left rear direction light (Tab. 3) P5 . Right front direction light (Tab. 3) P6 . Right rear direction light (Tab. 3) P7 . Left front position light (Tab. 5) P8 . Left rear position light (Tab. 5) P9 . Right front position light (Tab. 5) P10 . Right rear position light (Tab. 5) P11 . Left front low-beam headlight (Tab. 5) P12 . Right front low-beam headlight (Tab. 5) P13 . Left front high-beam headlight (Tab. 5) P14 . Right front high-beam headlight (Tab. 5) R1 . Starter triad relay (Tab. 1) R2 . Low-beam relay (Tab. 3) R3 . High-beam relay (Tab. 3) R4 . Services relay (Tab. 2) R5 . Stabilizer general solenoid valve relay (Tab. 8) R6 . Suspension block relay (Tab. 2) R7 . Sound-proofing relay (Tab. 7) R8 . Start-up relay (Tab. 1) R9 . Hydraulic circuit limitation relay (Tab. 7) R10. Danfoss solenoid valve power supply relay (Tab. 7)

Page 6

ELECTRICITY

1st Version

R11. Emergency pump contactor (Tab. 3) R12. Resistor 68Ω 4W (Tab. 3) R13. (Basket) defect optical indicator relay S1 . Tilting control system (Tab. 12) TR . Thermal starter (Tab. 1) T1 . Engine water temperature transmitter (Tab. 5) T2 . Fuel level transmitter (Tab. 5) KEY. Starter switch (Tab. 1) COLOUR LEGEND A : light blue B : white C : orange G : yellow H : grey L : blue M : brown N : black R : red S : pink V : green Z : violet Example : AB = light-blue/white

Page 7

1st Version

ELECTRICITY

TABLE OF RELAY POSITION ON ELECTRIC DIAGRAM

MASTER ELEMENT

POSITION

SLAVE ELEMENT

POSITION

1/16

ELEMENT OPEN

1/18

R10

7/6

ELEMENT OPEN

7/8

R11

3/3

ELEMENT OPEN

1/3

R13

11/18

ELEMENT CLOSED

11/13

3/18

ELEMENT OPEN

5/15

3/16

ELEMENT OPEN

5/18

2/18

ELEMENT OPEN

2/9

8/12

ELEMENT OPEN

6/13

2/16

ELEMENT OPEN

6/7

6/10

ELEMENT CLOSED

9/15

1/10

ELEMENT OPEN

1/5

7/3

ELEMENT OPEN

7/4

Page 8

ELECTRICITY

1st Version 40-PIN ROTARY FITTING CONNECTION DIAGRAM

BROWN CABLE GROUP

N° 01 02 03 04 05 06 07 08 09 10

COLOUR Brown-white Green-blue Grey-blue Orange-blue Yellow-blue Light blue-yellow Orange-black Yellow-red Orange-red Orange

DESCRIPTION Retracted stabilizer lamp Extended stabilizer micro-pressure switches Right front stabilizer Solenoid valve return Left front beam Right rear beam Right front beam Rear right beam Left rear beam Left front beam

GREY CABLE GROUP

N° 01 02 03 04 05 06 07 08 09 10

COLOUR Blue-red Pink Red-black Grey no. 4 Yellow-green Violet-black Grey-white Yellow-brown White-green White-red

DESCRIPTION Left front stabilizer Fuel level instrument Fuel reserve lamp Stabilizer general solenoid valve Slow-fast enabling signal Rear axle alignment Hydraulic circuit exclusion solenoid valve Reverse Start enabling signal Emergency pump key

BLACK CABLE GROUP

N° 01 02 03 04 05 06 07 08 09 10

COLOUR White Grey-green Violet-white Green-white Green-white Blue Blue-black Yellow-grey Black d. 6 Red d. 6

DESCRIPTION Position lights Air filter clogged Front axle alignment Crab turned Concentric turned Right direction lights Left direction lights Forward Negative power supply Positive power supply

Page 9

1st Version WHITE CABLE GROUP

N° 01 02 03 04 05 06 07 08 09 10

COLOUR Green-black Grey-black White no. 3 White no. 4 Yellow-green Grey-red Grey Brown Green White black

Page 10

DESCRIPTION High-beam headlights Low-beam headlights Thermal starter Ignition key current Start-up Battery charger lamp Engine oil low pressure lamp Engine stop Active rear suspensions Engine water temperature instrument

ELECTRICITY

1st Version

TABLE N°1

ELECTRICITY

Page 11

TABLE N°2

1st Version

Page 12

ELECTRICITY

1st Version

TABLE N°3

CONNECTION 9 PIN PM MATE - N - LOK

Page 13

1st Version

TABLE N°4

CONNECTION 8 PIN PM

Page 14

ELECTRICITY

1st Version

TABLE N°5

ELECTRICITY

Page 15

TABLE N°6

1st Version

Page 16

ELECTRICITY

1st Version

TABLE N°7

ELECTRICITY

Page 17

TABLE N°8

1st Version

Page 18

ELECTRICITY

1st Version

TABLE N°9

ELECTRICITY

Page 19

TABLE N°10

1st Version

Page 20

ELECTRICITY

1st Version

TABLE N°11

ELECTRICITY

Page 21

TABLE N°12

1st Version

Page 22

ELECTRICITY

POSITIVE POWER SUPPLY

I52 M6 R14 L12 L13 E29 E30

: : : : : : :

LEGEND Braking circuit pressure switch Slow-fast insertion manipulator Magnetic retainer relay Slow speed on lamp Fast speed on lamp Slow speed solenoid valve Fast speed solenoid valve

GEARBOX ELECTRIC CONTROL DIAGRAM

ELECTRICITY

1st Version

Page 23

1st Version MRT 1540 SOFTWARE INPUT-OUTPUT CONNECTORS INPUT connectors Power supply connector MA MA-01 MA-01

Black ø 1.5 Red black ø 1.5

Negative power supply Positive power supply

Connector M1 M1-01 M1-02 M1-03 M1-04 M1-05 M1-06 M1-07 M1-08 M1-09 M1-10 M1-11 M1-12

Blue-green Orange-red Light blue-yellow White no. 09 Grey no. 44 Orange-blue no. 04 Orange-green Orange-blue Yellow-red Yellow-green Violet-white Yellow-blue

Extended and lowered stabilizers Extension limitation proximity Up limitation proximity Rear axle locking Manipulator stabilizer output signal Manipulator stabilizer return signal Cab manipulator microswitches Basket manipulator microswitch Electronic pendulum 23 mt resting basket saddle proximity Basket sensor proximity Emergency key

Connector M2 M2-01 M2-02 M2-03 M2-04 M2-05 M2-06

Orange-red Brown-white Yellow-grey Grey-black -----------------------Green

Basket operation enabling signal button Basket engine stop button 23 mt on basket signal Anti-tilting -----------------------------------------------------Up operation exclusion microswitch

Connector M3 analog signals from cab manipulators M3-01 M3-02 M3-03 M3-04 M3-05 M3-06 M3-07

Page 24

Light blue-white Green-white Grey-blue Grey-white White-yellow Orange-white Pink-yellow

Tilting Lifting Optional Extension 2 Rotation Extension 3 Extension 1

ELECTRICITY

1st Version

Connector M4 analog signals from basket manipulator M4-01 M4-02 M4-03 M4-04 M4-05 M4-06 M4-07

Blue-black Green-black White-black Grey-black Yellow-black Orange-black Pink-black

Tilting Lifting Optional Extension 2 Rotation Extension 3 Extension 1

OUTPUT connectors Connector M5 analog signals for Danfoss solenoid valves M5-01 M5-02 M5-03 M5-04 M5-05 M5-06 M5-07

Blue Green White Grey Yellow Orange Pink

Tilting solenoid valve Lifting solenoid valve Optional solenoid valve Extension 2 solenoid valve Rotation solenoid valve Extension 3 solenoid valve Extension 1 solenoid valve

Connector M6 M6-01 M6-02 M6-03 M6-04 M6-05 M6-06 M6-07 M6-08 M6-09 M6-10 M6-11 M6-12

Orange-blue Grey no. 4 Grey-red Red White-green Yellow-brown Red-green Brown White-grey + diode White-grey + diode Violet-black Red-black ø 1.5

Stabilizer return solenoid valve Stabilizer general solenoid valve Signal for anti-tilting system configuration Rotation speed reduction solenoid valve Pendulum activated with stabilizers extended Tilting basket movement solenoid valve Red defect lamp Engine stop Cab Danfoss solenoid valve power supply control Basket Danfoss solenoid valve power supply control Locked rear axle blinking lamp Positive common

Page 25

Page 26

MM A A I I 0 0 1 2

G + N 1 D 2 V

POWER SUPPLY

M MMM MM 2 2 2 2 2 2 I I I I I I 0 0 0 0 0 0 1 2 3 4 5 6

OOOOOO

M MMM MMM 3 3 3 3 3 3 3 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

OOOOOOO

M MMM MMM MM M M M 1 1 1 1 1 1 1 1 1 1 1 1 I I I I I I I I I I I I 0 0 0 0 0 0 0 0 0 1 1 1 1 2 3 4 5 6 7 8 9 0 1 2

M MMM MMM 4 4 4 4 4 4 4 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

R12

OOOOOOO

M MMM MMM 5 5 5 5 5 5 5 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

OOOOOOO

R10

R11

DIAGRAM OF CONNECTIONS AND RELAYS OF THE ELECTRIC BOX BEHIND THE CAB

OOOOOOOOOOOO

GREEN AND RED LAMPS

K10

K11

M MMM MMM MM M M M 6 6 6 6 6 6 6 6 6 6 6 6 I I I I I I I I I I I I 0 0 0 0 0 0 0 0 0 1 1 1 1 2 3 4 5 6 7 8 9 0 1 2

OOOOOOOOOOOO

1st Version ELECTRICITY

OOOOOO

✷

✷ R8

R12

OOOOOOO

R10

R11

K1 = outriggers retract K2 = outriggers relay K3 = outriggers or wheels PAT signal relay K4 = basket version relay for rotation speed reduction K5 = 3° inclination relay - orange light in the cab turned on - push button panel and buzzer K6 = 23m basket free relay

OOOOOOO

LEGEND R1-R2-R3-R4 = basket or cab selection R5 = TS inclination R6 = lifting R7 = optional R8 = telescope 1 R9 = rotation R10 = telescope 3 R11 = telescope 1 R12 = Danfoss flow regulator selection

ALIMENTATION

OOOOOOOOOOOO

✷

K10

K11

OOOOOOOOOOOO

Danfoss flow regulator connection for lifting and descent (TS inclination only for 23m)

K7 = basket red light relay K8 = engine stopped relay K9 = contact N relay 12V cab K10 = contact N relay 12V basket K11 = rear axle locked yellow light

DIAGRAM OF CONNECTIONS AND RELAYS OF THE ELECTRIC BOX BEHIND THE CAB

✷ relay 5 A 2 contacts relay 16A 1contact all interchangeable R = controlled relay for Danfoss variable signal R = 12V control

GREEN AND RED LAMPS

ELECTRICITY

1st Version

Page 27

ELECTRICITY

Page 28

M MMM MMM MM M M M 6 6 6 6 6 6 6 6 6 6 6 6 I I I I I I I I I I I I 0 0 0 0 0 0 0 0 0 1 1 1 1 2 3 4 5 6 7 8 9 0 1 2 M MMM MMM 5 5 5 5 5 5 5 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

Extension 1 solenoid valve Extension 3 solenoid valve Slewing solenoid valve Extension 2 solenoid valve Optional solenoid valve Lifting solenoid valve Tilting solenoid valve

M MMM MMM 4 4 4 4 4 4 4 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

Extension 1 Extension 3 Slewing Extension 2 Optional Lifting Tilting

M MMM MMM 3 3 3 3 3 3 3 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

Extension 1 Extension 3 Slewing Extension 2 Optional Lifting Tilting

M MMM MM 2 2 2 2 2 2 I I I I I I 0 0 0 0 0 0 1 2 3 4 5 6

Ascent manoeuvre inhibiting microswitch ---------------------------------------------------Anti-overturning 23m aerial platform engaged signal Aerial platform engine stop button Aerial platform manoeuvre enabling button

OOOOOOO OOOOOOO OOOOOOO

Positive common contact Flashing rear axle locked light Danfoss solenoid valve power control from aerial platform. Danfoss solenoid valve power control from cab Engine stop Red fault light Tilting aerial platform movement solenoid valve Telltale activated with outriggers extended Slewing speed reduction solenoid valve General outrigger solenoid valve Outrigger retraction solenoid valve

MM A A I I 0 0 1 2

G + N 1 D 2 V

OOOOOO

DANFOSS PVG 32 MANIPULATEUR NACELLE

K10 K8 K6 K4 K2 R10 R9 R8 R7 R3 M MMM MMM MM M M M 1 1 1 1 1 1 1 1 1 1 1 1 I I I I I I I I I I I I 0 0 0 0 0 0 0 0 0 1 1 1 1 2 3 4 5 6 7 8 9 0 1 2

MANIPULATEUR CABINE ALIMENTATION

GREEN AND RED LAMPS

Saving key Aerial platform engaged proximity 23m aerial platform on hold proximity Electronic telltale Aerial platform manipulator microswitch Cab manipulator microswitches Outrigger retraction signal from manipulator Outrigger extension signal from manipulator Rear axle lock Ascent limiting proximity Extension limiting proximity Outriggers extended and lowered

OOOOOOOOOOOO

K9 K7 K5 K3 K1 R11 R12 R6 R5 R4 R1

DIAGRAM OF CONNECTIONS AND RELAYS OF THE ELECTRIC BOX BEHIND THE CAB

K11

OOOOOOOOOOOO

1st Version

ELECTRICITY CONNECTION OR RELAY

1st Version RATING PLATES ON THE COVER OF THE ELECTRIC BOX BEHIND THE CAB CONNECTION OR RELAY

Page 29

1st Version

ELECTRICITY

DESCRIPTION OF THE SIGNAL LAMPS AND RATING PLATES ON THE COVER OF THE ELECTRIC BOX BEHIND THE CAB CONNECTION ON OR OFF RELAY

. ... ... .

M1-01

. ... ... .

M1-02

. ... ... .

M1-03

. ... ... .

M1-04

. ... ... .

M1-05

. ... ... .

M1-06

. ... ... .

M1-07

. ... ... .

M1-08

. ... ... .

M1-09

. ... ... .

M1-10

. ... ... .

M1-11

. ... ... .

M1-12

. ... ... .

M2-01

. ... ... .

M2-02

. ... ... .

M2-03

. ... ... .

M2-04

. ... ... .

M2-06

. ... ... .

R1 - R2 R3-R4

. ... ... .

Page 30

DESCRIPTION STABILIZERS EXTENDED AND LOWERED STABILIZERS LIFTED I°+II° EXTENSION COMPLETELY RETRACTED I° OR II° EXTENSION EXTENDED SMALLER ARM HEIGHT 0.8 METRES LARGER ARM HEIGHT - EQUAL TO 0.8 METRES REAR AXLE FREE REAR AXLE LOCKED STABILIZER EXTEND CONTROL EXECUTION STABILIZER EXTEND CONTROL NOT EXECUTED STABILIZER RETURN CONTROL EXECUTION STABILIZER RETURN CONTROL NOT EXECUTED CAB CONTROL EXECUTION CAB CONTROLS NOT EXECUTED BASKET CONTROLS EXECUTE BASKET CONTROLS NOT EXECUTED ELECTRONIC PENDULUM ACTIVE (3°) ELECTRONIC PENDULUM NOT ACTIVE 23 METRE BASKET IN SEAT 23 METRE BASKET OUT OF SEAT BASKET NOT PRESENT ON RAPID CONNECTOR BASKET PRESENT ON RAPID CONNECTOR EMERGENCY KEY ACTIVATED EMERGENCY KEY NOT ACTIVATED BASKET OPERATION ENABLING SIGNAL BUTTON PRESSED BASKET OPERATION ENABLING SIGNAL BUTTON RELEASED BASKET CONSOLE ENGINE STOP BUTTON PRESSED BASKET CONSOLE ENGINE STOP BUTTON RELEASED 23 METRE BASKET CONSOLE CABLE CONNECTED 23 METRE BASKET CONSOLE CABLE DISCONNECTED OR USE OF 17 MT BASKET SAFETY SYSTEM NOT ACTIVE SAFETY SYSTEM ACTIVE SIGNAL ACTIVE: ARM LIFTED TO LIMIT SWITCH SIGNAL NOT ACTIVE: ARM UP OR DOWN OPERATION ALLOWED CONTROLS FROM BASKET OR CAB EXECUTED CONTROLS FROM BASKET OR CAB NOT EXECUTED TILTING CONTROL EXECUTED TILTING CONTROL NOT EXECUTED OR NOT ALLOWED LIFTING CONTROL EXECUTED LIFTING CONTROL NOT EXECUTED OR NOT ALLOWED

ELECTRICITY

1st Version

DESCRIPTION OF THE SIGNAL LAMPS AND RATING PLATES ON THE COVER OF THE ELECTRIC BOX BEHIND THE CAB CONNECTION ON OR OFF RELAY

. ... ... .

R10

. ... ... .

R11

. ... ... .

R12

. ... ... .

DESCRIPTION OPTIONAL CONTROL EXECUTED OPTIONAL CONTROL NOT EXECUTED OR NOT ALLOWED II° EXTENSION CONTROL EXECUTED II° EXTENSION CONTROL NOT EXECUTED OR NOT ALLOWED ROTATION CONTROL EXECUTED ROTATION CONTROL NOT EXECUTED OR NOT ALLOWED III° EXTENSION CONTROL EXECUTED III° EXTENSION CONTROL NOT EXECUTED OR NOT ALLOWED I° EXTENSION CONTROL EXECUTED I° EXTENSION CONTROL NOT EXECUTED OR NOT ALLOWED BASKET ON RAPID CONNECTOR BASKET NOT ON RAPID CONNECTOR STABILIZER RETURN CONTROL EXECUTED STABILIZER RETURN NOT EXECUTED OR NOT ALLOWED STABILIZER CONTROL EXECUTED STABILIZER CONTROL NOT EXECUTED SAFETY SYSTEM ACTIVE SAFETY SYSTEM NOT ACTIVE BASKET NOT ON RAPID CONNECTOR BASKET ON RAPID CONNECTOR ELECTRONIC PENDULUM ACTIVE ELECTRONIC PENDULUM NOT ACTIVE BASKET ON RAPID CONNECTOR AND BASKET OR CAB CONTROLS EXECUTED BASKET NOT ON RAPID CONNECTOR AND BASKET OR CAB CONTROLS NOT EXECUTED

. ... ... .

K10

. ... ... .

K11

. ... ... .

STABILIZERS LIFTED OR BASKET NOT ON RAPID CONNECTOR STABILIZERS LOWERED OR BASKET ON RAPID CONNECTOR BASKET CONSOLE ENGINE STOP BUTTON PRESSED BASKET CONSOLE ENGINE STOP BUTTON RELEASED CONTROLS EXECUTED FROM THE CAB IF ALLOWED CONTROL NOT EXECUTED FROM THE CAB OR NOT ALLOWED CONTROLS EXECUTED FROM THE BASKET IF ALLOWED CONTROL NOT EXECUTED FROM THE BASKET OR NOT ALLOWED REAR AXLE LOCKED (blinking LIGHT) REAR AXLE FREE

Page 31

1st Version

ELECTRICITY

ELECTRONIC BOARD ELECTRIC CIRCUIT

Page 32

ELECTRICITY

1st Version

THE INPUT ADAPTATION CIRCUIT IS REPEATED FOR 15 SECTIONS

Page 33

1st Version

INVERTED NUMBERING

Page 34

ELECTRICITY

1st Version

THE POWER CIRCUIT WILL BE REPLICATED FOR 22 OUTPUTS

Page 35

1st Version

Page 36

ELECTRICITY

OUTPUT 1 CONTROL OUTPUT 2 CONTROL OUTPUT 3 CONTROL OUTPUT 4 CONTROL OUTPUT 5 CONTROL OUTPUT 6 CONTROL OUTPUT 7 CONTROL SIGN 1 CONTROL OUTPUT 9 CONTROL OUTPUT 10 CONTROL OUTPUT 11 CONTROL

K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11

RELAY COIL CONTROLS OUTPUT 12 CONTROL OUTPUT 13 CONTROL OUTPUT 14 CONTROL OUTPUT 15 CONTROL OUTPUT 16 CONTROL OUTPUT 17 CONTROL OUTPUT 18 CONTROL OUTPUT 19 CONTROL OUTPUT 20 CONTROL OUTPUT 21 CONTROL

R12 R11 R10 R9 R8 R7 R6 R5 R1-R2-R3-R4 4053

ELECTRICITY

1st Version

Page 37

Page 38

LEVELLING - YELLOW LAMP

POSITION LIGHTS - GREEN LAMP

EXTENDED AND LOWERED STABILIZERS - BLUE LAMP

D 63

CONTACT AND STARTER KEY

C.E.C. PAT SUPPRESSION KEY

TOWER ROTATION BLOCK - RED LAMP

RETRACTED STABILIZERS - GREEN LAMP

TOWER ALIGNMENT - GREEN LAMP

REAR AXLE OSCILLATION BLOCK - FLASHING YELLOW LAMP

DIRECTION SELECTOR

TRANSMISSION RESET

STABILIZER UP DOWN EXTENSION SELECTOR

BASKET EMERGENCY KEY

C. E. C. PAT

ELECTRIC COMPONENT LAYOUT

FRONT AND REAR AXLE ALIGNMENT LAMP

LEFT REAR STABILIZER

RIGHT REAR STABILIZER

LEFT FRONT STABILIZER

FRONT RIGHT STABILIZER

STABILIZER CONTROL LEVER

LIGHT SWITCH

1st Version ELECTRICITY

LIFTING-TILTING-T2 DANFOSS MANIPULATOR

HYDRAULIC SYSTEM LP EXCLUSION SPEED CHANGE MANIPULATOR

T1-T3-ACCESSORY DANFOSS MANIPULATOR

ELECTRIC COMPONENT LAYOUT

HYDRAULIC MOVEMENT EXCLUSION MICROSWITCH

PARKING BRAKE TRANSMISSION SECTION MICROSWITCH

T3-ACCESSORY CONTROL SELECTOR

ELECTRICITY

1st Version

D 64

Page 39

Page 40

✷ BASKET PROXIMITY INDICATOR

PAT WINDER AND ANGLE INDICATOR

0.8 M HIGH ARM PROXIMITY INDICATOR

ELECTRIC SAFETY PUMP

✷ PENDULUM LEVELLING INDICATOR

LIFTING LIMIT SWITCH MICROSWITCH

TOWER ALIGNMENT MICROSWITCH

SAFETY PUMP CONTROL KEY

D 65

NOTE ✷ ONLY IN THE BASKET VERSION

ELECTRIC BOX UNDER THE STEP LADDER

BLOCKED TOWER MICROSWITCH

ELECTRIC HEADER

ELECTRIC COMPONENT LAYOUT

TOWER NOT ALIGNED = 5° PROXIMITY INDICATOR

STABILIZERS RESTING ON GROUND MICROSWITCH

RETRACTED STABILIZER PROXIMITY INDICATOR

RETRACTED ARM PROXIMITY INDICATOR

1st Version ELECTRICITY

FUSE BOX UNDER THE INSTRUMENT PANEL

SOFTWARE ELECTRONIC BOX

ELECTRIC COMPONENT LAYOUT

ELECTRICITY

1st Version

D 66

Page 41

Electric system 2nd Version page 45-88 from the truck n° 117102/5983 included the trucks n° 116122/5857 116123/5858 116678/5931 117099/5933 117100/5982 until the truck n°

120379/6132

ELECTRICITY

2nd Version

FUSE AND RELAY BOX

➠ 1

E5 E11

E10

➩

Page 45

ELECTRICITY

2nd Version

FUNCTIONAL DESCRIPTION OF THE FUSES IN THE BOX LOCATED UNDER THE COVER OF THE INSTRUMENT PANEL Ref.

Amps

Description

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15

10 5 7.5 10 15 5 7.5 10 3 10 10 7.5 3 Diode 10

Electronic pendulum + hydraulic circuit exclusion solenoid valve Gear switch + truck ignition power supply Light switch + buzzer from cab Beacon Available Direction lights Drive wheel selector Front windshield wiper and washer Instrument + lamp meter + lamp control check Front working lights Rear working lights Rear and top windshield wiper Stabiliser switch lighting Forward gear Emergency key + braking switch + translation solenoid valves

F16

7.5

F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28

7.5 15 10 15 15 7.5 10 15 10 10 5 Diode

Microswitch lock and tower alignment + transmission reset button Cab control manipulators Instrument panel stabilisers Anti-tipping system Logic + cage Danfoss solenoid valves Available Available Available Available (direct power supply) Ceiling light + emergency lights Available Reverse

FUNCTIONAL DESCRIPTION OF RELAYS IN THE BOX LOCATED UNDERNEATH THE COVER OF THE INSTRUMENT PANEL Ref.

Characteristics

Description

E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E11

20/30 Amps 20/30 Amps 20/30 Amps 20/30 Amps 20/30 Amps 20/30 Amps ....................... ....................... ....................... ....................... 12 Volt 84/168 Watt

Ignition enabling signal Hydraulic circuit exclusion Danfoss solenoid valve power supply Forward gear Reverse Parking brake on optical indicator ................................... ................................... ................................... ................................... Direction and emergency light flashing

Page 46

ELECTRICITY

2nd Version

ELECTRIC BOX UNDER CAB

E 12

F 30 F 31 F 32

E 19

E 18

E 17

E 16

E 15

F 29

E 14

E 13

F 33 F 34 F 35 F 36 F 37

FUNCTIONS DESCRIPTION E12) Ignition relay E13) Thermal starter relay E14) Low beam relay E15) High beam relay E16) Services relay E17) Stabiliser general solenoid valve relay E18) Suspension lock relay E19) Soundproofing relay F29) Fuse 80 A : General power supply F30) Fuse 10 A : Front left and back right position lights F31) Fuse 10 A : Front right and back left position lights F32) Fuse 10 A : Low beam lights F33) Fuse 10 A : High beam lights F34) Fuse 10 A : Stabiliser general solenoid valve F35) Fuse 10 A : Rear axle oscillating solenoid valves and soundproofing solenoid valve F36) Fuse 10 A : Front truck ignition power supply F37) Fuse 10 A : Rear truck ignition power supply C1) Circuit electronic stabiliser return

Page 47

2nd Version

ELECTRICITY

USERS LEGEND ELECTRIC SYSTEM MRT1540 MANITOU CAB 1996 VERSION WITH SOFTWARE (reference drawing No. 756) A1 . Buzzer (Tab. 3) A2 . Reverse engaged buzzer (Tab. 2) A3 . Pendulum active with cage buzzer (Tab. 11) B1 . Battery (12 VOLT - Tab. 1) C1 . Circuit electronic stabiliser return (Tab. 10) D1 . Light control switch (Tab. 3) D2 . Diode 1 amp (Tab. 6 - 11) E1 . Ignition enabling relay E2 . Hydraulic circuit exclusion relay E3 . Danfoss solenoid valve power supply relay E4 . Forward relay E5 . Reverse relay E6 . Parking brake optical indicator relay E7 . Available relay E8 . Available relay E9 . Available relay E10 . Available relay E11 . Direction/emergency light flashing (Tab. 4) E12 . Ignition relay E13 . Thermal starter relay E14 . Low beam relay E15 . High beam relay E16 . Services relay E17 . Stabiliser general solenoid valve relay E18 . Suspension lock relay E19 . Soundproofing relay E20 . Emergency pump contactor E21 . Optical defect indicator relay (cage) E22 . Slow - fast speed bistatic relay (Tab. 12) F1 . Fuse 10 A : Electronic pendulum + hydraulic circuit exclusion solenoid valve (Tab. 6) F2 . Fuse 5 A : Gear engaged switch + truck ignition power supply (Tab. 2) F3 . Fuse 7.5 A : Light switch + cab buzzer (Tab. 3) F4 . Fuse 10 A : Beacon (Tab. 5) F5 . Fuse 15 A : Available (Tab. 13) F6 . Fuse 5 A : Direction lights (Tab. 3) F7 . Fuse 7.5 A : Drive wheel command (Tab. 4) F8 . Fuse 10 A : Front windshield wiper + washer (Tab. 13) F9 . Fuse 3 A : Instruments + lamp control check (Tab. 1) F10 . Fuse 10 A : Front working lights (Tab. 13) F11 . Fuse 10 A : Rear working lights (Tab. 13) F12 . Fuse 7.5 A : Rear windshield wiper + top windshield wiper (Tab. 13) F13 . Fuse 3 A : Stabiliser switch lighting (Tab. 8) F14 . Diode 1 A : Available (Tab. 3) F15 . Fuse 10 A : Emergency key + braking pressure switch + translation solenoid valve (Tab. 7) F16 . Fuse 7.5 A : Microswitch lock and tower alignment + transmission reset button (Tab. 2) F17 . Fuse 7.5 A : Danfoss cab operating manipulators (Tab. 8) F18 . Fuse 15 A : Stabiliser instrument panel (Tab. 8) F19 . Fuse 10 A : Anti-tipping system (Tab. 12) F20 . Fuse 15 A : Board with logic + cage (Tab. 11) F21 . Fuse 15 A : Danfoss solenoid valves (Tab. 7) F22 . Fuse 7.5 A : Available (Tab. 3) F23 . Fuse 10 A : Available(Tab. 3) F24 . Fuse 15 A : Available(Tab. 3) F25 . Fuse 10 A : Available direct power supply (Tab. 3) F26 . Fuse 10 A : Emergency lights + ceiling light (Tab. 3) Page 48

ELECTRICITY

2nd Version

F27 . Fuse 5 A : Available(Tab. 3) F28 . Diode 3 A : Available(Tab. 2) F29 . Fuse 80 A : General power supply (Tab. 1) F30 . Fuse 10 A : Front left and back right position lights (Tab. 3) F31 . Fuse 10 A : Front right and back left position lights(Tab. 3) F32 . Fuse 10 A : Low beam lights (Tab. 4) F33 . Fuse 10 A : High beam lights (Tab. 4) F34 . Fuse 10 A : Stabiliser general solenoid valve (Tab. 5) F35 . Fuse 10 A : Rear axle oscillating solenoid valves and soundproofing solenoid valve (Tab. 6) F36 . Fuse 10 A : Front truck ignition power supply (Tab. 2) F37 . Fuse 10 A : Rear truck ignition power supply (Tab. 2) F38 . Fuse 30 A : Heating (Tab. 14) G1 . Alternator (Tab. 1) H1 . Hour meter (Tab. 1) I1 . Parking brake microswitch (Tab. 2) I2 . Forward-reverse gear manipulator (Tab. 4) I3 . Slow-fast gear microswitch (Tab. 2) I4 . Transmission reset button (Tab. 2) I5 . Stop lights pressure switch (Tab. 2) I6 . Proximity PNP rear axle alignment (Tab. 2) I7 . Proximity PNP Tower alignment (Tab. 2) I8 . Proximity PNP front axle alignment (Tab. 2) I9 . Emergency electric pump key (Tab. 7) I10 . Cab emergency key (Tab. 7) I11 . Fuel reserve level switch (Tab. 5) I12 . Air filter fouling pressure switch (Tab. 5) I13 . Pressure switch for low engine oil pressure (Tab. 5) I14 . Cab locked microswitch (Tab. 6) I15 . Cab aligned microswitch (Tab. 6) I16 . Right rear output stabiliser micro (Tab. 6) I17 . Left rear output stabiliser micro (Tab. 6) I18 . Left front output stabiliser micro (Tab. 6) I19 . Right front output stabiliser micro (Tab. 6) I20 . Hydraulic oil temperature thermal contact (Tab. 6) I21 . Engine water temperature thermal contact (Tab. 6) I22 . Hydraulic circuit exclusion button (Tab. 6) I23 . Arm microswitch (Tab. 6) F35 . Fuse 10 A : Rear axle oscillating solenoid valves and soundproofing solenoid valve (Tab. 6) I24 . Drive wheel selector (Tab. 4) I25 . Third extension - optional selector (Tab. 8) I26 . Stabiliser extension-return manipulator (Tab. 8) I27 . Beam-stabiliser selector (Tab. 8) I28 . Left front stabiliser button (Tab. 8) I29 . Right front stabiliser button (Tab. 9) I30 . Left rear stabiliser button (Tab. 9) I31 . Right rear stabiliser button (Tab. 9) I32 . Proximity PNP - Left rear stabiliser returned (Tab. 10) I33 . Proximity PNP - Right rear stabiliser returned (Tab. 10) I34 . Proximity PNP - Left front stabiliser returned (Tab. 10) I35 . Proximity PNP - Right front stabiliser returned (Tab. 10) I36 . Proximity PNP - Arm extension (Tab. 10) I37 . Proximity PNP - Arm rise 0.8 mt (Tab. 10) I38 . Electronic levelling pendulum (Tab. 10) I39 . Proximity PNP - 23 mt cage saddle (Tab. 11) I40 . Proximity PNP - (n.C.) cage present (Tab. 11) I41 . Lifting exclusion microswitch (Tab. 11) I42 . Cage engine stop button (Tab. 11) I43 . Cage buzzer button (Tab. 11) Page 49

2nd Version I44 . Contact active with 23 mt cage inserted (Tab. 11) I45 . Cage overload microswitch (Tab. 11) I46 . Cage door microswitch (Tab. 11) I47 . Cage start-up button (Tab. 12) I48 . Cage operation enabling button (Tab. 12) I49 . Cage operation selector (Tab. 12) I50 . Arm rise microswitch (Tab. 12) I51 . Anti-tipping system safety key (Tab. 12) I52 . Engine max. water temperature thermal contact (Tab. 5) I53 . Emergency light switch (Tab. 3) I54 . Beacon switch (Tab. 5) I55 . Brake oil level switch (Tab. 5) I56 . Braking pressure switch (Tab. 12) I57 . Front windshield wiper and washer switch (Tab. 13) I58 . Rear and top windshield wiper switch (Tab. 13) I59 . Front working light switch (Tab. 13) I60 . Rear working light switch (Tab. 13) KEY . Ignition switch (Tab. 1) L1 . Rear axle alignment optical indicator (Tab. 2) L2 . Front axle alignment optical indicator(Tab. 2) L3 . Rear axle locked optical indicator (Tab. 7) L4 . Position lights optical indicator (Tab. 3) L5 . Cab locked optical indicator (Tab. 6) L6 . Cab aligned optical indicator (Tab. 6) L7 . Stabilisers extended optical indicator (Tab. 6) L8 . Stabilisers retracted optical indicator (Tab. 10) L9 . Pendulum active optical indicator (Tab. 10) L10 . (Cage) defect optical indicator (Tab. 11) L11 . Pendulum active (cage) optical indicator (Tab. 11) L12 . Slow gear engaged optical indicator (Tab. 12) L13 . Fast gear engaged optical indicator (Tab. 12) L14 . Battery charge optical indicator (Tab. 1) L15 . High beam lights optical indicator (Tab. 3) L16 . Direction lights optical indicator (Tab. 4) L17 . Parking brake optical indicator (Tab. 4) L18 . Available optical indicator (Tab. 5) L19 . Fuel reserve optical indicator (Tab. 5) L20 . Fouled air filter optical indicator (Tab. 5) L21 . Low engine oil pressure optical indicator (Tab. 5) L22 . Max. engine water temperature optical indicator (Tab. 5) L23 . Low brake fluid level optical indicator (Tab. 5) M1 . Starter motor (Tab. 1) M2 . Emergency electric pump (Tab. 1) M3 . Cab left Danfoss manipulator (Tab. 8) M4 . Cab right Danfoss manipulator (Tab. 8) M5 . Cage operating manipulator (Tab. 12) M6 . Slow - fast speed manipulator (Tab. 12) M7 . Front windshield wiper (Tab. 13) M8 . Windshield cleaner pump (Tab. 13) M9 . Rear windshield wiper (Tab. 13) M10 . Top windshield wiper (Tab. 13) M11 . Heating fuel pump (Tab. 14) P1 . Left rear stop light (Tab. 2) P2 . Right rear stop light(Tab. 2) P3 . Left front direction light (Tab. 3) P4 . Left rear direction light (Tab. 3) P5 . Right front direction light (Tab. 3) P6 . Right rear direction light(Tab. 3) Page 50

ELECTRICITY

2nd Version

P7 . Left front position light (Tab. 3) P8 . Left rear position light(Tab. 3) P9 . Right front position light (Tab. 3) P10 . Right rear position light (Tab. 3) P11 . Left front lowbeam light (Tab. 4) P12 . Right front lowbeam light (Tab. 4) P13 . Left front highbeam light (Tab. 4) P14 . Left front highbeam light (Tab. 4) P15 . Cab ceiling light (Tab. 3) P16 . Beacon (Tab. 5) P17 . Front working light (Tab. 13) P18 . Rear working light (Tab. 13) R1 . Resistor 68 Ω 2 W (Tab. 1) R2 . Heating (Tab. 14) R3 . Heating thermostat (Tab. 14) SI . Lifting Danfoss solenoid valve (Tab. 7) S2 . First extension Danfoss solenoid valve (Tab. 7) S3 . Second extension Danfoss solenoid valve (Tab. 7) S4 . Rotation Danfoss solenoid valve (Tab. 7) S5 . Swinging Danfoss solenoid valve (Tab. 7) S6 . Third extension Danfoss solenoid valve (Tab. 7) S7 . Optional Danfoss solenoid valve (Tab. 7) S8 . Rotation speed reduction solenoid valve (Tab. 9) S9 . Stabiliser general solenoid valve (Tab. 5) S10 . Hydraulic circuit exclusion solenoid valve (Tab. 6) S11 . Left front beam solenoid valve (Tab. 8) S12 . Right front beam solenoid valve (Tab. 9) S13 . Left rear beam solenoid valve (Tab. 9) S14 . Right rear beam solenoid valve (Tab. 9) S15 . Stabiliser return solenoid valve (Tab. 8) S16 . Right front stabiliser solenoid valve (Tab. 9) S17 . Left front stabiliser solenoid valve (Tab. 8) S18 . Left rear stabiliser solenoid valve (Tab. 9) S19 . Right rear stabiliser solenoid valve (Tab. 9) S20 . Soundproofing solenoid valve (Tab. 9) S21 . Forward solenoid valve (Tab. 2) S22 . Reverse solenoid valve (Tab. 2) S23 . Rear axle oscillation solenoid valve (Tab. 6) S24 . Crabwise steering solenoid valve (Tab. 4) S25 . Cam drive solenoid valve (Tab. 4) S26 . Rear axle oscillation solenoid valve (Tab. 6) S27 . Slow speed solenoid valve (Tab. 12) S28 . Fast speed solenoid valve (Tab. 12) S29 . 23 mt cage movement solenoid valve (Tab. 9) S30 . Engine stop solenoid valve (Tab. 7) ST1. Anti-tipping system (Tab. 12) ST2. Fuel level instrument (Tab. 5) T1 . Fuel level transmitter (Tab. 5) TR . Thermo-starter (Tab. 1) COLOUR A : azure M : brown B : white N : black C : orange R : red G : yellow S : pink H : grey V : green L : blue Z : violet Example: AB = azure / white Page 51

2nd Version

ELECTRICITY

CONNECTION CARD FOR TINSLEY 40-POLE ROTATING TAP GROUP OF BROWN WIRES N° 01 02 03 04 05 06 07 08 09 10

CORRESP.COLOUR Brown-white Green-blue Grey-blue Orange-blue Yellow-blue Pale blue-yellow Orange-black Yellow-red Orange-red Orange

DESCRIPTION Outriggers retracted light Outrig. exten. pressure switch micro Right front outrigger solenoid valve Retraction solenoid valve Left rear outrigger arm solenoid valve Right rear outrigger arm solenoid valve Right front outrigger arm solenoid valve Right rear outrigger solenoid valve Left rear outrigger solenoid valve Left front outrigger arm solenoid valve

GROUP OF GREY WIRES N° 01 02 03 04 05 06 07 08 09 10

CORRESP.COLOUR Blue-red Pink Pink-black Grey N° 4 Yellow-green Violet-black Grey-white Yellow-brown White-green Violet

DESCRIPTION Left front outrigger solenoid valve Fuel level instrument Fuel reserve light General outrigger solenoid valve Slow-fast enabling Rear axle alignment light Hydr. circuit inhibiting solenoid valve Reverse running solenoid valve Start enabling Proximity 55°

GROUP OF BLACK WIRES N° 01 02 03 04 05 06 07 08 09 10

CORRESP.COLOUR White Grey-green Violet-white Green-white Green-white Blue Blue-black Yellow-grey Black Red

Page 52

DESCRIPTION Parking lights Air filter clogged light Front axle alignment light Crabwise steering solenoid valve Concentric steering solenoid valve Right turn signals Left turn signals Forward running solenoid valve Negative power supply Positive power supply

ELECTRICITY

2nd Version GROUP OF WHITE WIRES

N° 01 02 03 04 05 06 07 08 09 10

CORRESP.COLOUR Green-black Grey-black White N° 3 Black-red N° 2 Yellow-violet Grey-red Grey Brown Green White-black

DESCRIPTION High beams Low beams Thermo-starter Services Starting Battery charge light Low engine oil pressure light Engine stop Rear suspensions active Engine water temperature light

Page 53

TABLE N°1

2nd Version

Page 54

ELECTRICITY

2nd Version

TABLE N°2

ELECTRICITY

Page 55

TABLE N°3

2nd Version

Page 56

ELECTRICITY

2nd Version

TABLE N°4

ELECTRICITY

Page 57

TABLE N°5

2nd Version

Page 58

ELECTRICITY

2nd Version

TABLE N°6

ELECTRICITY

Page 59

TABLE N°7

2nd Version

Page 60

ELECTRICITY

2nd Version

TABLE N°8

ELECTRICITY

Page 61

TABLE N°9

2nd Version

Page 62

ELECTRICITY

2nd Version

TABLE N°10

ELECTRICITY

Page 63

TABLE N°11

2nd Version

Page 64

ELECTRICITY

2nd Version

TABLE N°12

ELECTRICITY

Page 65

TABLE N°13

2nd Version

Page 66

ELECTRICITY

2nd Version

TABLE N°14

ELECTRICITY

Page 67

2nd Version MRT 1540 SOFTWARE INPUT-OUTPUT CONNECTORS INPUT connectors Power supply connector MA MA-01 MA-01

Black ø 1.5 Red black ø 1.5

Negative power supply Positive power supply

Connector M1 M1-01 M1-02 M1-03 M1-04 M1-05 M1-06 M1-07 M1-08 M1-09 M1-10 M1-11 M1-12

Blue-green ø 0,5 Orange ø 0,5 Yellow-blue ø 0,5 White no. 09 Grey no. 44 Orange-blue no. 04 Orange-green Orange-blue Yellow-red Yellow-green Violet-white Yellow-blue

Connector M2 M2-01 M2-02 M2-03 M2-04 M2-05 M2-06

Orange-red Brown-white Yellow-grey Grey-black -----------------------Green

Basket operation enabling signal button Basket engine stop button 23 mt on basket signal Anti-tilting -----------------------------------------------------Up operation exclusion microswitch

Connector M3 analog signals from cab manipulators M3-01 M3-02 M3-03 M3-04 M3-05 M3-06 M3-07

Page 68

Light blue-white Green-white Grey-blue Grey-white White-yellow Orange-white Pink-yellow

Tilting Lifting Optional Extension 2 Rotation Extension 3 Extension 1

ELECTRICITY

2nd Version

Connector M4 analog signals from basket manipulator M4-01 M4-02 M4-03 M4-04 M4-05 M4-06 M4-07

Blue-black Green-black White-black Grey-black Yellow-black Orange-black Pink-black

Tilting Lifting Optional Extension 2 Rotation Extension 3 Extension 1

OUTPUT connectors Connector M5 analog signals for Danfoss solenoid valves M5-01 M5-02 M5-03 M5-04 M5-05 M5-06 M5-07

Blue Green White Grey Yellow Orange Pink

Tilting solenoid valve Lifting solenoid valve Optional solenoid valve Extension 2 solenoid valve Rotation solenoid valve Extension 3 solenoid valve Extension 1 solenoid valve

Connector M6 M6-01 M6-02 M6-03 M6-04 M6-05 M6-06 M6-07 M6-08 M6-09 M6-10 M6-11 M6-12

Orange-blue Grey no. 4 Grey-red Red White-green Yellow-brown Red-green Brown White-grey + diode White-grey + diode Violet-black Red-black ø 1.5

Page 69

2nd Version

ELECTRICITY

32-PIN COUPLING CONNECTION TO BOX WITH SOFTWARE N° 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21

CABLE COLOUR DESCRIPTION ............................. ......................................................................... Green-white Lifting by cab manipulators Azure-white Tilting by cab manipulators White-yellow Rotation by cab manipulators Grey-blue Optional by cab manipulators Orange-white Extension 3 by cab manipulators Pink-yellow Extension 1 by cab manipulators Grey-white Extension 2 by cab manipulators Brown Engine stop Yellow-violet Cage start-up Violet Cage buzzer Grey-black Anti-tipping signal Yellow-blue Emergency key White no. 9 Rear axle lock-out Blue-green Extended and lowered stabilisers Violet-black Rear axle locked blinking lamp Orange-blue no. 4 Manipulator stabiliser return signal Grey no. 44 Manipulator stabiliser extended signal Orange-blue stabiliser return solenoid valve Grey no. 4 Stabiliser general solenoid valve White-grey Danfoss solenoid valve power supply relay command (+ diodes) 22 Yellow-red Electronic pendulum 23 Orange-red Extension limit proximity 24 Light blue-white Rise limit proximity 25 Red Rotation speed reduction solenoid valve 26 Green Lifting solenoid valve 27 Blue Swinging solenoid valve 28 Yellow Rotation solenoid valve 29 White Optional solenoid valve 30 Orange Extension 3 solenoid valve 31 Pink Extension 1 solenoid valve 32 Grey Extension 2 solenoid valve Gnd Black ø2.5 Ground

Page 70

DESTINATION ................................. no. 02 connector M3 no. 01 connector M3 no. 05 connector M3 no. 03 connector M3 no. 06 connector M3 no. 07 connector M3 no. 04 connector M3 no. 08 connector M6 no. 10 24-pin coupling no. 11 24-pin coupling no. 04 connector M2 no. 12 connector M1 no. 04 connector M1 no. 01 connector M1 no. 11 connector M6 no. 06 connector M1 no. 05 connector M1 no. 01 connector M6 no. 02 connector M6 no. 09-10 + diodes connector M6 no. 09 connector M1 no. 02 connector M1 no. 03 connector M1 no. 04 connector M6 no. 02 connector M5 no. 01 connector M5 no. 05 connector M5 no. 03 connector M5 no. 06 connector M5 no. 07 connector M5 no. 04 connector M5 In common with Gnd 10pin, 24-pin couplings and no. 01 connector MA

ELECTRICITY

2nd Version

10-PIN COUPLING CONNECTION TO BOX WITH SOFTWARE N° 01 02 03 04 05 06 07

CABLE COLOUR DESCRIPTION Red-black ø1.5 Positive power supply for software Red-black ø1.5 Positive power supply for common relay board Red-black ø1.5 Positive power supply for cage commands Red-black Positive power supply for saddle proximity .......................... ......................................................................... Grey-red Signal for anti-tipping system configuration White-green Pendulum tripped with stabilisers extended (2 pieces) and lowered 08 Green Rise operating exclusion microswitch 09 .......................... ......................................................................... 10 Orange-green Cab manipulator microswitches Gnd Black ø2.5 Ground

DESTINATION no. 02 connector MA no. 12 connector M6 no. 01 24-pin coupling no. 20 24-pin coupling ................................. no. 03 connector M6 no. 05 connector M6 e no. 14 24-pin coupling no. 06 connector M2 ................................. no. 07 connector M1 In common with Gnd 32pin, 24-pin couplings and no. 01 connector MA

24-PIN COUPLING CONNECTION TO BOX WITH SOFTWARE N° COLORE CAVO 01 Red-black ø 1.5 02 Green-black 03 Pink-black 04 Grey-black 05 Yellow-black 06 Blue-black 07 Orange-black 08 White-black 09 Brown-white 10 Yellow-violet 11 Violet 12 Orange-blue 13 Orange-red 14 White-green 15 Yellow-brown 16 Red-green 17 Violet-white 18 Yellow-grey 19 Yellow-green 20 Red-black ø1.5 21 .......................... 22 .......................... 23 .......................... 24 .......................... Gnd Black ø2.5

DESCRIPTION Cage positive power supply Lifting by cage manipulator Extension 1 by cage manipulator Extension 2 by cage manipulator Rotation by cage manipulator Swinging 2 by cage manipulator Extension 3 by cage manipulator Optional by cage manipulator Cage engine stop command Cage ignition Cage buzzer Cage manipulator microswitch Cage operation enabling signal button Pendulum tripped with stabilisers ext./low. Cage tilting movement solenoid valve Anomaly red lamp Cage present proximity 23 mt cage inserted signal 23 mt cage resting saddle proximity Positive power supply for saddle proximity ......................................................................... ......................................................................... ......................................................................... ......................................................................... Ground

DESTINATION no. 03 10-pin coupling no. 02 connector M4 no. 07 connector M4 no. 04 connector M4 no. 05 connector M4 no. 01 connector M4 no. 06 connector M4 no. 03 connector M4 no. 02 connector M2 no. 10 32-pin coupling no. 11 32-pin coupling no. 08 connector M1 no. 01 connector M2 no. 07 10-pin coupling no. 06 connector M6 no. 07 connector M6 no. 11 connector M1 no. 03 connector M2 no. 10 connector M1 no. connector M6 ................................. ................................. ................................. ................................. In common with Gnd 32pin, 10-pin couplings and no. 01 connector MA

Page 71

Page 72

MM A A I I 0 0 1 2

G + N 1 D 2 V

POWER SUPPLY

M MMM MM 2 2 2 2 2 2 I I I I I I 0 0 0 0 0 0 1 2 3 4 5 6

OOOOOO

M MMM MMM 3 3 3 3 3 3 3 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

OOOOOOO

M MMM MMM MM M M M 1 1 1 1 1 1 1 1 1 1 1 1 I I I I I I I I I I I I 0 0 0 0 0 0 0 0 0 1 1 1 1 2 3 4 5 6 7 8 9 0 1 2

M MMM MMM 4 4 4 4 4 4 4 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

R12

OOOOOOO

M MMM MMM 5 5 5 5 5 5 5 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

OOOOOOO

R10

R11

DIAGRAM OF CONNECTIONS AND RELAYS OF THE ELECTRIC BOX BEHIND THE CAB

OOOOOOOOOOOO

GREEN AND RED LAMPS

K10

K11

M MMM MMM MM M M M 6 6 6 6 6 6 6 6 6 6 6 6 I I I I I I I I I I I I 0 0 0 0 0 0 0 0 0 1 1 1 1 2 3 4 5 6 7 8 9 0 1 2

OOOOOOOOOOOO

2nd Version ELECTRICITY

OOOOOO

✷

✷ R8

R12

OOOOOOO

R10

R11

OOOOOOO

LEGEND R1-R2-R3-R4 = basket or cab selection R5 = TS inclination R6 = lifting R7 = optional R8 = telescope 1 R9 = rotation R10 = telescope 3 R11 = telescope 1 R12 = Danfoss flow regulator selection

ALIMENTATION

OOOOOOOOOOOO

✷

K10

K11

OOOOOOOOOOOO

Danfoss flow regulator connection for lifting and descent (TS inclination only for 23m)

K7 = basket red light relay K8 = engine stopped relay K9 = contact N relay 12V cab K10 = contact N relay 12V basket K11 = rear axle locked yellow light

DIAGRAM OF CONNECTIONS AND RELAYS OF THE ELECTRIC BOX BEHIND THE CAB

✷ relay 5 A 2 contacts relay 16A 1contact all interchangeable R = controlled relay for Danfoss variable signal R = 12V control

GREEN AND RED LAMPS

ELECTRICITY

2nd Version

Page 73

ELECTRICITY

Page 74

M MMM MMM MM M M M 6 6 6 6 6 6 6 6 6 6 6 6 I I I I I I I I I I I I 0 0 0 0 0 0 0 0 0 1 1 1 1 2 3 4 5 6 7 8 9 0 1 2 M MMM MMM 5 5 5 5 5 5 5 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

Extension 1 solenoid valve Extension 3 solenoid valve Slewing solenoid valve Extension 2 solenoid valve Optional solenoid valve Lifting solenoid valve Tilting solenoid valve

M MMM MMM 4 4 4 4 4 4 4 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

Extension 1 Extension 3 Slewing Extension 2 Optional Lifting Tilting

M MMM MMM 3 3 3 3 3 3 3 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

Extension 1 Extension 3 Slewing Extension 2 Optional Lifting Tilting

M MMM MM 2 2 2 2 2 2 I I I I I I 0 0 0 0 0 0 1 2 3 4 5 6

OOOOOOO OOOOOOO OOOOOOO

MM A A I I 0 0 1 2

G + N 1 D 2 V

OOOOOO

DANFOSS PVG 32 MANIPULATEUR NACELLE

K10 K8 K6 K4 K2 R10 R9 R8 R7 R3 M MMM MMM MM M M M 1 1 1 1 1 1 1 1 1 1 1 1 I I I I I I I I I I I I 0 0 0 0 0 0 0 0 0 1 1 1 1 2 3 4 5 6 7 8 9 0 1 2

MANIPULATEUR CABINE ALIMENTATION

GREEN AND RED LAMPS

OOOOOOOOOOOO

K9 K7 K5 K3 K1 R11 R12 R6 R5 R4 R1

DIAGRAM OF CONNECTIONS AND RELAYS OF THE ELECTRIC BOX BEHIND THE CAB

K11

OOOOOOOOOOOO

2nd Version

ELECTRICITY CONNECTION OR RELAY

2nd Version RATING PLATES ON THE COVER OF THE ELECTRIC BOX BEHIND THE CAB CONNECTION OR RELAY

Page 75

2nd Version

ELECTRICITY

DESCRIPTION OF THE SIGNAL LAMPS AND RATING PLATES ON THE COVER OF THE ELECTRIC BOX BEHIND THE CAB CONNECTION ON OR OFF RELAY

. ... ... .

M1-01

. ... ... .

M1-02

. ... ... .

M1-03

. ... ... .

M1-04

. ... ... .

M1-05

. ... ... .

M1-06

. ... ... .

M1-07

. ... ... .

M1-08

. ... ... .

M1-09

. ... ... .

M1-10

. ... ... .

M1-11

. ... ... .

M1-12

. ... ... .

M2-01

. ... ... .

M2-02

. ... ... .

M2-03

. ... ... .

M2-04

. ... ... .

M2-06

. ... ... .

R1 - R2 R3-R4

. ... ... .

Page 76

ELECTRICITY

2nd Version

DESCRIPTION OF THE SIGNAL LAMPS AND RATING PLATES ON THE COVER OF THE ELECTRIC BOX BEHIND THE CAB CONNECTION ON OR OFF RELAY

. ... ... .

R10

. ... ... .

R11

. ... ... .

R12

. ... ... .

K10

. ... ... .

K11

. ... ... .

Page 77

2nd Version

ELECTRICITY

ELECTRONIC BOARD ELECTRIC CIRCUIT

Page 78

ELECTRICITY

2nd Version

THE INPUT ADAPTATION CIRCUIT IS REPEATED FOR 15 SECTIONS

Page 79

2nd Version

INVERTED NUMBERING

Page 80

ELECTRICITY

2nd Version

THE POWER CIRCUIT WILL BE REPLICATED FOR 22 OUTPUTS

Page 81

2nd Version

Page 82

ELECTRICITY

OUTPUT 1 CONTROL OUTPUT 2 CONTROL OUTPUT 3 CONTROL OUTPUT 4 CONTROL OUTPUT 5 CONTROL OUTPUT 6 CONTROL OUTPUT 7 CONTROL SIGN 1 CONTROL OUTPUT 9 CONTROL OUTPUT 10 CONTROL OUTPUT 11 CONTROL

K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11

RELAY COIL CONTROLS OUTPUT 12 CONTROL OUTPUT 13 CONTROL OUTPUT 14 CONTROL OUTPUT 15 CONTROL OUTPUT 16 CONTROL OUTPUT 17 CONTROL OUTPUT 18 CONTROL OUTPUT 19 CONTROL OUTPUT 20 CONTROL OUTPUT 21 CONTROL

R12 R11 R10 R9 R8 R7 R6 R5 R1-R2-R3-R4 4053

ELECTRICITY

2nd Version

Page 83

ELECTRICITY

REAR AXLE ALIGNEMENT GREEN LIGHT

AVAILABLE BLUE LIGHT REAR AXLE OSCILLATION BLOCK FLASHING YELLOW LIGHT INCLINATION RED LIGHT TURRET BLOCK GREEN LIGHT

GEAR SPEED REVERSE LEVER

LIGHT SWITCH CONTROL

PAT SYSTEM

TURRET ALIGNEMENT GREEN LIGHT OUTRIGGERS RETRACTED GREEN LIGHT OUTRIGGERS OUT AND LOWERED GREEN LIGHT

Page 84

IGNITION AND CONTACT KEY

FRONT AXLE ALIGNEMENT YELLOW LIGHT

PARKING LIGHT GREEN LIGHT

RESET TRANSMISSION

ELECTRIC COMPONENT LAYOUT

DIRECTION SELECTOR

2nd Version

BASKET SAFETY KEY

LEFT FRONT OUTRIGGER

PAT SYSTEM EXCLUSION KEY

RIGHT FRONT OUTRIGGER

ELECTRIC COMPONENT LAYOUT

LEFT REAR OUTRIGGER

RIGHT REAR OUTRIGGER

LIFTED LOWERED OR TELESCOPED OUTRIGGERS SELECTOR

OUTRIGGERS CONTROL LEVER

ELECTRICITY

2nd Version

Page 85

LIFTING-TILTING-T2 DANFOSS MANIPULATOR

HYDRAULIC SYSTEM LP EXCLUSION SPEED CHANGE MANIPULATOR

T1-T3-ACCESSORY DANFOSS MANIPULATOR

ELECTRIC COMPONENT LAYOUT

Page 86 HYDRAULIC MOVEMENT EXCLUSION MICROSWITCH

PARKING BRAKE TRANSMISSION SECTION MICROSWITCH

T3-ACCESSORY CONTROL SELECTOR

2nd Version ELECTRICITY

NOTE ✷ ONLY IN THE BASKET VERSION

ELECTRIC BOX UNDER THE STEP LADDER

BLOCKED TOWER MICROSWITCH

ELECTRIC HEADER

✷ BASKET PROXIMITY INDICATOR

PAT WINDER AND ANGLE INDICATOR

0.8 M HIGH ARM PROXIMITY INDICATOR

ELECTRIC SAFETY PUMP

✷ PENDULUM LEVELLING INDICATOR

LIFTING LIMIT SWITCH MICROSWITCH

TOWER ALIGNMENT MICROSWITCH

SAFETY PUMP CONTROL KEY

ELECTRIC COMPONENT LAYOUT

TOWER NOT ALIGNED = 5° PROXIMITY INDICATOR

STABILIZERS RESTING ON GROUND MICROSWITCH

RETRACTED STABILIZER PROXIMITY INDICATOR

RETRACTED ARM PROXIMITY INDICATOR

ELECTRICITY

2nd Version

Page 87

Page 88

FUSE BOX UNDER THE INSTRUMENT PANEL

SOFTWARE ELECTRONIC BOX

ELECTRIC COMPONENT LAYOUT

2nd Version ELECTRICITY

Electric system 2nd Version page 91-134 from the truck n° 120425/6144 until the truck n°

121778/6352

ELECTRICITY

2nd Version

FUSE AND RELAY BOX

➠ 1

E5 E11

E10

➩

Page 91

ELECTRICITY

2nd Version

FUNCTIONAL DESCRIPTION OF THE FUSES IN THE BOX LOCATED UNDER THE COVER OF THE INSTRUMENT PANEL Ref.

Amps

Description

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15

10 5 7.5 10 15 5 7.5 10 3 10 10 7.5 3 Diode 10

F16

7.5

F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28

7.5 15 10 15 15 7.5 10 15 10 10 5 Diode

FUNCTIONAL DESCRIPTION OF RELAYS IN THE BOX LOCATED UNDERNEATH THE COVER OF THE INSTRUMENT PANEL Ref.

Characteristics

Description

E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E11

20/30 Amps 20/30 Amps 20/30 Amps 20/30 Amps 20/30 Amps 20/30 Amps ....................... ....................... ....................... ....................... 12 Volt 84/168 Watt

Page 92

ELECTRICITY

2nd Version

ELECTRIC BOX UNDER CAB

E 14

E 15

E 16

E 17

E 18

E 19

E 13

E1 2 E 20

F 29

F30 F31 F32 F33 F34 F35 F36 F37

FUNCTIONS DESCRIPTION E12) Ignition relay E13) Thermal starter relay E14) Low beam relay E15) High beam relay E16) Services relay E17) Stabiliser general solenoid valve relay E18) Suspension lock relay E19) Soundproofing relay E20) 55° suspension lock relay F29) Fuse 80 A : General power supply F30) Fuse 10 A : Front left and back right position lights F31) Fuse 10 A : Front right and back left position lights F32) Fuse 10 A : Low beam lights F33) Fuse 10 A : High beam lights F34) Fuse 10 A : Stabiliser general solenoid valve F35) Fuse 10 A : Rear axle oscillating solenoid valves and soundproofing solenoid valve F36) Fuse 10 A : Front truck ignition power supply F37) Fuse 10 A : Rear truck ignition power supply C1) Circuit electronic stabiliser return

Page 93

2nd Version

ELECTRICITY

USERS LEGEND ELECTRIC SYSTEM MRT1540 MANITOU CAB 1996 VERSION WITH SOFTWARE (reference drawing No. 756) A1 . Buzzer (Tab. 3) A2 . Reverse engaged buzzer (Tab. 2) A3 . Pendulum active with cage buzzer (Tab. 11) B1 . Battery (12 VOLT - Tab. 1) C1 . Circuit electronic stabiliser return (Tab. 10) D1 . Light control switch (Tab. 3) D2 . Diode 1 amp (Tab. 6 - 11) E1 . Ignition enabling relay E2 . Hydraulic circuit exclusion relay E3 . Danfoss solenoid valve power supply relay E4 . Forward relay E5 . Reverse relay E6 . Parking brake optical indicator relay E7 . Available relay E8 . Available relay E9 . Available relay E10 . Available relay E11 . Direction/emergency light flashing (Tab. 4) E12 . Ignition relay E13 . Thermal starter relay E14 . Low beam relay E15 . High beam relay E16 . Services relay E17 . Stabiliser general solenoid valve relay E18 . Suspension lock relay E19 . Soundproofing relay E20 . 55° suspension lock relay E20 . Emergency pump contactor E21 . Optical defect indicator relay (cage) E22 . Slow - fast speed bistatic relay (Tab. 12) F1 . Fuse 10 A : Electronic pendulum + hydraulic circuit exclusion solenoid valve (Tab. 6) F2 . Fuse 5 A : Gear engaged switch + truck ignition power supply (Tab. 2) F3 . Fuse 7.5 A : Light switch + cab buzzer (Tab. 3) F4 . Fuse 10 A : Beacon (Tab. 5) F5 . Fuse 15 A : Available (Tab. 13) F6 . Fuse 5 A : Direction lights (Tab. 3) F7 . Fuse 7.5 A : Drive wheel command (Tab. 4) F8 . Fuse 10 A : Front windshield wiper + washer (Tab. 13) F9 . Fuse 3 A : Instruments + lamp control check (Tab. 1) F10 . Fuse 10 A : Front working lights (Tab. 13) F11 . Fuse 10 A : Rear working lights (Tab. 13) F12 . Fuse 7.5 A : Rear windshield wiper + top windshield wiper (Tab. 13) F13 . Fuse 3 A : Stabiliser switch lighting (Tab. 8) F14 . Diode 1 A : Available (Tab. 3) F15 . Fuse 10 A : Emergency key + braking pressure switch + translation solenoid valve (Tab. 7) F16 . Fuse 7.5 A : Microswitch lock and tower alignment + transmission reset button (Tab. 2) F17 . Fuse 7.5 A : Danfoss cab operating manipulators (Tab. 8) F18 . Fuse 15 A : Stabiliser instrument panel (Tab. 8) F19 . Fuse 10 A : Anti-tipping system (Tab. 12) F20 . Fuse 15 A : Board with logic + cage (Tab. 11) F21 . Fuse 15 A : Danfoss solenoid valves (Tab. 7) F22 . Fuse 7.5 A : Available (Tab. 3) F23 . Fuse 10 A : Available(Tab. 3) F24 . Fuse 15 A : Available(Tab. 3) F25 . Fuse 10 A : Available direct power supply (Tab. 3) Page 94

ELECTRICITY

2nd Version

F26 . Fuse 10 A : Emergency lights + ceiling light (Tab. 3) F27 . Fuse 5 A : Available(Tab. 3) F28 . Diode 3 A : Available(Tab. 2) F29 . Fuse 80 A : General power supply (Tab. 1) F30 . Fuse 10 A : Front left and back right position lights (Tab. 3) F31 . Fuse 10 A : Front right and back left position lights(Tab. 3) F32 . Fuse 10 A : Low beam lights (Tab. 4) F33 . Fuse 10 A : High beam lights (Tab. 4) F34 . Fuse 10 A : Stabiliser general solenoid valve (Tab. 5) F35 . Fuse 10 A : Rear axle oscillating solenoid valves and soundproofing solenoid valve (Tab. 6) F36 . Fuse 10 A : Front truck ignition power supply (Tab. 2) F37 . Fuse 10 A : Rear truck ignition power supply (Tab. 2) F38 . Fuse 30 A : Heating (Tab. 14) G1 . Alternator (Tab. 1) H1 . Hour meter (Tab. 1) I1 . Parking brake microswitch (Tab. 2) I2 . Forward-reverse gear manipulator (Tab. 4) I3 . Slow-fast gear microswitch (Tab. 2) I4 . Transmission reset button (Tab. 2) I5 . Stop lights pressure switch (Tab. 2) I6 . Proximity PNP rear axle alignment (Tab. 2) I7 . Proximity PNP Tower alignment (Tab. 2) I8 . Proximity PNP front axle alignment (Tab. 2) I9 . Emergency electric pump key (Tab. 7) I10 . Cab emergency key (Tab. 7) I11 . Fuel reserve level switch (Tab. 5) I12 . Air filter fouling pressure switch (Tab. 5) I13 . Pressure switch for low engine oil pressure (Tab. 5) I14 . Cab locked microswitch (Tab. 6) I15 . Cab aligned microswitch (Tab. 6) I16 . Right rear output stabiliser micro (Tab. 6) I17 . Left rear output stabiliser micro (Tab. 6) I18 . Left front output stabiliser micro (Tab. 6) I19 . Right front output stabiliser micro (Tab. 6) I20 . Hydraulic oil temperature thermal contact (Tab. 6) I21 . Engine water temperature thermal contact (Tab. 6) I22 . Hydraulic circuit exclusion button (Tab. 6) I23 . Arm microswitch (Tab. 6) F35 . Fuse 10 A : Rear axle oscillating solenoid valves and soundproofing solenoid valve (Tab. 6) I24 . Drive wheel selector (Tab. 4) I25 . Third extension - optional selector (Tab. 8) I26 . Stabiliser extension-return manipulator (Tab. 8) I27 . Beam-stabiliser selector (Tab. 8) I28 . Left front stabiliser button (Tab. 8) I29 . Right front stabiliser button (Tab. 9) I30 . Left rear stabiliser button (Tab. 9) I31 . Right rear stabiliser button (Tab. 9) I32 . Proximity PNP - Left rear stabiliser returned (Tab. 10) I33 . Proximity PNP - Right rear stabiliser returned (Tab. 10) I34 . Proximity PNP - Left front stabiliser returned (Tab. 10) I35 . Proximity PNP - Right front stabiliser returned (Tab. 10) I36 . Proximity PNP - Arm extension (Tab. 10) I37 . Proximity PNP - Arm rise 0.8 mt (Tab. 10) I38 . Electronic levelling pendulum (Tab. 10) I39 . Proximity PNP - 23 mt cage saddle (Tab. 11) I40 . Proximity PNP - (n.C.) cage present (Tab. 11) I41 . Lifting exclusion microswitch (Tab. 11) I42 . Cage engine stop button (Tab. 11) I43 . Cage buzzer button (Tab. 11) Page 95

2nd Version I44 . Contact active with 23 mt cage inserted (Tab. 11) I45 . Cage overload microswitch (Tab. 11) I46 . Cage door microswitch (Tab. 11) I47 . Cage start-up button (Tab. 12) I48 . Cage operation enabling button (Tab. 12) I49 . Cage operation selector (Tab. 12) I50 . Arm rise microswitch (Tab. 12) I51 . Anti-tipping system safety key (Tab. 12) I52 . Engine max. water temperature thermal contact (Tab. 5) I53 . Emergency light switch (Tab. 3) I54 . Beacon switch (Tab. 5) I55 . Brake oil level switch (Tab. 5) I56 . Braking pressure switch (Tab. 12) I57 . Front windshield wiper and washer switch (Tab. 13) I58 . Rear and top windshield wiper switch (Tab. 13) I59 . Front working light switch (Tab. 13) I60 . Rear working light switch (Tab. 13) I 61 . 55° lifting PNP proximity (Tab. 14) KEY . Ignition switch (Tab. 1) L1 . Rear axle alignment optical indicator (Tab. 2) L2 . Front axle alignment optical indicator(Tab. 2) L3 . Rear axle locked optical indicator (Tab. 7) L4 . Position lights optical indicator (Tab. 3) L5 . Cab locked optical indicator (Tab. 6) L6 . Cab aligned optical indicator (Tab. 6) L7 . Stabilisers extended optical indicator (Tab. 6) L8 . Stabilisers retracted optical indicator (Tab. 10) L9 . Pendulum active optical indicator (Tab. 10) L10 . (Cage) defect optical indicator (Tab. 11) L11 . Pendulum active (cage) optical indicator (Tab. 11) L12 . Slow gear engaged optical indicator (Tab. 12) L13 . Fast gear engaged optical indicator (Tab. 12) L14 . Battery charge optical indicator (Tab. 1) L15 . High beam lights optical indicator (Tab. 3) L16 . Direction lights optical indicator (Tab. 4) L17 . Parking brake optical indicator (Tab. 4) L18 . Available optical indicator (Tab. 5) L19 . Fuel reserve optical indicator (Tab. 5) L20 . Fouled air filter optical indicator (Tab. 5) L21 . Low engine oil pressure optical indicator (Tab. 5) L22 . Max. engine water temperature optical indicator (Tab. 5) L23 . Low brake fluid level optical indicator (Tab. 5) M1 . Starter motor (Tab. 1) M2 . Emergency electric pump (Tab. 1) M3 . Cab left Danfoss manipulator (Tab. 8) M4 . Cab right Danfoss manipulator (Tab. 8) M5 . Cage operating manipulator (Tab. 12) M6 . Slow - fast speed manipulator (Tab. 12) M7 . Front windshield wiper (Tab. 13) M8 . Windshield cleaner pump (Tab. 13) M9 . Rear windshield wiper (Tab. 13) M10 . Top windshield wiper (Tab. 13) M11 . Heating fuel pump (Tab. 14) P1 . Left rear stop light (Tab. 2) P2 . Right rear stop light(Tab. 2) P3 . Left front direction light (Tab. 3) P4 . Left rear direction light (Tab. 3) P5 . Right front direction light (Tab. 3) P6 . Right rear direction light(Tab. 3) Page 96

ELECTRICITY

2nd Version

ELECTRICITY

CONNECTION CARD FOR TINSLEY 40-POLE ROTATING TAP GROUP OF BROWN WIRES N° 01 02 03 04 05 06 07 08 09 10

CORRESP.COLOUR Brown-white Green-blue Grey-blue Orange-blue Yellow-blue Pale blue-yellow Orange-black Yellow-red Orange-red Orange

GROUP OF GREY WIRES N° 01 02 03 04 05 06 07 08 09 10

CORRESP.COLOUR Blue-red Pink Pink-black Grey N° 4 Yellow-green Violet-black Grey-white Yellow-brown White-green Violet

GROUP OF BLACK WIRES N° 01 02 03 04 05 06 07 08 09 10

CORRESP.COLOUR White Grey-green Violet-white Green-white Green-white Blue Blue-black Yellow-grey Black Red

Page 98

ELECTRICITY

2nd Version GROUP OF WHITE WIRES

N° 01 02 03 04 05 06 07 08 09 10

CORRESP.COLOUR Green-black Grey-black White N° 3 Black-red N° 2 Yellow-violet Grey-red Grey Brown Green White-black

DESCRIPTION High beams Low beams Thermo-starter Services Starting Battery charge light Low engine oil pressure light Engine stop Rear suspensions active Engine water temperature light

Page 99

TABLE N°1

2nd Version

Page 100

ELECTRICITY

2nd Version

TABLE N°2

ELECTRICITY

Page 101

TABLE N°3

2nd Version

Page 102

ELECTRICITY

2nd Version

TABLE N°4

ELECTRICITY

Page 103

TABLE N°5

2nd Version

Page 104

ELECTRICITY

2nd Version

TABLE N°6

ELECTRICITY

Page 105

TABLE N°7

2nd Version

Page 106

ELECTRICITY

2nd Version

TABLE N°8

ELECTRICITY

Page 107

TABLE N°9

2nd Version

Page 108

ELECTRICITY

2nd Version

TABLE N°10

ELECTRICITY

Page 109

TABLE N°11

2nd Version

Page 110

ELECTRICITY

2nd Version

TABLE N°12

ELECTRICITY

Page 111

TABLE N°13

2nd Version

Page 112

ELECTRICITY

2nd Version

TABLE N°14

ELECTRICITY

Page 113

2nd Version MRT 1540 SOFTWARE INPUT-OUTPUT CONNECTORS INPUT connectors Power supply connector MA MA-01 MA-01

Black ø 1.5 Red black ø 1.5

Negative power supply Positive power supply

Connector M1 M1-01 M1-02 M1-03 M1-04 M1-05 M1-06 M1-07 M1-08 M1-09 M1-10 M1-11 M1-12

Blue-green ø 0,5 Orange ø 0,5 Yellow-blue ø 0,5 White no. 09 Grey no. 44 Orange-blue no. 04 Orange-green Orange-blue Yellow-red Yellow-green Violet-white Yellow-blue

Connector M2 M2-01 M2-02 M2-03 M2-04 M2-05 M2-06

Orange-red Brown-white Yellow-grey Grey-black -----------------------Green

Basket operation enabling signal button Basket engine stop button 23 mt on basket signal Anti-tilting -----------------------------------------------------Up operation exclusion microswitch

Connector M3 analog signals from cab manipulators M3-01 M3-02 M3-03 M3-04 M3-05 M3-06 M3-07

Page 114

Light blue-white Green-white Grey-blue Grey-white White-yellow Orange-white Pink-yellow

Tilting Lifting Optional Extension 2 Rotation Extension 3 Extension 1

ELECTRICITY

2nd Version

Connector M4 analog signals from basket manipulator M4-01 M4-02 M4-03 M4-04 M4-05 M4-06 M4-07

Blue-black Green-black White-black Grey-black Yellow-black Orange-black Pink-black

Tilting Lifting Optional Extension 2 Rotation Extension 3 Extension 1

OUTPUT connectors Connector M5 analog signals for Danfoss solenoid valves M5-01 M5-02 M5-03 M5-04 M5-05 M5-06 M5-07

Blue Green White Grey Yellow Orange Pink

Tilting solenoid valve Lifting solenoid valve Optional solenoid valve Extension 2 solenoid valve Rotation solenoid valve Extension 3 solenoid valve Extension 1 solenoid valve

Connector M6 M6-01 M6-02 M6-03 M6-04 M6-05 M6-06 M6-07 M6-08 M6-09 M6-10 M6-11 M6-12

Orange-blue Grey no. 4 Grey-red Red White-green Yellow-brown Red-green Brown White-grey + diode White-grey + diode Violet-black Red-black ø 1.5

Page 115

2nd Version

ELECTRICITY

32-PIN COUPLING CONNECTION TO BOX WITH SOFTWARE N° 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21

Page 116

ELECTRICITY

2nd Version

10-PIN COUPLING CONNECTION TO BOX WITH SOFTWARE N° 01 02 03 04 05 06 07

Page 117

Page 118

MM A A I I 0 0 1 2

G + N 1 D 2 V

POWER SUPPLY

M MMM MM 2 2 2 2 2 2 I I I I I I 0 0 0 0 0 0 1 2 3 4 5 6

OOOOOO

M MMM MMM 3 3 3 3 3 3 3 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

OOOOOOO

M MMM MMM MM M M M 1 1 1 1 1 1 1 1 1 1 1 1 I I I I I I I I I I I I 0 0 0 0 0 0 0 0 0 1 1 1 1 2 3 4 5 6 7 8 9 0 1 2

M MMM MMM 4 4 4 4 4 4 4 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

R12

OOOOOOO

M MMM MMM 5 5 5 5 5 5 5 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

OOOOOOO

R10

R11

DIAGRAM OF CONNECTIONS AND RELAYS OF THE ELECTRIC BOX BEHIND THE CAB

OOOOOOOOOOOO

GREEN AND RED LAMPS

K10

K11

M MMM MMM MM M M M 6 6 6 6 6 6 6 6 6 6 6 6 I I I I I I I I I I I I 0 0 0 0 0 0 0 0 0 1 1 1 1 2 3 4 5 6 7 8 9 0 1 2

OOOOOOOOOOOO

2nd Version ELECTRICITY

OOOOOO

✷

✷ R8

R12

OOOOOOO

R10

R11

OOOOOOO

LEGEND R1-R2-R3-R4 = basket or cab selection R5 = TS inclination R6 = lifting R7 = optional R8 = telescope 1 R9 = rotation R10 = telescope 3 R11 = telescope 1 R12 = Danfoss flow regulator selection

ALIMENTATION

OOOOOOOOOOOO

✷

K10

K11

OOOOOOOOOOOO

Danfoss flow regulator connection for lifting and descent (TS inclination only for 23m)

K7 = basket red light relay K8 = engine stopped relay K9 = contact N relay 12V cab K10 = contact N relay 12V basket K11 = rear axle locked yellow light

DIAGRAM OF CONNECTIONS AND RELAYS OF THE ELECTRIC BOX BEHIND THE CAB

✷ relay 5 A 2 contacts relay 16A 1contact all interchangeable R = controlled relay for Danfoss variable signal R = 12V control

GREEN AND RED LAMPS

ELECTRICITY

2nd Version

Page 119

ELECTRICITY

Page 120

M MMM MMM MM M M M 6 6 6 6 6 6 6 6 6 6 6 6 I I I I I I I I I I I I 0 0 0 0 0 0 0 0 0 1 1 1 1 2 3 4 5 6 7 8 9 0 1 2 M MMM MMM 5 5 5 5 5 5 5 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

Extension 1 solenoid valve Extension 3 solenoid valve Slewing solenoid valve Extension 2 solenoid valve Optional solenoid valve Lifting solenoid valve Tilting solenoid valve

M MMM MMM 4 4 4 4 4 4 4 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

Extension 1 Extension 3 Slewing Extension 2 Optional Lifting Tilting

M MMM MMM 3 3 3 3 3 3 3 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

Extension 1 Extension 3 Slewing Extension 2 Optional Lifting Tilting

M MMM MM 2 2 2 2 2 2 I I I I I I 0 0 0 0 0 0 1 2 3 4 5 6

OOOOOOO OOOOOOO OOOOOOO

MM A A I I 0 0 1 2

G + N 1 D 2 V

OOOOOO

DANFOSS PVG 32 MANIPULATEUR NACELLE

K10 K8 K6 K4 K2 R10 R9 R8 R7 R3 M MMM MMM MM M M M 1 1 1 1 1 1 1 1 1 1 1 1 I I I I I I I I I I I I 0 0 0 0 0 0 0 0 0 1 1 1 1 2 3 4 5 6 7 8 9 0 1 2

MANIPULATEUR CABINE ALIMENTATION

GREEN AND RED LAMPS

OOOOOOOOOOOO

K9 K7 K5 K3 K1 R11 R12 R6 R5 R4 R1

DIAGRAM OF CONNECTIONS AND RELAYS OF THE ELECTRIC BOX BEHIND THE CAB

K11

OOOOOOOOOOOO

2nd Version

ELECTRICITY CONNECTION OR RELAY

2nd Version RATING PLATES ON THE COVER OF THE ELECTRIC BOX BEHIND THE CAB CONNECTION OR RELAY

Page 121

2nd Version

ELECTRICITY

DESCRIPTION OF THE SIGNAL LAMPS AND RATING PLATES ON THE COVER OF THE ELECTRIC BOX BEHIND THE CAB CONNECTION ON OR OFF RELAY

. ... ... .

M1-01

. ... ... .

M1-02

. ... ... .

M1-03

. ... ... .

M1-04

. ... ... .

M1-05

. ... ... .

M1-06

. ... ... .

M1-07

. ... ... .

M1-08

. ... ... .

M1-09

. ... ... .

M1-10

. ... ... .

M1-11

. ... ... .

M1-12

. ... ... .

M2-01

. ... ... .

M2-02

. ... ... .

M2-03

. ... ... .

M2-04

. ... ... .

M2-06

. ... ... .

R1 - R2 R3-R4

. ... ... .

Page 122

ELECTRICITY

2nd Version

DESCRIPTION OF THE SIGNAL LAMPS AND RATING PLATES ON THE COVER OF THE ELECTRIC BOX BEHIND THE CAB CONNECTION ON OR OFF RELAY

. ... ... .

R10

. ... ... .

R11

. ... ... .

R12

. ... ... .

K10

. ... ... .

K11

. ... ... .

Page 123

2nd Version

ELECTRICITY

ELECTRONIC BOARD ELECTRIC CIRCUIT

Page 124

ELECTRICITY

2nd Version

THE INPUT ADAPTATION CIRCUIT IS REPEATED FOR 15 SECTIONS

Page 125

2nd Version

INVERTED NUMBERING

Page 126

ELECTRICITY

2nd Version

THE POWER CIRCUIT WILL BE REPLICATED FOR 22 OUTPUTS

Page 127

2nd Version

Page 128

ELECTRICITY

OUTPUT 1 CONTROL OUTPUT 2 CONTROL OUTPUT 3 CONTROL OUTPUT 4 CONTROL OUTPUT 5 CONTROL OUTPUT 6 CONTROL OUTPUT 7 CONTROL SIGN 1 CONTROL OUTPUT 9 CONTROL OUTPUT 10 CONTROL OUTPUT 11 CONTROL

K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11

RELAY COIL CONTROLS OUTPUT 12 CONTROL OUTPUT 13 CONTROL OUTPUT 14 CONTROL OUTPUT 15 CONTROL OUTPUT 16 CONTROL OUTPUT 17 CONTROL OUTPUT 18 CONTROL OUTPUT 19 CONTROL OUTPUT 20 CONTROL OUTPUT 21 CONTROL

R12 R11 R10 R9 R8 R7 R6 R5 R1-R2-R3-R4 4053

ELECTRICITY

2nd Version

Page 129

ELECTRICITY

REAR AXLE ALIGNEMENT GREEN LIGHT

AVAILABLE BLUE LIGHT REAR AXLE OSCILLATION BLOCK FLASHING YELLOW LIGHT INCLINATION RED LIGHT TURRET BLOCK GREEN LIGHT

GEAR SPEED REVERSE LEVER

LIGHT SWITCH CONTROL

PAT SYSTEM

TURRET ALIGNEMENT GREEN LIGHT OUTRIGGERS RETRACTED GREEN LIGHT OUTRIGGERS OUT AND LOWERED GREEN LIGHT

Page 130

IGNITION AND CONTACT KEY

FRONT AXLE ALIGNEMENT YELLOW LIGHT

PARKING LIGHT GREEN LIGHT

RESET TRANSMISSION

ELECTRIC COMPONENT LAYOUT

DIRECTION SELECTOR

2nd Version

BASKET SAFETY KEY

LEFT FRONT OUTRIGGER

PAT SYSTEM EXCLUSION KEY

RIGHT FRONT OUTRIGGER

ELECTRIC COMPONENT LAYOUT

LEFT REAR OUTRIGGER

RIGHT REAR OUTRIGGER

LIFTED LOWERED OR TELESCOPED OUTRIGGERS SELECTOR

OUTRIGGERS CONTROL LEVER

ELECTRICITY

2nd Version

Page 131

LIFTING-TILTING-T2 DANFOSS MANIPULATOR

HYDRAULIC SYSTEM LP EXCLUSION SPEED CHANGE MANIPULATOR

T1-T3-ACCESSORY DANFOSS MANIPULATOR

ELECTRIC COMPONENT LAYOUT

Page 132 HYDRAULIC MOVEMENT EXCLUSION MICROSWITCH

PARKING BRAKE TRANSMISSION SECTION MICROSWITCH

T3-ACCESSORY CONTROL SELECTOR

2nd Version ELECTRICITY

NOTE ✷ ONLY IN THE BASKET VERSION

ELECTRIC BOX UNDER THE STEP LADDER

BLOCKED TOWER MICROSWITCH

ELECTRIC HEADER

✷ BASKET PROXIMITY INDICATOR

PAT WINDER AND ANGLE INDICATOR

0.8 M HIGH ARM PROXIMITY INDICATOR

ELECTRIC SAFETY PUMP

✷ PENDULUM LEVELLING INDICATOR

LIFTING LIMIT SWITCH MICROSWITCH

TOWER ALIGNMENT MICROSWITCH

SAFETY PUMP CONTROL KEY

ELECTRIC COMPONENT LAYOUT

TOWER NOT ALIGNED = 5° PROXIMITY INDICATOR

STABILIZERS RESTING ON GROUND MICROSWITCH

RETRACTED STABILIZER PROXIMITY INDICATOR

RETRACTED ARM PROXIMITY INDICATOR

ELECTRICITY

2nd Version

Page 133

Page 134

FUSE BOX UNDER THE INSTRUMENT PANEL

SOFTWARE ELECTRONIC BOX

ELECTRIC COMPONENT LAYOUT

2nd Version ELECTRICITY

Electric system 2nd Version page 137-180 from the truck n° 121779/6356

ELECTRICITY

2nd Version

FUSE AND RELAY BOX

➠ 1

E5 E11

E10

➩

Page 137

ELECTRICITY

2nd Version

FUNCTIONAL DESCRIPTION OF THE FUSES IN THE BOX LOCATED UNDER THE COVER OF THE INSTRUMENT PANEL Ref.

Amps

Description

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15

10 5 7.5 10 15 5 7.5 10 3 10 10 7.5 3 Diode 10

F16

7.5

F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28

7.5 15 10 15 15 7.5 10 15 10 10 5 Diode

FUNCTIONAL DESCRIPTION OF RELAYS IN THE BOX LOCATED UNDERNEATH THE COVER OF THE INSTRUMENT PANEL Ref.

Characteristics

Description

E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E11

20/30 Amps 20/30 Amps 20/30 Amps 20/30 Amps 20/30 Amps 20/30 Amps ....................... ....................... ....................... ....................... 12 Volt 84/168 Watt

Page 138

ELECTRICITY

2nd Version

ELECTRIC BOX UNDER CAB

E 12

F 30 F 31 F 32

E 17 E 18 E 19 E 20 E 21

E 16

E 15

F 29

E 14

E 13

F 33 F 34 F 35 F 36 F 37

FUNCTIONS DESCRIPTION E12) Ignition relay E13) Thermal starter relay E14) Low beam relay E15) High beam relay E16) Services relay E17) Stabiliser general solenoid valve relay E18) Suspension lock relay E19) Soundproofing relay E20) 55° suspension lock relay E21) Antioverturning system and logic alimentation relay F29) Fuse 100 A : General power supply F30) Fuse 10 A : Front left and back right position lights F31) Fuse 10 A : Front right and back left position lights F32) Fuse 10 A : Low beam lights F33) Fuse 10 A : High beam lights F34) Fuse 10 A : Stabiliser general solenoid valve F35) Fuse 10 A : Rear axle oscillating solenoid valves and soundproofing solenoid valve F36) Fuse 10 A : Truck ignition power supply F37) Fuse 10 A : Antioverturning system + software alimentation C1) Circuit electronic stabiliser return

Page 139

2nd Version

ELECTRICITY

USERS LEGEND ELECTRIC SYSTEM MRT1540 MANITOU CAB 1997 VERSION WITH SOFTWARE (reference drawing No. 924) A1 A2 A3 B1 C1 D1 D2

. Buzzer (Tab. 3) . Reverse engaged buzzer (Tab. 2) . Pendulum active with cage buzzer (Tab. 11) . Battery (12 VOLT - Tab. 1) . Circuit electronic stabiliser return (Tab. 10) . Light control switch (Tab. 3) . Diode 1 amp (Tab. 6 - 11)

Relay situated in the fuses box E1 . Ignition enabling relay (Tab. 1-4) E2 . Hydraulic circuit exclusion relay (Tab. 6) E3 . Danfoss solenoid valve power supply relay (Tab. 6-7) E4 . Forward relay (Tab. 2-4) E5 . Reverse relay(Tab. 2-4) E6 . Parking brake optical indicator relay (Tab. 2-4) E7 . Available relay E8 . Available relay E9 . Available relay E10 . Available relay E11 . Direction/emergency light flashing (Tab. 4) Relay situated in the electric box under cab E12 . Ignition relay (Tab. 1) E13 . Thermal starter relay (Tab. 1) E14 . Low beam relay (Tab. 3-4) E15 . High beam relay (Tab. 3-4) E16 . Services relay (Tab. 2) E17 . Stabiliser general solenoid valve relay (Tab. 5-8) E18 . Suspension lock relay (Tab. 2-6) E19 . Soundproofing relay (Tab. 6-9) E20 . 55° suspension lock relay (Tab. 6-14) E21 . Antioverturning system and logic alimentation relay (Tab. 2-12) Relay situated in the rear side of the truck E22 . Emergency pump contactor (Tab. 1-7) Relay situated in the cage push button panel E23 . Optical defect indicator relay (cage) (Tab. 11) Relay situated in the consolle slow - fast E24 . Slow - fast speed bistatic relay (Tab. 12) F1 F2 F3 F4 F5

. Fuse 10 A : Electronic pendulum + hydraulic circuit exclusion solenoid valve (Tab. 6) . Fuse 5 A : Gear engaged switch + truck ignition power supply (Tab. 2) . Fuse 7.5 A : Light switch + cab buzzer (Tab. 3) . Fuse 10 A : Beacon (Tab. 5) . Fuse 15 A : Available (Tab. 13)

Page 140

ELECTRICITY

2nd Version

F6 . Fuse 5 A : Direction lights (Tab. 3) F7 . Fuse 7.5 A : Drive wheel command (Tab. 4) F8 . Fuse 10 A : Front windshield wiper + washer (Tab. 13) F9 . Fuse 3 A : Instruments + lamp control check (Tab. 1) F10 . Fuse 10 A : Front working lights (Tab. 13) F11 . Fuse 10 A : Rear working lights (Tab. 13) F12 . Fuse 7.5 A : Rear windshield wiper + top windshield wiper (Tab. 13) F13 . Fuse 3 A : Stabiliser switch lighting (Tab. 8) F14 . Diode 1 A : Available (Tab. 3) F15 . Fuse 10 A : Emergency key + braking pressure switch + translation solenoid valve (Tab. 7) F16 . Fuse 7.5 A : Microswitch lock and tower alignment + transmission reset button (Tab. 2) F17 . Fuse 7.5 A : Danfoss cab operating manipulators (Tab. 8) F18 . Fuse 15 A : Stabiliser instrument panel (Tab. 8) F19 . Fuse 10 A : Anti-tipping system (Tab. 8) F20 . Fuse 15 A : Relay alimentation of the board with logic + 23 mt cage (Tab. 11) F21 . Fuse 15 A : Danfoss solenoid valves (Tab. 7) F22 . Fuse 7.5 A : Available (Tab. 3) F23 . Fuse 10 A : Available(Tab. 3) F24 . Fuse 15 A : Available(Tab. 3) F25 . Fuse 10 A : Available direct power supply (Tab. 3) F26 . Fuse 10 A : Emergency lights + ceiling light (Tab. 3) F27 . Fuse 5 A : Direct alimentation available (Tab. 3) F28 . Diode 1 A : Reverse gear (Tab. 2) F29 . Fuse 80 A : General power supply (Tab. 1) F30 . Fuse 10 A : Front left and back right position lights (Tab. 3) F31 . Fuse 10 A : Front right and back left position lights(Tab. 3) F32 . Fuse 10 A : Low beam lights (Tab. 4) F33 . Fuse 10 A : High beam lights (Tab. 4) F34 . Fuse 10 A : Stabiliser general solenoid valve (Tab. 5) F35 . Fuse 10 A : Rear axle oscillating solenoid valves and soundproofing solenoid valve (Tab. 6) F36 . Fuse 10 A : Truck ignition power supply (Tab. 2) F37 . Fuse 10 A : Antioverturning system + software alimentation (Tab. 2) F38 . Fuse 30 A : Heating (Tab. 14) G1 . Alternator (Tab. 1) H1 . Hour meter (Tab. 1) I1 . Parking brake microswitch (Tab. 2) I2 . Forward-reverse gear manipulator (Tab. 4) I3 . Slow-fast gear microswitch (Tab. 2) I4 . Transmission reset button (Tab. 2) I5 . Stop lights pressure switch (Tab. 2) I6 . Proximity PNP rear axle alignment (Tab. 2) I7 . Proximity PNP Tower alignment (Tab. 2) I8 . Proximity PNP front axle alignment (Tab. 2) I9 . Emergency electric pump key (Tab. 7) I10 . Cab emergency key (Tab. 7) I11 . Fuel reserve level switch (Tab. 5) I12 . Air filter fouling pressure switch (Tab. 5) I13 . Pressure switch for low engine oil pressure (Tab. 5) I14 . Cab locked microswitch (Tab. 6) I15 . Cab aligned microswitch (Tab. 6) Page 141

2nd Version

ELECTRICITY

I16 . Right rear output stabiliser micro (Tab. 6) I17 . Left rear output stabiliser micro (Tab. 6) I18 . Left front output stabiliser micro (Tab. 6) I19 . Right front output stabiliser micro (Tab. 6) I20 . Hydraulic oil temperature thermal contact (Tab. 6) I21 . Engine water temperature thermal contact (Tab. 6) I22 . Hydraulic circuit exclusion button (Tab. 6) I23 . Arm microswitch (Tab. 6) F35 . Fuse 10 A : Rear axle oscillating solenoid valves and soundproofing solenoid valve (Tab. 6) I24 . Drive wheel selector (Tab. 4) I25 . Third extension - optional selector (Tab. 8) I26 . Stabiliser extension-return manipulator (Tab. 8) I27 . Beam-stabiliser selector (Tab. 8) I28 . Left front stabiliser button (Tab. 8) I29 . Right front stabiliser button (Tab. 9) I30 . Left rear stabiliser button (Tab. 9) I31 . Right rear stabiliser button (Tab. 9) I32 . Proximity PNP - Left rear stabiliser returned (Tab. 10) I33 . Proximity PNP - Right rear stabiliser returned (Tab. 10) I34 . Proximity PNP - Left front stabiliser returned (Tab. 10) I35 . Proximity PNP - Right front stabiliser returned (Tab. 10) I36 . Proximity PNP - Arm extension (Tab. 10) I37 . Proximity PNP - Arm rise 0.8 mt (Tab. 10) I38 . Electronic levelling pendulum (Tab. 10) I39 . Proximity PNP - 23 mt cage saddle (Tab. 11) I40 . Proximity PNP - (n.C.) cage present (Tab. 11) I41 . Lifting exclusion microswitch (Tab. 11) I42 . Cage engine stop button (Tab. 11) I43 . Cage buzzer button (Tab. 11) I44 . Contact active with 23 mt cage inserted (Tab. 11) I45 . Cage overload microswitch (Tab. 11) I46 . Cage door microswitch (Tab. 11) I47 . Cage start-up button (Tab. 12) I48 . Cage operation enabling button (Tab. 12) I49 . Cage operation selector (Tab. 12) I50 . Arm rise microswitch (Tab. 12) I51 . Anti-tipping system safety key (Tab. 12) I52 . Engine max. water temperature thermal contact (Tab. 5) I53 . Emergency light switch (Tab. 3) I54 . Beacon switch (Tab. 5) I55 . Brake oil level switch (Tab. 5) I56 . Braking pressure switch (Tab. 12) I57 . Front windshield wiper and washer switch (Tab. 13) I58 . Rear and top windshield wiper switch (Tab. 13) I59 . Front working light switch (Tab. 13) I60 . Rear working light switch (Tab. 13) I 61 . 55° lifting PNP proximity (Tab. 14) I62 . Optional switch from the cage (Tab. 12) KEY . Ignition switch (Tab. 1) L1 . Rear axle alignment optical indicator (Tab. 2) Page 142

ELECTRICITY

2nd Version

L2 . Front axle alignment optical indicator(Tab. 2) L3 . Rear axle locked optical indicator (Tab. 7) L4 . Position lights optical indicator (Tab. 3) L5 . Cab locked optical indicator (Tab. 6) L6 . Cab aligned optical indicator (Tab. 6) L7 . Stabilisers extended optical indicator (Tab. 6) L8 . Stabilisers retracted optical indicator (Tab. 10) L9 . Pendulum active optical indicator (Tab. 10) L10 . (Cage) defect optical indicator (Tab. 11) L11 . Pendulum active (cage) optical indicator (Tab. 11) L12 . Slow gear engaged optical indicator (Tab. 12) L13 . Fast gear engaged optical indicator (Tab. 12) L14 . Battery charge optical indicator (Tab. 1) L15 . High beam lights optical indicator (Tab. 3) L16 . Direction lights optical indicator (Tab. 4) L17 . Parking brake optical indicator (Tab. 4) L18 . Available optical indicator (Tab. 5) L19 . Fuel reserve optical indicator (Tab. 5) L20 . Fouled air filter optical indicator (Tab. 5) L21 . Low engine oil pressure optical indicator (Tab. 5) L22 . Max. engine water temperature optical indicator (Tab. 5) L23 . Low brake fluid level optical indicator (Tab. 5) M1 . Starter motor (Tab. 1) M2 . Emergency electric pump (Tab. 1) M3 . Cab left Danfoss manipulator (Tab. 8) M4 . Cab right Danfoss manipulator (Tab. 8) M5 . Cage operating manipulator (Tab. 12) M6 . Slow - fast speed manipulator (Tab. 12) M7 . Front windshield wiper (Tab. 13) M8 . Windshield cleaner pump (Tab. 13) M9 . Rear windshield wiper (Tab. 13) M10 . Top windshield wiper (Tab. 13) M11 . Heating fuel pump (Tab. 14) P1 . Left rear stop light (Tab. 2) P2 . Right rear stop light(Tab. 2) P3 . Left front direction light (Tab. 3) P4 . Left rear direction light (Tab. 3) P5 . Right front direction light (Tab. 3) P6 . Right rear direction light(Tab. 3) P7 . Left front position light (Tab. 3) P8 . Left rear position light(Tab. 3) P9 . Right front position light (Tab. 3) P10 . Right rear position light (Tab. 3) P11 . Left front lowbeam light (Tab. 4) P12 . Right front lowbeam light (Tab. 4) P13 . Left front highbeam light (Tab. 4) P14 . Left front highbeam light (Tab. 4) P15 . Cab ceiling light (Tab. 3) P16 . Beacon (Tab. 5) P17 . Front working light (Tab. 13) Page 143

2nd Version P18 . Rear working light (Tab. 13) R1 . Resistor 68 Ω 2 W (Tab. 1) R2 . Heating (Tab. 14) R3 . Heating thermostat (Tab. 14) SI . Lifting Danfoss solenoid valve (Tab. 7) S2 . First extension Danfoss solenoid valve (Tab. 7) S3 . Second extension Danfoss solenoid valve (Tab. 7) S4 . Rotation Danfoss solenoid valve (Tab. 7) S5 . Swinging Danfoss solenoid valve (Tab. 7) S6 . Third extension Danfoss solenoid valve (Tab. 7) S7 . Optional Danfoss solenoid valve (Tab. 7) S8 . Rotation speed reduction solenoid valve (Tab. 9) S9 . Stabiliser general solenoid valve (Tab. 5) S10 . Hydraulic circuit exclusion solenoid valve (Tab. 6) S11 . Left front beam solenoid valve (Tab. 8) S12 . Right front beam solenoid valve (Tab. 9) S13 . Left rear beam solenoid valve (Tab. 9) S14 . Right rear beam solenoid valve (Tab. 9) S15 . Stabiliser return solenoid valve (Tab. 8) S16 . Right front stabiliser solenoid valve (Tab. 9) S17 . Left front stabiliser solenoid valve (Tab. 8) S18 . Left rear stabiliser solenoid valve (Tab. 9) S19 . Right rear stabiliser solenoid valve (Tab. 9) S20 . Soundproofing solenoid valve (Tab. 9) S21 . Forward solenoid valve (Tab. 2) S22 . Reverse solenoid valve (Tab. 2) S23 . Rear axle oscillation solenoid valve (Tab. 6) S24 . Crabwise steering solenoid valve (Tab. 4) S25 . Cam drive solenoid valve (Tab. 4) S26 . Rear axle oscillation solenoid valve (Tab. 6) S27 . Slow speed solenoid valve (Tab. 12) S28 . Fast speed solenoid valve (Tab. 12) S29 . 23 mt cage movement solenoid valve (Tab. 9) S30 . Engine stop solenoid valve (Tab. 7) S31 . 23 mt cage left rotation solenoid valve (Tab. 12) S32 . 23 mt cage right rotation solenoid valve (Tab. 12) ST1 . Anti-tipping system (Tab. 12) ST2 . Fuel level instrument (Tab. 5) ST3 . Electric battery lock out (Tab. 1) T1 . Fuel level transmitter (Tab. 5) TR . Thermo-starter (Tab. 1) COLOUR A : azure M : brown B : white N : black C : orange R : red G : yellow S : pink H : grey V : green L : blue Z : violet Example: AB = azure / white Page 144

ELECTRICITY

2nd Version CONNECTION CARD FOR TINSLEY 44-POLE ROTATING TAP

Nº 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030 031 032 033 034 035 036 037 038 039 040 041 042 043 044

Page 145

TABLE N°1

2nd Version

Page 146

ELECTRICITY

2nd Version

TABLE N°2

ELECTRICITY

Page 147

TABLE N°3

2nd Version

Page 148

ELECTRICITY

2nd Version

TABLE N°4

ELECTRICITY

Page 149

TABLE N°5

2nd Version

Page 150

ELECTRICITY

2nd Version

TABLE N°6

ELECTRICITY

Page 151

TABLE N°7

2nd Version

Page 152

ELECTRICITY

2nd Version

TABLE N°8

ELECTRICITY

Page 153

TABLE N°9

2nd Version

Page 154

ELECTRICITY

2nd Version

TABLE N°10

ELECTRICITY

Page 155

TABLE N°11

2nd Version

Page 156

ELECTRICITY

2nd Version

TABLE N°12

ELECTRICITY

Page 157

TABLE N°13

2nd Version

Page 158

ELECTRICITY

2nd Version

TABLE N°14

ELECTRICITY

Page 159

2nd Version MRT 1540 SOFTWARE INPUT-OUTPUT CONNECTORS INPUT connectors Power supply connector MA MA-01 MA-01

Black ø 1.5 Red black ø 1.5

Negative power supply Positive power supply

Connector M1 M1-01 M1-02 M1-03 M1-04 M1-05 M1-06 M1-07 M1-08 M1-09 M1-10 M1-11 M1-12

Blue-green ø 0,5 Orange ø 0,5 Yellow-blue ø 0,5 White no. 09 Grey no. 44 Orange-blue no. 04 Orange-green Orange-blue Yellow-red Yellow-green Violet-white Yellow-blue

Connector M2 M2-01 M2-02 M2-03 M2-04 M2-05 M2-06

Orange-red Brown-white Yellow-grey Grey-black -----------------------Green

Basket operation enabling signal button Basket engine stop button 23 mt on basket signal Anti-tilting -----------------------------------------------------Up operation exclusion microswitch

Connector M3 analog signals from cab manipulators M3-01 M3-02 M3-03 M3-04 M3-05 M3-06 M3-07

Page 160

Light blue-white Green-white Grey-blue Grey-white White-yellow Orange-white Pink-yellow

Tilting Lifting Optional Extension 2 Rotation Extension 3 Extension 1

ELECTRICITY

2nd Version

Connector M4 analog signals from basket manipulator M4-01 M4-02 M4-03 M4-04 M4-05 M4-06 M4-07

Blue-black Green-black White-black Grey-black Yellow-black Orange-black Pink-black

Tilting Lifting Optional Extension 2 Rotation Extension 3 Extension 1

OUTPUT connectors Connector M5 analog signals for Danfoss solenoid valves M5-01 M5-02 M5-03 M5-04 M5-05 M5-06 M5-07

Blue Green White Grey Yellow Orange Pink

Tilting solenoid valve Lifting solenoid valve Optional solenoid valve Extension 2 solenoid valve Rotation solenoid valve Extension 3 solenoid valve Extension 1 solenoid valve

Connector M6 M6-01 M6-02 M6-03 M6-04 M6-05 M6-06 M6-07 M6-08 M6-09 M6-10 M6-11 M6-12

Orange-blue Grey no. 4 Grey-red Red White-green Yellow-brown Red-green Brown White-grey + diode White-grey + diode Violet-black Red-black ø 1.5

Page 161

2nd Version

ELECTRICITY

32-PIN COUPLING CONNECTION TO BOX WITH SOFTWARE N° 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21

Page 162

ELECTRICITY

2nd Version

10-PIN COUPLING CONNECTION TO BOX WITH SOFTWARE N° 01 02 03 04 05 06 07

Page 163

Page 164

MM A A I I 0 0 1 2

G + N 1 D 2 V

POWER SUPPLY

M MMM MM 2 2 2 2 2 2 I I I I I I 0 0 0 0 0 0 1 2 3 4 5 6

OOOOOO

M MMM MMM 3 3 3 3 3 3 3 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

OOOOOOO

M MMM MMM MM M M M 1 1 1 1 1 1 1 1 1 1 1 1 I I I I I I I I I I I I 0 0 0 0 0 0 0 0 0 1 1 1 1 2 3 4 5 6 7 8 9 0 1 2

M MMM MMM 4 4 4 4 4 4 4 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

R10

OOOOOOO

M MMM MMM 5 5 5 5 5 5 5 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

OOOOOOO

R11

R12

DIAGRAM OF CONNECTIONS AND RELAYS OF THE ELECTRIC BOX BEHIND THE CAB

OOOOOOOOOOOO

GREEN AND RED LAMPS

K10

M MMM MMM MM M M M 6 6 6 6 6 6 6 6 6 6 6 6 I I I I I I I I I I I I 0 0 0 0 0 0 0 0 0 1 1 1 1 2 3 4 5 6 7 8 9 0 1 2

OOOOOOOOOOOO

K11

2nd Version ELECTRICITY

OOOOOO

✷

R10

OOOOOOO

R11

R12

✷

OOOOOOO

LEGEND R1-R2-R3-R4 = basket or cab selection R5 = TS inclination R6 = lifting R7 = optional R8 = telescope 1 R9 = rotation R10 = telescope 3 R11 = telescope 1 R12 = Danfoss flow regulator selection

ALIMENTATION

OOOOOOOOOOOO

✷

K10

OOOOOOOOOOOO

K11

K7 = basket red light relay K8 = engine stopped relay K9 = contact N relay 12V cab K10 = contact N relay 12V basket K11 = rear axle locked yellow light

Danfoss flow regulator connection for lifting and descent (TS inclination only for 23m)

DIAGRAM OF CONNECTIONS AND RELAYS OF THE ELECTRIC BOX BEHIND THE CAB

✷ relay 5 A 2 contacts relay 16A 1contact all interchangeable R = controlled relay for Danfoss variable signal R = 12V control

GREEN AND RED LAMPS

ELECTRICITY

2nd Version

Page 165

ELECTRICITY

Page 166

M MMM MMM MM M M M 6 6 6 6 6 6 6 6 6 6 6 6 I I I I I I I I I I I I 0 0 0 0 0 0 0 0 0 1 1 1 1 2 3 4 5 6 7 8 9 0 1 2 M MMM MMM 5 5 5 5 5 5 5 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

Extension 1 solenoid valve Extension 3 solenoid valve Slewing solenoid valve Extension 2 solenoid valve Optional solenoid valve Lifting solenoid valve Tilting solenoid valve

M MMM MMM 4 4 4 4 4 4 4 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

Extension 1 Extension 3 Slewing Extension 2 Optional Lifting Tilting

M MMM MMM 3 3 3 3 3 3 3 I I I I I I I 0 0 0 0 0 0 0 1 2 3 4 5 6 7

Extension 1 Extension 3 Slewing Extension 2 Optional Lifting Tilting

OOOOOOO OOOOOOO OOOOOOO

MM A A I I 0 0 1 2

G + N 1 D 2 V

ALIMENTATION

OOOOOO

DANFOSS PVG 32 MANIPULATEUR NACELLE MANIPULATEUR CABINE

M MMM MM 2 2 2 2 2 2 I I I I I I 0 0 0 0 0 0 1 2 3 4 5 6

K7 K5 K3 K1 R11 R9 R7 R5 R4 R1 M MMM MMM MM M M M 1 1 1 1 1 1 1 1 1 1 1 1 I I I I I I I I I I I I 0 0 0 0 0 0 0 0 0 1 1 1 1 2 3 4 5 6 7 8 9 0 1 2

OOOOOOOOOOOO

GREEN AND RED LAMPS

OOOOOOOOOOOO

K10 K8 K6 K4 K2 R12 R10 R8 R6 R3 R2

DIAGRAM OF CONNECTIONS AND RELAYS OF THE ELECTRIC BOX BEHIND THE CAB

K11

2nd Version

ELECTRICITY CONNECTION OR RELAY

2nd Version RATING PLATES ON THE COVER OF THE ELECTRIC BOX BEHIND THE CAB CONNECTION OR RELAY

Page 167

2nd Version

ELECTRICITY

DESCRIPTION OF THE SIGNAL LAMPS AND RATING PLATES ON THE COVER OF THE ELECTRIC BOX BEHIND THE CAB CONNECTION ON OR OFF RELAY

. ... ... .

M1-01

. ... ... .

M1-02

. ... ... .

M1-03

. ... ... .

M1-04

. ... ... .

M1-05

. ... ... .

M1-06

. ... ... .

M1-07

. ... ... .

M1-08

. ... ... .

M1-09

. ... ... .

M1-10

. ... ... .

M1-11

. ... ... .

M1-12

. ... ... .

M2-01

. ... ... .

M2-02

. ... ... .

M2-03

. ... ... .

M2-04

. ... ... .

M2-06

. ... ... .

R1 - R2 R3-R4

. ... ... .

Page 168

ELECTRICITY

2nd Version

DESCRIPTION OF THE SIGNAL LAMPS AND RATING PLATES ON THE COVER OF THE ELECTRIC BOX BEHIND THE CAB CONNECTION ON OR OFF RELAY

. ... ... .

R10

. ... ... .

R11

. ... ... .

R12

. ... ... .

K10

. ... ... .

K11

. ... ... .

Page 169

2nd Version

ELECTRICITY

ELECTRONIC BOARD ELECTRIC CIRCUIT

Page 170

ELECTRICITY

2nd Version

THE INPUT ADAPTATION CIRCUIT IS REPEATED FOR 15 SECTIONS

Page 171

2nd Version

INVERTED NUMBERING

Page 172

ELECTRICITY

2nd Version

THE POWER CIRCUIT WILL BE REPLICATED FOR 22 OUTPUTS

Page 173

2nd Version

Page 174

ELECTRICITY

OUTPUT 1 CONTROL OUTPUT 2 CONTROL OUTPUT 3 CONTROL OUTPUT 4 CONTROL OUTPUT 5 CONTROL OUTPUT 6 CONTROL OUTPUT 7 CONTROL SIGN 1 CONTROL OUTPUT 9 CONTROL OUTPUT 10 CONTROL OUTPUT 11 CONTROL

K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11

RELAY COIL CONTROLS OUTPUT 12 CONTROL OUTPUT 13 CONTROL OUTPUT 14 CONTROL OUTPUT 15 CONTROL OUTPUT 16 CONTROL OUTPUT 17 CONTROL OUTPUT 18 CONTROL OUTPUT 19 CONTROL OUTPUT 20 CONTROL OUTPUT 21 CONTROL

R12 R11 R10 R9 R8 R7 R6 R5 R1-R2-R3-R4 4053

ELECTRICITY

2nd Version

Page 175

ELECTRICITY

REAR AXLE ALIGNEMENT GREEN LIGHT

AVAILABLE BLUE LIGHT REAR AXLE OSCILLATION BLOCK FLASHING YELLOW LIGHT INCLINATION RED LIGHT TURRET BLOCK GREEN LIGHT

GEAR SPEED REVERSE LEVER

LIGHT SWITCH CONTROL

PAT SYSTEM

TURRET ALIGNEMENT GREEN LIGHT OUTRIGGERS RETRACTED GREEN LIGHT OUTRIGGERS OUT AND LOWERED GREEN LIGHT

Page 176

IGNITION AND CONTACT KEY

FRONT AXLE ALIGNEMENT YELLOW LIGHT

PARKING LIGHT GREEN LIGHT

RESET TRANSMISSION

ELECTRIC COMPONENT LAYOUT

DIRECTION SELECTOR

2nd Version

BASKET SAFETY KEY

LEFT FRONT OUTRIGGER

PAT SYSTEM EXCLUSION KEY

RIGHT FRONT OUTRIGGER

ELECTRIC COMPONENT LAYOUT

LEFT REAR OUTRIGGER

RIGHT REAR OUTRIGGER

LIFTED LOWERED OR TELESCOPED OUTRIGGERS SELECTOR

OUTRIGGERS CONTROL LEVER

ELECTRICITY

2nd Version

Page 177

LIFTING-TILTING-T2 DANFOSS MANIPULATOR

HYDRAULIC SYSTEM LP EXCLUSION SPEED CHANGE MANIPULATOR

T1-T3-ACCESSORY DANFOSS MANIPULATOR

ELECTRIC COMPONENT LAYOUT

Page 178 HYDRAULIC MOVEMENT EXCLUSION MICROSWITCH

PARKING BRAKE TRANSMISSION SECTION MICROSWITCH

T3-ACCESSORY CONTROL SELECTOR

2nd Version ELECTRICITY

NOTE ✷ ONLY IN THE BASKET VERSION

ELECTRIC BOX UNDER THE STEP LADDER

BLOCKED TOWER MICROSWITCH

ELECTRIC HEADER

✷ BASKET PROXIMITY INDICATOR

PAT WINDER AND ANGLE INDICATOR

0.8 M HIGH ARM PROXIMITY INDICATOR

ELECTRIC SAFETY PUMP

✷ PENDULUM LEVELLING INDICATOR

LIFTING LIMIT SWITCH MICROSWITCH

TOWER ALIGNMENT MICROSWITCH

SAFETY PUMP CONTROL KEY

ELECTRIC COMPONENT LAYOUT

TOWER NOT ALIGNED = 5° PROXIMITY INDICATOR

STABILIZERS RESTING ON GROUND MICROSWITCH

RETRACTED STABILIZER PROXIMITY INDICATOR

RETRACTED ARM PROXIMITY INDICATOR

ELECTRICITY

2nd Version

Page 179

Page 180

FUSE BOX UNDER THE INSTRUMENT PANEL

SOFTWARE ELECTRONIC BOX

ELECTRIC COMPONENT LAYOUT

2nd Version ELECTRICITY

SAFETY SYSTEM 80-8-80-M9 EN

SAFETY SYSTEM

PAT DS 100 at page 2

PAT DS 50 at page 19

Page 1

Page 2

1 = MICROPROCESSOR DISPLAY 2 = LIFTING CYLINDER PRESSURE TRANSDUCERS 3 = COMPENSATION CYLINDER PRESSURE TRANSDUCERS 4 = ARM ANGLE SIGNAL SENSOR 5 = ARM LENGTH SIGNAL SENSOR 6 = EXTENSION CABLE

SAFETY SYSTEM

DA 313

DS 100

DA 313

PAT DS 100 SAFETY SYSTEM

SAFETY SYSTEM

PAT DS 100

DESCRIPTION OF THE SAFETY SYSTEM COMPONENTS (PAT) 1) MICROPROCESSOR DISPLAY The DS100 display is positioned on the cab instrument panel and receives the signal directly from the sensors on the lifting and compensation cylinder. The display provides the operator with information about many important functions for using the machine correctly, and specifically:

DISPLAY DIAGRAM Capacity indication Tilting lamp with progressive bars 90% 100% CODE SWL = Maximum LOAD = Load on the forks load indication from the diagram

Tilting lamp at 90%

RAD = Working radius in metres

ANG. = Arm angle in degrees

STOP

LNG = Arm length in metres

Lamp on Lamp on wheels stabiliz.

Movements blocked Selector for type of equipment

- SWL - LOAD - ANG - LNG - LED BARS - RAD - CODE

2 1 3 4 5

(Diagram of allowable loads under all conditions). (Real load applied on the equipment). (Arm angle in degrees). (Length of the extensions). (Percentage of the weight). (Work radius; from the centre of the tower to the centre of the load). (Machine diagram code - on front wheel - 360° on wheel - and optional equipment).

Page 3

PAT DS 100

SAFETY SYSTEM

OPERATING MODE TABLE (Code) SELECTOR ON INSTRUMENT PANEL

EQUIPMENT ON THE TS

DIAGRAM ON

POSITION

PROGRAM CODE EXTENSION-DOWN AND STOPPED

ARM ARM UP

FORKS

STAB. 360°

001

101

GOMME FRONTALI (*)

020

120

WHEELS 360°

021

121

HOIST 3 TON.

STAB. 360°

003

103

FRONT WHEELS (*)

023

123

HOIST 4 TON.

STAB. 360°

004

104

FRONT WHEELS (*)

024

124

HOIST 5 TON.

STAB. 360°

005

105

FRONT WHEELS (*)

025

125

TRELLIS JIB P600

STAB. 360°

006

106

FRONT WHEELS (*)

026

126

2 3 4 5 6

(*) - Rotation lock pin inserted

C 57

RADIUS IN METERS

Page 4

SAFETY SYSTEM

PAT DS 100

REPLACING EPROM MEMORY DATA - Open the DISPLAY by loosening the fastening screws (Detail 1 - Photo A). The DISPLAY will open into two parts (Photo B).

Photo. A

- Remove the EPROM (Detail 1 - Photo B) making sure to note the assembly direction (see the grooves Detail 2 - Photo B). C 58

- Replace it exactly by reversing the operation, making sure not to bend the contacts.

☞ 1

Photo B

➛

➛ MRT 1540 SERIAL NO. ...................... DATE ..................................

1 C 59

Page 5

SAFETY SYSTEM

PAT DS 100

2-3) LIFTING AND COMPENSATION CYLINDER PRESSURE TRANSDUCERS The system to display the weight of the load lifted must read 4 pressure points: there are two sensors mounted on each of the lifting and compensation cylinders (one on the bottom side and one on the stem side). The sensors consist of a membrane and 4 extension cells which, under the action of the hydraulic pressure, are deformed and create a resistance. That value is converted from a hydraulic to an electric parameter into volts.

Procedures To replace the sensor fittings perform the steps indicated in order: unscrew the counter nuts 1 and 2 (Photo A), unscrew the socket dowel 3 (Photo A), then unscrew the lock ring 4, the sensor fitting is detached, and disconnect the electric wires. Replace by doing the exact opposite. WARNING These fittings are hermetically sealed; if water leaks in, they will not read the load in an effective manner.

4) ARM ANGLE SIGNAL SENSOR

Photo A

Signals the tilt angle of the arm in degrees by means of an oil-bath internal pendulum 1 (Photo A). WARNING: in case of malfunction, do not open the sensor; escaping oil might cause it to malfunction. Replace the entire sensor. WARNING: the sensor should be mounted in the original position; if this is impossible, recall that it must be mounted parallel to the arm axis, therefore: - position the horizontal arm (0°) checking with the graduated level - if the position is correct, the display will indicate 0°

Page 6

C 60

SAFETY SYSTEM

PAT DS 100

5) ARM LENGTH SIGNAL SENSOR Photo A

The length sensor is a multiple-turn potentiometer, connected to a cable to read the length of the extension from pin to pin. The motion is transmitted by means of two gears; they are engaged by means of an OR inside the gearing that acts as a clutch. During assembly, check that there is clearance between the two gears to avoid possible wear.

☞ ☞ ☞

C 61

Adjustments - when replacing the cable, pre-load the winder with 3 to 5 turns - check that the cable is in line with the external edge of the winder 1 (Photo A), if necessary, adjust by shimming the fastening screw 1 (Photo B) Potentiometer adjustment (to be performed when replacing the cable, gears and potentiometer) - fully retract the arm - turn the potentiometer register 1 (Photo C) clockwise up to the limit switch stop - read the length on the display (LNG) 4.9 mt - completely extend the arm to check that it operates efficiently

Photo B

POTENTIOMETER DISASSEMBLY - Disassemble the two screws that support the gear stop - Remove the gearing, by pulling it out - Unscrew the potentiometer fastening nut - Extract the potentiometer and disconnect the electric wires

C 62

RE-ASSEMBLY - Connect the electric wires - Insert the potentiometer referring to the mandatory position notch - Tighten the fastening nut - Insert the gears into their seat - Replace the stop support

☞ Photo C

☞

C 63

Page 7

SAFETY SYSTEM

PAT DS 100

CONNECTOR INSIDE THE WINDER

▲

Posit.

Pendulum

Winder

Posit. 1 = Winder wiring (3) ➛ Negative power supply Pendulum wiring (3) ➛ Negative power supply Posit. 2 = Winder signal (2) Posit. 3 = Winder wiring (1) ➛ Positive power supply Pendulum wiring (1) ➛ Positive power supply Posit. 4 = Pendulum signal (2) Pendulum signal on display (4) Posit. 5 = Pendulum box outgoing cable (4)

Page 8

SAFETY SYSTEM

PAT DS 100

ERROR CODE

Error n° “O” Overload Error n° “V” Prewarning

Error n° "E01" Error:

Fallen below the radius range or angle range exceeded.

Cause:

Fallen below the minimum radius or exceeding the maximum angle specified in the respective load chart due to luffing up the boom too far.

Elimination: Luff down the boom to a radius or angle preset in the load chart.

Error n° “E02” Error:

Maximum radius exceeded or fallen below the angle range.

Cause:

The maximum radius was exceeded or fallen below the minimum angle specified the respective load chart due to luffing down the boom too far.

Elimination: Luff up the boom to a radius or angle preset in the load chart.

Error n° “E04” Error:

Operating mode not available.

Cause:

- Incorrect setting of operating mode switch in the console - Slewing range not admissible

Elimination: - Set operating mode switch correctly observing the assignment to the crane configuration. - Slew back into admissible slewing range.

Page 9

PAT DS 100

SAFETY SYSTEM

Error n° “E05” Error:

Prohibited lenght range

Cause:

a. Boom has been extended too far or not enough, e.g. if operation is only admitted up to a certain boom lenght or for load charts of jibs with the boom having to be extended to a certain lenght. b. The lenght sensor adjustment was modified, e.g. rope slid off the lenght sensor reel. c. Clutch between lenght sensor port and drive is defective. d. Failure of the +5V-supply for the analog part of the LMI-analog board. e. Cable between the central unit and lenght sensor defective or slack. f. Lenght potentiometer defective.

Elimination: a. Retract or extend boom to the correct lenght. b. Retract the boom. Check the prestress of the cable reel (the rope has to be under traction). Open the lenght sensor anbd carefully turn the lenght pot counterclockwise to the detent by use of a screwdriver. c. Completely replace the clutch with the drive wheel and adjust lenght sensor pot as described at b.) d. Check +5V-voltage. If there is no voltage or break down at a charge of 50 ohm approximately, exchange analog board. e. Check cable as well as connector and exchange, if necessary. f. Replace lenght potentiometer.

Error n° “E07” Error:

No acknowledgement from the overload relay.

Cause:

Overload relay is caught, defective or is not being driven.

Elimination: Replace the relay or the connection board.

Error n° “E11” Error:

Fallen below limit for the measuring channel “Lenght telescopic boom”.

Cause:

a. Cable between lenght sensor and central unit defective, not connected or water in the connectors. b. Lenght sensor pot defective. c. Electronic board in the measuring channeldefective.

Elimination: a. Check cable and connectors as well and repace, if necessary. b. Replace lenght sensor potentiometer. c. Replace main board or analog board.

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SAFETY SYSTEM

PAT DS 100

Error n° “E12” Error:

Fallen below lower limit value for the measuring channel “pressure transducer piston side, lifting cylinder”.

Cause:

a. Cable leading from the central unit to the pressure transducers defective or water in the connectors. b. Pressure transducer defective. c. Electronic board in the measuring channel defective.

Elimination: a. Check cable and connectors as well and replace, if necessary. b. Replace pressure transducer. c. Replace processor or analog board.

Error n° “E13” Error:

Fallen below lower limit value for the measuring channel “pressure transducer rod side, lifting cylinder”.

Cause:

a. Cable leading from the central unit to the pressure transducers defective or water in the connectors. b. Pressure transducer defective. c. Electronic board in the measuring channel defective.

Elimination: a. Check cable and connectors as well and replace, if necessary. b. Replace pressure transducer. c. Replace processor or analog board.

Error n° “E14” Error:

Fallen below lower limit value for the measuring channel “Compensation lenght”.

Cause:

a. Cable leading from the central unit to the pressure transducers defective or water in the connectors. b. Pressure transducer defective. c. Electronic board in the measuring channel defective.

Elimination: a. Check cable and connectors as well and replace, if necessary. b. Replace pressure transducer. c. Replace processor or analog board.

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PAT DS 100

SAFETY SYSTEM

Error n° “E15” Error:

Fallen below lower limit value for the measuring channel “angle main boom”.

Cause:

a. Cable leading from the central unit to the pressure transducers defective or water in the connectors. b. Angle sensor is defective. c. Electronic board in the measuring channel defective.

Elimination: a. Check cable and connectors as well and replace, if necessary b. Replace angle sensor. b. Replace processor or analog board.

Error n° “E16” Error:

Fallen below lower limit value for the measuring channel “Lifting Angle”.

Cause:

a. Cable leading from the central unit to the pressure transducers defective or water in the connectors. b. Pressure transducer defective. c. Electronic board in the measuring channel defective.

Elimination: a. Check cable and connectors as well and replace, if necessary. b. Replace pressure transducer. c. Replace processor or analog board.

Error n° “E17” Error:

Fallen below lower limit value for channel “cable reel potentiometer" or "compensation cylinder pression sensors".

Cause:

a. Potentiometer in question is outside the admissible adj.range b. Potentiometer is defective. c. Electronic board in the measuring channel defective.

Elimination: a. Turn the potentiometer into admissible adjudting range. b. Replace main board. c. Replace main board or analog board.

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SAFETY SYSTEM

PAT DS 100

Error n° “E18” Not available

Error n° “E19” Error:

Reference voltage id defective

Cause:

a. The total of the supply and reference voltages is less than 2.7 volts. b. A/D converter is defective.

Elimination: a. Check supply voltage. b. Replace main board

Error n° “E21” Error:

Upper limit value for the measuring channel “lenght telescopic boom” exceeded.

Cause:

a. Cable between lenght sensor and central unit defective, not connected or water in the connectors. b. Lenght sensor pot defective. c. Electronic board in the measuring channel defective.

Elimination: a. Check cable and connectors as well and replace, if necessary. b. Replace lenght sensor potentiometer. c. Replace main board or analog board.

Error n° “E22” Error:

Upper limit value for the measuring channel “pressure transducer piston side, lifting cylinder ” exceeded.

Cause:

a. Cable leading from the central unit to the pressure transducers defective or water in the connectors. b. Pressure transducer defective. c. Electronic board in the measuring channel defective.

Elimination: a. Check cable and connectors as well and replace, if necessary. b. Replace pressure transducer. c. Replace processor or analog board.

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PAT DS 100

SAFETY SYSTEM

Error n° “E23” Error:

Upper limit value for the measuring channel “pressure transducer rod side, lifting cylinder” exceeded.

Cause:

a. Cable leading from the central unit to the pressure transducers defective or water in the connectors. b. Pressure transducer defective. c. Electronic board in the measuring channel defective.

Elimination: a. Check cable and connectors as well and replace, if necessary. b. Replace pressure transducer. c. Replace processor or analog board.

Error n° “E24” Error:

Upper limit value for the measuring channel “Compensation lenght ” exceeded.

Cause:

a. Cable leading from the central unit to the pressure transducers defective or water in the connectors. b. Pressure transducer defective. c. Electronic board in the measuring channel defective.

Elimination: a. Check cable and connectors as well and replace, if necessary. b. Replace pressure transducer. c. Replace processor or analog board.

Error n° “E25” Error:

Upper limit value for the measuring channel “Main boom angle” exceeded.

Cause:

a. Cable leading from the central unit to the pressure transducers defective or water in the connectors. b. Pressure transducer defective. c. Electronic board in the measuring channel defective.

Elimination: a. Check cable and connectors as well and replace, if necessary. b. Replace pressure transducer. c. Replace processor or analog board.

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SAFETY SYSTEM

PAT DS 100

Error n° “E26” Error:

Upper limit value for the measuring channel “Lifting angle” exceeded.

Cause:

a. Cable leading from the central unit to the pressure transducers defective or water in the connectors. b. Pressure transducer defective. c. Electronic board in the measuring channel defective.

Elimination: a. Check cable and connectors as well and replace, if necessary. b. Replace pressure transducer. c. Replace processor or analog board.

Error n° “E27” Error:

Upper limit value for the measuring channel “cable reel potentiometer" or "compensation cylinder pression sensors" exceeded.

Cause:

a. Potentiometer in question is outside the admissible adj.range b. Potentiometer is defective. c. Electronic board in the measuring channel defective.

Elimination: a. Turn the potentiometer into admissible adjudting range. b. Replace main board. c. Replace main board or analog board.

Error n° “E28” Not available

Error n° “E29” Error:

Reference voltage id defective

Cause:

a. The total of the supply and reference voltages is less than 3.3 volts. b. A/D converter is defective.

Elimination: a. Check supply voltage. b. Replace main board

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PAT DS 100

SAFETY SYSTEM

Error n° “E31” Error:

Error in the system program.

Cause:

a. The system program PROM is defective. b. The processor board is defective.

Elimination: a. Replace the system program PROM (PROM). b. Replace the processor board.

Error n° “E38” Error:

Wrong system program in the LMI

Cause:

The system program in the LMI does not correspond to the programmings in the data EPROM.

Elimination: a. Replace the system program EPROM. b. Replace the Data EPROM.

Error n° “E41” Error:

Error in the internal RAM.

Cause:

Processor 80C535 defective.

Elimination: - Replace processor 80C535. - Replace processor board.

Error n° “E42” Error:

Error in the first part of the external RAM.

Cause:

a. Processor board defective. b. External RAM defective.

Elimination: a. Replace processor board. b. Replace external RAM.

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SAFETY SYSTEM

PAT DS 100

Error n° “E49” Error:

Faulty data in on-line operation

Cause:

Afetr loading the data in on-line programming, the write/read memory on the memory extension does not contain any valid data

Elimination: a. Replace memory extension b. Replace on-line interface c. Exchange SLI main board Error n° “E51” Error:

Error in the crane data EPROM.

Cause:

a. Defective crane data EPROM. b. Processor board defective.

Elimination: a. Replace crane data EPROM. b. Replace processor board.

Error n° “E89” Error:

Commutation of operating mode under load.

Cause:

The operating mode has been commuted in the console while crane was under load.

Elimination: Set down load.

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PAT DS 50

Manitou

MRT 1540

PAT DS 50

SAFETY SYSTEM

SYSTEM DESCRIPTION

The PAT DS 50 safety system consists of a central microprocessor unit with an integrated angle sensor. The length of the arm is measured by means of a length sensor and the lifted load by four pressure sensors. The system operates by comparing the real values with the stored maximum allowable values. The real values resulting from the measurement of the lifted load are compared to the maximum allowable values stored inside the main memory. This memory includes the system program, load diagrams as well as the machine data. The correction values determined when starting the machine are stored inside an EE-Prom. The maximum allowable data stored in the memory are used as a reference for the real measurements. An overload signal is activated the moment in which the limits are exceeded . The instrument panel contains an analog load proportional indicator, leds and a selector to choose the type of accessory used.

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SAFETY SYSTEM

PAT DS 50

INSTALLATION

Length sensor 67 152 06 0002

Central unit 24 050 06 0003 Instrument panel 50 050 06 0001

Lifting cylinder

Quadruple pressure sensor 44 313 06 0004

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PAT DS 50

SAFETY SYSTEM

CENTRAL UNIT 24 050 06 0003

The central unit is housed inside a die-cat aluminium box. The angle sensor is built into the central unit and must be installed on the telescopic arm.

Connection board

Angle sensor

Serial interface

Analog extension

Length sensor cable 4x0.5

Electric cable 7x0.5

Instrument panel cable 14x0.5

Pressure sensor cable 14x0.5

Passage for portable terminal connection

Base board

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SAFETY SYSTEM

PAT DS 50

CONNECTION BOARD 24 050 30 0011

The different sensors, the console and the electric system are connected to the motherboard while the analog extension is connected to the connection board. All inputs and outputs are connected with the corresponding protection circuits (filters).

Connection terminal board for measurement sensors and electric system

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PAT DS 50

SAFETY SYSTEM

MOTHERBOARD 24 050 30 0001

The motherboard contains the power supply, an analog input, a digital output (relay), 3 digital inputs and the CPU. The system and data program is impressed on an E-Prom, type 27C512. It is possible to store correction values on a standard EE-Prom. The angle sensor is also housed on the motherboard. There are connectors to complete the necessary connections such as to the series interface, analog extension, portable terminal and the connection board.

Analog ground

Portable terminal connection

Angle sensor X5 connection

to insert for the operator on line

Angle sensor Fuse Serial interface connector Cut-off relay State relay Pressure sensor Ub correction

MP 7 pressure 1

analog ground

MP 5 angle time correction

length

Analog extension connection

Standard EE-Prom

System and data E-Prom 27C512

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SAFETY SYSTEM

PAT DS 50

ANALOG EXTENSION 24 050 30 0010

The analog extension contains three additional strain inputs (pressure sensor), a digital input, which can be filtered according to either negative or positive logic, and a “red led” board to display errors.

Digital input 4

Error indicator

Analog ground

Motherboard connection

MP 1 pressure 2

Load indicator connection

MP 3 pressure 3

MP 4 pressure 4

Pressure sensor

Load indicator recording

X3 input pressure 2

X4 input pressure 3

X5 input pressure 4

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PAT DS 50

SAFETY SYSTEM

INSTRUMENT PANEL 50 050 06 0001

Authorised work conditions led

Selector

Overload warning led

Instrument

Overload led

red

Load indicator

yellow

Accessory selector 1 Forks 2 Basket 3 Hoist 4 Jib P600/PT600

green

Module

Terminal board

Lamp

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SAFETY SYSTEM

PAT DS 50

QUADRUPLE PRESSURE SENSOR 44 313 06 0004

The quadruple pressure sensor measurement cylinders are built with stainless steel and have a large overload capacity. The strain measurements form an integral bridge on the measurement bodies. They are housed in an aluminium box, which also contains the control electronics. A pipe fitting M16 x 1.5 is used for the hydraulic connection.

X1 1 + Ub DMS 2 + Signal DMS 1 3 - Signal DMS 1 4 + Signal DMS 2 5 - Signal DMS 2 6 Ground X2

Cable gland

1 + Ub DMS 2 + Signal DMS 3 3 - Signal DMS 3 4 + Signal DMS 4 5 - Signal DMS 4 6 Ground

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SAFETY SYSTEM

PAT DS 50

PRESSURE SENSOR OUTPUT SIGNALS

Error

Motherboard

Work area

Lifting cylinder bottom side

Error

Work area

Error

Work area

Error

Work area

Error

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MP 1 Analog extension

Lifting cylinder stem side

MP 3 Analog extension

Compensation cylinder bottom side

MP 4 Analog extension

compensation cylinder stem side

SAFETY SYSTEM

PAT DS 50

LENGTH SENSOR 67 152 06 0002

The length sensor consists of a spring-loaded cable winder. As an option it is possible to install a rotating electric collector. The unwinding length is measured by a potentiometer 10 KΩ (10 rotations). The motion is transmitted with the help of plastic gears with a built-in automatic clutch. The connection cable must have double protection!

ELECTRIC STRUCTURE The potentiometer is fed with 5 V for two resistors in series. These series resistors are needed to recognise short-circuits and/or interruptions in the length measurement system.

Error

Work area

Signal

LENGTH SENSOR BASE ADJUSTMENT When the arm has retracted, the length potentiometer must be at the end of the stroke in the clockwise direction. In this case, the output voltage must be 0.500 V.

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PAT DS 50

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SAFETY SYSTEM

PAT DS 50

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PAT DS 50

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SAFETY SYSTEM

PAT DS 50

ERROR CODE

Error n° “O” Overload Error n° “V” Prewarning Error n° “H” Disconnection engaged Error n° "E01" Error:

Fallen below the radius range or angle range exceeded.

Cause:

Fallen below the minimum radius or exceeding the maximum angle specified in the respective load chart due to luffing up the boom too far.

Elimination: Luff down the boom to a radius or angle preset in the load chart. Error n° “E02” Error:

Maximum radius exceeded or fallen below the angle range.

Cause:

The maximum radius was exceeded or fallen below the minimum angle specified the respective load chart due to luffing down the boom too far.

Elimination: Luff up the boom to a radius or angle preset in the load chart. Error n° “E04” Error:

Incorrect setting of operating mode.

Cause:

The operating mode is not quitted or the selected operating mode or the slewing range is incorrect.

Elimination: - Quit the operating mode - Set the operating mode in accordance with the assignment to the operating condition. Error n° “E05” Error:

Prohibited lenght range

Cause:

PAT DS 50

SAFETY SYSTEM

No acknowledgement from the overload relay.

Cause:

Overload relay is caught, defective or is not being driven.

Elimination: Replace the relay or the connection board. Error n° “E11” Error:

Fallen below limit for the measuring channel “Lenght telescopic boom”.

Cause:

a. Cable between lenght sensor and central unit defective, not connected or water in the connectors. b. Lenght sensor pot defective. c. Electronic board in the measuring channeldefective.

Elimination: a. Check cable and connectors as well and repace, if necessary. b. Replace lenght sensor potentiometer. c. Replace main board or analog board. Error n° “E12” Error:

Fallen below lower limit value for the measuring channel “pressure transducer piston side, lifting cylinder”.

Cause:

a. Cable leading from the central unit to the pressure transducers defective or water in the connectors. b. Pressure transducer defective. c. Electronic board in the measuring channel defective.

Elimination: a. Check cable and connectors as well and replace, if necessary. b. Replace pressure transducer. c. Replace processor or analog board.

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SAFETY SYSTEM

PAT DS 50

Error n° “E13” Error:

Fallen below lower limit value for the measuring channel “pressure transducer rod side, lifting cylinder”.

Cause:

a. Cable leading from the central unit to the pressure transducers defective or water in the connectors. b. Pressure transducer defective. c. Electronic board in the measuring channel defective.

Elimination: a. Check cable and connectors as well and replace, if necessary. b. Replace pressure transducer. c. Replace processor or analog board. Error n° “E14” Error:

Fallen below lower limit value for the measuring channel “pressure transducer piston side, compensation cylinder”.

Cause:

a. Cable leading from the central unit to the pressure transducers defective or water in the connectors. b. Pressure transducer defective. c. Electronic board in the measuring channel defective.

Elimination: a. Check cable and connectors as well and replace, if necessary. b. Replace pressure transducer. c. Replace processor or analog board. Error n° “E15” Error:

Fallen below lower limit value for the measuring channel “angle main boom”.

Cause:

a. Angle sensor defective. b. Electronic board in the measuring channel defective.

Elimination: a. Replace angle sensor. b. Replace processor or analog board. Error n° “E16” Error:

Fallen below lower limit value for the measuring channel “pressure transducer rod side, compensation cylinder”.

Cause:

a. Cable leading from the central unit to the pressure transducers defective or water in the connectors. b. Pressure transducer defective. c. Electronic board in the measuring channel defective.

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SAFETY SYSTEM

Elimination: a. Check cable and connectors as well and replace, if necessary. b. Replace pressure transducer. c. Replace processor or analog board. Error n° “E21” Error:

Upper limit value for the measuring channel “lenght telescopic boom” exceeded.

Cause:

a. Cable between lenght sensor and central unit defective, not connected or water in the connectors. b. Lenght sensor pot defective. c. Electronic board in the measuring channel defective.

Elimination: a. Check cable and connectors as well and replace, if necessary. b. Replace lenght sensor potentiometer. c. Replace main board or analog board. Error n° “E22” Error:

Upper limit value for the measuring channel “pressure transducer piston side, lifting cylinder” exceeded.

Cause:

a. Cable leading from the central unit to the pressure transducers defective or water in the connectors. b. Pressure transducer defective. c. Electronic board in the measuring channel defective.

Elimination: a. Check cable and connectors as well and replace, if necessary. b. Replace pressure transducer. c. Replace processor or analog board. Error n° “E23” Error:

Upper limit value for the measuring channel “pressure transducer rod side, lifting cylinder” exceeded.

Cause:

a. Cable leading from the central unit to the pressure transducers defective or water in the connectors. b. Pressure transducer defective. c. Electronic board in the measuring channel defective.

Elimination: a. Check cable and connectors as well and replace, if necessary. b. Replace pressure transducer. c. Replace processor or analog board.

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SAFETY SYSTEM

PAT DS 50

Error n° “E24” Error:

Upper limit value for the measuring channel “pressure transducer piston side, compensation cylinder” exceeded.

Cause:

a. Cable leading from the central unit to the pressure transducers defective or water in the connectors. b. Pressure transducer defective. c. Electronic board in the measuring channel defective.

Elimination: a. Check cable and connectors as well and replace, if necessary. b. Replace pressure transducer. c. Replace processor or analog board. Error n° “E26” Error:

Upper limit value for the measuring channel “pressure transducer rod side, compensation cylinder” exceeded.

Cause:

a. Cable leading from the central unit to the pressure transducers defective or water in the connectors. b. Pressure transducer defective. c. Electronic board in the measuring channel defective.

Elimination: a. Check cable and connectors as well and replace, if necessary. b. Replace pressure transducer. c. Replace processor or analog board. Error n° “E31” Error:

Error in the system program.

Cause:

a. The system program PROM is defective. b. The processor board is defective.

Elimination: a. Replace the system program PROM (PROM). b. Replace the processor board. Error n° “E37” Error:

Error in the logic program.

Cause:

a) b) c)

The processor board is defective. System program EPROM. Processor 80C537 defective.

Elimination: a) b) c)

Replace the processor board Replace system program EPROM Replace Processor 80C537.

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PAT DS 50

SAFETY SYSTEM

Error n° “E38” Error:

Wrong system program in the LMI

Cause:

The system program in the LMI does not correspond to the programmings in the data EPROM.

Elimination: a. Replace the system program EPROM. b. Replace the Data EPROM. Error n° “E41” Error:

Error in the internal RAM.

Cause:

Processor 80C535 defective.

Elimination: - Replace processor 80C535. - Replace processor board. Error n° “E42” Error:

Error in the first part of the external RAM.

Cause:

a. Processor board defective. b. External RAM defective.

Elimination: a. Replace processor board. b. Replace external RAM. Error n° “E48” Error:

At cyclic RAM test:Error in the internal RAM.

Cause:

a. Processor board defective. b. External RAM defective.

Elimination: a. Replace processor board. b. Replace external RAM. Error n° “E51” Error:

Error in the crane data EPROM.

Cause:

a. Defective crane data EPROM. b. Processor board defective.

Elimination: a. Replace crane data EPROM. b. Replace processor board.

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SAFETY SYSTEM

PAT DS 50

Error n° “E57” Error:

Error in the serial crane data EEPROM.

Cause:

a. EEPROM not initialised. b. EEPROM defective. c. Processor board defective

Elimination: a. Initialised EEPROM. b. Replace processor board. c. Replace processor board.

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