Manitou 578 3

R
BP 249 Z. I.
44 158 ANCENIS CEDEX FRANCE
TEL : +33 (0)2 40 09 10 11
YOUR CONCESSIONAIRE
REF : 547 363 EN (05 / 04)
ACCESS
PLATFORM
120 AETJ
REPAIRS MANUAL
1st EDITION 06 / 2002
ISSUE DATE COMMENTS
06/2002 1st edition
11/2003 Updated
12/2003 Variable speed drive unit parameters modification
05/2004 Updated 35-8-21-M.84

80-6-M.84
80-8-11-M.84
80-8-85-M.84
CONTENTS
GROUPS SECTIONS MACHINES
0 General Points
0-1-M.84
0-1-M.84 EN Technical characteristics 120 AETJ
30 Reducer
30-2-63-M.84
30-2-63-M.84 EN Removing the wheel reducer / brake 120 AETJ
35 Steering Axle
35-8-21-M.84
35-8-21-M.84 EN Free-wheeling 120 AETJ
55 Arms - Platform
55-2-21-M.84
55-2-21-M.84 EN Removing the wear pads 120 AETJ
70 Hydraulics
70-2-52-M.84
70-2-52-M.84 EN Removing the distributor elements 120 AETJ
70-2-80-M.84
70-2-80-M.84 EN Removing the cylinders 120 AETJ
70-5-M.84
70-5-M.84 EN Hydraulic pressure 120 AETJ
70-6-M.84
70-6-M.84 EN Hydraulic layout 120 AETJ
80 Electricity
80-2-11-M.84
80-2-11-M.84 EN Removing the variable speed drive unit 120 AETJ
80-2-12-M.84
80-2-12-M.84 EN Removing the traction batteries 120 AETJ
80-2-13-M.84
80-2-13-M.84 EN Removing the electrical cable looms 120 AETJ
80-6-M.84
80-6-M.84 EN Electrical layouts 120 AETJ
80-8-11-M.84
80-8-11-M.84 EN Checking the operation of the Sevcon 120 AETJ
variable speed drive unit
CONTENTS
GROUPS SECTIONS MACHINES
80-8-85-M.84
80-8-85-M.84 EN Testing the manipulator 120 AETJ
80-8-86-M.84
80-8-86-M.84 EN Positioning and adjusting the contactors 120 AETJ
100 Troubleshooting
100-M.84
100-M.84 EN Troubleshooting 120 AETJ
GROUPS 0
GENERAL
POINTS
TECHNICAL CHARACTERISTICS
120 AETJ 0-1-M.84
0-1-M.84 EN
11 / 2003
0-1-M.84
0-1-M.84
1
CHARACTERISTICS
ELECTRIC PUMP
- Electrical supply 48 V
- Output 3,7 KW
- Cubic capacity 4,8 cm3
- Pressure 200 bars
ELECTRIC WHEEL MOTORS
0-1-M.84 - Type T 17 - 2 KW
ELECTRICAL CIRCUIT
- Battery 48 V - 300 Ah
- Charger 50 Ah (single-phase)
BOARD FUSES
- Motherboard : 10 A
- Output 325 A
- Electric pump 100 A
- Emergency pump 100 A
2
120 AETJ
SPECIFICATIONS
- Use Indoors Outdoors
- Capacity 230 Kg 120 Kg

i.e. i.e.
2 people 1 person
+wind 45Km/h
0-1-M.84
- Control system Electro-hydraulic
- Turret rotation 350°
- Operating speed 0,6 km/h

- Transport speed 6 km/h
- Operating height 11950 mm

- Floor height 9950 mm
- Max off-centring 7000 mm
- Access platform weight

• Empty 6550 kg
• Under nominal load 6780 kg
- No. of gears 2
- Traversable gradient 25%
- Max permissible slope 5% or 3°
TYRES
LOAD PER UNDER MAX LOAD+ OFF

SUPPORT SURFACE
DIMENSIONS TYPE TYRE EMPTY CENTRING ON 1 WHEEL STAMPING
FOR 1 WHEEL ON GROUND
F R F/R
600 X 190 BANDAGE 1655 KG 1620 KG 4200 KG 212 CM2 20 DAN/CM2
Tightening torque for the front and rear wheel nuts 19 daNm
3
DIMENSIONS
120AETJ
A1 5477
A2 3740
B 1200
C 2163
D 1650
0-1-M.84 E 104
F 2228
G 1550
H 3250 G
I 3340
H
J 2138
I
J
F
A1
A2
C
E
B D
4
120AETJ K1 2483
K2 3242
K3 6506
K4 4353
L1 9950
L2 8794
L3 4773 0-1-M.84
L4 595
2 1 0 1 2 3 4 5 6 7 8
12
K1
11
10
L1
9
L2
K2 7
5
L3
K3 3
K4 2
1
L4
2 2 3 4 5 6 7 8
5
FILTER ELEMENT
0-1-M.84
1
DESCRIPTION REFERENCE REPLACE
1 - Hydraulic return oil filter cartridge 599004 Every 900 H
LUBRICANTS
COMPONENTS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING REFERENCE
HYDRAULIC OIL RÉSERVOIR 12 Litres MANITOU 20 L. 582 297

HYDRAULIC OIL ISO 46 55 L. 546 108
209 L. 546 109
WHEEL MOTOR (EACH ONE) 0.8 Litre SHELL 2 L. 661 998

SPIRAX OIL A90 20 L. 661 950
50 L. 661 950
TURRET ROTATION MOTOR 1.5 Litres
GENERAL GREASING SHELL RETINAX HD cartridge 161 589

GREASE 400 Gr.
BEARING TURRET RING GREASING SHELL ALVANIA EP LF 2 1 Kg 545 836

GREASE
TURRET RING TEETH LUBRICATION SHELL MALLEUS GL 205 Aerosol 545 834
OIL
6
GROUPS 30
REDUCER
REMOVING THE WHEEL
REDUCER/BRAKE
120 AETJ 30-2-63-M.84
30-2-63-M.84 EN
11 / 2003
30-2-63-M.84
REMOVING THE WHEEL REDUCER / BRAKE
UP TO PLATFORM NO. 505578: REDUCER 598694
- Set the lower arm to maximum for optimum accessibility. A

- Raise the rear of the platform and place a wedge under the chassis.
- Remove the rear wheels 1 (Fig. A) (10 bolts, No. 19 spanner).
- Open the rear cover 2 (Fig. A) (4 bolts, No. 4 hex spanner).
- Mark and remove the electric motor power cables.
1 30-2-63-M.84
- Remove the electric motors 3 (Fig. B) (8 bolts, No. 9 hex spanner). B

- Remove the brake control hoses 5 (Fig. C) (No. 19 spanner).
- Place a MA8S bung in each hose to prevent any oil leaks.
- Remove the reducers 4 (Fig. B) (16 bolts, No. 10 spanner).
RE-ASSEMBLY 3
- Same operations as above in reverse order.
5
C
FROM PLATFORM NO. 505579: REDUCER 599538
- Same procedure as for removing reducer 598694.
RE-ASSEMBLY 4
When fastening reducers 599538, position the CHC M12x45 bolts at

the same level as the brake controls are installed on each reducer.
1
REDUCTEUR DE ROUES
30-2-63-M.84
RAD REDUKTION
10 DC 40 REDUCTOR DE RUEDA 120 AETJ
WHEEL REDUCING
JUSQU'A LA MACHINE
BIS DER MASCHINE
HASTA LA MAQUINA
UP TO MACHINE
N°: 505578 17
18
19
20
21
22
19
23
24
25
2
26
2
3
4 13
14
5
6 15
7 16
8
1
9
10
11
12
P.A.O
20 / 06 / 03
REDUCTEUR DE ROUES
RAD REDUKTION
10 DC 46 REDUCTOR DE RUEDA 120 AETJ
WHEEL REDUCING
A PARTIR DE LA MACHINE
AB DER MASCHINE
A PARTIR DE LA MAQUINA
FROM MACHINE
N°: 505579 20
21
22
23
3
24
25
22
36
2 26
27 28 35
29 30
3
4
5
6
3
7 31
8 29
9 32
10
11
12
13 34
14 33
15
16
17
18
19
1
P.A.O
20 / 06 / 03
30-2-63-M.84
GROUPS 35
STEERING
AXLE
FREE-WHEELING
120 AETJ
35-8-21-M.84 EN
35-8-21-M.84
05 / 2004
35-8-21-M.84
FREE-WHEELING
The platform may only be towed a short distance and only by a

machine with significant braking performance, in order to hold it: the
two machines must be connected by a tow bar.
- To set the platform to free wheel, it must not be subject to any trans- A
lation stresses from slopes. The wheels must be able to turn freely.
1
- If possible, raise the platform to free the drive wheels in order to faci-
litate the operation.
- Loosen bolt 1 (Fig. A) on each wheel 22 mm from the edge, up to the

resistance point, without forcing it (20 Nm).
35-8-21-M.84
- The machine can be towed as a trailer.
Warning: do not loosen the bolt more than 22 mm,

otherwise it may break.
RE-INSTALLATION
- Turn the wheel gently from left to right to reset the gear while retigh-
tening the screws (1) (Fig. A). Pay attention to the torque when tigh-
tening (150 Nm).
1
GROUPS 55
ARMS
PLATFORM
REMOVING THE WEAR PADS
120 AETJ
55-2-21-M.84 EN
55-2-21-M.84
11 / 2003
55-2-21-M.84
INDEX
A - REMOVING THE TELESCOPE CYLINDER WEAR PADS ........................... P2
B - REMOVING THE TELESCOPE ARM WEAR PADS .................................. P 2
C - REMOVING THE MOBILE TUBE WEAR PADS ....................................... P2
55-2-21-M.84
1
A - REMOVING THE TELESCOPE CYLINDER WEAR PADS
- Remove the telescope cylinder: see the REMOVING THE TELE- A1

SCOPE CYLINDER section.
- Remove the wear pads 1 (Fig. A1) (8 bolts, No. 10 spanner).
1
RE-ASSEMBLY
B - REMOVING THE TELESCOPE ARM WEAR PADS
- Remove the telescope cylinder: see the REMOVING THE TELE- B1

55-2-21-M.84 SCOPE CYLINDER section.
- Lift the basket with a hoist to relieve the pads.
- Remove the top of the jib pad fasteners 2 (Fig. B1) (16 bolts, No. 6
hex spanner).
- Pay attention to the position of the adjustment plates 3 (Fig. B1).

2
- Remove the pads.
3
RE-ASSEMBLY
- If necessary, position the adjustment plates:

Plates 3 (Fig. B1): see PR catalogue for reference.
C - REMOVING THE MOBILE TUBE WEAR PADS
- Remove the telescope cylinder: see the REMOVING THE TELE- C1

SCOPE CYLINDER section.
4
- Lift the basket with a hoist to relieve the pads.
- Remove the upper and lower top of the jib pad fasteners 4 (Fig. C1)
(8 bolts, No. 19 spanner, No. 6 hex spanner).
- Pay attention to the position of the adjustment plates 5 (Fig. C1).
- Remove the pads.

4
- Remove the mobile tube mobile, holding the tube with a hoist and
the basket with a forklift truck. 5
2
- Remove the base of the jib pads 6 (Fig. C2) (hammer, chisel). C2
- Pay attention to the position of the adjustment plates 7 (Fig. C2). 6
7
RE-ASSEMBLY
- Same operations as above in reverse order: the base of the jib pads
must be forcibly emmancher with a hammer.
- If necessary, position the adjustment plates:

Plates 7 (Fig. C2): see PR catalogue for reference.
55-2-21-M.84
3
FLECHE TELESCOPIQUE
55-2-21-M.84
TELESKOPAUSELEGER
5 BA 240 AGUILON TELESCOPICO 120 AETJ
TELESCOPIC JIB
JUSQU'A LA MACHINE
BIS DER MASCHINE
HASTA LA MAQUINA
UP TO MACHINE
N°: 505421
12 25
41 26
13 5
40 11
36
39
22
9
10
12
33
34 37 8 45
34 38
35 43
44
4
8
30
7 29
24
2 31
32 23
4
1 28 24
6 23
28
3
27 19
16 20
20
17 21
14
15
18
42
P.A.O
12 / 04 / 02
GROUPS 70
HYDRAULICS
REMOVING THE DISTRIBUTOR
ELEMENTS
120 AETJ
70-2-52-M.84 EN
70-2-52-M.84
11 / 2003
70-2-52-M.84
REMOVING THE DISTRIBUTOR ELEMENTS
- Switch off the electrical power supply. A

- Open the right-hand cover.
1
- Remove the hoses (Spanners Nos. 19, 24, 27, 30).
- Mark each solenoid 1 (Fig. A) (Adhesive and marker) according to the

writing on the yellow rings on the power cable looms and then remo-
ve the loom connectors 2 (Fig. A) (flat screwdriver).
2
- Remove the bolts 3 (Fig. B) (4 bolts, No. 17 spanner).
- Remove the element(s) requiring to be replaced (various flat and hex

spanners).
Before removing any hose or distributor component, operate the tap-

pets on the electro-valves by pulling and then pushing them in order
70-2-52-M.84
to decompress the circuit (Fig. C)
1
DISTRIBUTEUR
70-2-52-M.84
KOMMANDOSTEUERVENTIL
10 DA 213 DITRIBUIDOR 120 AETJ
VALVE BLANK
POUR REP : 12 POUR REP : 6 - 10 - 11 - 13 POUR REP : 6 - 10 - 11 - 12 - 13 1 Distributor
FUR HINW : 12 18 FUR HINW : 6 - 10 - 11 - 13 19 FUR HINW : 6 - 10 - 11 - 12 - 13
2 Plug
PARA FIG : 12 PARA FIG : 6 - 10 - 11 - 13 PARA FIG : 6 - 10 - 11 - 12 - 13
20 3 35-BAR reducer
FOR ITEM : 12 FOR ITEM : 6 - 10 - 11 - 13 FOR ITEM : 6 - 10 - 11 - 12 - 13
4 150-BAR restrictor
5 Main 180-BAR restrictor
6 Electro-valve
12
13 7 Plug
8 180-BAR balancing valve
9 10 9 80-BAR overload valve
11 10 Electro-valve
8 11 Electro-valve
12 Electro-valve
13 Electro-valve
14 Non-return valve
7 15 Plug
5
6 16 100-BAR reducer
4 17 2-BAR non-return valve
18 Solenoid
2
PENDULAR ARM EV12- EV13 19 Solenoid
20 Connection port
14
3 23BASKET TILTING SYSTEM EV14-EV15
EV3 EV2 B5
B4 15
A5
TÉLESCOPE EEXTENSION SYSTEM EV10-EV11
2 B3
A4
B2
A3
B1
A2 14
T1
BASKET ROTATION
A1 SYSTEM H16-H17 TELESCOPE ARM RAISING SYSTEM EV8-EV9
STEERING SYSTEM EV1-EV5 ARM 1 / 2 RAISING SYSTEM EV6-EV7
B6
8 F .
B7 PRESS
ANTI-ROLLOVER BARS H20-H21 M1 A6
B8 T
M2 A7 1
B9
A8
7
A9
16
17
PLATFORM ROTATION SYSTEM H18-H19 15
P.A.O
12 / 04 / 02
REMOVING THE CYLINDERS
120 AETJ
70-2-80-M.84 EN
70-2-80-M.84
11 / 2003
70-2-80-M.84
INDEX
A - REMOVING THE STEERING CYLINDER ................................................P 2
B - REMOVING THE TELESCOPE CYLINDER .............................................P 4
C - REMOVING THE ANTI-ROLLOVER BAR CYLINDERS ...............................P 6
70-2-80-M.84
1
A - REMOVING THE STEERING CYLINDER
- Raise the front of the platform and place a wedge under the chas- A1
sis.
- Remove the front wheels 1 (Fig. A1) (12 nuts, No. 30 spanner).
1
- Decompress the cylinder supply hoses: see the REMOVING THE
DISTRIBUTOR ELEMENTS section.
- Mark and remove the hydraulic hoses (No. 19 spanner).
- Remove the articulation shaft 2 (Fig. A2) (1 bolt, No. 13 spanner).
- Remove the articulation shaft 3 (Fig. A3) (2 circlips, circlips clamp).
- Remove the steering cylinder 4 (Fig. A3).

A2
RE-ASSEMBLY

2
70-2-80-M.84 Remember to install the steering latch 5 (Fig. A2) before installing the
shaft 2 (Fig. A2).
5
A3
3
4
2
HYDRAULIQUE (Vérin de direction)
HYDRAULIK (Lenkungzylinder)
10 CE 34 HYDRAULICO (Cilindro de dirección) 120 AETJ
HYDRAULIC (Steering cylinder)
Ø 25 mm
Course - Hub - Carrera - Stroke : 179 mm
7
A
S B 6
INT
JO
DE C
E T TE ATZ S
D
1 CH GS TA
PO HTUNE JUN
DIC GO D
E 2
E F
JU L KIT
A
SE G
3
G
5
F
E
D
C
B
A
4
3
P.A.O
12 / 04 / 02
70-2-80-M.84
B - REMOVING THE TELESCOPE CYLINDER
- Raise the basket to access the cylinder foot axle 6 (Fig. B1). B1
- In horizontal position, extend the telescope enough to access the 7
8
articulation shaft 7 (Fig. B1).
- Wedge the basket in place with lifting equipment.

DISTRIBUTOR ELEMENTS section.
6
- Remove the protective casing 8 (Fig. B1) (2 bolts, No. 10 spanner).
- Remove the articulation shaft 7 (Fig. A3) (2 circlips, circlips clamp).
- Remove the cylinder supply hoses 9 (Fig. B2) (No. 24 spanner).
- Remove the articulation shaft 6 (Fig. A2) (1 bolt, No. 13 spanner). B2

- Remove the telescope cylinder by extending the arm from the front 6
(Fig. B3).
RE-ASSEMBLY

70-2-80-M.84
9
B3
The cylinder's chambers contain oil under pressure. To remove the
valve block, you must equalize the pressures by progressively uns-
10
crewing the 4 bolts 10 (Fig. B3) (No. 6 hex spanner) and letting the
oil escape.
4
HYDRAULIQUE (Vérin de télescopage)
HYDRAULIK (Zusammenstroll zylinder)
10 CC 82 HYDRAULICO (Cilindro de telescopaje) 120 AETJ
HYDRAULIC (Telescope cylinder)
Ø 35 mm
A
S B
INT
JO
DE C
E T TE ATZ S
D
1 CH GS TA
PO HTUNE JUN
DIC GO D
E 2
E F
JU L KIT
A
SE G
H
5
7
G
E
F
E
D
3
4 B
C
B
A
6
5
P.A.O
12 / 04 / 02
70-2-80-M.84
C - REMOVING THE ANTI-ROLLOVER BAR CYLINDERS
- Set the platform in transport position (Telescope retracted, arms in C1

low position).
- Remove the battery covers and the batteries: see the REMOVING 11
THE TRACTION BATTERIES section.

DISTRIBUTOR ELEMENTS section. 13
- Mark and remove the hydraulic hoses 11 (Fig. C1) (No. 19 span-
ner).
- Remove the articulation shafts 12 (Fig. C1) (8 circlips, circlips

12
clamp).
- Remove the cylinders 13 (Fig. C1).
RE-ASSEMBLY
70-2-80-M.84
6
HYDRAULIQUE (Vérin de stabilisation)
HYDRAULIK (Stabilizer zylinder)
10 CF 38 HYDRAULICO (Cilindro de estabilizador) 120 AETJ
HYDRAULIC (Stabilizer cylinder)
Ø 18 mm
A
TS B
OIN
EJ C
TE D TZ
S
ET A D
1 CH GS TA
PO HTUNE JUN E
DIC GO D
E F
2
JU L KIT
A
SE G
7
G
5
F
E
D
C
B
A
4
3
P.A.O
12 / 04 / 02
70-2-80-M.84
HYDRAULIC PRESSURE
120 AETJ
70-5-M.84 EN
70-5-M.84
11 / 2003
70-5-M.84
ADJUSTING THE HYDRAULIC PRESSURES
Most of the adjustments are made by two people: one works the
controls on the base console, the other adjusts the valves
- Open the right-hand cover 1 (Fig. A) and remove it.
Adjusting the anti-rollover bar pressure reducer (Hydraulic layout

No. 2).
1
- Switch the platform on.

B
- Connect the manometer to pressure port M2 (Fig. B).
M2 2
- Raise the platform a few centimetres to release deployment of the
anti-rollover bars.
- Fully extend the telescope and hold down the extend control while
making the adjustment
- Adjust the tare on pressure reducer 2 (Fig. B) (No. 17 spanner, No. 4

hex spanner) to 40 bar.
- Disconnect the manometer and re-insert the bung. 70-5-M.84
Adjusting the pressure reducer (Hydraulic layout No. 7). C

M1
- Connect the manometer to pressure port M1 (Fig. C).
3
- Adjust the tare on pressure reducer 3 (Fig. C) (No. 13 spanner, No.
4 hex spanner) to 100 bar.
- Disconnect the manometer and re-insert the bung.
Adjusting the main relief valve (Hydraulic layout No. 10). D

4
- Connect the manometer to pressure port M (Fig. D) on the distribu-

tor block.
- Adjust the tare on pressure reducer 4 (Fig. C) (No. 13 spanner, No. M

4 hex spanner) to 180 bar.
- Disconnect the manometer and re-insert the bung.
1
Adjusting the compensation / tilt balancing valve (Hydraulic E
layout No. 17).
5
- Switch off the machine and disconnect the electrical circuit.
- Decompress the compensation / tilt control hoses: see the REMO- 12

6
VING THE DISTRIBUTOR ELEMENTS section.
9
- Remove hose 5 (Fig. E) (No. 24 spanner) connected to A5. 7
8
- Insert a T connector (M/M/F12S) 7 (Fig. E) between hose 5 and
connection 6.
- Add a straight connector (M/F 16x150-12S) 8 (Fig. E) and then

connect the manometer 9 (Fig. E) to this. F
- Switch the machine on.

10
- Raise the telescope arm 10 (Fig. F) to mid-stroke on the cylinder and
then extend the tilting cylinder 11 (Fig. F) to the maximum extent.
- Instruct the telescope arm to lower and check the pressure displayed
on the manometer during descent: the value must be 180 bars.
- If this is not the case, adjust the tare on the balancing valve 12 (Fig.
F) (No. 24 spanner, No. 17 spanner) to 180 bars. 11
70-5-M.84
- Switch off the machine, remove the manometer and then reconnect
hose 5 in its original configuration.
Adjusting the compensation / tilt sequencing valve (Hydraulic

layout No. 18). G
14
13
- Decompress the compensation / tilt control hoses: see the REMO- 15
VING THE DISTRIBUTOR ELEMENTS section.
- Remove hose 13 (Fig. G) (No. 24 spanner) connected to B5. 9

7
- Insert a T connector (M/M/F12S) 7 (Fig. E) between hose 13 and
8
connection 14.
- Add a straight connector (M/F 16x150-12S) 8 (Fig. E) and then

connect the manometer 9 (Fig. E) to this.
- Raise the telescope arm 10 (Fig. F) to mid-stroke on the cylinder and

then extend the tilting cylinder 11 (Fig. F) to the maximum extent.
- Raise the telescope and adjust the tare on balancing valve 15 (Fig.
F) (No. 13 spanner, No. 4 hex spanner) during ascent to 80 bars.
- Switch off the machine, remove the manometer and then reconnect
hose 13 in its original configuration.
2
Adjusting the pressure stat (Hydraulic layout No. 19). H

17
- Open the right-hand turret cover.
- Remove the sealing screw 16 (Fig. H) (No. 3 hex spanner) located

between the terminals on the pressure stat 17 (Fig. H) to access the
setting screw.
- Remove hose 18 (Fig. I) (No. 24 spanner) connected to B6.

16
- Insert a T connector (M/M/F12S) 7 (Fig. I) between hose 18 and
connection 19.
I
- Add a straight connector (M/F 16x150-12S) 8 (Fig. I) and then
connect the manometer 20 (Fig. I) (Minimum capacity 250 bar) to 19
this and take the manometer into the basket.
7
18
- Instruct the platform to travel without operating the steering and 8
monitor the pressure displayed on the manometer (Fig. J):
- On start-up, a pressure spike of up to 210 bar.

- Rapid drop in pressure to below 100 bar. 20
70-5-M.84
- Slow drop and then very slow drop in pressure down to 20
bar.
- At 20 bar, pressure stat triggers and then the pump.
Pressure increases in the brake line. Pump and pressure J
stat cut out. P(bar)
- Repeated at regular intervals.
120
- If the pressure stat triggers below 20 bar, adjust it by tightening the 100
setting screw to increase the trigger pressure.
80
- If the pressure stat triggers above 20 bar, loosen the setting screw by
60
several turns to proceed as described above: Adjustment is always
made by tightening the screw. 40
20bars
- Conduct a new travel test. 20
t(s)
- When adjustment is complete, switch the machine off, reconnect
hose 18 in its original configuration and re-insert the sealing screw
16.
3
HYDRAULIC LAYOUT
120 AETJ
70-6-M.84 EN
70-6-M.84
11 / 2003
70-6-M.84
HYDRAULIC LAYOUT
70-6-M.84
1
GROUPS 80
ELECTRICITY
REMOVING THE VARIABLE SPEED
DRIVE UNIT
120 AETJ
80-2-11-M.84 EN
80-2-11-M.84
11 / 2003
80-2-11-M.84
REMOVING THE VARIABLE SPEED DRIVE UNIT
UP TO PLATFORM NO . 505490
- Switch off the electrical supply and then disconnect the batteries: see A
the REMOVING THE TRACTION BATTERIES section.
1
- Open the rear cover (4 bolts, No. 4 hex spanner).
- Disconnect the cable connectors.
- Remove the two variable speed drive components 1 (Fig. A) (8 bolts,

No. 13 spanner)
RE-ASSEMBLY
- Perform the above-mentioned operations in reverse order.
FROM PLATFORM NO . 505491
- Switch off the electrical supply and then disconnect the batteries: see B
the REMOVING THE TRACTION BATTERIES section.
- Open the rear cover (4 bolts, No. 4 hex spanner).
- Remove the protective cover (Fig. B) (2 bolts, No. 10 spanner).
- Disconnect the cable connectors.
- Remove the two variable speed drive components 1 (Fig. A) (8 bolts, 80-2-11-M.84
No. 13 spanner). 2
RE-ASSEMBLY
1
REMOVING THE TRACTION BATTERIES
120 AETJ
80-2-12-M.84 EN
80-2-12-M.84
11 / 2003
80-2-12-M.84
REMOVING THE TRACTION BATTERIES
UP TO PLATFORM NO . 505490 : BATTERIES 598121

- Raise the platform a few centimetres to release the engagement of A
the anti-rollover bars 1 (Fig. A).
- Switch off the electrical supply.
- Remove the left-hand and right-hand battery covers 2 (Fig. A) (4 but-

terfly bolts).
- Disconnect the cable looms connected to the + and - terminals (No.

16 spanner).
- Remove the battery fasteners 3 (Fig. B) (4 bolts, No. 12 hex span- 2

ner). 1
- Remove the batteries (individual weight: 248.5 kg) from their housing
using a hoist and slings fastened to the side flanges on the tank 4 B
(Fig. B) or using a forklift truck's forks.
3
RE-ASSEMBLY
FROM PLATFORM NO. 505490: BATTERIES 599364

- Raise the platform a few centimetres to release the engagement of
the anti-rollover bars 1 (Fig. A).
- Switch off the electrical supply. C

- Remove the left-hand and right-hand battery covers 2 (Fig. A). 80-2-12-M.84
5
- Disconnect the cable looms connected to the + and - terminals (No.
16 spanner).
- Remove the battery fasteners 5 (Fig. C) (4 bolts, No. 12 hex span-

ner). 6
- Remove the batteries (individual weight: 263 kg) from their housing
using a hoist and slings fastened to the side flanges on the tank 6
(Fig. C) or using a forklift truck's forks. 7
RE-ASSEMBLY
When re-assembling, remember to fit the cross-strut 7 (Fig. C) at the

back of the tank between the tank flange and the side of the chassis.
1
REMOVING THE CABLE LOOMS
120 AETJ
80-2-13-M.84 EN
80-2-13-M.84
11 / 2003
80-2-13-M.84
INDEX
A - LOCATION OF THE CABLE LOOMS.................................................... P2
B - BASKET CONSOLE CABLE LOOM .................................................... P 3
C - MAIN BOX CABLE LOOM ................................................................ P 6
D - BASE CONSOLE CABLE LOOM ..................................................... P 10
E - OTHER CABLE LOOMS ................................................................. P 12
80-2-13-M.84
1
A - LOCATION OF THE CABLE LOOMS
1
3
80-2-13-M.84
No. CABLE LOOM

1 Basket console
2 BUS CAN extension
3 Main box
4 Base console
5 Variable speed drive
6 Distributor
7 Overload cable loom
2
B - BASKET CONSOLE CABLE LOOM -1
80-2-13-M.84
No. DESCRIPTION
J4 Clip pin
H6 Overload light
H7 Slope light
H8 Travel light
H9 Arms 1/2 raising light
H10 Arm 3 raising light
H14 Tilt light
H15 Telescope light
H16 Pendular arm light
H17 Buzzer
S13 Travel switch
S14 Raising arms 1/2 switch
S15 Raising arm 3 switch
S17 3-position selector
S18 Tilt switch
S19 Telescope switch
S20 Pendular arm switch
S21 Horn button
S22 Emergency Stop
3
BASKET CONSOLE CABLE LOOM - CARD CONNECTIONS
CABLE CONNECTION CONTACT DESCRIPTION

CAN 1 Spare
CAN 2 Spare
CAN 3 Spare
CAN 4 Spare
113 CAN 5 Info. Bus Can.
315 A-IN 1 Manipulator side analogue input 0V / 2.5V / 5V
318 A-IN 2 Manipulator longitudinal analogue input 0V / 2.5V / 5V
A-IN 3 Spare
A-IN 4 Spare
A-IN 5 Spare
A-IN 6 Spare
A-IN 7 Spare
A-IN 8 Spare
0 D-OUT 1 Spare
328 D-OUT 2 0V card - lower arm LED
327 D-OUT 3 0V card - upper arm LED
322 D-OUT 4 0V card - telescope LED
321 D-OUT 5 0V card - pendular arm LED
D-OUT 6 Spare
323 D-OUT 7 0V card - compensation arm LED
D-OUT 8 Spare
D-OUT 9 Spare
D-OUT 10 Spare
D-OUT 11 Spare
D-OUT 12 Spare
329 D-OUT 13 0V card - travel LED
331 D-OUT 14 0V card - overload alarm LED
320 D-OUT 15 0V card - buzzer
330 D-OUT 16 0V card - slope LED
D-OUT 17 Spare
D-OUT 18 Spare
D-OUT 19 Spare
80-2-13-M.84 D-OUT 20 Spare
D-OUT 21 Spare
D-OUT 22 Spare
D-OUT 23 Spare
D-OUT 24 Spare
319 D-IN 1 0V manipulator trigger
D-IN 2 Spare
311 D-IN 3 0V travel switch
D-IN 4 Spare
312 D-IN 5 0V overload contactor
316 D-IN 6 0V steer left switch
317 D-IN 7 0V steer right switch
306 D-IN 8 0V movement selector
310 D-IN 9 0V lower arm switch
309 D-IN 10 0V upper arm switch
304 D-IN 11 0V telescope switch
303 D-IN 12 0V pendular arm switch
305 D-IN 13 0V compensation switch
308 D-IN 14 0V movement selector (basket rotation)
307 D-IN 15 0V movement selector (turret rotation)
302 D-IN 16 0V horn
4
BASKET CONSOLE CABLE LOOM - CABLE ALLOCATION
CABLE CONNECTION COLOUR DESCRIPTION

311 S13/D-IN-3 YELLOW
121 S18/S20 YELLOW
121 S20/S19 YELLOW
121 S19/S15 YELLOW
121 S15/S13 YELLOW
121 S13/S14 YELLOW
121 S21/S17 YELLOW
121 S17/S17 YELLOW
308 S17/D-IN14 YELLOW
331 H6/D-OUT-14 YELLOW
106 J4-106/H14 RED
121 S18/S17 YELLOW
106 H14/H16 RED
106 H16/H15 RED
106 H15/H10 RED
106 H10/H8 RED
106 H8/H9 RED
106 H9/H6 RED
106 H6/H7 RED 80-2-13-M.84
106 H17/J4-106 RED
106 J4-106/B+ RED
316 D-IN-6/P CLIPS 6V-2 YELLOW
317 D-IN-7/P CLIPS 6V-3 YELLOW
318 A-IN-2/P CLIPS 6V-4 YELLOW
319 D-IN-1/P CLIPS 3V YELLOW
103 NEG/P CLIPS 3V WHITE
106 B+/P CLIPS 3V RED
315 A-IN-1/P CLIPS 6V-1 YELLOW
BRIDGE S17/S17 YELLOW
5
C - MAIN BOX CABLE LOOM -3
80-2-13-M.84
6
80-2-13-M.84
No. DESCRIPTION
J2-107 Clip pin
J2-109 Clip pin
J2-111 Clip pin
J2-118 Clip pin
J4-103 Clip pin
J4-105 Clip pin
J4-106 Clip pin
J4-121 Clip pin
J4-123 Clip pin
KA3 24V relay
KA4 24V relay
KA5 24V relay
S4 Emergency pump switch
7
MAIN BOX CABLE LOOM - CARD CONNECTIONS
CABLE CONNECTION CONTACT DESCRIPTION

CAN 1 Spare
CAN 2 Spare
CAN 3 Spare
CAN 4 Spare
A-IN 1 Spare
A-IN 2 Spare
A-IN 3 Spare
A-IN 4 Spare
A-IN 5 Spare
A-IN 6 Spare
A-IN 7 Spare
A-IN 8 Spare
D-OUT 1 Spare
227 D-OUT 2 0V card - lower arm electro-valve
231 D-OUT 3 0V card - overload LED
226 D-OUT 4 0V card - upper arm electro-valve
220 D-OUT 5 0V card - anti-rollover arm output electro-valve
224 D-OUT 6 0V card - pendular arm electro-valve
D-OUT 7 Spare
221 D-OUT 8 0V card - turret rotation electro-valve
225 D-OUT 9 0V card - telescope electro-valve
228 D-OUT 10 0V card - KA3 raise / lower selection coil
219 D-OUT 11 0V card - jib rotation electro-valve
222 D-OUT 12 0V card - basket rotation electro-valve
D-OUT 13 Spare
223 D-OUT 14 0V card - compensation / tilt electro-valve
234 D-OUT 15 0V card - steer left electro-valve
229 D-OUT 16 0V card - steer right electro-valve
101 D-OUT 17 Counting info - timer input 01
D-OUT 18 Spare
217 D-OUT 19 0V card - horn
80-2-13-M.84 218 D-OUT 20 0V card - rotating light
230 D-OUT 21 0V card - maintenance alarm LED
233 D-OUT 22 0V card - brake reservoir electro-valve
238 D-OUT 23 0V card - anti-rollover bar return electro-valve
235 D-OUT 24 0V card - KM3 steering pump coil
215 D-IN 1 0V jib rotation right switch
214 D-IN 2 0V lower arm raising switch
213 D-IN 3 0V lower arm lowering switch
212 D-IN 4 0V upper arm raising switch
211 D-IN 5 0V upper arm lowering switch
208 D-IN 6 0V turret left rotation switch rotation
207 D-IN 7 0V turret right rotation switch rotation
205 D-IN 8 0V telescope retraction switch
206 D-IN 9 0V telescope extension switch
201 D-IN 10 0V compensation raising switch
202 D-IN 11 0V compensation lowering switch
209 D-IN 12 0V pendular arm raising switch
210 D-IN 13 0V pendular arm lowering switch
204 D-IN 14 0V basket left rotation switch
203 D-IN 15 0V basket right rotation switch
216 D-IN 16 0V jib left rotation switch
8
MAIN BOX CABLE LOOM - CABLE ALLOCATION

102 PL-8/VARIABLE SPEED DRIVE YELLOW
101 PL-1/D-OUT-17 YELLOW
121 S3/J4-121 YELLOW
104 S2/VARIABLE SPEED DRIVE YELLOW
106 J4-106 F. AV/J4-106 C. RED
230 D-OUT-21/CI 5002001 YELLOW
110 S2/CHARGER YELLOW
105 J4-105/CHARGER YELLOW
105 J4-105/S3 YELLOW
228 D-OUT-10/KA3-A1 YELLOW
106 KA3-A2/J4-106 RED
106 KA3-11/J4-106 RED
235 D-OUT-24/VAR SPEED DRIVE YELLOW
117 KA4-14/VAR SPEED DRIVE YELLOW 80-2-13-M.84
118 J2-118/VAR SPEED DRIVE YELLOW
106 J4-106/J4-106 RED
106 J4-106 C./VAR SPEED DRIVE RED
103 J4-103/VAR SPEED DRIVE WHITE
103 J4-103/NEG. WHITE
112 CAN-6/VAR SPEED DRIVE YELLOW
113 CAN-5/VAR SPEED DRIVE YELLOW
106 J4-106/B+ RED
103 KA4-A2/J4-106 WHITE
103 KA5-A2/J4-103 WHITE
103 KA5-11/J4-103 WHITE
BRIDGE KA5-14/KA4-11 YELLOW
103 KA4-A2/J4-103 WHITE
103 J4 121/J4 103 WHITE
S4/EMERGENCY PUMP WHITE
S4/EMERGENCY PUMP BROWN
9
D - BASE CONSOLE CABLE LOOM -4
80-2-13-M.84
No. DESCRIPTION
5002001 CRESTO CIRCUIT
J4 Clip pin
PL Timer
S2 Emergency Stop
S3 3-position selector
S5 Turret rotation switch
S6 Telescope switch
S7 Pendular arm switch
S8 Jib rotation switch
S9 Basket rotation switch
S10 Arms 1 / 2 raising switch
S11 Arm 3 raising switch
S12 Reverse tilt switch
S23 Dead man's switch
10
BASE CONSOLE CABLE LOOM - CABLE ALLOCATION

242 S12/S5 YELLOW
242 S5/S10 YELLOW
242 S10/S11 YELLOW
242 S11/S6 YELLOW
242 S6/S8 YELLOW
242 S8/S7 YELLOW
242 S7/S9 YELLOW
106 S3/S3 RED
106 PL-2/J4-106 RED
101 PL-1/D-OUT-17 YELLOW
106 J4-106/S3 RED
108 S3/S23 YELLOW
242 S23/S12 YELLOW
108 S3/VARIABLE SPEED DRIVE YELLOW 80-2-13-M.84
106 J4-106 F. AV/J4-106 C RED
106 J4-106/CI 5002001 RED
110 S2/CHARGER YELLOW
105 J4-105/S3 YELLOW
11
E - OTHER CABLE LOOMS
VARIABLE SPEED DRIVE CABLE LOOM -5
Bridge
80-2-13-M.84
Bridge
12
DISTRIBUTOR CABLE LOOM -6
80-2-13-M.84
13
ELECTRICAL LAYOUTS
120 AETJ
80-6-M.84 EN
80-6-M.84
05 / 2004
80-6-M.84
INDEX
A - POWER SECTION - SINGLE MANIPULATOR ..........................................P 2
B - BASE CONTROL SECTION - SINGLE MANIPULATOR ..............................P 4
C - BASKET CONTROL SECTION - SINGLE MANIPULATOR ..........................P 6
D - POWER SECTION - DUAL MANIPULATOR ............................................P 8
E - BASE CONTROL SECTION - DUAL MANIPULATOR ...............................P 10
F - BASKET CONTROL SECTION 1- DUAL MANIPULATOR ........................P 12
G - BASKET CONTROL SECTION 2- DUAL MANIPULATOR .......................P 14
80-6-M.84
1
A - POWER SECTION - SINGLE MANIPULATOR
80-6-M.84
2
80-6-M.84
3
B - BASE CONTROL SECTION - SINGLE MANIPULATOR
80-6-M.84
4
80-6-M.84
5
C - BASKET CONTROL SECTION - SINGLE MANIPULATOR
80-6-M.84
6
80-6-M.84
7
D - POWER SECTION - DUAL MANIPULATOR
80-6-M.84
8
677523
1
4
80-6-M.84
Lower arm Telescope retracted
9
E - BASE CONTROL SECTION - DUAL MANIPULATOR
80-6-M.84
10
120 AETJ
677523
Version 1
Page 2/4
80-6-M.84
11
F - BASKET CONTROL SECTION 1- DUAL MANIPULATOR
DEAD JIB rotation Basket rotation Horn

MAN'S selection selection
Emergency stop 01
Basket rotation
JIB rotation
green
SQ5
Overload yellow (x)
detection grey (y)
brown
white
Left joystick A5
80-6-M.84 Interface
Overload Slope
2-axis
joystick alarm
(red)
12
120 AETJ
Horn Slope
cut-out
677523
Version 1 - Page 3/4
Slope cut-out
Horn
Pendular arm selection
Telescope selection
Compensation selection
JIB rotation
Turret rotation
Basket rotation
Upper arm selection
Lower arm selection
Translation selection
Overload
Out-of NEUTRAL
Buzzer
Pendular arm
Telescope
Compensation
JIB rotation
Turret rotation
+5V supply Basket rotation
Rotation instructions Upper arm
Steer left Lower arm
Steer right Translation
Traction instructions Slope
Dead man's Faults/alarm
(Optional) (Optional) (Optional) (Optional) (Optional) (Optional) (Optional) (Optional) (Optional)
d Slope Travel Lower Upper Basket Turret JIB Compensation Telescope Pendular harm
80-6-M.84
arm arm Rotation Rotation Rotation
(All the LEDs are supplied with 24V)
13
G - BASKET CONTROL SECTION 2 - DUAL MANIPULATOR
Pendular arm Compensation Telescop

selection selection selection
DEAD MAN's
Pendular arm selection
Telescop selection
Translation
green
yellow
blue
black
grey
violet
red
pink
brown
white
Right joystick A7
Traction Out-of NEUTRAL (48V) DEAD

MAN's led
80-6-M.84
14
120 AETJ
677523
Lower arm
Version 1 - Page 4/4
selection
Pendular selection
Telescope selection
Lower arm selection
Travel selection
Out-of NEUTRAL
Lower arm selection
Steer left
Steer right
Traction instructions
80-6-M.84
15
CHECKING THE OPERATION OF THE
SEVCON VARIABLE SPEED DRIVE UNIT
120 AETJ
80-8-11-M.84 EN
80-8-11-M.84
05 / 2004
80-8-11-M.84
INDEX
A - VARIABLE SPEED DRIVE PARAMETERS ..............................................P 2
B - TESTING THE VARIABLE SPEED DRIVE ...............................................P 4
C - ERROR MESSAGES .........................................................................P 6
D - DIAGNOSTIC LED STATUSES ............................................................P 7
E - USING THE CALIBRATOR .................................................................P 8
80-8-11-M.84
1
A - VARIABLE SPEED DRIVE PARAMETERS
Microprocessor W598800.007 : Single manipulator

Microprocessor W598800.008 : Dual manipulator
Calibrator Minimum Maximum Actual
Reference CAN Name Description Value Value Step Value
1.1.1A 0 Armature I Max (A) 50 350 10 500
1.1.1F 1 Field I Max (A) 10 50 1 50
1.1.2 2 Traction Accel Delay (s) 0.1 5.0 0.1 1.8
1.1.3 3 Traction Decel Delay (s) 0.1 5.0 0.1 0.1
1.1.3A 100 Traction Direction Decel Delay (s) 0.1 5.0 0.1 0.8
1.1.4 4 Traction Creep Speed (%) 0 25 1 3
1.1.5 5 Flat Regen Direction Braking (A) 50 350 10 400
1.1.6 91 Tilt Regen Direction Braking (A) 50 350 10 500
1.1.7 6 Traction Regen Time (ms) 0 300 10 10
1.1.8 7 Brake Threshold (V) 0,09 3,20 0,016 0.8
1.1.9 8 Traction Maximum Speed (%) 0 100 1 100
1.1.10 9 Elevated Speed (%) 0 100 1 12
1.1.11 10 Tilt Speed (%) 0 100 1 100
1.1.12 11 Traction Cut 3 Speed (%) 0 100 1 100
1.1.13 12 Review delay (h) 0 100 1 50
1.1.14 13 Customers Options 0 7 1 0
1.1.15 102 Low Speed Traction Speed (%) 0 100 1 100
1.1.16 16 Low Battery Start (V) 14.5 48.0 0.5 18.0
1.1.17 17 Low Battery Cutout (V) 14.5 48.0 0.5 14.5
1.1.18 18 High Battery Start (V) 14.5 75.0 0.5 65.0
1.1.19 19 High Battery Cutout (V) 14.5 75.0 0.5 70.0
1.1.20 20 Battery Protection Level (V) 14.5 48.0 0.5 14.5
1.1.21 21 Battery Protection Delay (s) 0.1 2.5 0.1 0.5
1.1.22 61 Traction Alarm On

1.4.2 22 BDI Battery Voltage (V) 24 96 2 48
1.4.3 23 BDI Reset Level (V) 2.00 2.50 0.01 2.15
1.4.4 24 BDI Discharge Level (V) 1.50 1.99 0.01 1.73
1.4.5 25 BDI Warning Level (%) 0 90 1 30
1.4.6 26 BDI Cutout Level (%) 0 90 1 20

1.6.1 95 CAN Mode Aboma
1.6.2 39 Chop Select On
1.6.3 40.3 BDI On
80-8-11-M.84 1.6.4 40.1 Fault Log On
1.6.5 40.2 Service Log On
1.6.6 40.4 EU / US Functionality EU
1.6.7 94 Traction Full Speed (KPH) 0 160 1 21
1.6.8 Traction Full Speed (MPH) 0 100 0 13
1.6.9 101 Accelerator Characteristic Centre-Pot

1.7.1 33 Armature I Low (A) 10 240 10 90
1.7.2 34 Field I Low (A) 5 25 1 6
1.7.3 35 Armature I Mid (A) 100 500 10 200
1.7.4 36 Field I Mid (A) 5 40 1 25
1.7.5 37 Armature I High (A) 260 350 10 400
1.7.6 38 Field I High (A) 25 50 1 40
1.7.7 44 Armature Resistance (mOhm) 0 255 1 13
1.7.8 45 Field Resistance (Ohm) 0,25 2.50 0.01 1.26
1.7.9 41 Drive Proportional Gain 0 255 1 4
1.7.10 42 Drive Integral Gain 0 16 1 8
1.7.11 43 Brake Proportional Gain 0 255 1 40
1.7.12 92 Brake Integral Gain 0 16 1 15
1.7.13 93 Speed Estimate Gain 0 2.50 0.01 1.5
2
EPROM EPROM
W598800.007 W598800.008
Calibrator CAN Name Description Minimum Maximum Actual
Reference Value Value Step Value
1.8.1 31 Display Default Hours Key
1.8.2 32 Display Status Type Off
1.8.3 30 Display Contrast 0 127 1 30
1.8.4 27 FFD Indicator 1 Off
1.8.5 28 FFD Indicator 2 Off
1.8.6 29 Display Fault Messages Off

2.1.1 46 Pump I Max 50 350 10 350
2.1.2 47 Ramp Up Delay 0.1 5.0 0.1 3.0
2.1.3 48 Ramp Down Delay 0.1 0.5 0.1 0.5
2.1.4 49 Pump Creep Speed 0 25 1 19
Actual
Calibrator CAN Name Description Minimum Maximum Step Value
Reference Value Value Without With With JIB
JIB JIB
2.3.1 67 Boom 1 Up Speed (%) 0 100 1 90 100
2.3.2 68 Boom 1 Down Speed (%) 0 100 1 40 40
2.3.3 56 Boom 1 Cutback Speed (%) 0 100 1 100 100
2.3.4 69 Boom 2 Up Speed (%) 0 100 1 63 59
2.3.5 70 Boom 2 Down Speed (%) 0 100 1 39 35
2.3.6 57 Boom 2 Cutback Speed (%) 0 100 1 100 100
2.3.7 71 Jib Up Speed (%) 0 100 1 40 36
2.3.8 72 Jib Down Speed (%) 0 100 1 25 22
2.3.8A 103 Jib Rotate Left Speed (%) 0 100 1 1 32 30
2.3.8B 104 Jib Rotate Right Speed (%) 0 100 1 1 32 30
2.3.9 73 Tele In Speed (%) 0 100 1 100 100
2.3.10 74 Tele Out Speed (%) 0 100 1 100 100
2.3.11 75 Slew Left Speed (%) 0 100 1 32 26
2.3.12 76 Slew Right Speed (%) 0 100 1 32 26
2.3.13 98 Cage Rotate Left Speed (%) 0 100 1 32 20
2.3.14 99 Cage Rotate Right Speed (%) 0 100 1 32 20
2.3.15 96 Cage Level Forward Speed (%) 0 100 1 70 67
2.3.16 97 Cage Level Reverse Speed (%) 0 100 1 35 30
2.3.17 14 Y-Axis Forward Voltage (V) 0.00 5.00 0.02 4.06 4.48
2.3.18 15 Y-Axis Reverse Voltage (V) 0.00 5.00 0.02 0.52 0.52
2.3.19 50 X-Axis Left Voltage (V) 0.00 5.00 0.02 0.52 4.48
2.3.20 51 X-Axis Right Voltage (V) 0.00 5.00 0.02 4.06 0.52 80-8-11-M.84

2.5.1 77 Boom 1 Up Speed (%) 0 100 1 100
2.5.2 78 Boom 1 Down Speed (%) 0 100 1 90
2.5.3 58 Boom 1 Cutback Speed (%) 0 100 1 100
2.5.4 79 Boom 2 Up Speed (%) 0 100 1 100
2.5.5 80 Boom 2 Down Speed (%) 0 100 1 70
2.5.6 59 Boom 2 Cutback Speed (%) 0 100 1 25
2.5.7 81 Jib Up Speed (%) 0 100 1 90
2.5.8 82 Jib Down Speed (%) 0 100 1 75
2.5.9 83 Tele In Speed (%) 0 100 1 100
2.5.10 84 Tele Out Speed (%) 0 100 1 100
2.5.11 85 Slew Left Speed (%) 0 100 1 60
2.5.12 86 Slew Right Speed (%) 0 100 1 60
2.5.13 87 Cage Level Forward Speed (%) 0 100 1 50
2.5.14 88 Cage Level Reverse Speed (%) 0 100 1 60
2.5.15 89 Cage Rotate Left Speed (%) 0 100 1 50
2.5.16 90 Cage Rotate Right Speed (%) 0 100 1 50
2.5.17 60 Overload Cutback Speed (%) 0 100 1 50
3
B - TESTING THE VARIABLE SPEED DRIVE
STATUS
Calibrator reference Parameter displayed Setting Min Setting Max Step Log info
1.2.1 Battery voltage 0V 127 V 0.1 V +
1.2.2 Armature Motor voltage 0V 127 V 0.5 V
1.2.3 Field Motor Voltage 0V 127 V 0.5 V
1.2.4 Armature Motor Current 12:00 AM 625 A 5:00 AM +
1.2.5 Field Motor Current 12:00 AM 64 A 0.25 A +
1.2.6 Armature MOSFET Voltage 0V 127 V 0.5 V
1.2.7 Controller temp. -30° C +225° C 1° C + -
1.2.8 Capacitor Voltage 0V 127 V 0.5 V
1.2.9 Speed estimation 0% 100% 0.50%
1.2.10 Speed estimation 0 KPH 60 KPH 1.0 KPH
1.2.11 Speed estimation 0 MPH 60 MPH 1.0 MPH
1.2.12 Key Switch Hours Count 0 Hrs 65279.9 Hrs 0.1 Hrs
1.2.13 Traction Pulsing Hours Count (Drive) 0 Hrs 65279.9 Hrs 0.1 Hrs
1.2.14 CAN fail node None Output, EOutput n/a
1.2.15 CAN error count - - -
1.2.16 CAN error code - - -
- Service Log Reset Press + followed by - to reset service log
TRACTION VARIATOR
Calibrator reference Input displayed Setting Max Step Log info
1.3.1 Accelerator % range 0% 100 % 1%
1.3.2 Accelerator voltage range 0.0 V 5.0 V 0.02 V
1.3.3 Deadman switch Open Closed -
1.3.4 Joystick Forward switch Open Closed -
1.3.5 Joystick Reverse switch Open Closed -
1.3.6 Steer Left switch Open Closed -
1.3.7 Steer Right switch Open Closed -
1.3.8 Horn switch switch Open Closed -
1.3.9 Traction select switch Open Closed -
1.3.10 Tilt switch switch Open Closed -
1.3.11 Boom rest switch Open Closed -
1.3.12 8m high switch Open Closed -
1.3.13 Brake release switch Open Closed -
1.3.14 BDI Input switch Open Closed -
1.3.15 Frame fault switch Open Closed -
1.3.16 Drive Inhibit switch Open Closed -
1.3.17 Bars sens switch Open Closed -
1.3.18 Joystick NTRL switch switch Open Closed -
1.3.19 LS traction switch switch Open Closed -
1.3.20 Software xxxxxx xxxxxx
1.3.21 Controller Serial number 0 99999999 -
1.3.22 Controller type xxnnn -
PUMP STATUS
Calibrator reference Parameter displayed Min display Max display Step size Log info
80-8-11-M.84
2.2.1 Battery voltage 0V 127 V 0.1 V +
2.2.2 Motor voltage 0V 127 V 0.5 V
2.2.3 Motor current 12:00 AM 625 A 5:00 AM +
2.2.4 MOSFET voltage 0V 127 V 0.5 V
2.2.5 Controller temp. -30° C +225° C 1° C + -
- Service Log Reset Press + followed by

- to reset service log
4
UPPER BOX TEST INFORMATION
Calibrator reference Input displayed Min display Max display Step size
2.4.1 Y axis joystick % Range 0% 100% 1%
2.4.2 Y axis joystick voltage Range 0.0 V 5.0 V 0.02 V
2.4.3 X axis joystick % Range 0% 100% 1%
2.4.4 X axis joystick voltage Range 0.0 V 5.0 V 0.02 V
2.4.5 Deadman Switch Open Closed -
2.4.6 Joystick Forward Switch Open Closed -
2.4.7 Joystick Reverse Switch Open Closed -
2.4.8 Steer Left Switch Open Closed -
2.4.9 Steer Right Switch Open Closed -
2.4.10 Traction select Switch Open Closed -
2.4.11 Boom 1 select Switch Open Closed -
2.4.12 Boom 2 select Switch Open Closed -
2.4.13 Jib select Switch Open Closed -
2.4.14 Tele select Switch Open Closed -
2.4.15 Slew select Switch Open Closed -
2.4.16 Cage level select Switch Open Closed -
2.4.17 Cage rotate Switch Open Closed -
80-8-11-M.84
5
C - ERROR MESSAGES
Calibrator display Display Led Description & comments Checks-Actions

OK Stdt YES Traction operational and OK. No action required.
Displayed briefly when the unit is swit-
TESTING RUN TESTS YES ched on. No action required.
PLEASE WAIT YES Wrong choice of calibration protocol. Set the calibration protocol to "AUTO".
The BDI has triggered a cut-out at the

BDI CUTOUT BDI CUT 7F Charge the batteries.
programmed battery level.
Temperature of variable speed drive Let the variable speed drive cool down -
THERMAL CUTBACK OVER TEMP. 8F
higher than 75° - Let the drive cool down. Check its installation, the overall cleanli-
ness and the fan.
Release the dead man's contact - Check
Accelerator activated when unit swit-
ACCEL. FAULT ACCEL. FAULT 6F the accelerator cable, personality acce-
ched on.
lerator zero and max.
Release the dead man's contact and the
SEQUENCE FAULT SEQ. FAULT 2F Dead man's contact activated or joystick
joystick - Check the dead man's signals
pushed when machine switched on.
and the joystick's instructions.
Release the steering and dead man's
2 DIR. FAULT 2 DIR. FAULT 2F Two directions selected at the same
controls - Check the steering switch
time.
cables.
Battery level lower than low battery Release the dead man's control or the
BATTERIE LOW BAT. LOW 7F reverser - Check the battery voltage and
setting.
charge.
Release the dead man's control or the
Battery level lower than low battery
BATTERIE HIGH BAT. HIGH 7F reverser - Check the battery voltage and
setting.
charge and whether B+ is connected.
PERS ERROR PERS ERRORF 1F Parameters set outside the range. Change the defective settings.
CRC ERROR CRC ERROR 1F One or more settings have been corrupted. Check all the settings.
Switch off the machine - Check whether

A contactor coil is short-circuiting or the coils are short-circuiting, whether the
COIL S/C COIL S/C 9F
wrongly connected control is connected directly to B+ and
the cabling.
Reset FS1 or the reverser to zero -
MOSFET S/C FET S/C 3F MOSFET short-circuiting. Check A, F1, F2, the B- cable and whe-
ther MOSFET is short-circuiting.
Switch off the machine- Check the BUS
SYSTEM FAULT CAN FAULT 12 F The modules are not communicating.
CAN cable looms and connections.
Check the line contactor and the power
P. UP TRAC. WELD P. UP WELD OFF Line contactor contacts welded shut.
and control cable looms.
VARIOUS INTERNAL If one of these messages appears, the
CONTROLLER POWER FAIL OFF variable speed drive has failed one of Contact SEVCON.
UP MESSAGES its internal power auto-tests.
80-8-11-M.84
6
D - DIAGNOSTIC LED STATUSES
Led status Description

Illuminated No problem, conditions normal
Unlit Problem with the internal variable speed drive
1 Flashing Personality out of reach
2 Flashing Incorrect start-up sequence
3 Flashing MOSFET short-circuiting
4 Flashing Power contactor short-circuiting or motor circuit open
5 Flashing Spare
6 Flashing Problem with accelerator, slave potentiometer
or sped sensor cable
7 Flashing Low/high battery voltage or BDI cut off
8 Flashing Temperature of variable speed drive too high
9 Flashing Coil contactor short-circuiting
12 Flashing BUS CAN connection fault
80-8-11-M.84
7
E - USING THE CALIBRATOR
DESCRIPTION D1
- The calibrator (Fig. D1) (Ref. 622813) is used to adjust and configu- SEVCON
re the variable speed drive. It is also used as a diagnostic tool, CAN CALIBRATOR
displaying the variable speed drive's various voltage, current and

temperature values and the status of all its inputs.
Controller A Controller B
Menu
INSTALLATION Value - +
1
- Please refer to the section on REMOVING THE VARIABLE SPEED
DRIVE to access the electronic module.
- Locate the loom cable connected to 2 (Fig. D2) on the electronic

module; then take the calibrator's plug 1 (Fig. D1) and, depending D2
on the circumstances:
- Connect it to the spare socket on the loom.
- If the loom does not have a spare socket, slip the adaptor
cable (Ref. 677519) between the loom and the module's
connector and then connect it to the spare socket on this
cable. 2
CALIBRATOR MENU
- See the illustration below.
MiseSwitch on
sous tension
1 Traction 2 Pump
OK OK
80-8-11-M.84 2.1 Pump 2.2 Pump 2.3 Pump 2.4 Pump 2.5 Pump 2.6 Pump
Personalities Status Upper Box Pers Upper Box Test Lower Box Pers Lower Box Test
1.1 Traction 1.2 Traction 1.3 Traction 1.4 Traction 1.5 Traction 1.6 Traction 1.7 Traction 1.8 traction
Personalities Status Test BDI Fault Log Setup Motor Setup Display
1.1.1A Trac Pers 1.1.1F Trac Pers 1.1.2 Trac Pers 1.1.3 Trac Pers 1.1.4 Trac Pers 1.1.5 Trac Pers 1.1.6 Trac Pers
I. Max I. Max Accel Decel Creep Speed Flat Regen ...
8
TESTING THE MANIPULATOR
120 AETJ
80-8-85-M.84 EN
80-8-85-M.84
05 / 2004
80-8-85-M.84
INDEX
A - SINGLE MANIPULATOR ....................................................................P 2
B - DUAL MANIPULATOR .......................................................................P 4
80-8-85-M.84
1
A - SINGLE MANIPULATOR
With the calibrator
- Connect the calibrator (Ref. 622813) to the variable speed drive: see A1
Chapter CHECKING THE OPERATION FO THE SEVCON VARIA-
BLE SPEED DRIVE, paragraph USING THE CALIBRATOR. 4
3
- Climb into the platform's basket with the calibrator.

1
- Select menus 2-4-2 and 2-4-4 (UPPER BOX TEST) on the calibrator
and note the voltage values from the signals from the manipulator.
- Then select menus 2-3-17, 2-3-18, 2-3-19 and 2-3-20 (UPPER BOX
PERS) on the calibrator to adjust the limit values for the voltages deli-
vered by the manipulator. 2
Menus 2-4-2 and 2-4-4

Signals from the manipulator
noted on the calibrator 0.5 2.5 4.5
Menus 2-3-17 to 2-3-20 0 0.52 2.5 4.48 5

Min/ max calibration values
for the signals from the manipulator
- Lastly, select menus 2-4-1 and 2-4-3 (UPPER BOX TEST) on the
calibrator and check :
- That the proportional signal shows a good progression (i.e.

0 to 100%).
- That it shows 0% in Neutral and 100% only when the mani-

pulator arrives almost at the limit switch.
This procedure must be performed every time

the manipulator is replaced.
With a voltmeter
- Take the voltmeter and climb into the access platform's basket.
- Open the front of the basket console 3 (Fig. A1) (Flat screwdriver)
80-8-85-M.84 and then locate the wires (Fig. A2).
A2
OLD
ANCIENNE NEW
NOUVELLE
NORME
STANDART NORME
STANDART
VERT
GREEN VERT
GREEN (HORS NEUTRE
(NEUTRAL - MANIPULATEUR)
POSITION - MANIPULATOR)
JAUNE (X)
YELLOW JAUNE (X)(X)
(X) YELLOW (COMMANDE ROTATION TOURELLE)
(TURRET ROTATION)
BLUE
BLEU YELLOW/BLACK
JAUNE/NOIR (BP DIRECTIONBUTTON)
(STEER LEFT GAUCHE)
BLACK
NOIR GREY/BLACK
GRIS/NOIR (STEER
(BP RIGHT DROITE)
DIRECTION BUTTON)
GREY
GRIS (Y) GREY (Y)
GRIS (Y) (LONGITUDINAL
(COMMANDE AXIS)
TRANSLATION)
VIOLET
VIOLET GREEN/BLACK
VERT/NOIR (DEAD MAN'S
(GACHETTE TRIGGER)
HOMME MORT)
RED
ROUGE BROWN/BLACK (POWER SUPPLY
MARRON/NOIR (ALIMENTATION - TRIGGER)
- GACHETTE)
PINK
ROSE WHITE/BLACK
BLANC/NOIR (POWER SUPPLY--BP
(ALIMENTATION STEERING BUTTONS)
DIRECTION)
Y 0V BROWN
MARRON BROWN
MARRON (LONGITUDINAL- AXIS)
(ALIMENTATION TRANSLATION)
X
+24V 3W +48V WHITE
BLANC WHITE
BLANC (( ++BATTERIE)
BATTERY)
63V - 470µf
2
- Place the voltmeter's wands on the connector's clips to take the mea-
surements.
- To test the analogue outputs: work with the manipulator's casing 2

(Fig. A1) by moving it forwards, backwards, left or right and check the
values the voltmeter displays (Fig. A3).
A3
X 4.5V GG(Y)
(Y)
0V BM
Manipulateur
Manipulator vers
FORWARD
L'AVANT
FORWARD - AVANCE
TRANSLATION
Y Y Y
0.5V YJ(X)
(X) 2.5V YELLOW
JAUNE (X)(X) 4.5V YJ (X)
X X 2.5V GREY
GRIS (Y)
(Y)
0V BM 0V MARRON
BROWN X 0V BM
Manipulateur à GAUCHE
Manipulator to THE LEFT NEUTRE
NEUTRAL Manipulateur
Manipulator à DROITE
to THE RIGHT
Rotation
LEFTde tourelleROTATION
TURRET à GAUCHE Rotation de tourelle
RIGHT TURRET à DROITE
ROTATION
Y
X 0.5V G
G (Y)
(Y)
0V B
M
Manipulateur
Manipulator vers
toTHE REAR
L'ARRIERE
REAR - RECUL
TRANSLATION
- To test the logic outputs: operate the manipulator's dead man's pedal
1 (Fig. A1) and check the values the voltmeter displays (Fig. A4); then
press the manipulator's steering buttons 4 (Fig. A1) and check the
values the voltmeter displays (Fig. A5).
A4
80-8-85-M.84
OLD NEW OLD NEW

ANCIENNE NOUVELLE ANCIENNE NOUVELLE
STANDART STANDART STANDART STANDART
NORME NORME NORME NORME
V VIOLET
VIOLET GREEN/BLACK
VERT/NOIR 0V VIOLET
VIOLET GREEN/BLACK
VERT/NOIR
RED
ROUGE BROWN/BLACK
MARRON/NOIR RED
ROUGE BROWN/BLACK
MARRON/NOIR
0V BROWN
MARRON BROWN
MARRON 0V BROWN
MARRON BROWN
MARRON
Gachette
Trigger inau Gachette
Trigger
NEUTRAL
NEUTRE ACTIVATED
ACTIONNEE
3
A5
OLD NEW
O. S. N. S. ANCIENNE NOUVELLE O. S. N. S.
STANDART STANDART
A. N. N. N. NORME NORME A. N. N. N.
0V BB(L)
(G)Y/B
J/N V BLUE
BLEU(L)
(G) YELLOW/BLACK
JAUNE/NOIR
V BLACK (R)
NOIR (D) GREY/BLACK
GRIS/NOIR 0V BN(R)
(D)G/BG/N
PR M/N
W/B PINK
ROSE WHITE/BLACK
BLANC/NOIR PR W/BM/N
0V BM B M 0V BROWN
MARRON MARRON
BROWN 0V BM B M
Steer
Direction NEUTRAL
NEUTRE Steer
Direction
LEFT
GAUCHE RIGHT
DROITE
"V" indicates that a random voltage can be measured

on the indicated wire.
80-8-85-M.84
4
B - DUAL MANIPULATOR
With the calibrator
- Connect the calibrator (Ref. 622813) to the variable speed drive: see B1
Chapter CHECKING THE OPERATION FO THE SEVCON VARIA-
7 8
BLE SPEED DRIVE, paragraph USING THE CALIBRATOR.
5
- Climb into the platform's basket with the calibrator. 9
- Select menus 2-4-2 and 2-4-4 (UPPER BOX TEST) on the calibrator
and note the voltage values from the signals from the manipulator.
- Then select menus 2-3-17, 2-3-18, 2-3-19 and 2-3-20 (UPPER BOX
PERS) on the calibrator to adjust the limit values for the voltages deli-
vered by the manipulator. 6
Menus 2-4-2 and 2-4-4

Signals from the manipulator
noted on the calibrator 0.5 2.5 4.5
Menus 2-3-17 to 2-3-20 0 0.52 2.5 4.48 5

Min/ max calibration values
for the signals from the manipulator
- Lastly, select menus 2-4-1 and 2-4-3 (UPPER BOX TEST) on the
calibrator and check :
- That the proportional signal shows a good progression (i.e.

0 to 100%).
- That it shows 0% in Neutral and 100% only when the mani-

pulator arrives almost at the limit switch.
This procedure must be performed every time

the manipulator is replaced.
With a voltmeter
- Take the voltmeter and climb into the access platform's basket.
- Remove and open the basket console 5 (Fig. B1) (4 bolts, No. 4 hex
spanner) and then locate the wires: 80-8-85-M.84
- Connected to the manipulator 6 (Fig. B1 - B2) (Translation +

Steering).
- Connected to the manipulator 7 (Fig. B1 - B3) (Turret rotation

+ Upper arm).
5
B2
OLD NEW
ANCIENNE NOUVELLE
STANDART
NORME STANDART
NORME
GREEN
VERT GREEN
VERT (NEUTRAL
(HORS POSITION
NEUTRE - MANIPULATOR)
- MANIPULATEUR)
BLUE
BLEU YELLOW/BLACK
JAUNE/NOIR (STEER
(BP LEFT BUTTON)
DIRECTION GAUCHE)
BLACK
NOIR GREY/BLACK
GRIS/NOIR (STEER
(BP RIGHT DROITE)
DIRECTION BUTTON)
GREY
GRIS (Y)
(Y) GREY (Y)
GRIS (Y) (LONGITUDINAL
(COMMANDE AXIS)
TRANSLATION)
VIOLET
VIOLET GREEN/BLACK
VERT/NOIR (DEAD MAN'S
(GACHETTE TRIGGER)
HOMME MORT)
RED
ROUGE BROWN/BLACK
MARRON/NOIR (POWER SUPPLY
(ALIMENTATION - TRIGGER)
- GACHETTE)
PINK
ROSE WHITE/BLACK
BLANC/NOIR (POWER SUPPLY- -BP
(ALIMENTATION STEERING BUTTONS)
DIRECTION)
0V BROWN
MARRON BROWN
MARRON (POWER SUPPLY- TRANSLATION)
(ALIMENTATION - LONGITUDINAL AXIS)
Y
+24V 3W +48V WHITE
BLANC WHITE
BLANC ( ++ BATTERIE)
BATTERY)
63V - 470µf
B3
VERT
GREEN (HORS NEUTRE
(NEUTRAL - MANIPULATEUR)
POSITION - MANIPULATOR)
JAUNE (X) (COMMANDE ROTATION)
YELLOW (X) (TURRET ROTATION)
X GRIS (Y)
GREY (Y) (COMMANDE ELEVATION BRAS 3)
(UPPER ARM)
Y MARRON
BROWN (ALIMENTATION)
(POWER SUPPLY)
WHITE
BLANC ( +(BATTERIE)
+ BATTERY)
- Place the voltmeter's wands on the connector's clips to take the mea-
surements.
- To test the analogue outputs:
- Work with the manipulator's casing 6 (Fig. B1) (Translation

+ Steering) by moving it forwards, backwards and check the
values the voltmeter displays (Fig. B4).
B4
80-8-85-M.84 2.5V GREY

GRIS (Y)
(Y) 4.5V G (Y)
0.5V GG (Y)
(Y)
Y 0V BM Y 0V MARRON
BROWN 0V M
B
Y
Manipulator
ManipulateurtoTHE
vers REAR NEUTRAL
NEUTRE Manipulator FORWARD
Manipulateur vers
REAR TRANSLATION
L'ARRIERE - RECUL FORWARD
L'AVANT TRANSLATION
- AVANCE
- Work with the manipulator's casing 7 (Fig. B1) (Turret rotation

+ Upper arm) by moving it forwards, backwards, left or right
and check the values the voltmeter displays (Fig. B5).
6
B5
4.5V GG (Y)
(Y)
0V BM
48V WB
Manipulatorvers
Manipulateur FORWARD
L'AVANT
UPPER
LEVAGE ARMdu RAISING
bras (3)
0.5V YJ (X)
(X) 2.5V YELLOW
JAUNE (X) (X) 4.5V YJ (X)
(X)
2.5V GREY (Y)
GRIS (Y)
0V BM 0V BROWN
MARRON 0V BM
48V WB 48V BLANC
WHITE 48V WB
Manipulateur
Manipulatorvers la GAUCHE
to THE LEFT NEUTRE
NEUTRAL Manipulator vers
Manipulateur to THE RIGHT
la DROITE
LEFT TURRET
Rotation ROTATION
de tourelle à GAUCHE RIGHT TURRET
Rotation ROTATION
de tourelle à DROITE
0.5V GG (Y)
(Y)
0V BM
48V WB
Manipulateur
Manipulatorvers L'ARRIERE
toTHE REAR
DESCENTE
UPPER du bras (3)
ARM LOWERING
- To test the logic outputs:
- Press the manipulator's steering buttons 8 (Fig. B1) and

check the values the voltmeter displays (Fig. B6); then ope-
rate the manipulator's dead man's pedal 9 (Fig. B1) and
check the values the voltmeter displays (Fig. B7).
B6
OLD NEW
O. S. N. S. ANCIENNE NOUVELLE O. S. N. S.
A. N. N. N. STANDART
NORME STANDART
NORME A. N. N. N.
0V BB(L)
(D) Y/BJ/N V BLUE
BLEU(L)
(D) YELLOW/BLACK
JAUNE/NOIR 80-8-85-M.84
V BLACK (R) GREY/BLACK
NOIR (G) GRIS/NOIR 0V BN(R)
(G) G/B
G/N
0V PR B/N
W/B 0V PINK
ROSE WHITE/BLACK
BLANC/NOIR 0V PR W/B
B/N
Steer NEUTRAL Steer
Direction
LEFT
NEUTRE Direction
RIGHT
GAUCHE DROITE
7
B7
ANCIENNE
OLD NOUVELLE
NEW ANCIENNE
OLD NOUVELLE
NEW
NORME STANDART
STANDART NORME NORME STANDART
STANDART NORME
0V VIOLET GREEN/BLACK
VERT/NOIR 0V VIOLET
VIOLET GREEN/BLACK
VERT/NOIR
V RED
ROUGE BROWN/BLACK
MARRON/NOIR 0V RED
ROUGE BROWN/BLACK
MARRON/NOIR
48V WHITE
BLANC WHITE
BLANC 48V WHITE
BLANC BLANC
WHITE
Gachette
Trigger inau Gachette
Trigger
NEUTRAL
NEUTRE ACTIVATED
ACTIONNE
"V" indicates that a random voltage can be measured

on the indicated wire.
80-8-85-M.84
8
POSITIONING AND ADJUSTING
THE CONTACTORS
120 AETJ
80-8-86-M.84 EN
80-8-86-M.84
11 / 2003
80-8-86-M.84
INDEX
A - POSITION OF THE SENSORS .............................................................P 2
B - ADJUSTING THE ANTI-ROLLOVER BARS OUTPUT SENSOR ....................P 3
C - ADJUSTING THE SLOPE SENSOR ......................................................P 3
D - ADJUSTING THE LOW ARM SENSOR ..................................................P 4
E - ADJUSTING THE RETRACTED TELESCOPE SENSOR..............................P 4
F - ADJUSTING THE OVERLOAD SENSOR.................................................P 4
80-8-86-M.84
1
A - LOCATION OF THE SENSORS
Retracted telescope
sensor
Low arm sensor

Overload sensor
Stabiliser output
sensor
80-8-86-M.84
Slope sensor Stabilisers
2
B - ADJUSTING THE ANTI-ROLLOVER BARS' OUTPUT SENSOR
UP TO PLATFORM No. 505490: B1

- Raise the platform a few centimetres to release full engagement of
the anti-rollover bars.
- Remove the left-hand and right-hand battery covers (4 butterfly

bolts).
- Unscrew the fixing screws 1 (Fig. B1) (2 screws, flat screwdriver).
- Trigger the sensors 2 (Fig. B1), one after the other, by placing them 2
in contact with the anti-rollover bar 1
- Re-tighten the screws.
- Check the setting by instructing the basket to rise: if its ascent is

interrupted, adjust the sensor setting.
FROM PLATFORM No. 505491: B2

- Raise the platform a few centimetres to release full engagement of
the anti-rollover bars. 3
- Remove the left-hand and right-hand battery covers (toggles).
- Unscrew the fixing screws 3 (Fig. B2) (2 bolts, No. 13 spanner).
- Trigger the sensors 4 (Fig. B2), one after the other, by placing them
4
in contact with the stabilising bar
- Re-tighten the bolts.
- Check the setting by instructing the basket to rise: if its ascent is

interrupted, adjust the sensor setting.
C - ADJUSTING THE SLOPE SENSOR
The slope sensors are preset by the manufacturer. The only

parameter that can be adjusted is the sensor initialisation.
- Set the platform on a horizontal surface and switch it on.

80-8-86-M.84
- Open the right-hand cover.
- Open the LEFT-HAND battery cover (butterfly bolts or toggles).
- Grasp the unconnected cable coming from the sensor.
- Remove the plastic cap from the end of the cable (flat screwdriver).
- Take an electric cable stripped at both ends and connect the slope
sensor cable to the battery's -24V terminal: the green LED under the
sensor flashes several times and then stops when the sensor is set.
3
D - ADJUSTING THE LOW ARM SENSOR
UP TO PLATFORM No. 505421: D1

- Set the platform in transport position (Telescope retracted, arms 5
lowered) and leave it switched on.
- Remove the protective cover 5 (Fig. D1) (2 bolts, No. 10 spanner)

situated under the left-hand side of the intermediate joint 6 (Fig. D2).
- Loosen the lock nuts 7 (Fig. D1) (No. 24 spanner)
- Tighten or loosen the sensor 8 (Fig. D1) until the LED next to the 7
power supply cable switches from red to green. 8
- Re-tighten the lock nuts.
- Refit the protective cover.

D2
FROM PLATFORM No. 505422 6
- Locate the sensor 9 (Fig. D2) between the two sides of the interme-
diate joint.
- Same procedure as for adjusting platforms UP TO PLATFORM No.

505421 except for removing and refitting the protective cover.
E - ADJUSTING THE RETRACTED TELESCOPE SENSOR
- Locate the sensor 10 (Fig. E1) located at the front between the two E1
counterweights.
10
- The follow the same procedure as for ADJUSTING THE LOW ARM
SENSOR.
80-8-86-M.84
F - ADJUSTING THE OVERLOAD SENSOR
- Raise the basket 50cm above the floor in a horizontal position. F1

- Remove the protective cover 11 (Fig. F1) (2 bolts, No. 10 spanner).
- Place 250kg in the basket.
- Loosen bolt 12 (Fig. F2) (No. 14 spanner) until the overload sensor
13 (Fig. F2) triggers: the platform's alarm sounds.
11
4
F2
The contactor has a certain reaction time when the bolt is being
untightened. Stop at the limit for triggering the contactor.
12
- Relieve the weight on the basket: the platform's alarm no longer
sounds.
13
- Replace the weight in the basket: the platform's alarm sounds.
- Refit the protective cover.
80-8-86-M.84
5
GROUPS 100
TROUBLE
SHOOTING
TROUBLESHOOTING
120 AETJ
100-M.84 EN
100-M.84
11 / 2003
100-M.84
TROUBLE SHOOTING
100-M.84

Manitou 578 3

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R

REF : 547 363 EN (05 / 04)

ISSUE DATE COMMENTS

06/2002 1st edition

12/2003 Variable speed drive unit parameters modification

05/2004 Updated 35-8-21-M.84

ELECTRIC WHEEL MOTORS

- Use Indoors Outdoors

- Capacity 230 Kg 120 Kg

- Control system Electro-hydraulic

- Turret rotation 350°

- Operating speed 0,6 km/h

- Operating height 11950 mm

- Access platform weight

- Traversable gradient 25%

- Max permissible slope 5% or 3°

LOAD PER UNDER MAX LOAD+ OFF

1 - Hydraulic return oil filter cartridge 599004 Every 900 H

COMPONENTS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING REFERENCE

HYDRAULIC OIL RÉSERVOIR 12 Litres MANITOU 20 L. 582 297

WHEEL MOTOR (EACH ONE) 0.8 Litre SHELL 2 L. 661 998

GENERAL GREASING SHELL RETINAX HD cartridge 161 589

BEARING TURRET RING GREASING SHELL ALVANIA EP LF 2 1 Kg 545 836

UP TO PLATFORM NO. 505578: REDUCER 598694

- Set the lower arm to maximum for optimum accessibility. A

- Remove the rear wheels 1 (Fig. A) (10 bolts, No. 19 spanner).

- Open the rear cover 2 (Fig. A) (4 bolts, No. 4 hex spanner).

- Mark and remove the electric motor power cables.

- Remove the electric motors 3 (Fig. B) (8 bolts, No. 9 hex spanner). B

- Place a MA8S bung in each hose to prevent any oil leaks.

- Remove the reducers 4 (Fig. B) (16 bolts, No. 10 spanner).

- Same procedure as for removing reducer 598694.

- Same operations as above in reverse order.

When fastening reducers 599538, position the CHC M12x45 bolts at

The platform may only be towed a short distance and only by a

- Loosen bolt 1 (Fig. A) on each wheel 22 mm from the edge, up to the

Warning: do not loosen the bolt more than 22 mm,

A - REMOVING THE TELESCOPE CYLINDER WEAR PADS ........................... P2

B - REMOVING THE TELESCOPE ARM WEAR PADS .................................. P 2

C - REMOVING THE MOBILE TUBE WEAR PADS ....................................... P2

- Remove the telescope cylinder: see the REMOVING THE TELE- A1

- Remove the wear pads 1 (Fig. A1) (8 bolts, No. 10 spanner).

- Same operations as above in reverse order.

B - REMOVING THE TELESCOPE ARM WEAR PADS

- Remove the telescope cylinder: see the REMOVING THE TELE- B1

- Lift the basket with a hoist to relieve the pads.

- Pay attention to the position of the adjustment plates 3 (Fig. B1).

- Same operations as above in reverse order.

- If necessary, position the adjustment plates:

C - REMOVING THE MOBILE TUBE WEAR PADS

- Remove the telescope cylinder: see the REMOVING THE TELE- C1

- Pay attention to the position of the adjustment plates 5 (Fig. C1).

- Remove the pads.

- If necessary, position the adjustment plates:

- Switch off the electrical power supply. A

- Mark each solenoid 1 (Fig. A) (Adhesive and marker) according to the

- Remove the element(s) requiring to be replaced (various flat and hex

Before removing any hose or distributor component, operate the tap-

A - REMOVING THE STEERING CYLINDER ................................................P 2

B - REMOVING THE TELESCOPE CYLINDER .............................................P 4

C - REMOVING THE ANTI-ROLLOVER BAR CYLINDERS ...............................P 6

- Mark and remove the hydraulic hoses (No. 19 spanner).

- Remove the articulation shaft 2 (Fig. A2) (1 bolt, No. 13 spanner).