MRT 1540 PDF

UNIT 80
ELECTRICITY
LOCATION OF PROXIMITY SENSORS
MICROSWITCHES
80-7-81-M9 EN
ELECTRICITY
PROXIMITY SWITCHES AND MICROSWITCHES
E1
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
☞ 1
machine translation and to turn on the red “parking

brake” light on the instrument panel.
E2
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

FUNCTIONS = Exclusively that of signal-
ling, through the electro-
☞ 2
nic board and lighting the
cab lamp, that the stabili-
zers have retracted; it has
no lock effect on the ope-
rations.
☞ 1
ADJUSTMENT = It is positioned at a distan-
ce 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 interferen-
ce 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.
E4
D) 5° Proximity switch (Detail 1 - Photo E4):
FUNCTIONS = This proximity switch, located on
the rear of the chassis, signals that 1
the tower is turned more than 5° to
the right or to the left of the front
longitudinal axis, locking the rear
☞
axle oscillation.
ADJUSTMENT = 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): E5
FUNCTIONS = (Detail 1) The microswitch signals
to the operator the longitudinal ali-
gnment of the tower frame by ligh-
ting the green lamp on the instru-
ment panel. 2
(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.
☞
ADJUSTMENT = (Detail 1) The green lamp should
turn on only when the tower is ali-
gned so that its rotation can be ☞ 1
locked.
(Detail 2) The red lamp should turn
on only when the tower rotation
lock pin is inserted in the appro-
priate seat. E6
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):
☞ 1
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 E7

FUNCTIONS = To interrupt the contact before the
limit switch pressure peak occurs
supplying erroneous data to the
safety system display. 1
ADJUSTMENT = Put the arm at the up limit switch,
position the microswitch so that is ☞
pressed 1 mm before the mecha-
nical stop, leaving an overstroke
clearance to avoid mechanical
breakage.
Page 3
ELECTRICITY
H) Retracted arm proximity switch E8

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

I) Arm angle proximity switch 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.
Warning:
☞ 1

Page 4
ELECTRICITY
Proximity switches and Microswitches

(Basket version)
L) Proximity switch on rapid connector E10

ADDITIONAL
FUNCTIONS
FOR BASKET = Activate safety devices.
ADJUSTMENT = Adjust the special screw (Detail 1 -
Photo E11), to 2-3 mm from the
sensor.
1
☞
Warning:
N.B. It’s possible to check the correct function of the proxi-
mity 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
1
☞
E12
M) Proximity switch on the arm saddle (Detail

1 - Photo E12) with 23m basket:
FUNCTIONS = To raise and lower the stabilizers
with the arm lowered below 0.8 m
and with the basket arm in the
☞
road traffic position.
ADJUSTMENT = It must be adjusted so that with the 1
basket arm in the road traffic posi-
tion (resting on the fork on the
arm), the sensor is 2-3 mm away.
Warning:
Page 5
ELECTRICITY
N) Microswitch on door (Detail 1 - Photo E13) E14

and platform (Detail 1 - Photo E14) with basket
extendible up to 17m:
FUNCTIONS = Used to enable the operations
from the basket.
ADJUSTMENT = They must be adjusted so that,
with the door closed and with the
basket open or closed, the micro-
switches are pressed and the red 1
lamp on the console is off.
☞
E13
☞ 1
O) Microswitch on 17 m basket (Detail 1 - Photo E15

E15) (France version):
FUNCTIONS = It blocks the movements of the
basket under overload conditions.
ADJUSTMENT = It must be adjusted so that the
sensor is 5-6 mm from the set
screw.
☞ 1
Page 6
WIRING DIAGRAMS
80-6-M9 EN
INDEX
Electric system 1st Version page 1-41

until the truck n° 117101/5948
included the truck n° 118104/5989
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


Electric system 1st Version page1-41

included the truck n° 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 Amper-
age”.
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

Fig. B
☞
➠
7,5
7,5
7,5
7,5
7,5
7,5
7,5
7,5
7,5
7,5
7,5
1
10
1 2 3 4 5 6 7 8 9 10 11 12
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
1st Version ELECTRICITY
CAB FUSE HOLDER BOX

Fig. C
1 25 4 15 7 10 10 10
3
15
15
5
6
15
15
8
9
10
10
11
12
10
10
➠
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
ELECTRIC BOX UNDER CAB Fig. D
1
2 3 4 5 6 7 8
10
10
10
10
10
10
10
10
10 11 12 13 14 15 16 17
18
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
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
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
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
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
TABLE OF RELAY POSITION ON ELECTRIC DIAGRAM
MASTER ELEMENT POSITION SLAVE ELEMENT POSITION
R1 1/16 ELEMENT OPEN 1/18
R13 11/18 ELEMENT CLOSED 11/13
R7 6/10 ELEMENT CLOSED 9/15
Page 8
40-PIN ROTARY FITTING CONNECTION DIAGRAM
BROWN CABLE GROUP
N° COLOUR DESCRIPTION
01 Brown-white Retracted stabilizer lamp
02 Green-blue Extended stabilizer micro-pressure switches
03 Grey-blue Right front stabilizer
04 Orange-blue Solenoid valve return
05 Yellow-blue Left front beam
06 Light blue-yellow Right rear beam
07 Orange-black Right front beam
08 Yellow-red Rear right beam
09 Orange-red Left rear beam
10 Orange Left front beam
GREY CABLE GROUP
01 Blue-red Left front stabilizer
02 Pink Fuel level instrument
03 Red-black Fuel reserve lamp
04 Grey no. 4 Stabilizer general solenoid valve
05 Yellow-green Slow-fast enabling signal
06 Violet-black Rear axle alignment
07 Grey-white Hydraulic circuit exclusion solenoid valve
08 Yellow-brown Reverse
09 White-green Start enabling signal
10 White-red Emergency pump key
BLACK CABLE GROUP
01 White Position lights
02 Grey-green Air filter clogged
03 Violet-white Front axle alignment
04 Green-white Crab turned
05 Green-white Concentric turned
06 Blue Right direction lights
07 Blue-black Left direction lights
08 Yellow-grey Forward
09 Black d. 6 Negative power supply
10 Red d. 6 Positive power supply
Page 9
WHITE CABLE GROUP
01 Green-black High-beam headlights
02 Grey-black Low-beam headlights
03 White no. 3 Thermal starter
04 White no. 4 Ignition key current
05 Yellow-green Start-up
06 Grey-red Battery charger lamp
07 Grey Engine oil low pressure lamp
08 Brown Engine stop
09 Green Active rear suspensions
10 White black Engine water temperature instrument
Page 10
TABLE N°1
Page 11
TABLE N°2
Page 12
CONNECTION
9 PIN PM
MATE - N - LOK
TABLE N°3
Page 13
CONNECTION
8 PIN PM
TABLE N°4
Page 14
TABLE N°5
Page 15
TABLE N°6
Page 16
TABLE N°7
Page 17
TABLE N°8
Page 18
TABLE N°9
Page 19
TABLE N°10
Page 20
TABLE N°11
Page 21
TABLE N°12
Page 22
GEARBOX ELECTRIC CONTROL DIAGRAM
LEGEND
ELECTRICITY
I52 : Braking circuit pressure switch

M6 : Slow-fast insertion manipulator
POSITIVE POWER SUPPLY
R14 : Magnetic retainer relay
L12 : Slow speed on lamp
L13 : Fast speed on lamp
E29 : Slow speed solenoid valve
E30 : Fast speed solenoid valve
1st Version
Page 23
MRT 1540 SOFTWARE INPUT-OUTPUT CONNECTORS
INPUT connectors
Power supply connector MA
MA-01 Black ø 1.5 Negative power supply

MA-01 Red black ø 1.5 Positive power supply
Connector M1
M1-01 Blue-green Extended and lowered stabilizers

M1-02 Orange-red Extension limitation proximity
M1-03 Light blue-yellow Up limitation proximity
M1-04 White no. 09 Rear axle locking
M1-05 Grey no. 44 Manipulator stabilizer output signal
M1-06 Orange-blue no. 04 Manipulator stabilizer return signal
M1-07 Orange-green Cab manipulator microswitches
M1-08 Orange-blue Basket manipulator microswitch
M1-09 Yellow-red Electronic pendulum
M1-10 Yellow-green 23 mt resting basket saddle proximity
M1-11 Violet-white Basket sensor proximity
M1-12 Yellow-blue Emergency key
Connector M2
M2-01 Orange-red Basket operation enabling signal button

M2-02 Brown-white Basket engine stop button
M2-03 Yellow-grey 23 mt on basket signal
M2-04 Grey-black Anti-tilting
M2-05 ------------------------ ------------------------------------------------------
M2-06 Green Up operation exclusion microswitch
Connector M3 analog signals from cab manipulators
M3-01 Light blue-white Tilting

M3-02 Green-white Lifting
M3-03 Grey-blue Optional
M3-04 Grey-white Extension 2
M3-05 White-yellow Rotation
M3-06 Orange-white Extension 3
M3-07 Pink-yellow Extension 1
Page 24
Connector M4 analog signals from basket manipulator
M4-01 Blue-black Tilting

M4-02 Green-black Lifting
M4-03 White-black Optional
M4-04 Grey-black Extension 2
M4-05 Yellow-black Rotation
M4-06 Orange-black Extension 3
M4-07 Pink-black Extension 1
OUTPUT connectors
Connector M5 analog signals for Danfoss solenoid valves
M5-01 Blue Tilting solenoid valve

M5-02 Green Lifting solenoid valve
M5-03 White Optional solenoid valve
M5-04 Grey Extension 2 solenoid valve
M5-05 Yellow Rotation solenoid valve
M5-06 Orange Extension 3 solenoid valve
M5-07 Pink Extension 1 solenoid valve
Connector M6
M6-01 Orange-blue Stabilizer return solenoid valve

M6-02 Grey no. 4 Stabilizer general solenoid valve
M6-03 Grey-red Signal for anti-tilting system configuration
M6-04 Red Rotation speed reduction solenoid valve
M6-05 White-green Pendulum activated with stabilizers extended
M6-06 Yellow-brown Tilting basket movement solenoid valve
M6-07 Red-green Red defect lamp
M6-08 Brown Engine stop
M6-09 White-grey + diode Cab Danfoss solenoid valve power supply control
M6-10 White-grey + diode Basket Danfoss solenoid valve power supply control
M6-11 Violet-black Locked rear axle blinking lamp
M6-12 Red-black ø 1.5 Positive common
Page 25
GREEN AND RED LAMPS DIAGRAM OF CONNECTIONS AND RELAYS OF THE
ELECTRIC BOX BEHIND THE CAB
Page 26
R1 R4 R5 R6 R12 R11 K1 K3 K5 K7 K9
OOOOOOOOOOOO
M1
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
1st Version
R2 R3 R7 R8 R9 R10 K2 K4 K6 K8 K10
K11
POWER SUPPLY
OO OOOOOO OOOOOOO OOOOOOO OOOOOOO OOOOOOOOOOOO

MA M2 M3 M4 M5 M6
G + M MMM MM M MMM MMM M MMM MMM M MMM MMM M MMM MMM MM M M M

N 1 2 2 2 2 2 2 3 3 3 3 3 3 3 4 4 4 4 4 4 4 5 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6 6 6 6
D 2 I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I
V 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1
1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 0 1 2
MM
A A
I I
0 0
1 2
ELECTRICITY
Danfoss flow regulator connection
for lifting and descent (TS
✷ relay 5 A 2 contacts inclination only for 23m)
relay 16A 1contact all interchangeable
ELECTRICITY
R = controlled relay for Danfoss variable signal

R = 12V control
✷ ✷
R1 R4 R5 R6 R12 R11 K1 K3 K5 K7 K9
OOOOOOOOOOOO
M1
✷ ✷
R2 R3 R7 R8 R9 R10 K2 K4 K6 K8 K10
K11
1st Version
ALIMENTATION

MA M2 M3 M4 M5 M6
LEGEND
R1-R2-R3-R4 = basket or cab selection K1 = outriggers retract K7 = basket red light relay
R5 = TS inclination K2 = outriggers relay K8 = engine stopped relay
R6 = lifting K3 = outriggers or wheels PAT signal relay K9 = contact N relay 12V cab
R7 = optional K4 = basket version relay for rotation speed K10 = contact N relay 12V basket
R8 = telescope 1 reduction K11 = rear axle locked yellow light
R9 = rotation K5 = 3° inclination relay - orange light in the
R10 = telescope 3 cab turned on - push button panel and
R11 = telescope 1 buzzer
Page 27
R12 = Danfoss flow regulator selection K6 = 23m basket free relay
M6
1
2
M
I
Positive common contact
OOOOOOOOOOOO
1
1
K11
M
Flashing rear axle locked light
I
Danfoss solenoid valve power control from aerial
1
0
M
I
platform.
DIAGRAM OF CONNECTIONS AND RELAYS OF THE
6 6
0 0
8 9
MM
I I
Danfoss solenoid valve power control from cab
Engine stop
6 6 6
0 0 0
5 6 7
MMM
I I I
Red fault light
K10
K9
Tilting aerial platform movement solenoid valve

Telltale activated with outriggers extended
6 6 6
0 0 0
2 3 4
MMM
I I I
Slewing speed reduction solenoid valve
K7
K8
General outrigger solenoid valve
Outrigger retraction solenoid valve
M
6
0
1
I
K6
K5
M5
K3
K4
OOOOOOO
5 5 5
0 0 0
5 6 7
MMM
Extension 1 solenoid valve
DANFOSS
I I I
PVG 32 Extension 3 solenoid valve
Slewing solenoid valve
MMM
K1
K2
5 5 5
0 0 0
2 3 4
I I I
Optional solenoid valve
M Lifting solenoid valve
Tilting solenoid valve
R10
R11
0
1
I
M4
R12
MANIPULATEUR
R9
OOOOOOO
4 4 4
0 0 0
5 6 7
MMM
Extension 1
NACELLE
I I I
Extension 3
R8
R6
Slewing
4 4 4
0 0 0
2 3 4
MMM
Extension 2
I I I
Optional
R7
R5
Lifting
M
Tilting
4
0
1
I
R4
R3
MANIPULATEUR
M3
R1
R2
OOOOOOO
Extension 1
3 3 3
0 0 0
5 6 7
MMM
I I I
CABINE
Extension 3
Slewing
M1
3 3 3
0 0 0
2 3 4
MMM
Extension 2
I I I
Optional
1
1
2
M
OOOOOOOOOOOO
Lifting
I
Saving key
1
1
1
M
Aerial platform engaged proximity Tilting

I
0
1
I
23m aerial platform on hold proximity

1
1
0
M
Electronic telltale
1 1
0 0
8 9
MM
I I
Aerial platform manipulator microswitch

M2
Cab manipulator microswitches

1 1 1
0 0 0
5 6 7
MMM
I I I
Outrigger retraction signal from manipulator

OOOOOO
0 0
5 6
MM
Ascent manoeuvre inhibiting microswitch

2 2
I I
Outrigger extension signal from manipulator ----------------------------------------------------

Rear axle lock
MMM
0 0 0
2 3 4
MMM
Anti-overturning
1 1 1
0 0 0
2 3 4
2 2 2
I I I
I I I
Ascent limiting proximity 23m aerial platform engaged signal

Extension limiting proximity Aerial platform engine stop button
Outriggers extended and lowered
M
Aerial platform manoeuvre enabling button

1
0
1
0
1
I
I
LAMPS
GREEN AND RED
ALIMENTATION
MA
OO
MM
G +
A A
N 1
D 2
V
0 0
1 2
I I
Page 28
CONNECTION RATING PLATES ON THE COVER
OR
RELAY OF THE ELECTRIC BOX BEHIND THE CAB
CONNECTION
OR
RELAY
Page 29
DESCRIPTION OF THE SIGNAL LAMPS AND RATING PLATES ON THE COVER OF THE
CONNECTION .
ON ... ...
OR .
RELAY OFF DESCRIPTION
.
... ...
M1-01 . STABILIZERS EXTENDED AND LOWERED
STABILIZERS LIFTED
.
... ...
M1-02 . I°+II° EXTENSION COMPLETELY RETRACTED
I° OR II° EXTENSION EXTENDED
.
... ...
M1-03 . SMALLER ARM HEIGHT 0.8 METRES
LARGER ARM HEIGHT - EQUAL TO 0.8 METRES
.
... ...
M1-04 . REAR AXLE FREE
REAR AXLE LOCKED
.
... ...
M1-05 . STABILIZER EXTEND CONTROL EXECUTION
STABILIZER EXTEND CONTROL NOT EXECUTED
.
M1-06 ... ... STABILIZER RETURN CONTROL EXECUTION
.
STABILIZER RETURN CONTROL NOT EXECUTED
.
M1-07 ... ... CAB CONTROL EXECUTION
.
CAB CONTROLS NOT EXECUTED
.
M1-08 ... ... BASKET CONTROLS EXECUTE
.
BASKET CONTROLS NOT EXECUTED
.
M1-09 ... ... ELECTRONIC PENDULUM ACTIVE (3°)
.
ELECTRONIC PENDULUM NOT ACTIVE
.
M1-10 ... ... 23 METRE BASKET IN SEAT
.
23 METRE BASKET OUT OF SEAT
.
M1-11 ... ... BASKET NOT PRESENT ON RAPID CONNECTOR
.
BASKET PRESENT ON RAPID CONNECTOR
.
M1-12 ... ... EMERGENCY KEY ACTIVATED
.
EMERGENCY KEY NOT ACTIVATED
.
M2-01 ... ... BASKET OPERATION ENABLING SIGNAL BUTTON PRESSED
.
BASKET OPERATION ENABLING SIGNAL BUTTON RELEASED
.
M2-02 ... ... BASKET CONSOLE ENGINE STOP BUTTON PRESSED
.
BASKET CONSOLE ENGINE STOP BUTTON RELEASED
.
M2-03 ... ... 23 METRE BASKET CONSOLE CABLE CONNECTED
.
23 METRE BASKET CONSOLE CABLE DISCONNECTED OR USE OF 17 MT BASKET
.
M2-04 ... ... SAFETY SYSTEM NOT ACTIVE
.
SAFETY SYSTEM ACTIVE
.
... ...
M2-06 . SIGNAL ACTIVE: ARM LIFTED TO LIMIT SWITCH
SIGNAL NOT ACTIVE: ARM UP OR DOWN OPERATION ALLOWED
.
... ...
R1 - R2 . CONTROLS FROM BASKET OR CAB EXECUTED
R3-R4 CONTROLS FROM BASKET OR CAB NOT EXECUTED
.
... ...
R5 . TILTING CONTROL EXECUTED
TILTING CONTROL NOT EXECUTED OR NOT ALLOWED
.
... ...
R6 . LIFTING CONTROL EXECUTED
LIFTING CONTROL NOT EXECUTED OR NOT ALLOWED
Page 30
CONNECTION .
ON ... ...
OR .
.
... ...
R7 . OPTIONAL CONTROL EXECUTED
OPTIONAL CONTROL NOT EXECUTED OR NOT ALLOWED
.
... ...
R8 . II° EXTENSION CONTROL EXECUTED
II° EXTENSION CONTROL NOT EXECUTED OR NOT ALLOWED
.
... ...
R9 . ROTATION CONTROL EXECUTED
ROTATION CONTROL NOT EXECUTED OR NOT ALLOWED
.
... ...
R10 . III° EXTENSION CONTROL EXECUTED
III° EXTENSION CONTROL NOT EXECUTED OR NOT ALLOWED
.
... ...
R11 . I° EXTENSION CONTROL EXECUTED
I° EXTENSION CONTROL NOT EXECUTED OR NOT ALLOWED
.
... ...
R12 . BASKET ON RAPID CONNECTOR
BASKET NOT ON RAPID CONNECTOR
.
... ...
K1 . STABILIZER RETURN CONTROL EXECUTED
STABILIZER RETURN NOT EXECUTED OR NOT ALLOWED
.
... ...
K2 . STABILIZER CONTROL EXECUTED
STABILIZER CONTROL NOT EXECUTED
.
... ...
K3 . SAFETY SYSTEM ACTIVE
SAFETY SYSTEM NOT ACTIVE
.
... ...
K4 . BASKET NOT ON RAPID CONNECTOR
BASKET ON RAPID CONNECTOR
.
... ...
K5 . ELECTRONIC PENDULUM ACTIVE
K6 .
... ...
BASKET ON RAPID CONNECTOR AND BASKET OR CAB CONTROLS EXECUTED
.
BASKET NOT ON RAPID CONNECTOR AND BASKET OR CAB CONTROLS NOT
EXECUTED
.
... ...
K7 . STABILIZERS LIFTED OR BASKET NOT ON RAPID CONNECTOR
STABILIZERS LOWERED OR BASKET ON RAPID CONNECTOR
.
... ...
K8 . BASKET CONSOLE ENGINE STOP BUTTON PRESSED
.
... ...
K9 . CONTROLS EXECUTED FROM THE CAB IF ALLOWED
CONTROL NOT EXECUTED FROM THE CAB OR NOT ALLOWED
.
... ...
K10 . CONTROLS EXECUTED FROM THE BASKET IF ALLOWED
CONTROL NOT EXECUTED FROM THE BASKET OR NOT ALLOWED
.
... ...
K11 . REAR AXLE LOCKED (blinking LIGHT)
REAR AXLE FREE
Page 31
ELECTRONIC BOARD ELECTRIC CIRCUIT
Page 32
THE INPUT ADAPTATION CIRCUIT

IS REPEATED FOR 15 SECTIONS
Page 33
INVERTED
NUMBERING
Page 34
THE POWER CIRCUIT WILL BE

REPLICATED FOR 22 OUTPUTS
Page 35
Page 36
ELECTRICITY
RELAY COIL CONTROLS

1st Version
OUTPUT 1 CONTROL K1 OUTPUT 12 CONTROL R12

SIGN 1 CONTROL K8 OUTPUT 19 CONTROL R5
OUTPUT 9 CONTROL K9 OUTPUT 20 CONTROL R1-R2-R3-R4
OUTPUT 10 CONTROL K10 OUTPUT 21 CONTROL 4053
OUTPUT 11 CONTROL K11
Page 37
ELECTRIC COMPONENT LAYOUT
Page 38
REAR AXLE OSCILLATION
BLOCK - FLASHING YELLOW LAMP LIGHT SWITCH
TOWER ALIGNMENT - GREEN LAMP
RETRACTED STABILIZERS - GREEN LAMP C. E. C. PAT

STABILIZER
TOWER ROTATION BLOCK - RED LAMP CONTROL LEVER
FRONT RIGHT
STABILIZER
BASKET
EMERGENCY KEY LEFT FRONT
D 63
STABILIZER
RIGHT REAR
1st Version
EXTENDED AND LOWERED

STABILIZERS - BLUE LAMP STABILIZER
LEFT REAR STA-
STABILIZER UP BILIZER
DOWN EXTENSION
POSITION LIGHTS - GREEN LAMP SELECTOR
LEVELLING - YELLOW LAMP
C.E.C. PAT
SUPPRESSION KEY
TRANSMISSION RESET
FRONT AND REAR

AXLE ALIGNMENT
LAMP
CONTACT AND
STARTER KEY
DIRECTION SELECTOR
ELECTRICITY
HYDRAULIC SYSTEM
LP EXCLUSION
LIFTING-TILTING-T2 SPEED CHANGE
DANFOSS MANIPULATOR MANIPULATOR
ELECTRICITY
T3-ACCESSORY CONTROL
SELECTOR
T1-T3-ACCESSORY
DANFOSS MANIPULATOR
D 64
PARKING BRAKE
TRANSMISSION
1st Version
SECTION
MICROSWITCH
HYDRAULIC
MOVEMENT
EXCLUSION
MICROSWITCH
Page 39
RETRACTED ARM
Page 40
ELECTRIC HEADER PROXIMITY INDICATOR
ELECTRIC
SAFETY PUMP LIFTING LIMIT SWITCH SAFETY PUMP
CONTROL KEY MICROSWITCH
0.8 M HIGH ARM

PAT WINDER AND PROXIMITY
ANGLE INDICATOR INDICATOR
BLOCKED TOWER
MICROSWITCH
✷ BASKET PROXIMITY
INDICATOR RETRACTED STABILIZER
PROXIMITY INDICATOR
D 65
1st Version
✷ PENDULUM
LEVELLING
INDICATOR STABILIZERS
RESTING ON
GROUND
MICROSWITCH
ELECTRIC BOX UNDER TOWER NOT ALIGNED = 5°

THE STEP LADDER PROXIMITY INDICATOR
NOTE TOWER ALIGNMENT

✷ ONLY IN THE BASKET VERSION MICROSWITCH
ELECTRICITY
ELECTRICITY
SOFTWARE ELECTRONIC BOX
FUSE BOX UNDER THE INSTRUMENT PANEL
D 66
1st Version
Page 41
included the trucks n° 116122/5857
116123/5858
116678/5931
117099/5933
117100/5982

ELECTRICITY 2nd Version
FUSE AND RELAY BOX
➠
1 2 3 4 5 6 7 8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28
E1 E2 E3 E4 E5
E11
➩
E6 E7 E8 E9 E10 ➩
Page 45
2nd Version ELECTRICITY
FUNCTIONAL DESCRIPTION OF THE FUSES IN THE BOX LOCATED

UNDER THE COVER OF THE INSTRUMENT PANEL
Ref. Amps Description

F1 10 Electronic pendulum + hydraulic circuit exclusion solenoid valve
F2 5 Gear switch + truck ignition power supply
F3 7.5 Light switch + buzzer from cab
F4 10 Beacon
F5 15 Available
F6 5 Direction lights
F7 7.5 Drive wheel selector
F8 10 Front windshield wiper and washer
F9 3 Instrument + lamp meter + lamp control check
F10 10 Front working lights
F11 10 Rear working lights
F12 7.5 Rear and top windshield wiper
F13 3 Stabiliser switch lighting
F14 Diode Forward gear
F15 10 Emergency key + braking switch + translation solenoid valves
F16 7.5 Microswitch lock and tower alignment +

transmission reset button
F17 7.5 Cab control manipulators
F18 15 Instrument panel stabilisers
F19 10 Anti-tipping system
F20 15 Logic + cage
F21 15 Danfoss solenoid valves
F22 7.5 Available
F23 10 Available
F24 15 Available
F25 10 Available (direct power supply)
F26 10 Ceiling light + emergency lights
F27 5 Available
F28 Diode Reverse
FUNCTIONAL DESCRIPTION OF RELAYS IN THE BOX LOCATED

UNDERNEATH THE COVER OF THE INSTRUMENT PANEL
Ref. Characteristics Description

E1 20/30 Amps Ignition enabling signal
E2 20/30 Amps Hydraulic circuit exclusion
E3 20/30 Amps Danfoss solenoid valve power supply
E4 20/30 Amps Forward gear
E5 20/30 Amps Reverse
E6 20/30 Amps Parking brake on optical indicator
E7 ....................... ...................................
E8 ....................... ...................................
E9 ....................... ...................................
E10 ....................... ...................................
E11 12 Volt 84/168 Watt Direction and emergency light flashing
Page 46
ELECTRIC BOX UNDER CAB
E 12
E 13 E 14 E 15 E 16 E 17 E 18 E 19
F 29
10
10
10
10
10
10
10
10
F 30 F 31 F 32 F 33 F 34 F 35 F 36 F 37
C1
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
USERS LEGEND ELECTRIC SYSTEM MRT1540 MANITOU

CAB 1996 VERSION WITH SOFTWARE (reference drawing No. 756)
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
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)
F25 . Fuse 10 A : Available direct power supply (Tab. 3)
F26 . Fuse 10 A : Emergency lights + ceiling light (Tab. 3)
Page 48

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)
H1 . Hour meter (Tab. 1)
I2 . Forward-reverse gear manipulator (Tab. 4)
I3 . Slow-fast gear microswitch (Tab. 2)
I4 . Transmission reset button (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)
I11 . Fuel reserve level switch (Tab. 5)
I12 . Air filter fouling pressure switch (Tab. 5)
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)
I23 . Arm microswitch (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)
I39 . Proximity PNP - 23 mt cage saddle (Tab. 11)
I40 . Proximity PNP - (n.C.) cage present (Tab. 11)
I42 . Cage engine stop button (Tab. 11)
I43 . Cage buzzer button (Tab. 11)
Page 49
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)
L2 . Front axle alignment optical indicator(Tab. 2)
L3 . Rear axle locked optical indicator (Tab. 7)
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)
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)
P2 . Right rear stop light(Tab. 2)
P6 . Right rear direction light(Tab. 3)
Page 50

P8 . Left 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)
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)
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)
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
CONNECTION CARD FOR TINSLEY 40-POLE ROTATING TAP
GROUP OF BROWN WIRES
N° CORRESP.COLOUR DESCRIPTION
01 Brown-white Outriggers retracted light
02 Green-blue Outrig. exten. pressure switch micro
03 Grey-blue Right front outrigger solenoid valve
04 Orange-blue Retraction solenoid valve
05 Yellow-blue Left rear outrigger arm solenoid valve
06 Pale blue-yellow Right rear outrigger arm solenoid valve
07 Orange-black Right front outrigger arm solenoid valve
08 Yellow-red Right rear outrigger solenoid valve
09 Orange-red Left rear outrigger solenoid valve
10 Orange Left front outrigger arm solenoid valve
GROUP OF GREY WIRES
01 Blue-red Left front outrigger solenoid valve
03 Pink-black Fuel reserve light
04 Grey N° 4 General outrigger solenoid valve
05 Yellow-green Slow-fast enabling
06 Violet-black Rear axle alignment light
07 Grey-white Hydr. circuit inhibiting solenoid valve
08 Yellow-brown Reverse running solenoid valve
09 White-green Start enabling
10 Violet Proximity 55°
GROUP OF BLACK WIRES
01 White Parking lights
02 Grey-green Air filter clogged light
03 Violet-white Front axle alignment light
04 Green-white Crabwise steering solenoid valve
05 Green-white Concentric steering solenoid valve
06 Blue Right turn signals
07 Blue-black Left turn signals
08 Yellow-grey Forward running solenoid valve
09 Black Negative power supply
10 Red Positive power supply
Page 52
GROUP OF WHITE WIRES
01 Green-black High beams
02 Grey-black Low beams
03 White N° 3 Thermo-starter
04 Black-red N° 2 Services
05 Yellow-violet Starting
06 Grey-red Battery charge light
07 Grey Low engine oil pressure light
09 Green Rear suspensions active
10 White-black Engine water temperature light
Page 53
TABLE N°1
Page 54
TABLE N°2
Page 55
TABLE N°3
Page 56
TABLE N°4
Page 57
TABLE N°5
Page 58
TABLE N°6
Page 59
TABLE N°7
Page 60
TABLE N°8
Page 61
TABLE N°9
Page 62
TABLE N°10
Page 63
TABLE N°11
Page 64
TABLE N°12
Page 65
TABLE N°13
Page 66
TABLE N°14
Page 67
INPUT connectors

Connector M1
M1-01 Blue-green ø 0,5 Extended and lowered stabilizers

M1-02 Orange ø 0,5 Extension limitation proximity
M1-03 Yellow-blue ø 0,5 Up limitation proximity
Connector M2

M2-05 ------------------------ ------------------------------------------------------

Page 68

OUTPUT connectors

Connector M6

Page 69
32-PIN COUPLING CONNECTION TO BOX WITH SOFTWARE
N° CABLE COLOUR DESCRIPTION DESTINATION

01 ............................. ......................................................................... .................................
02 Green-white Lifting by cab manipulators no. 02 connector M3
03 Azure-white Tilting by cab manipulators no. 01 connector M3
04 White-yellow Rotation by cab manipulators no. 05 connector M3
05 Grey-blue Optional by cab manipulators no. 03 connector M3
06 Orange-white Extension 3 by cab manipulators no. 06 connector M3
07 Pink-yellow Extension 1 by cab manipulators no. 07 connector M3
08 Grey-white Extension 2 by cab manipulators no. 04 connector M3
09 Brown Engine stop no. 08 connector M6
10 Yellow-violet Cage start-up no. 10 24-pin coupling
11 Violet Cage buzzer no. 11 24-pin coupling
12 Grey-black Anti-tipping signal no. 04 connector M2
13 Yellow-blue Emergency key no. 12 connector M1
14 White no. 9 Rear axle lock-out no. 04 connector M1
15 Blue-green Extended and lowered stabilisers no. 01 connector M1
16 Violet-black Rear axle locked blinking lamp no. 11 connector M6
17 Orange-blue no. 4 Manipulator stabiliser return signal no. 06 connector M1
18 Grey no. 44 Manipulator stabiliser extended signal no. 05 connector M1
19 Orange-blue stabiliser return solenoid valve no. 01 connector M6
20 Grey no. 4 Stabiliser general solenoid valve no. 02 connector M6
21 White-grey Danfoss solenoid valve power supply no. 09-10 + diodes
relay command (+ diodes) connector M6
22 Yellow-red Electronic pendulum no. 09 connector M1
23 Orange-red Extension limit proximity no. 02 connector M1
24 Light blue-white Rise limit proximity no. 03 connector M1
25 Red Rotation speed reduction solenoid valve no. 04 connector M6
26 Green Lifting solenoid valve no. 02 connector M5
27 Blue Swinging solenoid valve no. 01 connector M5
28 Yellow Rotation solenoid valve no. 05 connector M5
29 White Optional solenoid valve no. 03 connector M5
30 Orange Extension 3 solenoid valve no. 06 connector M5
31 Pink Extension 1 solenoid valve no. 07 connector M5
32 Grey Extension 2 solenoid valve no. 04 connector M5
Gnd Black ø2.5 Ground In common with Gnd 10-
pin, 24-pin couplings and
no. 01 connector MA
Page 70

01 Red-black ø1.5 Positive power supply for software no. 02 connector MA
02 Red-black ø1.5 Positive power supply for common relay board no. 12 connector M6
03 Red-black ø1.5 Positive power supply for cage commands no. 01 24-pin coupling
04 Red-black Positive power supply for saddle proximity no. 20 24-pin coupling
05 .......................... ......................................................................... .................................
06 Grey-red Signal for anti-tipping system configuration no. 03 connector M6
07 White-green Pendulum tripped with stabilisers extended no. 05 connector M6 e
(2 pieces) and lowered no. 14 24-pin coupling
08 Green Rise operating exclusion microswitch no. 06 connector M2
09 .......................... ......................................................................... .................................
10 Orange-green Cab manipulator microswitches no. 07 connector M1
no. 01 connector MA
N° COLORE CAVO DESCRIPTION DESTINATION

01 Red-black ø 1.5 Cage positive power supply no. 03 10-pin coupling
02 Green-black Lifting by cage manipulator no. 02 connector M4
03 Pink-black Extension 1 by cage manipulator no. 07 connector M4
04 Grey-black Extension 2 by cage manipulator no. 04 connector M4
05 Yellow-black Rotation by cage manipulator no. 05 connector M4
06 Blue-black Swinging 2 by cage manipulator no. 01 connector M4
07 Orange-black Extension 3 by cage manipulator no. 06 connector M4
08 White-black Optional by cage manipulator no. 03 connector M4
09 Brown-white Cage engine stop command no. 02 connector M2
10 Yellow-violet Cage ignition no. 10 32-pin coupling
12 Orange-blue Cage manipulator microswitch no. 08 connector M1
13 Orange-red Cage operation enabling signal button no. 01 connector M2
14 White-green Pendulum tripped with stabilisers ext./low. no. 07 10-pin coupling
15 Yellow-brown Cage tilting movement solenoid valve no. 06 connector M6
16 Red-green Anomaly red lamp no. 07 connector M6
17 Violet-white Cage present proximity no. 11 connector M1
18 Yellow-grey 23 mt cage inserted signal no. 03 connector M2
19 Yellow-green 23 mt cage resting saddle proximity no. 10 connector M1
20 Red-black ø1.5 Positive power supply for saddle proximity no. connector M6
21 .......................... ......................................................................... .................................
22 .......................... ......................................................................... .................................
23 .......................... ......................................................................... .................................
24 .......................... ......................................................................... .................................
no. 01 connector MA
Page 71
Page 72
R1 R4 R5 R6 R12 R11 K1 K3 K5 K7 K9
OOOOOOOOOOOO
M1
M MMM MMM MM M M M
1 1 1 1 1 1 1 1 1 1 1 1
0 0 0 0 0 0 0 0 0 1 1 1
1 2 3 4 5 6 7 8 9 0 1 2
2nd Version
R2 R3 R7 R8 R9 R10 K2 K4 K6 K8 K10
K11
POWER SUPPLY

MA M2 M3 M4 M5 M6

N 1 2 2 2 2 2 2 3 3 3 3 3 3 3 4 4 4 4 4 4 4 5 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6 6 6 6
V 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1
1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 0 1 2
MM
A A
I I
0 0
1 2
ELECTRICITY
ELECTRICITY

R = 12V control
✷ ✷
R1 R4 R5 R6 R12 R11 K1 K3 K5 K7 K9
OOOOOOOOOOOO
M1
✷ ✷
R2 R3 R7 R8 R9 R10 K2 K4 K6 K8 K10
K11
2nd Version
ALIMENTATION

MA M2 M3 M4 M5 M6
LEGEND
Page 73
M6
1
2
M
I
OOOOOOOOOOOO
1
1
K11
M
I
1
0
M
I
platform.
6 6
0 0
8 9
MM
I I
Engine stop
6 6 6
0 0 0
5 6 7
MMM
I I I
Red fault light
K10
K9

6 6 6
0 0 0
2 3 4
MMM
I I I
K7
K8
M
6
0
1
I
K6
K5
M5
K3
K4
OOOOOOO
5 5 5
0 0 0
5 6 7
MMM
DANFOSS
I I I
MMM
K1
K2
5 5 5
0 0 0
2 3 4
I I I
R10
R11
0
1
I
M4
R12
MANIPULATEUR
R9
OOOOOOO
4 4 4
0 0 0
5 6 7
MMM
Extension 1
NACELLE
I I I
Extension 3
R8
R6
Slewing
4 4 4
0 0 0
2 3 4
MMM
Extension 2
I I I
Optional
R7
R5
Lifting
M
Tilting
4
0
1
I
R4
R3
MANIPULATEUR
M3
R1
R2
OOOOOOO
Extension 1
3 3 3
0 0 0
5 6 7
MMM
I I I
CABINE
Extension 3
Slewing
M1
3 3 3
0 0 0
2 3 4
MMM
Extension 2
I I I
Optional
1
1
2
M
OOOOOOOOOOOO
Lifting
I
Saving key
1
1
1
M

I
0
1
I

1
1
0
M
Electronic telltale
1 1
0 0
8 9
MM
I I

M2

1 1 1
0 0 0
5 6 7
MMM
I I I

OOOOOO
0 0
5 6
MM

2 2
I I

Rear axle lock
MMM
0 0 0
2 3 4
MMM
Anti-overturning
1 1 1
0 0 0
2 3 4
2 2 2
I I I
I I I

M

1
0
1
0
1
I
I
LAMPS
GREEN AND RED
ALIMENTATION
MA
OO
MM
G +
A A
N 1
D 2
V
0 0
1 2
I I
Page 74
OR
CONNECTION
OR
RELAY
Page 75
CONNECTION .
ON ... ...
OR .
.
... ...
STABILIZERS LIFTED
.
... ...
.
... ...
.
... ...
REAR AXLE LOCKED
.
... ...
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
... ...
.
... ...
.
... ...
.
... ...
Page 76
CONNECTION .
ON ... ...
OR .
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
K6 .
... ...
.
EXECUTED
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
REAR AXLE FREE
Page 77
Page 78

Page 79
INVERTED
NUMBERING
Page 80

Page 81
Page 82
ELECTRICITY
RELAY COIL CONTROLS

2nd Version

Page 83
FRONT AXLE ALIGNEMENT
REAR AXLE ALIGNEMENT

DIRECTION SELECTOR
YELLOW LIGHT
GREEN LIGHT
PARKING LIGHT GREEN LIGHT
AVAILABLE BLUE LIGHT

RESET TRANSMISSION

BLOCK FLASHING YELLOW
LIGHT
INCLINATION RED LIGHT
TURRET BLOCK GREEN LIGHT
TURRET ALIGNEMENT GREEN

LIGHT
OUTRIGGERS RETRACTED
GREEN LIGHT
OUTRIGGERS OUT AND
LOWERED GREEN LIGHT
PAT SYSTEM
CONTACT KEY
IGNITION AND
LIGHT SWITCH CONTROL
GEAR SPEED REVERSE
LEVER
Page 84
LEFT FRONT RIGHT FRONT
OUTRIGGER OUTRIGGER
OUTRIGGERS
BASKET SAFETY KEY CONTROL LEVER
ELECTRICITY
LIFTED LOWERED OR
TELESCOPED OUTRIGGERS
SELECTOR
RIGHT REAR
OUTRIGGER
2nd Version
LEFT REAR
OUTRIGGER
PAT SYSTEM
EXCLUSION KEY
Page 85
HYDRAULIC SYSTEM
LP EXCLUSION
Page 86
DANFOSS MANIPULATOR MANIPULATOR
SELECTOR
T1-T3-ACCESSORY
DANFOSS MANIPULATOR
PARKING BRAKE
TRANSMISSION
2nd Version
SECTION
MICROSWITCH
HYDRAULIC
MOVEMENT
EXCLUSION
MICROSWITCH
ELECTRICITY
RETRACTED ARM
ELECTRIC
ELECTRICITY
0.8 M HIGH ARM

BLOCKED TOWER
MICROSWITCH
PROXIMITY INDICATOR
2nd Version
✷ PENDULUM
LEVELLING
RESTING ON
GROUND
MICROSWITCH

Page 87
Page 88

2nd Version
ELECTRICITY

FUSE AND RELAY BOX
➠
1 2 3 4 5 6 7 8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28
E1 E2 E3 E4 E5
E11
➩
E6 E7 E8 E9 E10 ➩
Page 91


F4 10 Beacon
F5 15 Available

F20 15 Logic + cage
F22 7.5 Available
F23 10 Available
F24 15 Available
F27 5 Available
F28 Diode Reverse


E7 ....................... ...................................
E8 ....................... ...................................
E9 ....................... ...................................
E10 ....................... ...................................
Page 92
E1 2
E 13 E 14 E 15 E 16 E 17 E 18 E 19 E 20
F 29
10
10
10
10
10
10
10
10
F30 F31 F32 F33 F34 F35 F36 F37
C1
E12) Ignition relay

E14) Low beam relay
E16) Services relay
E20) 55° suspension lock relay
F36) Fuse 10 A : Front truck ignition power supply
F37) Fuse 10 A : Rear truck ignition power supply
Page 93

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
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)
F20 . Fuse 15 A : Board with logic + cage (Tab. 11)
Page 94

F28 . Diode 3 A : Available(Tab. 2)
F36 . Fuse 10 A : Front truck ignition power supply (Tab. 2)
F37 . Fuse 10 A : Rear truck ignition power supply (Tab. 2)
Page 95

I 61 . 55° lifting PNP proximity (Tab. 14)
Page 96

ST1. Anti-tipping system (Tab. 12)
ST2. Fuel level instrument (Tab. 5)
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
Page 97
GROUP OF BROWN WIRES
01 Brown-white Outriggers retracted light
02 Green-blue Outrig. exten. pressure switch micro
03 Grey-blue Right front outrigger solenoid valve
04 Orange-blue Retraction solenoid valve
05 Yellow-blue Left rear outrigger arm solenoid valve
06 Pale blue-yellow Right rear outrigger arm solenoid valve
07 Orange-black Right front outrigger arm solenoid valve
08 Yellow-red Right rear outrigger solenoid valve
09 Orange-red Left rear outrigger solenoid valve
10 Orange Left front outrigger arm solenoid valve
GROUP OF GREY WIRES
01 Blue-red Left front outrigger solenoid valve
03 Pink-black Fuel reserve light
04 Grey N° 4 General outrigger solenoid valve
05 Yellow-green Slow-fast enabling
06 Violet-black Rear axle alignment light
07 Grey-white Hydr. circuit inhibiting solenoid valve
08 Yellow-brown Reverse running solenoid valve
09 White-green Start enabling
10 Violet Proximity 55°
GROUP OF BLACK WIRES
01 White Parking lights
02 Grey-green Air filter clogged light
03 Violet-white Front axle alignment light
04 Green-white Crabwise steering solenoid valve
05 Green-white Concentric steering solenoid valve
06 Blue Right turn signals
07 Blue-black Left turn signals
08 Yellow-grey Forward running solenoid valve
09 Black Negative power supply
10 Red Positive power supply
Page 98
GROUP OF WHITE WIRES
01 Green-black High beams
02 Grey-black Low beams
03 White N° 3 Thermo-starter
04 Black-red N° 2 Services
05 Yellow-violet Starting
06 Grey-red Battery charge light
07 Grey Low engine oil pressure light
09 Green Rear suspensions active
10 White-black Engine water temperature light
Page 99
TABLE N°1
Page 100
TABLE N°2
Page 101
TABLE N°3
Page 102
TABLE N°4
Page 103
TABLE N°5
Page 104
TABLE N°6
Page 105
TABLE N°7
Page 106
TABLE N°8
Page 107
TABLE N°9
Page 108
TABLE N°10
Page 109
TABLE N°11
Page 110
TABLE N°12
Page 111
TABLE N°13
Page 112
TABLE N°14
Page 113
INPUT connectors

Connector M1

Connector M2

M2-05 ------------------------ ------------------------------------------------------

Page 114

OUTPUT connectors

Connector M6

Page 115

01 ............................. ......................................................................... .................................
no. 01 connector MA
Page 116

05 .......................... ......................................................................... .................................
09 .......................... ......................................................................... .................................
no. 01 connector MA

21 .......................... ......................................................................... .................................
22 .......................... ......................................................................... .................................
23 .......................... ......................................................................... .................................
24 .......................... ......................................................................... .................................
no. 01 connector MA
Page 117
Page 118
R1 R4 R5 R6 R12 R11 K1 K3 K5 K7 K9
OOOOOOOOOOOO
M1
M MMM MMM MM M M M
1 1 1 1 1 1 1 1 1 1 1 1
0 0 0 0 0 0 0 0 0 1 1 1
1 2 3 4 5 6 7 8 9 0 1 2
2nd Version
R2 R3 R7 R8 R9 R10 K2 K4 K6 K8 K10
K11
POWER SUPPLY

MA M2 M3 M4 M5 M6

N 1 2 2 2 2 2 2 3 3 3 3 3 3 3 4 4 4 4 4 4 4 5 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6 6 6 6
V 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1
1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 0 1 2
MM
A A
I I
0 0
1 2
ELECTRICITY
ELECTRICITY

R = 12V control
✷ ✷
R1 R4 R5 R6 R12 R11 K1 K3 K5 K7 K9
OOOOOOOOOOOO
M1
✷ ✷
R2 R3 R7 R8 R9 R10 K2 K4 K6 K8 K10
K11
2nd Version
ALIMENTATION

MA M2 M3 M4 M5 M6
LEGEND
Page 119
M6
1
2
M
I
OOOOOOOOOOOO
1
1
K11
M
I
1
0
M
I
platform.
6 6
0 0
8 9
MM
I I
Engine stop
6 6 6
0 0 0
5 6 7
MMM
I I I
Red fault light
K10
K9

6 6 6
0 0 0
2 3 4
MMM
I I I
K7
K8
M
6
0
1
I
K6
K5
M5
K3
K4
OOOOOOO
5 5 5
0 0 0
5 6 7
MMM
DANFOSS
I I I
MMM
K1
K2
5 5 5
0 0 0
2 3 4
I I I
R10
R11
0
1
I
M4
R12
MANIPULATEUR
R9
OOOOOOO
4 4 4
0 0 0
5 6 7
MMM
Extension 1
NACELLE
I I I
Extension 3
R8
R6
Slewing
4 4 4
0 0 0
2 3 4
MMM
Extension 2
I I I
Optional
R7
R5
Lifting
M
Tilting
4
0
1
I
R4
R3
MANIPULATEUR
M3
R1
R2
OOOOOOO
Extension 1
3 3 3
0 0 0
5 6 7
MMM
I I I
CABINE
Extension 3
Slewing
M1
3 3 3
0 0 0
2 3 4
MMM
Extension 2
I I I
Optional
1
1
2
M
OOOOOOOOOOOO
Lifting
I
Saving key
1
1
1
M

I
0
1
I

1
1
0
M
Electronic telltale
1 1
0 0
8 9
MM
I I

M2

1 1 1
0 0 0
5 6 7
MMM
I I I

OOOOOO
0 0
5 6
MM

2 2
I I

Rear axle lock
MMM
0 0 0
2 3 4
MMM
Anti-overturning
1 1 1
0 0 0
2 3 4
2 2 2
I I I
I I I

M

1
0
1
0
1
I
I
LAMPS
GREEN AND RED
ALIMENTATION
MA
OO
MM
G +
A A
N 1
D 2
V
0 0
1 2
I I
Page 120
OR
CONNECTION
OR
RELAY
Page 121
CONNECTION .
ON ... ...
OR .
.
... ...
STABILIZERS LIFTED
.
... ...
.
... ...
.
... ...
REAR AXLE LOCKED
.
... ...
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
... ...
.
... ...
.
... ...
.
... ...
Page 122
CONNECTION .
ON ... ...
OR .
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
K6 .
... ...
.
EXECUTED
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
REAR AXLE FREE
Page 123
Page 124

Page 125
INVERTED
NUMBERING
Page 126

Page 127
Page 128
ELECTRICITY
RELAY COIL CONTROLS

2nd Version

Page 129

DIRECTION SELECTOR
YELLOW LIGHT
GREEN LIGHT

RESET TRANSMISSION

LIGHT

LIGHT
GREEN LIGHT
OUTRIGGERS OUT AND
LOWERED GREEN LIGHT
PAT SYSTEM
CONTACT KEY
IGNITION AND
GEAR SPEED REVERSE
LEVER
Page 130
OUTRIGGER OUTRIGGER
OUTRIGGERS
ELECTRICITY
LIFTED LOWERED OR
SELECTOR
RIGHT REAR
OUTRIGGER
2nd Version
LEFT REAR
OUTRIGGER
PAT SYSTEM
EXCLUSION KEY
Page 131
HYDRAULIC SYSTEM
LP EXCLUSION
MANIPULATOR
Page 132
DANFOSS MANIPULATOR
SELECTOR
T1-T3-ACCESSORY
DANFOSS MANIPULATOR
PARKING BRAKE
TRANSMISSION
2nd Version
SECTION
MICROSWITCH
HYDRAULIC
MOVEMENT
EXCLUSION
MICROSWITCH
ELECTRICITY
RETRACTED ARM
ELECTRIC
ELECTRICITY
0.8 M HIGH ARM

BLOCKED TOWER
MICROSWITCH
PROXIMITY INDICATOR
2nd Version
✷ PENDULUM
LEVELLING
RESTING ON
GROUND
MICROSWITCH

Page 133
Page 134

2nd Version
ELECTRICITY
FUSE AND RELAY BOX
➠
1 2 3 4 5 6 7 8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28
E1 E2 E3 E4 E5
E11
➩
E6 E7 E8 E9 E10 ➩
Page 137


F4 10 Beacon
F5 15 Available

F20 15 Logic + cage
F22 7.5 Available
F23 10 Available
F24 15 Available
F27 5 Available
F28 Diode Reverse


E7 ....................... ...................................
E8 ....................... ...................................
E9 ....................... ...................................
E10 ....................... ...................................
Page 138
E 12
E 13 E 14 E 15 E 16 E 17 E 18 E 19 E 20 E 21
F 29
10
10
10
10
10
10
10
5
F 30 F 31 F 32 F 33 F 34 F 35 F 36 F 37
C1
E12) Ignition relay

E14) Low beam relay
E16) Services relay
E20) 55° suspension lock relay
E21) Antioverturning system and logic alimentation relay
F36) Fuse 10 A : Truck ignition power supply
F37) Fuse 10 A : Antioverturning system + software alimentation
Page 139

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)
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


Page 140

F20 . Fuse 15 A : Relay alimentation of the board with logic + 23 mt cage (Tab. 11)
F27 . Fuse 5 A : Direct alimentation available (Tab. 3)
F28 . Diode 1 A : Reverse gear (Tab. 2)
F36 . Fuse 10 A : Truck ignition power supply (Tab. 2)
F37 . Fuse 10 A : Antioverturning system + software alimentation (Tab. 2)
Page 141

I 61 . 55° lifting PNP proximity (Tab. 14)
I62 . Optional switch from the cage (Tab. 12)
Page 142

Page 143

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)
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
Page 144
Nº CORRISP. COLORE DESCRIZIONE RIF. POSIZIONE

001 Brown-white Outriggers retracted light 10/9
002 Green-blue sec.0,5 Outrig. exten. pressure switch micro 6/5
003 Grey-blue Right front outrigger solenoid valve 9/4
004 Orange-blue Outriggers retraction solenoid valve 8/14
005 Yellow-blue Left rear outrigger arm solenoid valve 9/7
006 Pale blue-yellow Right rear outrigger arm solenoid valve 9/11
007 Orange-black Right front outrigger arm solenoid valve 9/3
008 Yellow-red Right rear outrigger solenoid valve 9/12
009 Orange-red Left rear outrigger solenoid valve 9/8
010 Orange Left front outrigger arm solenoid valve 8/15
011 Blue-red Left front outrigger solenoid valve 8/17
012 Pink sec. 0,5 Fuel level instrument 5/7
013 Pink-black sec. 0,5 Fuel reserve light 5/6
014 Grey n.4 General outrigger solenoid valve 8/12
015 Yellow-green Slow-fast enabling signal 2/6
016 Violet-black sec. 0,5 Rear axle alignment light 2/11
017 Grey-white Hydr. circuit inhibiting solenoid valve 6/14
018 Yellow-brown Reverse running solenoid valve 2/6
019 White-green sec. 0,5 Start enabling 1/11
020 Violet n.7 Proximity 55° 14/12
021 White Parking lights 3/3
022 Grey-green sec. 0,5 Air filter clogged light 5/9
023 Violet-white sec. 0,5 Front axle alignment light 2/15
024 Green-white Crabwise steering solenoid valve 4/17
025 Green-white Concentric steering solenoid valve 4/17
026 Blue Right turn signals 3/15
027 Blue-black Left turn signals 3/16
028 Yellow-grey Forward running solenoid valve 2/4
029 Green-black sec. 0,5 Relay control high beams 3/9
030 Grey-black sec. 0,5 Relay control low beams 3/7
031 White n.3 Relay control thermo-starter 1/16
032 Black-red n.2 Relay control services 2/18
033 Yellow-violet Relay control starting 1/10
034 Grey-red sec. 0,5 Battery charge light 1/4
035 Grey sec. 0,5 Low engine oil pressure light 5/11
036 Brown Engine stop 7/14
037 Green Rear suspensions active 6/8
038 White-black sec. 0,5 Engine water temperature light 5/13
039 ----------------------- ----------------------------------------- ----
040 ----------------------- ----------------------------------------- ----
041 Green-black sec. 2,5 Negative power supply for logic and pat 12/12
042 Yellow sec. 2,5 Positive power supply for logic and pat 12/10
043 Black sec. 10,0 Negative power supply ----
044 Brown sec. 10,0 Positive power supply 1/11
Page 145
TABLE N°1
Page 146
TABLE N°2
Page 147
TABLE N°3
Page 148
TABLE N°4
Page 149
TABLE N°5
Page 150
TABLE N°6
Page 151
TABLE N°7
Page 152
TABLE N°8
Page 153
TABLE N°9
Page 154
TABLE N°10
Page 155
TABLE N°11
Page 156
TABLE N°12
Page 157
TABLE N°13
Page 158
TABLE N°14
Page 159
INPUT connectors

Connector M1

Connector M2

M2-05 ------------------------ ------------------------------------------------------

Page 160

OUTPUT connectors

Connector M6

Page 161

01 ............................. ......................................................................... .................................
no. 01 connector MA
Page 162

05 .......................... ......................................................................... .................................
09 .......................... ......................................................................... .................................
no. 01 connector MA

21 .......................... ......................................................................... .................................
22 .......................... ......................................................................... .................................
23 .......................... ......................................................................... .................................
24 .......................... ......................................................................... .................................
no. 01 connector MA
Page 163
Page 164
K11
R2 R3 R6 R8 R10 R12
OOOOOOOOOOOO K2 K4 K6 K8 K10
M1
M MMM MMM MM M M M
1 1 1 1 1 1 1 1 1 1 1 1
0 0 0 0 0 0 0 0 0 1 1 1
1 2 3 4 5 6 7 8 9 0 1 2
2nd Version
R1 R4 R5 R7 R9 R11
K1 K3 K5 K7 K9
POWER SUPPLY

MA M2 M3 M4 M5 M6

N 1 2 2 2 2 2 2 3 3 3 3 3 3 3 4 4 4 4 4 4 4 5 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6 6 6 6
V 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1
1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 0 1 2
MM
A A
I I
0 0
1 2
ELECTRICITY
ELECTRICITY

R = 12V control K11
✷ ✷ ✷
R2 R3 R6 R8 R10 R12
OOOOOOOOOOOO K2 K4 K6 K8 K10
M1
✷
R1 R4 R5 R7 R9 R11
K1 K6 K5 K7 K9
2nd Version
ALIMENTATION

MA M2 M3 M4 M5 M6
LEGEND
Page 165
M6
K11
K10
1
2
M
I
OOOOOOOOOOOO
K9
1
1
M
I
1
0
M
I
platform.
6 6
0 0
8 9
MM
K8
K7
I I
Engine stop
6 6 6
0 0 0
5 6 7
MMM
I I I
Red fault light
K5
K6

6 6 6
0 0 0
2 3 4
MMM
I I I
K4
K3
M
6
0
1
I
K2
K1
M5
OOOOOOO
5 5 5
0 0 0
5 6 7
MMM
DANFOSS
I I I
MMM
5 5 5
0 0 0
2 3 4
I I I
R12

R11
0
1
I
M4
R10
MANIPULATEUR
R9
OOOOOOO
4 4 4
0 0 0
5 6 7
MMM
Extension 1
NACELLE
I I I
Extension 3
R7
R8
Slewing
4 4 4
0 0 0
2 3 4
MMM
Extension 2
I I I
Optional
R5
R6
Lifting
M
Tilting
4
0
1
I
R3
R4
MANIPULATEUR
M3
R2
R1
OOOOOOO
Extension 1
3 3 3
0 0 0
5 6 7
MMM
I I I
CABINE
Extension 3
Slewing
M1
3 3 3
0 0 0
2 3 4
MMM
Extension 2
I I I
Optional
1
1
2
M
OOOOOOOOOOOO
Lifting
I
Saving key
1
1
1
M

I
0
1
I

1
1
0
M
Electronic telltale
1 1
0 0
8 9
MM
I I

M2

1 1 1
0 0 0
5 6 7
MMM
I I I

OOOOOO
0 0
5 6
MM

2 2
I I

Rear axle lock
MMM
0 0 0
2 3 4
MMM
Anti-overturning
1 1 1
0 0 0
2 3 4
2 2 2
I I I
I I I

M

1
0
1
0
1
I
I
LAMPS
GREEN AND RED
ALIMENTATION
MA
OO
MM
G +
A A
N 1
D 2
V
0 0
1 2
I I
Page 166
OR
CONNECTION
OR
RELAY
Page 167
CONNECTION .
ON ... ...
OR .
.
... ...
STABILIZERS LIFTED
.
... ...
.
... ...
.
... ...
REAR AXLE LOCKED
.
... ...
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
... ...
.
... ...
.
... ...
.
... ...
Page 168
CONNECTION .
ON ... ...
OR .
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
K6 .
... ...
.
EXECUTED
.
... ...
.
... ...
.
... ...
.
... ...
.
... ...
REAR AXLE FREE
Page 169
Page 170

Page 171
INVERTED
NUMBERING
Page 172

Page 173
Page 174
ELECTRICITY
RELAY COIL CONTROLS

2nd Version

Page 175

DIRECTION SELECTOR
YELLOW LIGHT
GREEN LIGHT

RESET TRANSMISSION

LIGHT

LIGHT
GREEN LIGHT
OUTRIGGERS OUT AND
LOWERED GREEN LIGHT
PAT SYSTEM
CONTACT KEY
IGNITION AND
GEAR SPEED REVERSE
LEVER
Page 176
OUTRIGGER OUTRIGGER
OUTRIGGERS
ELECTRICITY
LIFTED LOWERED OR
SELECTOR
RIGHT REAR
OUTRIGGER
2nd Version
LEFT REAR
OUTRIGGER
PAT SYSTEM
EXCLUSION KEY
Page 177
HYDRAULIC SYSTEM
LP EXCLUSION
MANIPULATOR
Page 178
DANFOSS MANIPULATOR
SELECTOR
T1-T3-ACCESSORY
DANFOSS MANIPULATOR
PARKING BRAKE
TRANSMISSION
2nd Version
SECTION
MICROSWITCH
HYDRAULIC
MOVEMENT
EXCLUSION
MICROSWITCH
ELECTRICITY
RETRACTED ARM
ELECTRIC
ELECTRICITY
0.8 M HIGH ARM

BLOCKED TOWER
MICROSWITCH
PROXIMITY INDICATOR
2nd Version
✷ PENDULUM
LEVELLING
RESTING ON
GROUND
MICROSWITCH

Page 179
Page 180

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
SAFETY SYSTEM
Page 2
6 5
DA 313
DA 313
4
DA 313 DA 313 3
2
PAT DS 100
DS 100
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
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 di-
rectly from the sensors on the lifting and compensation cylinder.
The display provides the operator with information about many important functions for us-
ing the machine correctly, and specifically:
DISPLAY DIAGRAM
Capacity indication Tilting lamp
with progressive bars 90% 100%
CODE RAD = Working
radius in metres
SWL = Maximum LOAD = Load on ANG. = Arm LNG = Arm

load indication the forks angle in degrees length in metres
from the diagram
Tilting lamp Lamp on Lamp on

STOP wheels stabiliz.
at 90%
Movements
blocked
2 1
Selector for 3
type of 4
equipment 5
6
- SWL (Diagram of allowable loads under all conditions).

- LOAD (Real load applied on the equipment).
- ANG (Arm angle in degrees).
- LNG (Length of the extensions).
- LED BARS (Percentage of the weight).
- RAD (Work radius; from the centre of the tower to the centre of the load).
- CODE (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 EQUIPMENT ON DIAGRAM ON PROGRAM

INSTRUMENT THE TS CODE
PANEL
EXTENSION-DOWN ARM
POSITION AND STOPPED ARM UP
1 FORKS STAB. 360° 001 101

" GOMME FRONTALI (*) 020 120
" WHEELS 360° 021 121
2
3 HOIST 3 TON. STAB. 360° 003 103
" FRONT WHEELS (*) 023 123
4 HOIST 4 TON. STAB. 360° 004 104
5 HOIST 5 TON. STAB. 360° 005 105
6 TRELLIS JIB P600 STAB. 360° 006 106
(*) - Rotation lock pin inserted
C 57
RADIUS IN METERS
Page 4
REPLACING EPROM MEMORY DATA
- Open the DISPLAY by loosening the fastening screws (Detail 1 - Photo A). Photo. A
The DISPLAY will open into two parts (Photo B).
- Remove the EPROM (Detail 1 - Photo B) making

sure to note the assembly direction (see the grooves
Detail 2 - Photo B).
- Replace it exactly by reversing the operation, making C 58

sure not to bend the contacts.
☞ 1
Photo B
2
➛
➛
1
SERIAL NO. ......................
DATE ..................................
C 59
MRT 1540
Page 5
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 bot-
tom 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.
4 2 1
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.
C 60 1
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
5) ARM LENGTH SIGNAL SENSOR

Photo A
The length sensor is a multiple-turn potentiometer, con-
nected 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 1
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)
Photo B
- 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 effi-
ciently
POTENTIOMETER DISASSEMBLY
C 62
- 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 1 ☞
RE-ASSEMBLY
- Connect the electric wires
- Insert the potentiometer referring to the mandatory posi-
tion notch Photo C
- Tighten the fastening nut
- Insert the gears into their seat
- Replace the stop support
☞
1
C 63
Page 7
CONNECTOR INSIDE THE WINDER
Posit.
▲
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 1
2 2
3 3
4 4
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
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
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.
Page 10
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
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”
rod side, lifting cylinder”.

Error n° “E14”
Error: Fallen below lower limit value for the measuring channel “Compensation
lenght”.

Page 11
Error n° “E15”
Error: Fallen below lower limit value for the measuring channel “angle main boom”.
b. Angle sensor is 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”.

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.
Elimination: a. Turn the potentiometer into admissible adjudting range.

b. Replace main board.
Page 12
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.

Error n° “E22”
Error: Upper limit value for the measuring channel “pressure transducer piston side,
lifting cylinder ” exceeded.

Page 13
Error n° “E23”
Error: Upper limit value for the measuring channel “pressure transducer rod side, lif-
ting cylinder” exceeded.

Error n° “E24”
Error: Upper limit value for the measuring channel “Compensation lenght ” exceeded.

Error n° “E25”
Error: Upper limit value for the measuring channel “Main boom angle” exceeded.

Page 14
Error n° “E26”
Error: Upper limit value for the measuring channel “Lifting angle” exceeded.

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.
Elimination: a. Turn the potentiometer into admissible adjudting range.

b. Replace main 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
Page 15
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.
Page 16
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.
Page 17
PAT DS 50
Manitou
MRT 1540
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 maxi-
mum allowable values stored inside the main memory. This memory includes the system pro-
gram, 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 meas-
urements. 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.
Page 20
INSTALLATION
Length sensor 67 152 06 0002
Central unit 24 050 06 0003
Instrument panel 50 050 06 0001
Lifting cylinder
2 4
Quadruple
pressure
sensor
44 313 06 0004
1 3
Page 21
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
Page 22
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
Page 23
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 connec-
tions such as to the series interface, analog extension, portable terminal and the connection
board.
Analog ground Portable terminal connection
Angle sensor X5 to insert for the operator on line

connection
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
Page 24
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
Load indicator
MP 4 pressure 4 recording
Pressure sensor X3 input

pressure 2
X4 input
pressure 3
X5 input
pressure 4
Page 25
INSTRUMENT PANEL 50 050 06 0001
Authorised work conditions led Selector
Overload warning led Instrument
Overload led red
Load indicator yellow
Accessory green
selector
1 Forks
2 Basket Module
3 Hoist
4 Jib P600/PT600
Terminal board
Lamp
Lamp
Lamp
Page 26
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
1 + Ub DMS
Cable gland 2 + Signal DMS 3
3 - Signal DMS 3
4 + Signal DMS 4
5 - Signal DMS 4
6 Ground
Page 27
PRESSURE SENSOR OUTPUT SIGNALS
Error Motherboard
Work area Lifting cylinder

bottom side
Error
MP 1 Analog
extension
Error
Lifting cylinder
Work area stem side
Error MP 3
Analog
extension
Error
Compensation cylinder
Work area bottom side
Error MP 4
Analog
extension
Error
compensation cylinder
Work area stem side
Error
Page 28
LENGTH SENSOR 67 152 06 0002
The length sensor consists of a spring-loaded cable winder. As an option it is possible to in-
stall 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.
Page 29
Page 30
Page 31
Page 32
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: 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.
Page 33
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”.
c. Electronic board in the measuring channeldefective.
Elimination: a. Check cable and connectors as well and repace, if necessary.

Error n° “E12”
piston side, lifting cylinder”.

Page 34
Error n° “E13”
rod side, lifting cylinder”.

Error n° “E14”
piston side, compensation cylinder”.

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”
rod side, compensation cylinder”.
Page 35

Error n° “E21”
Error: Upper limit value for the measuring channel “lenght telescopic boom” exceeded.

Error n° “E22”
lifting cylinder” exceeded.

Error n° “E23”
Error: Upper limit value for the measuring channel “pressure transducer rod side, lif-
ting cylinder” exceeded.

Page 36
Error n° “E24”
compensation cylinder” exceeded.

Error n° “E26”
Error: Upper limit value for the measuring channel “pressure transducer rod side,
compensation cylinder” exceeded.

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) The processor board is defective.

b) System program EPROM.
c) Processor 80C537 defective.
Elimination: a) Replace the processor board

b) Replace system program EPROM
c) Replace Processor 80C537.
Page 37
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.


Error n° “E48”
Error: At cyclic RAM test:Error in the internal 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.

Page 38
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.

c. Replace processor board.
Page 39

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UNIT 80

PROXIMITY SWITCHES AND MICROSWITCHES

A) Operation enabling microswitch:

machine translation and to turn on the red “parking

B) Stabilizer beam microswitch

C) Retracted stabilizer proximity switch

E) Cab blocked - cab aligned microswitch

F) Danfoss distribution microswitch

FUNCTIONS = To signal the arm up operation to

G) Arm up limit switch microswitch E7

H) Retracted arm proximity switch E8

N.B. When the proximity switch is active and transmits a

I) Arm angle proximity switch E9

N.B. When the proximity switch is active and transmits a

Proximity switches and Microswitches

L) Proximity switch on rapid connector E10

M) Proximity switch on the arm saddle (Detail

N) Microswitch on door (Detail 1 - Photo E13) E14

O) Microswitch on 17 m basket (Detail 1 - Photo E15

Electric system 1st Version page 1-41

Electric system 2nd Version page 45-88

until the truck n° 120379/6132

Electric system 2nd Version page 91-134

until the truck n° 121778/6352

Electric system 2nd Version page 137-180

until the truck n° 117101/5948

The electric circuit is protected by fuses located :

INSTRUMENT PANEL FUSES

1) Fuse 7.5 A direction indicator power supply

CAB FUSE HOLDER BOX

1) Fuse 25 A available or heater glow plug power supply (if present).

ELECTRIC BOX UNDER CAB Fig. D

LEGEND FOR MRT1540 ELECTRIC PLANT USERS WITH SOFTWARE

F11 . Fuse 15A stabilizers (Tab. 8)

I44 . Active contact with 23 mt basket on (Tab. 11)

TABLE OF RELAY POSITION ON ELECTRIC DIAGRAM

MASTER ELEMENT POSITION SLAVE ELEMENT POSITION

R1 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

R2 3/18 ELEMENT OPEN 5/15

R3 3/16 ELEMENT OPEN 5/18

R4 2/18 ELEMENT OPEN 2/9

R5 8/12 ELEMENT OPEN 6/13

R6 2/16 ELEMENT OPEN 6/7

R7 6/10 ELEMENT CLOSED 9/15

R8 1/10 ELEMENT OPEN 1/5

R9 7/3 ELEMENT OPEN 7/4

BROWN CABLE GROUP

GREY CABLE GROUP

BLACK CABLE GROUP

WHITE CABLE GROUP

I52 : Braking circuit pressure switch

Power supply connector MA

MA-01 Black ø 1.5 Negative power supply

M1-01 Blue-green Extended and lowered stabilizers

M2-01 Orange-red Basket operation enabling signal button

Connector M3 analog signals from cab manipulators

M3-01 Light blue-white Tilting

Connector M4 analog signals from basket manipulator

M4-01 Blue-black Tilting