78 Xe SM

REPAIR MANUAL
MANUEL DE RÉPARATION
REPARATURANLEITUNG
MANUAL DE REPARACIÓN
MANUALE RIPARAZIONE
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MANITOU BF
Head office: 430, Rue de l’Aubinière
44150 Ancenis - FRANCE
Share capital: 39,548,949 euros
857 802 508 RCS Nantes
Tel: +33 (0)2 40 09 10 11
www.manitou.com
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GENERAL INSTRUCTIONS AND SAFETY NOTICE
TECHNICAL CHARACTERISTICS 1-1
BRAKE
FREE-WHEELING 2-1
HYDRAULIC
HYDRAULIC 3-1
ELECTRICITY
ELECTRICITY 4-1
TRANSMISSION
HYDROSTATIC 5-1
GROUPS 0
GENERAL
POINTS
0-1-M.69
TECHNICAL CHARACTERISTICS
78 XE
0-1-M.69 EN
07 / 2004
0-1-M.69
0-1-M.69
FRONT
REAR
1
CHARACTERISTICS
ELECTRIC PUMP
- Supply 24 V
- Output 3.2 KW
- Cubic capacity 4,8 cm3
- Pressure 190 bar +/- 10 bar
0-1-M.69
ELECTRICAL CIRCUIT
- Battery 4 elements, each of 6V-180 Ah

- Charger 24 V - 30 Ah
- Variator (Type) Curtis 24V - 300Ah
2
78 XE
SPECIFICATIONS
- Use Indoors
- Capacity:
- Standard platform 230 Kg including 2 people
- Extension extended 110 Kg including 1 people
0-1-M.69
- Control system Electro-hydraulic
- Lifting system Single scissors
- Platform movement speed:

- High speed 4 km/h
- High torquee 2.4 Km/h
- Time to raise/lower scissors 20 seconds on lowering
- Operating height 7760 mm

- Floor height 5760 mm
- Height with guard rails folded 1763 mm
- Overall basket size:

- Extension retracted 1670 x 768 mm
- Extension extended 2595 x 759 mm
- Floor area:
- Extension retracted 1670 x 557 mm
- Extension extended 2544 x 665 mm
- Platform weight, empty 1380 +/- 30 Kg
- No. of gears 2
- Handleadle gradient 25%
- Inclinaison, alarm activation 3,5% or 2°
- Maximum authorized wind speed 0 km/h
FRONT / REAR TYRES
DIMENSIONS TYPE LOAD PER UNDER MAX. LOAD AREA OF GROUND STAMPING
TYRE UNLOADED ON 1 WHEEL CONTACT FOR 1 WHEEL
14” x 4,5” Rubber tyre 332 kg 800 kg 75 cm2 10,7 daN/cm2
- Wheel nut tightening torque:

- Front wheels 7 DaNm
- Rear wheels 7 DaNm
WHEAL GEARED MOTORS

- Motor White hydraulics CE12255300
3
DIMENSIONS
78 XE
A 5732
B 899
0-1-M.69
C 50
D 1701
E 100
F 1765
G 809
H 82
I 995
J 2117
K 1763 Guard
folded
rails
L 1262
M 1883
N 411
O 451
P 404
Q 617
R 14.5°
Centre of gravity
Centre of gravity
4
78 XE
0-1-M.69
5
FILTER ELEMENT
0-1-M.69
DESIGNATION REFERENCE REPLACE AFTER
1 - Hydraulic oil filter cartridge 596353 900h
LUBRICANTS
COMPONENTS TO LUBRICATE CAPACITY RECOMMENDATION PACK REFERENCE
1.HYDRAULIC OIL RESERVOIR 12 Litres MANITOU hydraulic oil 20 L. 582 297

ISO 46 55 L. 546 108
209 L. 546 109
2.WHEEL MOTOR MOUNTING SHELL Retinax HD Cartridge 161 589

grease 400 Gr.
6
GROUPS 35
REAR AXLE
FREE-WHEELING 35-8-21-M.69
78 XE
35-8-21-M.69 EN
07 / 2004
35-8-21-M.69
FREE-WHEELING
- If there is a power failure or a translation problem, the machine can A

be moved over short distances, with or without using a hoist, at a
speed not exceeding 8.0 km/h.
- Open the left-hand cowl 1 (Fig. A).
35-8-21-M.69
1 4
REAR
- Unscrew the knurled rod situated on the main distributor 2 (Fig. B). B
- Push in button 3 (Fig. B) on the main distributor.
- Pump with the hand pump at the back of the frame 4 until the brakes
release (Fig. A).
- Move the machine: WARNING, if the machine is unpowered the stee-

ring does not work.
- To re-engage the brakes, screw in the wheel 2 (Fig. B); the circuit will
come into operation again when pressure is restored to the hydraulic
circuit.
3 2
Warning: when the brakes are loosened and the platform is in

free-wheeling mode, there is nothing to stop the platform from
moving. Provide chocks to check its movement.
1
REMOVING THE DISTRIBUTOR
ELEMENTS
78 XE 70-2-56-M.69
70-2-56-M.69 EN
07 / 2004
70-2-56-M.69
INDEX
A - DISMANTLING THE DISTRIBUTOR ELEMENTS .......................................P 2
B - MACHINES UP TO NO. 506004 PLUS NO 506006 - EXCEPT FOR MACHINE

NOS 504839, 505166, 505869, 505992, 505998, 505999: HYDRAULIC
CIRCUIT WITHOUT STEERING DISCHARGE UNIT
70-2-56-M.69
B1 - MAIN CIRCUIT ...........................................................................P 3

B2 - LIFTING CIRCUIT ........................................................................P 4
B3 - STEERING-TRANSLATION CIRCUIT ...................................................P 5
C - MACHINES FROM NO. 506005 PLUS NOS 504839, 505166, 505869,

505992, 505998, 505999 EXCEPT NO. 506006: HYDRAULIC CIRCUIT
WITH STEERING DISCHARGE UNIT
C1 - MAIN CIRCUIT ...........................................................................P 6

C2 - LIFTING CIRCUIT ........................................................................P 7
C3 - STEERING-TRANSLATION CIRCUIT ...................................................P 8
D - DISTRIBUTOR DETAILS ...................................................................P 9
1
A - DISMANTLING THE DISTRIBUTOR ELEMENTS
- Set la platform in rest position (basket lowered) and cut off the elec- A
trical supply using the battery cut-out.
- Open the left-hand cowl 1 (Fig. A) and remove it.
1
REAR
70-2-56-M.69 - Locate the distributor 2 (Fig. B). B
REAR
- Locate and remove the hoses (Spanners Nos. 19, 22 & 24). C
- Locate each solenoid 3 (Fig. C) according to the cable loom's mar-
kings (adhesive + marker) and remove the cable looms manually 3
(Deutsch type connectors).
- Remove the fixing screws 4 (Fig. C) (2 screws; No. 10 spanner, No.
5 hex spanner) and remove the distributor block.
- Remove the elements to be replaced (various flat and hex spanners).
RE-ASSEMBLY
- Perform the above operations in reverse order.
- Please refer to the Index to ensure you re-assemble correctly.
2
B1 - MAIN
FRONT
CIRCUIT
Electric pump
Main block power
supply
Return
Hydraulic unit
3
P
T Suction
Hydraulic
tank
E
Hydraulic
pump
REAR Manual brake Return to

release pump tank
70-2-56-M.69
70-2-56-M.69
B2 - LIFTING
FRONT
CIRCUIT
Hydraulic
Descent tank
4
Raising
Hydraulic unit
REAR
Steering
Left Forward FRONT
cylinder
translation
motor Steer
right
Reverse
B3 - STEERING-TRANSLATION
Steer left
Left-
hand
brake
A
CIRCUIT
B2
A2 B
5
D A1
B1
Reverse
Hydraulic unit Right

translation
Right motor
-hand Forward
brake
REAR
70-2-56-M.69
70-2-56-M.69
FRONT
C1 - MAIN
CIRCUIT
Electric pump
Main block power
supply
Return
Hydraulic unit
6
P
T Suction
Hydraulic
tank
E
Hydraulic
pump
Manual brake Return to

REAR release pump tank
FRONT
C2 - LIFTING
CIRCUIT
Hydraulic
Descent tank
7
Raising
Hydraulic unit
REAR
70-2-56-M.69
70-2-56-M.69
Steering Steering FRONT
discharge Left Forward
cylinder
block translation
motor Steer
right
Reverse
C3 - STEERING-TRANSLATION
Steer left
Left-hand
brake B2 A
CIRCUIT
A2 B
8
D A1
B1
Reverse
Hydraulic unit Right

translation
Right
motor
-hand Forward
brake
REAR
DISTRIBUTEUR
KOMMANDOSTEUERVENTIL
10 DA 218 DITRIBUIDOR No. Designation Hydrau. layout 78 XE
VALVE BLANK 1 Distributor
2 Pressure restrictor,190 Bars No. 2
POUR REP : 3 - 13 - 16 - 18 POUR REP : 4 - 7 - 12 - 14 21 3 Translation-lifting selector No. 1
FUR HINW : 3 - 13 - 16 - 18 20 FUR HINW : 4 - 7 - 12 - 14 4 Manual descent valve No. 4
PARA FIG : 3 - 13 - 16 - 18 PARA FIG : 4 - 7 - 12 - 14 5 Pressure restricter 165 Bars No. 3
FOR ITEM : 3 - 13 - 16 - 18 FOR ITEM : 4 - 7 - 12 - 14 6 Flow divider 3L/min No. 5
D - DETAILS
LEFT-HAND MOTOR REVERSE 7 Steering selector No. 7

8 Pressure restricter,120 Bars No. 6
LEFT-HAND MOTOR FORWARD
B2 9 Brake cut-off valve No. 8
19 10 Equalising valve, 105 Bars No. 11
TO BRAKES A2
TO BRAKE RELEASE PUMP B1
RIGHT-HAND MOTOR FORWARD
STEER LEFT E
RIGHT-HAND MOTOR REVERSE
STEER RIGHT
A1 17
RAISE SCISSORS B D
T
16
L
A
OF THE HYDRAULIC UNIT
RETURN TO TANK P
PRESSURE
18
9
C
PRESSURE PORT 11 14 13
11 Manual pump non-return valve No. 9
15 12 Steering only valve No. 10
13 F/R travel selector No. 12
14 Deceleration valve No. 13
15 Free-wheeling valve No. 14
16 Torque mode distributor No. 17
10 17 Torque mode flow divider No. 16
18 Torque mode distributor No. 15
19 Brake jet, 0.8mm No. 19
12
1
3 7
4
2 5 8
6 9
P.A.O
20 / 07 / 03
70-2-56-M.69
REMOVING THE CYLINDERS
78 XE
70-2-80-M.69 EN
70-2-80-M.69
07 / 2004
70-2-80-M.69
INDEX
A - DISMANTLING THE STEERING CYLINDER ............................................P 2
B - DISMANTLING THE LIFTING CYLINDER ...............................................P 4
70-2-80-M.69
1
A - DISMANTLING THE STEERING CYLINDER
- Raise the front of platform 1 (Fig. A1) and put a chock under the A1
chassis.
- Cut the power to the platform using the battery cut-out.
FRONT
- Remove hydraulic hoses 2 (Fig. A2) (No. 19 spanner) supplying the A2

steering cylinder.
70-2-80-M.69 - Remove the split pin 3 (Fig. A2) (multi-grip pliers) and remove the 3
articulation axle 4 (Fig. A2). 5
- Swivel the wheels manually to the right to disengage the fitting at the 4
base of the cylinder 5 (Fig. A2) on the chassis lug.
- Remove the fixing nut 6 (Fig. A2) (No. 24 spanner) and remove the
cylinder. 2
RE-ASSEMBLY
- Perform the above operations in reverse order. Use a new pin for
fixing the base of the cylinder.
- Test the assembly.
2
HYDRAULIQUE (Vérin de direction)
HYDRAULIK (Lenkungzylinder)
10 CE 37 HIDRAULICO (Cilindro de dirección) 78 XE 81 XE
HYDRAULIC (Steering cylinder)
Ø 20 mm
Course - Hub - Carrera - Stroke : 204 mm
A
TS B
OIN
EJ C
ED
E TT SATZ AS
T D
CH G
PO HTUNE JUN
E 2 6
DIC GO D
E F
JU L KIT
A
SE G
3
G
5
F
E
D
C
B
A
4
3
P.A.O
24 / 06 / 02
70-2-80-M.69
B - DISMANTLING THE LIFTING CYLINDER
- Set the platform to maintenance position: B1

- Instruct the basket 7 (Fig. B1) to rise high enough for the
stay 8 (Fig. B1) to be able to swivel and be placed vertical- 7
ly, facing downwards.
- Instruct the basket to lower gently until the stay's fork 9 (Fig.
B1) comes into contact with the bearing 10 (Fig. B1). 8
- Instruct the basket to descend from the base console and then cut off
the power to the platform using the battery cut-out.
10
9
REAR
- Depressurise the lifting line
- Unscrew the wheel 11 (Fig. B2) manually.
- Open the left-hand cowl 12 (Fig. B3) and pull the lever 13
(Fig. B4) on the distributor.
70-2-80-M.69
- Retighten the wheel 11 (Fig. B2).
B2 B3 B4
11
FRONT
12
13
- Remove the return hose 14 (Fig. B5) (screwdriver). B5

- Remove the lifting hose 15 (Fig. B5) (No. 24 spanner).
18 15
- Place a sling around the body of the cylinder to hold it (minimum
weight of cylinder: 25kg).
- Remove the cotter pin 16 (Fig. B5) (4 screws, No. 10 spanner) and
the circlips 17 (Fig. B5) (external circlip pliers) from each of the cylin-
der's shafts.
- Remove the shafts 18 (Fig. B5), starting with the shaft at the top of 16
the cylinder.
17 14
- Remove the cylinder.
RE-ASSEMBLY
- Perform the above operations in reverse order and finish by topping
up the oil tank to compensate for what has flowed from the cylinder.
- Conduct a lifting test.
4
HYDRAULIQUE (Vérin de levage)
HYDRAULIK (Aufwinden zylinder)
10 CA 195 HYDRAULICO (Cilindro de levantamiento) 78 XE
HYDRAULIC (Lifting cylinder)
Ø 45 mm
Course - Hub - Carrera - Stroke : 820 mm
A
S B
INT
JO
E DE C 7
T Z
ET AT S D
CH GS TA 2
PO HTUNE JUN
DIC GO D
E
E F
JU L KIT
A
SE G
G
6
F
5
E
C
D
C
B
A
5
4
3
P.A.O
20 / 07 / 03
70-2-80-M.69
HYDRAULIC PRESSURE
78 XE
70-5-M.69 EN
70-5-M.69
07 / 2004
70-5-M.69
INDEX
A - PRESSURE SETTING FOR THE MAIN UNIT ...........................................P 2
B - PRESSURE SETTING FOR THE STEERING DISCHARGE UNIT: FROM NO.

506005 PLUS NOS. 504839, 505166, 505869, 505992, 505998 &
505999 EXCEPT NO. 506006 ............................................................P 3
70-5-M.69
1
Before proceeding with the pressure setting operations described in
this chapter, you must obtain a hydraulic manometer 0 - 200 bars.
A - PRESSURE SETTING FOR THE MAIN UNIT
Setting the main pressure restrictor (N° 2 on hydraulic layout): A1

- Open the left-hand cowl 1 (Fig. A1).
- Use the battery cut-out to switch on the platform.
70-5-M.69
- Connect the manometer to the pressure port 2 (Fig. A2). A2

- Disconnect the electro-valve's coils 3 (Fig. A2). 3
- Instruct the platform to move forwards or backwards.
- Check on the manometer that the main pressure restrictor 4 (Fig. A2)
is set to 190 bars.
- If this is not the case, alter the pressure setting (No. 13 spanner, No.
4 hex spanner) to 190 bars.
- Disconnect the manometer.
2 4
Adjusting the steering cylinder's pressure restrictor (N°6 on A3

hydraulic layout):
- Connect the manometer to the pressure port 2 (Fig. A3).
- Instruct the wheels to swivel to the left up to the end stop and hold
the instruction throughout the whole of the adjustment operation.
- Check on the manometer that the steering cylinder's pressure res-

trictor 5 (Fig. A3), the third from the left under the double electro-
valve, is set to 60 bars.
- If this is not the case, alter the pressure setting (No. 13 spanner, No. 5
2
4 hex spanner) to 60 bars.
- Disconnect the manometer.
Setting the lifting pressure restrictor (N°3 on hydraulic layout):
- Place a load of 230 kg (maximum load) in the basket.
- Instruct the basket to rise, which must take place without a problem.
2
- Lower the basket to the low position and add an extra 20 kg to the A4
existing 230 kg load.
- Instruct the basket to rise and check that the action does not take
place.
- If one of the two tests fails the conditions described, alter the setting
on the lifting pressure restrictor 6 (Fig. A4) (No. 13 spanner, No. 6 hex
spanner), the second from the left under the manual descent valve,
and retest both lifting modes
B - SETTING THE PRESSURE ON THE STEERING DISCHARGE

UNIT: FROM NO. 506005 PLUS NOS. 504839, 505166,
505869, 505992, 505998 & 505999 EXCEPT NO. 506006
B1 70-5-M.69
Adjusting the steering discharge pressure restrictor (N° 22 on
the hydraulic layout): 7
- Set the platform to maintenance position:

8
stay 8 (Fig. B1) to be able to swivel and be placed verti-
cally, facing downwards.
B1) comes into contact with the bearing 10 (Fig. B1).
10
- Switch the platform off.
9
REAR
- Locate and remove the pressure restrictor 12 (Fig. B2) (No. 13 span- B2
ner) from the steering discharge unit 11 (Fig. B2) situated on the back
of the chassis (under the scissors).
12 11
- Adjust the restrictor as shown in Figure B3 and then refit it in the unit. B3
- Switch the platform on.
- Return the basket to the low position and then conduct a steering test
during translation.
3
HYDRAULIC LAYOUT
78 XE
70-6-M.69 EN
70-6-M.69
07 / 2004
70-6-M.69
EV: Electro-valve -: Rest E: Excited No. Description
Functions
1 3 4 7G 7D 10 12Av 12Ar 13 15 17 20 21 1 Translation-lifting selector
Stop - - - - - - - - - - - - - 2 Main pressure restrictor
Stop + steering - - - E or E - - - - - - - - 3 Lifting pressure restrictor
Translation + steering - - - E or E E E or E E - - - - 4 Emergency descent valve
Translation basket low + steer left - - - E - E E or E E - - - E 5 Steering priority flow divider
Translation torque speed - - - - - - - - E E E - - 6 Steering cylinder pressure restrictor
Translation high speed - - - - - - - - E - - - - 7 Steering selector
BRAKES Raise scissors E - - - - - - - - - - - - 8 Brake line shut-off valve
Lower scissors E - E - - - - - - - - E - 9 Manual pump non-return valve
21 STEERING 10 Steering relief valve
P 11 Equalising valve
40 bar 12 Forward - reverse selector
T A 13 Sliding stop valve (Time-delayed)
CI 595767 14 Free-wheeling valve
22 15 Torque mode distributor
16 Torque mode flow divider
17 Torque mode distributor
B A
18 Motor slide jet
HYDRAULIC LAYOUT
19 Brake jet
7 15 20 Base of cylinder valve
21 Steering discharge distributor
22 Steering discharge pressure restrictor
120 bar
6 18 B2
Ø1 mm
17
14
11
A2
5 13 16 Translation
1
motors
10 B1
3 L / min 12
105 bar
Ø 0.8 mm D
A1
19
8
LIFTING
E CYLINDER
9
4 L
3
1 165 bar
190 bar
20
P T
78 XE
Manual brake
595810 - Version A
release
pump Mot. 3.2 kW
1.5 cc 4.8 cc
70-6-M.69
LOCATION OF THE HYDRAULIC
COMPONENTS 70-7-M.69
78 XE
70-7-M.69 EN
07 / 2004
70-7-M.69
LOCATION OF THE HYDRAULIC COMPONENTS
70-7-M.69
Left-hand
hydraulic
motor
Lifting cylinder
Steering
cylinder
Distributor
FRONT
Steering OP
ST
discharge
ST O
P
unit Right-hand
hydraulic
motor
Oil tank
Left-hand Electric pump

brake unit
Right-hand
brake unit
Manual
REAR
pump
1
REMOVING THE VARIABLE SPEED
DRIVE UNITS
78 XE
80-2-04-M.69 EN
80-2-04-M.69
07 / 2004
80-2-04-M.69
INDEX
A - MACHINES UP TO NO. 505557, EXCEPT NO. 505556:

SEVCON VARIABLE SPEED DRIVE ...............................................................P 2
B - MACHINES FROM NO. 505557, PLUS NO. 505556:

CURTIS VARIABLE SPEED DRIVE.................................................................P 3
80-2-04-M.69
1
SEVCON VARIABLE SPEED DRIVE
- Set the machine to maintenance position : A1

- Instruct the basket 1 (Fig. A1) to rise high enough for the
1
stay 2 (Fig. A1) to be able to swivel and be placed vertical-
A1) comes into contact with the bearing 4 (Fig. A1). 2
- Switch the platform off using the battery cut-out.
4 REAR
- Open the right-hand cowl 5 (Fig. A2) and disconnect the battery : A2
- First of all disconnect the Earth 6 (Fig. A2) (No. 10 span-
ner).
- Then disconnect the positive 7 (Fig. A2) (No. 10 spanner).
- Close the right-hand cowl.
5
6
7
FRONT
80-2-04-M.69
- Remove the fixing screws 8 (Fig. A3) (6 screws, No. 5 hex spanner) A3
and remove the upper cowl from the lower control box 9 (Fig. A3).
8
- Locate the variable speed drive 10 (Fig. A3) at the back of the box.
10
- Disconnect the control cable loom 11 (Fig. A4). A4

- Locate and disconnect the power cables connected to the terminals 13 12
12 (Fig. A4) (4 cables, No. 10 spanner).
B
+
- Remove the fixing screws 13 (Fig. A4) (4 screws, No. 10 spanner)

B
-
from the variable speed drive and then remove the drive itself.
M
2
11
12
RE-ASSEMBLY
2
CURTIS VARIABLE SPEED DRIVE
- Set the machine to maintenance position: B1

stay 2 (Fig. B1) to be able to swivel and be placed vertical- 1
B1) comes into contact with the bearing 4 (Fig. B1). 2
4 REAR
- Open the right-hand cowl 5 (Fig. B2) and disconnect the battery: B2
- First of all disconnect the Earth 6 (Fig. B2) (No.10 spanner).
- Then disconnect the positive 7 (Fig. B2) (No.10 spanner).
- Close the right-hand cowl.
5
6
FRONT 7
80-2-04-M.69
- Remove the fixing screws 8 (Fig. B3) (6 screws, No. 5 hex spanner) B3
and remove the upper cowl from the lower control box 9 (Fig. B3).
8
- Locate the variable speed drive 14 (Fig. B3) at the back of the box.
14
- Disconnect the control cable loom from the connectors 15 (Fig. B4). B4
- Locate and disconnect the power cables connected to the terminals 17 15
16 (Fig. B4) (No. 13 spanner).
- Remove the fixing screws 17 (Fig. B4) (4 screws, No. 10 spanner)
S
from the variable speed drive and then remove the drive itself.
U
AT
S1
ST
S2
B-
M-
B+
16
RE-ASSEMBLY
3
REMOVING THE TRACTION BATTERIES
78 XE
80-2-12-M.69 EN
80-2-12-M.69
07 / 2004
80-2-12-M.69
REMOVING THE TRACTION BATTERIES
- Set the machine in the low position and switch of the electrical power A
via the battery cut-out.
- Open the battery cover 1 (Fig. A).
- Disconnect the cables connected to the battery terminals:

- First of all disconnect the Earth 2 (Fig. A) (No. 10 spanner).
- Then disconnect the positive 3 (Fig. A) (No. 10 spanner).
2
1 3
FRONT
- Disconnect the connection cables between the batteries 4 (Fig. B). B

- Remove the battery fixing bracket 5 (Fig. B) (2 wingnuts). 4
- Remove the batteries 6 (Fig. B).
5
RE-ASSEMBLY
6
80-2-12-M.69
1
REMOVING THE ELECTRICAL
CABLE LOOMS
78 XE
80-2-13-M.69 EN
80-2-13-M.69
07 / 2004
80-2-13-M.69
INDEX
A - MACHINES TO NO. 505557, EXCEPT NO. 505556: CABLING WITHOUT BUS-

CAN
A1 - LOCATION OF THE CABLE LOOMS ...........................................................P 3
A2 - MISCELLANEOUS CABLE LOOMS - NOS. 2, 3 ............................................P 4
A3 - MAIN CONSOLE CABLE LOOM - NO. 4......................................................P 5
A4 - BASE CONSOLE CABLE LOOM - NO. 5 .....................................................P 6
A5 - FRAME CABLE LOOM - NO. 6..................................................................P 7
A6 - MISCELLANEOUS CABLE LOOMS - NOS. 7, 8 ............................................P 8
A7 - CABLE LOOMS COUPURE CHARGEUR - NO. 9 ...........................................P 9
B - MACHINES FROM NO. 505558, PLUS N° 505556 - TO NO. 506098 (FOR

CABLE LOOMS NOS. 14 & 16): CABLING WITH BUS-CAN
B1 - LOCATION OF THE CABLE LOOMS .........................................................P 11
B2 - BASKET CONSOLE - NO. 10 .................................................................P 12

80-2-13-M.69
B3 - MISCELLANEOUS CABLE LOOMS - NOS. 11, 12 .....................................P 13
B4 - MISCELLANEOUS CABLE LOOMS - NOS. 13, 14 ......................................P 14
B5 - BASE CONSOLE CABLE LOOM - NO. 15 ................................................P 16
C - MACHINES FROM NO.506099: CABLING WITH BUS-CAN & DISPLAY MODULE
C1 - LOCATION OF THE CABLE LOOMS .........................................................P 19
C2 - BASE CONSOLE CABLE LOOM - NO. 20 .................................................P 20
C3 - DISPLAY /S10 MODULE CONNECTION CABLE LOOM - NO. 21 ...................P 21
1
80-2-13-M.69
2
A1 - LOCATION OF THE CABLE LOOMS
MACHINES TO NO. 505557, EXCEPT NO. 505556
ST O 9
80-2-13-M.69
No. CABLE LOOM

1 Basket console
2 Connection to intermediate terminal 7 G 1.5
3 Multi-wire cable for console 19 G 1.5
4 Main console cable loom
5 Base console cable loom
6 Frame cable loom
7 Distributor cable loom
8 Descent electro-valve cable loom
9 Charger cut-out cable loom
3
A2 - MISCELLANEOUS CABLE LOOMS - NOS. 2, 3
To alarmsonore
Vers avertisseur
1 29
596499 6 28
Câble multifilaire
Console multi-wirepupitre
cable
No. 22
Rep. 28
29
5 4
2 5 4
3 28 3
7 2
4
8 29
5 8 1
To pupitre
Vers basketpanier
console
7
8
C
9 To cable loom connec-
Vers faisceau
10 tion tovers
liaison intermediate
bornier
11 terminal block
intermédiaire
12
595848
595848
13
10 12 5 4
14
13 12
17 7
X H J 15
14 11
5 W K 14 16 15 10
V L
13 F A C 15 16 9
U M 8 1
9 8
3
T
S
R
P
N
16
Shunt
D
6 2 19 18 17
1 4 11
595848
Cable loomliaison
Faisceau connection
vers
1 to intermediate termi-
bornier intermédiaire
80-2-13-M.69 2 nal Rep.
block 3
No. 3
21 Shunt
3
4 C1 C1
5
6
4 5
4 5 Shunt 21 1 8
1 8
3 6
2 7 A 2
3 6
7
1 8
1 8 4 5
4 5
C 7
8
To console multi- 9
Vers câble ToVers
main console
faisceau
wire cable
multifilaire pupitre 10 C2 C2 Shunt principal
cable loom pupitre
No. 4
22
596499
596499 11 595853
595853- rep. 4
12
4 5
12 13 Shunt 1 8
22 9 16
11 14
10 15
10
9
15
16
B 11 14
1 8 12 13
4 5
D 13
14
15
16 C3 C3
Shunt Shunt
19 23 24 24 23 19
4
A3 - MAIN CONSOLE CABLE LOOM - NO. 4
35
9
1 4
38 5 14 50
51 15
22 57
23 58 24 17 56 595853
Main console
Faisceau cablepupitre
principal loom
Vers
Tofaisceau
base
pupitre base No.
Rep. 44
console cable
595854 - rep.55
loom No.
595854
To variable
4 5
speed
Vers drive
variateur
1 8 4 5 6
3
17
22 50
25 A
31 7
18 16 1 8
34 21
1 8
4 5 To connection
Vers faisceaucable
loom
liaisontovers
intermedia-
bornier
51 52 53 54 teintermédiaire
terminal block
12 13
Vers masse 595848
No. 3 - -595848
rep. 3
To Earth 4 5
11 14
B
10 15
1 8
9 89
57 To battery
Vers faisceau
cut-out
coupure chargeur 94
No. 60
rep. 99
C B
A
16
To contacteur
Vers power 90
contactor
de puissance VersTocapteur
tilt
sensor
devers
45 47
19 6 7
93
To distributor
Vers faisceau
43 13 80-2-13-M.69
cable loom
A distributeur
No. 7- -595852
41 27 595852 rep. 7
34 47 41 92 1 12
53 42 36 92
33 48 11 7 60
25 89
90 89
89
49 12 6 7 26
93 To frame
94
23 Vers faisceau
cable loombâti
58 35 46 10 8 3 B 49 596382
No.- rep.
6 6
37 44 45 43 36 20 596382
6
Delivered connected
Livrés connectés together
ensemble 1 12
89 52
89 89
27 9 18
33 8 17 26
31 7 16 21
37 6
54 5 38
48 4 20
19 3 12 46
56 2 11 18
42 1 10 44
To
Verstime delay
carte card + variable
temporisation
+ speed
interfacedrive interface
variateur
24
To charger
cut-out
Vers coupe
cable loom
batterie
5
A4 - BASE CONSOLE CABLE LOOM - NO. 5
595854
Faisceau
Base pupitre
console cable base
loom
Rep.
No. 55
17 10
7
B C 22 D
8 18 9 2
11 6
5
8 5 11 1
4 1 4 3 B6 A3
16
B5 A2
14
4 B4 A1
12 4 3
16
A 3
3
13 15 18
23 2
10 13
6
8
7
E
24
80-2-13-M.69
24 17
23
ToVers
main console
faisceau
15 22
cable pupitre
principal loom
5 14
595853No.- rep.
4 4
595853
1 4
A Timer
Horamètre
B Emergency Stop
Arrêt d'urgence
C Base/basket selector
Sélecteur base/panier
D Lifting/descent selector
Sélecteur montée/descente
E Fusible
Fuse
6
A5 - FRAME CABLE LOOM - NO. 6
11 9 32 Shunt Shunt
32 10 8
12 7
To Vers
mainfaisceau
console
principal pupitre
cable loom
595853
No. - rep. 4
4 595853
1 6
32 4 32
32 3 5 24 5 13 16 3
B
ALIM PERMANENTE
LAMPE A ECLAT
16 11 12
15 10
14
15 9
4 8 24
To rotating
Vers Spare cable
Faisceau
gyrophare libre To anti-rollover
Vers capteur barres
light loom
bars sensor
anti-renversement
80-2-13-M.69
596382
Faisceau
Frame cablebâti
loom
No. 66
Rep.
13 12 14
To work/transport
Vers capteur mode
travail/transport
mode sensor
7
A6 - MISCELLANEOUS CABLE LOOMS - NOS. 7, 8
11 9 7
35 10 8
595853 12 7
ToVers
mainfaisceau
console
cable loom
principal
595853
pupitre
No.- 4
rep. 4
A
1 6
2 4 6
1 3 5
595852
Distributor distributeur
Faisceau cable loom
No. 77
Rep.
EV DIRECTION GAUCHE
EV DIRECTION DROITE
EV DECELERATION
EV DESCENTE
EV DESCENTE
EV MONTEE
EV COUPLE
EV COUPLE
EV AVANCE
EV RECUL
9 10 EV FREIN
15 12
36 38
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2
5 8
16 13
38 14 12 14 2 1 3 14 4 14 37 14 7 13 6 39 16 14 36 14 15 14
37 39
Shunt
Boitier box
de dérivation
(Nodeopposite
(Pas connexion
connection)
opposée) 1 8
1 8
2
2 1 2 1
2 2 1 1 Male Male
Mâle Mâle
597080
80-2-13-M.69 595850 Anti-interference
Faisceaux
Descent electro-
Faisceau cable looms
anti-parasite
valve
EV cable
descente
loom No. 8
Rep. 8
Female
Femelle Female
Femelle
ToVers
lifting
vérin 1
2 1 2 1 2 1
cylinder
de levage 2 1
2 1 2
8
A7 - CHARGER CUT-OUT CABLE LOOMS - NO. 9
596344 597479
SEVCON
Kit coupurecharger cut-out
chargeur kit No. 9
SEVCON ZIVAN
Kit charger
coupure cut-outZIVAN
chargeur kit No. 9
Machines
Machines to No.N°505189
jusqu'au 505189 Machines from No. 505190
Machines à partir du N°505190
Rep. 9 Rep. 9
Tocontacteur
power To power
Vers Vers contacteur
To charger cut-out decontactor
puissance To charger cut-out decontactor
puissance
Vers faisceau Vers faisceau
cable chargeur
coupure loom cable loom
coupure chargeur
rep.44
No. No.
rep.44
2 1 2 1
1
1
To ZIVAN
Vers charger
chargeur ZIVAN
2
2
2 2 1 1
3
To SEVCON
Vers charger
chargeur SEVCON
80-2-13-M.69
9
80-2-13-M.69
10
B1 - LOCATION OF THE CABLE LOOMS
MACHINES FROM NO. 505558, PLUS NO. 505556 - TO NO. 506098
10
11
19
12
18
16
13
P
TO
14 80-2-13-M.69
S
P
ST O
15
17
No. CABLE LOOM

10 Basket console
11 Intermediate connector/basket console cable loom
12 E18/S6 module - intermediate connector cable loom
13 Box cable loom
14 Load indicator cable loom
16 Cable loom E18/S6 - S10
17 Timer cable loom
11
B2 - BASKET CONSOLE - NO. 10
8 5 6 4 8
J3 J2 J4 14
4 1 3 1 7 1
E10/E3
E10/E2
E10/S1
E10/E1
+ BATT
CAN high
CAN low
+ BATT
- BATT
E10/E10a
- BATT
E10/E9a
+ BATT
E10/E8a
E10/S3
E10/E7
E10/S2
E10/E6
E10/E12
E10/E5
E10/E11
E10/E4
MODULE E12/S3
To J4J4
Vers Vers J3
To J3 To Vers
connector
clip clip
(Module
(Module E12/S3)
E12/S3) (Module
(Module E12/S3)
E12/S3) No. 5
rep. 5 connecteur
597632
Basket console A To be
brancher 19 20 21
Pupitre panier connected
sur avertisseur 18 12 8
No. 10
Rep. 1 tosonore
alarm 14 13 9 8
22 8 5
17
23 7 6 5 4 3 2 1 4 3 2 1
18 20 16 15 14 13 11 10 9
A Console connector
Connecteur pupitre
B Buzzer
C Emergency
Arrêt Stop
d'urgence
D Tilt indicator
Voyant devers
E Movementmouvement
Sélecteur selector
F Speed selector
Sélecteur vitesse
G Alarm
Avertisseur sonore
H Manipulator
Manipulateur
C D E
80-2-13-M.69 5
6 4 11
4
8 22
3 1
1
To console
Vers clips +
3 2 1
clips
rep. No. 8
8 pupitre 61 61 2
Vers J2
To J2
ModuleE12/S3
module E12/S3 25 27 24 21 12 27
4 A 26
51
F
E
A
6 25
B
C
PIN
1 Red
Rouge
1 2 3 F H Pink
Rose
2 White
Blanc
10
B
+ - - Green
Vert Violet
Violet
G 6 23 14 Grey
Gris Blue
Bleu
24 Black
2
13 Noir
Wire
FilNo.20
rep.20 Wire No.18/23
Fil rep.18/23 17 Brown
Marron
1
15
9 16
19
12
B3 - MISCELLANEOUS CABLE LOOMS - NOS. 11, 12
To basket console
Vers pupitre panier
No. 10 597632
597632 - rep. 10
4 P 5
N E
D Vers
To faisceau
cable 597629
loom 597629
M
C A
F 6
L G
B
K H 7 6 1
J 6 1
3 1 5
5 2
2
2 4 3
4 3
597629 597578
Connection
Liaison interme-
connecteur Liaison base
Connection
diate
intermédiaire/
connector base / interme-
/connecteur
/pupitreconsole
basket panier diate connector
intermédiaire
No. 11
Rep. 11 No. 12
Rep. 12
80-2-13-M.69
1 2 3
1 6
1 6 1 2 3
2 2 5 5
3 4 4 4 6
6
3 4
5
To cable
Vers loom 597578
faisceau 597578
Vers
To J5J5
(ModuleE18/S6)
(Module E18/S6)
4
MEM
4
J5 J3 J1
16
6
1
3
8
M1/S3
- Batt
M1/S6a
M1/S1
+ Batt-P
- Batt
Fil11
CAN low
COM +
CAN high
M1/S2
+ Batt-P
M1/E5
M1/E11
M1/E4
M1/E10
M1/E3
M1/E9
M1/E2
M1/E8
Fil11
Fil 22
M1/E6
M1/E1
wire
wire
wire
ESAU
MODULE E18/S6
ESAU
ESAU
7
8
4 5 6
1 0 9
2
3
COMMUN +
LED RUN
2 2
M1/E17a
+ Batt-P
wire
M1/E15
M1/E16
M1/E12
M1/E13
M1/E18
M1/E14
PROGRAMME
M1/E7
M1/S5
4 M1/S4
W.517700-042
ES Fil
+ Batt
+ Batt
1 - Batt
- Batt
- Batt
1 - Batt
- Batt
AU
COMMUN +
J4
7
CAN high
J2
CAN low
14
5
8
- Batt
13
B4 - MISCELLANEOUS CABLE LOOMS - NOS. 13, 14
To variable speed drive

Vers variateur
2
8 16
6 15
3 1 26 27
7
6 14
5 87
4
3 5 22 86 +
87a 23
4 11 85
2 10
30
1 9
8
24 25
17 17
16 16
3
VersTocontacteur
power
2
decontactor
puissance
4 1
D
80-2-13-M.69
18 1 2
19
To alarm sonore
Vers avertisseur
21
C
2
20 To flashing
Vers feu à éclat
light
596641
Box cablecaisson
Faisceau loom
No. 13
Rep. 13
14
19 5 To J3
Vers J3
(Module E18/S6)
2
1
18 6
36 40
25
27 To J4
Vers J4
4 8 24 (Module E18/S6)
26
3 J4
2 1 - Batt
20 4 5 6 + Batt-P 6
1 5 22 5 - Batt 3 7 - Batt 3
2 8 ES wire 1
AU Fil 1
M1/S5
21 2 2
ESFilwire
AU
1 0 9
CAN low
23
COMMUN + COM +
CAN high 4
1
To tilt
Vers capteur
sensor
4 M1/S4 J5
devers 8
7
B
C A
PROGRAMME
W.517700-042
11 10
CAN high
CAN low M1/S3 4
- Batt 2
- Batt
COMMUN + M1/S6a
M1/S1 3
10
J3
50 7 14 8 To J2
Vers J2
6 13 (Module E18/S6) J2
51 5 50 1 - Batt
9 4 8 + Batt
3
11 - Batt M1/S2 16
2 9 16 + Batt + Batt-P
8
17 1 8 - Batt
7 M1/E15 M1/E5
17 16 + Batt-P
M1/E11
9 M1/E16 M1/E4
M1/E12 M1/E10
M1/E17a M1/E3
M1/E13 M1/E9
51 51 M1/E18 M1/E2
M1/E14 M1/E8
7
50 50 55 14
M1/E7 AU
ES Fil 11
wire
Fil 22
AUwire
ES
M1/E6
9
LED RUN M1/E1
1 80-2-13-M.69
J1
MEM
MODULE E18/S6
A B
To capteur
Vers work/transport
mode
mode sensor
travail/transport
1 50
2 1 2 1
VersTochargeur
charger
2 50
50 50 51 51
To capteur
Vers anti-rollover
barres
bars sensor
anti-renversement
VersTochargeur
charger
597620
Témoin
Loadde charge
indicator
Rep.
No. 14
14
15
80-2-13-M.69
B5 - BASE
J4
1 - Batt + Batt-P 6
4 5 6
5 - Batt 3 7 - Batt 3
M1/S5 2 8 wire
ESAU Fil 11
1
1 0 9
AU
ESFil
wire
2 2
2
CAN low
COMMUN + COM +
CAN high 4
3
1
4 M1/S4 J5
1 2 3
9 10 11
4
8
5
C
4 5 6
3
12
6
PROGRAMME
7 8
14 15 16
W.517700-042
8
CONSOLE CABLE LOOM
CAN high
-
11
CAN low 4
Base
M1/S3
- Batt 2
- Batt
Vers
COMMUN + M1/S6a
To J1
3
J1
M1/S1
Faisceau
NO.
1
2
J3
(Module E18/S6)
Rep.
console
16
15
No. 15
597573
15
J2
4
1 - Batt
pupitre
8 + Batt
- Batt M1/S2 16
+ Batt 8
+ Batt-P
- Batt
cablebase
loom
M1/E15 M1/E5
C Emergency
11
+ Batt-P
B Base/basket
M1/E11
M1/E16 M1/E4
A Lifting/descent
A
Arrêt d'urgence
M1/E12 M1/E10
Stop
M1/E17a M1/E3
10
M1/E13 M1/E9
M1/E18 M1/E2
5
selector
M1/E14 M1/E8
7
3
2
1
M1/E7 ESAU
wire
Fil 1
selector
14
ES
AUwire
Fil 2
6
M1/E6
9
9
LED RUN M1/E1
1
J1
MEM
MODULE E18/S6
J4
1 - Batt + Batt-P 6
4 5 6
5 - Batt 3 7 - Batt 3
M1/S5 2 8 AU Fil 1
1 0 9
AU ES
Fil 2wire 2 CAN
ES low
wire 1
COMMUN + COM +
CAN high 4
1
4 M1/S4 J5
8
4 5 6
3 7
E18/S6
MODULE S10
Rep.
8
Connection
2
1 0 9
B6 - MISCELLANEOUS
No. 16
PROGRAMME
597619
16
Ro-11
Ro-10 LED RUN W.517700-042
E18/S6 -- S10
S10
Ro-9
1
2
2
1
Liaison modules
Ro-8 CAN high CAN high
2
1
1 2
modules
Ro-7 CAN low
CAN low M1/S3 4
Ro-6 - BATT - Batt 2
Ro-5 - Batt
COMMUN +
COMMUN + M1/S6a
Ro-4
3
4
4 3 3
3
4
Ro-3 M1/S1
4
3
Ro-2 CAN high
J3
Ro-12 CAN low
Vers
Ro-1 - BATT
Vers
COMMUN +
CABLE LOOMS
J2
1 - Batt
-
8 + Batt
To module
To module
- Batt M1/S2 16
+ Batt 8
+ Batt-P
moduleS10
- Batt
S10
module E19/S6
E19/S6
17
M1/E15 M1/E5
NOS.
+ Batt-P
M1/E11
M1/E16 M1/E4
M1/E12 M1/E10
M1/E17a M1/E3
M1/E13 M1/E9
M1/E18 M1/E2
M1/E14 M1/E8
16, 17
7
M1/E7 AU
ES Fil 1
wire
14
ESAU
wire 2
Fil 2
M1/E6
9
LED RUN M1/E1
1
J1
MEM
MODULE E18/S6
Timer
No.
speed
Rep.
loom
ToVers
variateur
1
variable
drive
596368
1717
cable
Faisceau
horamètre
8
2
Vers To
1 2
3
4 3 2 1
5
timer
horamètre
1
3
2
80-2-13-M.69
B7 - MSCELLANEOUS CABLE LOOMS - NOS. 18, 19
CAN high
CAN low
- BATT
COMMUN +
CAN high
CAN low
- BATT
COMMUN +
MODULE S10
LED RUN
7
8
4 5 6
1 0 9
2
3
Ro-11
Ro-12
Ro-1
Ro-10
Ro-9
Ro-8
Ro-7
Ro-6
Ro-5
Ro-3
Ro-2
Ro-4
43 7
2 1 To steering discharge
Vers EV
electro-valve
décharge direction
6 5 4 3 2 1
6 1
597574
EV DECHARGE DIRECTION
To module
Vers moduleS10
S10
Cable loom
Faisceau distributeur
distributeur
No. 18
Rep. 18 7
7 12
33
8 9 10 11
x7
EV DIRECTION GAUCHE
EV SELECTION TRANSLATION
1 32
EV DIRECTION DROITE
FAISCEAU EV DESCENTE
x4
43 16
EV DESCENTE
EV MONTEE
SHUNT
EV AVANCE
EV COUPLE
EV COUPLE
EV RECUL
EV FREIN
15 13
14 12
80-2-13-M.69 SHUNT
2 11
E
1 2 1 2 1 2 1 2
1 2 1 2 1 2 1 2 1 2 1 2 1 2
13 16 6 16 5 16 8 16
9 32 3 32 10 32 4 32 14 32 15 32 12 32
597575
Cable loom
Faisceau
Descent EV
EV descente
No. 19
Rep. 19
To lifting
Vers vérin
cylinder 2 1
de levage
12 32
18
C1 - LOCATION OF THE CABLE LOOMS
MACHINES FROM NO. 506099
10
21
11
12
19
18
16
13
80-2-13-M.69
P
TO
S
14
P
ST O
20
No. CABLE LOOM

10 Basket console
11 Intermediate connector / basket console cable loom
12 Module E18/S6 - intermediate connector cable loom
13 Box cable loom
14 Load indicator cable loom
16 E18/S6 - S10 cable loom
21 Display/Module S10 connection cable loom
19
80-2-13-M.69
C2 -
J4
1 - Batt + Batt-P 6
4 5 6
5 - Batt 3 7 - Batt 3
M1/S5 2 8 wire
ESAU Fil 1
1
1 0 9
AU Fil CAN low
2
ES2wire 2
COMMUN + COM +
D
CAN high 4
3
1
4 M1/S4 J5
9 10 11
4
8
5
C
6
3
12
PROGRAMME
1 2 3 4 5 6 7 8
14 15 16
W.517700-042
8
CAN high
BASE CONSOLE CABLE LOOM
CAN low M1/S3 4
J1 J1
-
module
- Batt - Batt
11
COMMUN + M1/S6a
E18/S6
vers
M1/S1 3
Faisceau
to module
E18/S6
NO.
B
A
D
C
J3
1
2
No.
20
20
J2
20
676906
Rep. 20
1 - Batt
Cable loompupitre
8 + Batt
9
4
B
- Batt 16
Display
M1/S2
+ Batt 8
+ Batt-P
Afficheur
- Batt
consolebase
Emergency
base
Base/basket
M1/E15 M1/E5
+ Batt-P
M1/E11
Lifting/descent
M1/E16 M1/E4
11
Stop
Arrêt d'urgence
M1/E12 M1/E10
A
M1/E17a M1/E3
M1/E13 M1/E9
selector
10
M1/E18 M1/E2
8
selector
M1/E14 M1/E8
7
5
M1/E7 ESAU
wire
Fil 1
14
3
1
wire
ESAU Fil 22
M1/E6
9
LED RUN M1/E1

6
1
9
J1
MEM
MODULE E18/S6
C3 - DISPLAY/S10 MODULE CONNECTION CABLE LOOM - NO. 21
597977
Display/Module S10
Faisceau liaison
connection cable loom
Afficheur/Module S10
No. 21
Rep. 21
To module
Vers moduleS10
S10 To l'afficheur
Vers display
2 4
2 1
2 1
2
1
3 4
3 4
1 3
F1 F2 - + P 80-2-13-M.69
CAN high
CAN low
- BATT
COMMUN +
CAN high
CAN low
- BATT
COMMUN +
MODULE S10
LED RUN
7
8
4 5 6
1 0 9
2
3
Ro-11
Ro-12
Ro-1
Ro-10
Ro-9
Ro-8
Ro-7
Ro-6
Ro-5
Ro-3
Ro-2
Ro-4
21
ELECTRICAL LAYOUTS
78 XE
80-6-M.69 EN
80-6-M.69
07 / 2004
80-6-M.69
INDEX
A - MACHINES TO NO. 505557, EXCEPT NO. 505556 ............................P 2
B - MACHINES FROM NO. 505558, PLUS NO. 505556

MACHINES TO NO. 506098.............................................................P 4
C - MACHINES FROM NO. 506099 ........................................................P 6
80-6-M.69
1
A - MACHINES TO NO. 505557, EXCEPT NO. 505556
Horn
A6
Manipulator
12
L
15(-) P2-3
POT1
11
K 14
P2-2
OFF S9 ON 2
(tortoise) (hare)
Tilt LED
V 13
12 P2-1
A1
9
A 12
P1-12
Forward S8
/descent
P 11
3 P1-11
6
Reverse
/lifting S7
3 H 10
8 9 P1-10
S6
SWITCH
11 8 7 5 31 4 2 32
10 1
12
4 3 F 9
Lifting Translation 9 6 10 11 P1-9
3A 5
Steer C 8
8
5 P1-8
left
S5
3A
J 7
3 4 P1-7
S4
Steer
right Horn button 15
7
T 6
A5 P1-6
W 5
P1-5
80-6-M.69
R 4
P1-4
3
U 3
P1-3
2
78 XE Dead Man's
system
N 2
S3
595855 - Version B
P1-2
Machines to No. 505557 9 S 1

P1-1
ES2
except No. 505556

Emergency stop
B - Addition of anti-interference/charger cut-ou-/diode on timer 10/07/02

A - Modification to adapt to card CI596434 (Time delays & variable speed drive interface card) 13/11/01
Version MODIFICATIONS Draw. Date
2
High translation
Low position cable loom
limit cable loom
151
P7-1 Flashing light Under power
LS2 Tilt
A7 A8
A3 Battery level
Timer
LS1
P8-1 P8-2 P9-1 P9-2
P4-1 P4-3 A9
15(-) A11
P7-4
151 20 15(-) 103 15(-)
P4-2 Descent
5A
SOL12 electro-valve
10V
P3-20 P3-21 P3-15 1 J-12 2
15(-) 12 103 17 103 15(-) 104B 15(-) 5A

SOL11
Descent
P3-9 electro-valve
13
SOL9
Torque electro-valve
tortoise/hare
13
SOL8
P3-13
P3-23
11
SOL7
Forward motion
P7-6 P3-11 electro-valve
19
10
SOL6 SOL5 Deceleration
Reverse motion electro-valve
P3-10 electro-valve
12
19
SOL4 Brake electro-valve
LS1
6
P3-19
8
SOL3 Steer left electro-valve
P7-5
P3-8
7
SOL2 Steer right electro-valve
17 9 13 12 4 3 1 10
P3-22
P3-4 P3-7
4
D5 D13 D10 D2 2
D7 D14 D9 D1 D12 D4 SOL1 Lifting electro-valve

D18
D3 11 41
D15 D11
R3 R4
14 D8 P3-1 P3-14
R1 R2
5
8
80-6-M.69
16 50 Variable speed drive designatio
D17
7
6 Time delay card + variable 25 1 : +Batt
6
speed drive interface 16 2 : Speed selection
Tempo 5 J-5
K1 5 sec. 21 3 : Validation trigger
D19 CI596434 34
4
4 : Basket command
8 15 3
K2 18 5 : Transport/work position
2
17 sensor information
1
22 PWM 6 : Motor contactor coil
7 : Lifting electro-valve
8 : Manipulator signal
M2 B+ B-
18 M1
7
MC1
MC1
15 9
22 16
14 B1-B4
D17
4
200 AMP
101
F1
103
5 104
105 BD1
S1
S2
BASKET ES1 CH1

LIFTING
STOP STOP
Emergency
DESCENT BASE stop
Battery cut-out
N Battery charger
3
80-6-M.69
AXIS
MODULE E12/S3 BASKET CARD MODULE E18/S6 BASE CARD
MIDPOINT
ABBREVIATION AND CORRESPONDENCE ABBREVIATION AND CORRESPONDENCE ABBREVIATION AND CORRESPONDENCE ABBREVIATION AND CORRESPONDENCE
TRIGGER
MANIPULATOR
STEER RIGHT BUTTON
STEER LEFT BUTTON

LONGITUDINAL
TO INPUTS TO OUTPUTS TO INPUTS TO OUTPUTS
v
E1 = HORN BUTTON S1 = SPARE E1 = EMERGENCY STOP S1 = HORN
E2 = TORQUE BUTTON S2 = BASKET FAULT LIGHT E2 = BASKET CONTROL S2 = 6-SEC DELAYED POWER CONTACTOR
HORN BUTTON
TRANSPORT SELECTOR
EMERGENCY STOP
TORQUE BUTTON
E3 = TRANSPORT SELECTOR S3 = ALARM E3 = LIFTING S3 = VARIABLE SPEED DRIVE SEQUENCE
E4 = SPARE E4 = DESCENT S4 = RAU RELAY / POWER CONTACTOR
ALARM
E5 = STEER LEFT BUTTON E5 = SPARE S5 = FLASHING LIGHTS
r
g
n
vt
m
bl
ro
bc
E6 = STEER RIGHT BUTTON E6 = SPARE S6a = 0-5V. VARIABLE SPEED DRIVE
E7 = DEAD MAN'S SYSTEM ( TRIGGER ) E7 = SPARE
+
E8a = MANIPULATOR NEUTRAL E8 = SPARE
MACHINES TO NO. 506098
E9a = MANIP. LONGITUDINAL SIGNAL E9 = SPARE

N-23
E10a = SPARE E10 = SPARE
N-24
Bc-8
R-12
Ro-9
B-11
Vt-10
E11 = SPARE BASKET FAULT E11 = SPARE
E12 = EMERGENCY STOP LIGHT E12 = LOW POSITION CABLE LOOM
E13 = STABILITY DETECTOR
E14 = TILT
E15 = SPARE
N-18
N/S-20
G-17
R-21
Vt-16
Bc-19
V-15
B-13
N-14
J-22
E16 = BATTERY CHARGER
MODULE S10 E17a = BATTERY 80% DISCHARGED
E18 = SPARE
M-3 A 1
ABBREVIATION AND CORRESPONDENCE
4
Vt-2 B 2
TO OUTPUTS B-1 C 3
D 4
S1 = TORQUE ELECTRO-VALVE Bc-5 E 5
S2 = FORWARD MOTION ELECTRO-VALVE Ro-4 F 6
S3 = TRANSLATION SELECTION ELECTRO-VALVE
S4 = STEER RIGHT ELECTRO-VALVE
S5 = LIFTING ELECTRO-VALVE
S6 = SPARE
S7 = STEER LEFT ELECTRO-VALVE
S8 = BRAKE ELECTRO-VALVE
S9 = REVERSE MOTION ELECTRO-VALVE
B-11
J-18
J-22
Ro-9
R-12
V-15
B-13
N-21
N-14
Vt-10
G-17
Vt-16
Bc-19
S10 = DESCENT ELECTRO-VALVE

N/S-20
6
5
4
3
2
1
5
4
8
8
6
14
4
3
2
1
J3
6
5
J2
J4
4
7
1
1
1
4
E10/E3
E10/E2
E10/S1
E10/E1
LED RUN
- BATT
2
E10/S3
E10/E7
E10/S2
E10/E6
E10/E5
E10/E4
+ BATT
+ BATT
- BATT
E10/E9a
E10/E8a
E10/E12
E10/E11
CAN low
+ BATT
CAN high
E10/E10a
3
4 2 3 1
1
10
MODULE E12/S3
POCKET DIAGNOSTIC KIT
2
2 1
2 1
DESCENT EV
12
BLUE
DESCENT EV
4 5 6 MODULE S10
12
BLUE
FLASHING LIGH
REAR 3 7 J4 5
2
2 1
2 1
DESCENT EV
12
BLUE
DESCENT EV
4 5 6 MODULE S10
12
BLUE 3 7 J4
REAR
4 5 6
1
6
FLASHING LIGHTS
TRANSLATION EV 2 8 N-21 - Batt + Batt-P
3 7
5
1 0 9
- Batt - Batt
12
BLUE 2 8
Ro-11 Ro-11 R-20 M1/S5 1 0 9 ES wire 1
BRAKE EV E3/S10
Ro-10 Ro-10 V-23 V-22 ES wire 2 CAN low
E3/S9 RAU
12
BLUE Ro-9 Ro-9 J-26 COMMUN + COMMUN +
STEER LEFT EV E3/S8
Ro-8 Ro-8
4
6 3 5 2 4 1
CAN high O-24 CAN high
E3/S7
Ro-7
1
J-27
12
BLUE E3/S6 CAN low
4
STEERING Ro-6 Ro-6 O-25 M1/S4
J5
E3/S5 - BATT
DISCHARGE EV
8
Ro-5 Ro-5
1 2 3 4
1 2 3 4
E3/S4 COMMUN +
Ro-4 Ro-4 J-1
1 2
BLUE E3/S3 LED
LIFTING EV Ro-3 Ro-3 RUN
E3/S2
Ro-2 Ro-2 CAN high
E3/S1
12
BLUE Ro-12 CAN low
STEER RIGHT EV
PROGRAMME
B-1 Ro-1 - BATT
1 2 3 4
1 2 3 4
COMMUN + W.517700-044
12
BLUE
TRANSLATION
SELECTION EV
CAN high
12
BLUE
4
FWD CAN low M1/S3 Vt-5
TRANSLATION EV
n
2
- Batt - Batt N-19
12
1 2 3 4
BLUE COMMUN + M1/S6a Ro-6
r
HORN
3
TORQUE EV M1/S1 1 R-18 +
12
BLUE J3
TORQUE EV
1
FUS 2
J2
1
N-17 - Batt
-24V
8
+ Batt
- Batt M1/S2
1
SUPPLY
8
R-16 FUS 1 V-8

16
+ Batt + Batt-P
1
+24V
1
2
BATTERY POWER
N-11 - Batt
BATTERY
CHARGER
3
4
5
M1/E15 M1/E5
LEVER INFO
R-9 + Batt-P
M1/E11
3 1 2
V-6 DESCENT
Black 3 M1/E16 M1/E4
BATTERY CHARGE
Black
2
3
1
M1/E12 M1/E10
2
2 1
Black 4 V-5
1
Black M1/E17a M1/E3 LIFTING
4
M1/E13 M1/E9
V-4
CABLE LOOM
M1/E18 M1/E2 BASKET CONTROL
ANTI-ROLL BARS
G-10
M1/E14 M1/E8
1 3
CABLE LOOM
G-10 BASE CONTROL
7
R-7 ES wire 1
M1/E7
TRANSPORT/WORK
A B
14
R-7
TILT
ES wire 2 V-2
V-8
C
N-11
M1/E6
9
V-1
M1/E1 EMERGENCY STOP
1
LED RUN
J1
MEM
MODULE E18/S6
J-1
Ro-6
Vt-5
V-8
Deleted if module AF2x16 present
POWER
3
1
2
1
2
3
CONTACTOR
78 XE
B-4
J-2
J-3
597586 - Version B
4
5
16
Machines from No. 505558
2
4
8
1
1
1
0V
Main
+12V
+ after
+ after
contactor
plus No. 505556 - to No. 506098
discharged
Accel. 0-5V
Battery 80%
incrementation
Emergency Stop
Emergency Stop
B - Cancels and replaces drawing ref. 597586-A. Addition of "Steering discharge EV" connection. IB 09.09.03
Operating sequence
VARIABLE SPEED DRIVE TIMER
80-6-M.69
80-6-M.69
MODULE E12/S3 MODULE E18/S6
AXIS
MIDPOINT
ABBREVIATION FOR INPUTS ABBREVIATION FOR OUTPUTS ABBREVIATION FOR INPUTS ABBREVIATION FOR OUTPUTS
TRIGGER
MANIPULATOR
E1 = HORN BUTTON S1 = SPARE E1 = EMERGENCY STOP S1 = HORN
LONGITUDINAL
STEER RIGHT BUTTON
STEER LEFT BUTTON

C - MACHINES
E2 = TORQUE BUTTON S2 = BASKET FAULT LIGHT E2 = BASKET CONTROL S2 = 6-SEC DELAYED POWER CONTACTOR
E3 = TRANSPORT SELECTOR S3 = ALARM E3 = LIFTING S3 = VARIABLE SPEED DRIVE SEQUENCE
v
E4 = SPARE E4 = DESCENT S4 = RAU RELAY / POWER CONTACTOR
E5 = STEER LEFT BUTTON E5 = SPARE S5 = FLASHING LIGHTS
TRANSPORT SELECTOR
HORN BUTTON
EMERGENCY STOP
TORQUE BUTTON
E6 = STEER RIGHT BUTTON E6 = SPARE S6a = 0-5V. VARIABLE SPEED DRIVE
E7 = DEAD MAN'S SYSTEM ( TRIGGER ) E7 = SPARE
ALARM
E8a = MANIPULATOR NEUTRAL E8 = SPARE
r
g
n
vt
m
bl
ro
E9a = MANIP. LONGITUDINAL SIGNAL E9 = SPARE
bc
E10a= SPARE E10 = SPARE
+
FROM NO.
E11 = SPARE E11 = SPARE

E12 = EMERGENCY STOP E12 = LOW POSITION CABLE LOOM
N-23
E13 = STABILITY DETECTOR
N-24
E14 = TILT
Bc-8
BASKET FAULT
E15 = SPARE LIGHT
E16 = BATTERY CHARGER
E17a= BATTERY 80% DISCHARGED
E18 = SPARE
506099
N-18
N/S-20
R-12
Ro-9
B-11
Bc-5
G-17
R-21
Vt-16
Bc-19
V-15
Vt-10
B-13
N-14
J-22
MODULE S10
ABBREVIATION FOR OUTPUTS
S1 = TORQUE ELECTRO-VALVE TORTOISE/HARE

S2 = FORWARD MOTION ELECTRO-VALVE
6
S3 = TRANSLATION SELECTION ELECTRO-VALVE
5
1
2
6
4
3
S4 = STEER RIGHT ELECTRO-VALVE E

S5 = LIFTING ELECTRO-VALVE
A
D
6
5
4
3
2
1
S6 = STEER DISCHARGE ELECTRO-VALVE

J-22
B-11
V-15
B-13
Ro-9
R-12
N-18
R-21
N-14
G-17
Vt-10
Vt-16
Bc-19
N/S-20
S7 = STEER LEFT ELECTRO-VALVE

M-3
C B-1
4
3
2
1
B Vt-2
F Ro-4
6
5
S8 = BRAKE ELECTRO-VALVE
S9 = REVERSE MOTION ELECTRO-VALVE
S10 = DESCENT ELECTRO-VALVE
8
4
5
8
14
J3
J2
J4
4
7
3
1
1
E10/E3
E10/E2
E10/S1
E10/E1
- BATT
+ BATT
- BATT
E10/S3
E10/E7
E10/S2
E10/E6
E10/E5
E10/E4
+ BATT
CAN low
LED RUN
CAN high
E10/E9a
E10/E8a
E10/E12
E10/E11
+ BATT
E10/E10a
BASKET CONSOLE
4
2
3
4 2 3 1
10
DISPLAY
1
MODULE E12/S3
2
2
2
DESCENT EV
1
1
12
BLUE
DESCENT EV
4 5 6
12
BLUE 3 7
J4
REAR MODULE S10 4 5 6

6
2 8 N-21 + Batt-P
FLASHING LIGHTS
TRANSLATION EV - Batt 3 7
5
3
1 0 9
- Batt 8 - Batt
12
BLUE 2
6 3 5
Ro-11 Ro-11 R-20 M1/S5

1 0 9 ES wire 1
BRAKE EV E3/S10
Ro 10 Ro 10
2
2
2
DESCENT EV
1
1
12
BLUE
DESCENT EV
4 5 6
12
BLUE 3 7
J4
REAR MODULE S10 4 5 6
1
2 8 N-21 + Batt-P
FLASHING LIGHTS
TRANSLATION EV - Batt 3 7
5
3
1 0 9
- Batt 8 - Batt
12
BLUE 2
Ro-11 Ro-11 R-20 M1/S5
1 0 9 ES wire 1
BRAKE EV E3/S10
Ro-10 Ro-10 V-23 V-22 ES wire 2 CAN low
E3/S9 RAU
12
BLUE Ro-9 Ro-9 J-26 COMMUN + COMMUN +
STEER LEFT EV E3/S8
4
6 3 5 2 4 1
Ro-8 Ro-8 O-24 CAN high
E3/S7 CAN high
1
Ro-7 Ro-7 J-27
12
BLUE E3/S6 CAN low
J5
4
STEERING Ro-6 Ro-6 O-25 M1/S4
E3/S5 - BATT
DISCHARGE EV
8
Ro-5 Ro-5
1 2 3 4
1 2 3 4
E3/S4 COMMUN +
Ro-4 Ro-4 J-1
1 2
BLUE E3/S3 LED
LIFTING EV Ro-3 Ro-3 RUN
E3/S2
Ro-2 Ro-2 CAN high
E3/S1
12
BLUE Ro-12 CAN low
STEER RIGHT EV PROGRAMME
B-1 Ro-1 - BATT
1 2 3 4
1 2 3 4
COMMUN + W.517700-045
12
BLUE
TRANSLATION
SELECTION EV
CAN high
12
BLUE
4
FORWARD CAN low M1/S3 Vt-5
2
TRANSLATION EV
n
- Batt - Batt N-19
12
1 2 3 4
BLUE COMMUN + M1/S6a Ro-6
r
HORN
TORQUE EV M1/S1 R-18 +

1
12
BLUE
J3
TORQUE EV
1
FUS 2
J2
1
N-17 - Batt
SUPPLY
8
-24V
+ Batt
- Batt M1/S2
FUS 1
8
R-16 V-8
16
+ Batt + Batt-P
1 2
2
1
1
+24V
BATTERY POWER
N-11 - Batt
3
4
3
M1/E15 M1/E5
LEVEL INFO
1 R-9 + Batt-P
M1/E11
2 V-6
BATTERY CHARGER
DESCENT
7
M1/E16 M1/E4
3
2
Black Black
1
2
3
2
BATTERY CHARGE
M1/E12 M1/E10
2
1 V-5
4
1
Black Black M1/E17a M1/E3 LIFTING
4
M1/E13 M1/E9
vt
V-4
CABLE LOOM
M1/E18 M1/E2 BASKET CONTROL
ANTI-ROLL BARS
G-10
M1/E14 M1/E8
CABLE LOOM
1 3
G-10 BASE CONTROL
7
R-7 ES wire 1
M1/E7
TRANSPORT/WORK
A B
14
R-7
V-8 ES wire 2 V-2
DEVERS
N-11 LED RUN
M1/E6 EMERGENCY STOP
9
V-1
M1/E1
1
J1
MEM
MODULE E18/S6
J-1
Ro-6
Vt-5
V-8
POWER
CONTACTOR
78 XE
B-4
J-2
J-3
677046
9
4
3
16 8
2
1
1
Machines FROM No. 506099
0V
+12V
Main
VARIABLE
contactor
sequence
Operating
+ after ES
+ after ES
discharged
Cancels and replaces Ref. CI 597586-B
Accel. 0-5V
Battery 80%
Incrementation
SPEED DRIVE
80-6-M.69
LOCATION OF THE ELECTRICAL
COMPONENTS
78 XE
80-7-M.69 EN
80-7-M.69
07 / 2004
80-7-M.69
INDEX
A - MACHINES UP TO NO. 505557, EXCEPT NO. 505556........................P 2

MACHINES UP TO NO. 506098........................................................P 3
C - MACHINES FROM NO. 506099 ........................................................P 4
80-7-M.69
1
A - MACHINES UP TO NO. 505557, EXCEPT NO. 505556
Basket console
Distributor
Circuit breaker
Time delay
Electric pump
card
Horn
80-7-M.69 Rotating
light
Fuse
Charger
Descent
electro-valve
Steering FRONT
discharge
unit
Anti-rollover bars
Work/transport sensor
mode sensor
Batteries
Main
contactor Tilt sensor
Variable Base console

speed drive
REAR
2
MACHINES UP TO NO. 506098
Basket console
Circuit breaker
Distributor Master
module E18/S6
Fuse
Slave
module S10 80-7-M.69
Electric pump
Rotating Charger
light
Descent
electro-valve
FRONT
Steering
discharge
unit
Variable Anti-rollover
speed drive bars sensor
Work/transport Batteries
mode sensor
Horn Tilt sensor
REAR Base console

Main
contactor
3
C - MACHINES FROM NO. 506099
Basket console
Circuit breaker
Distributor Master
module E18/S6
Fuse
Slave
module S10
80-7-M.69
Electric pump
Charger
Descent
electro-valve
FRONT
Steering
discharge
unit
Variable Anti-rollover bars

speed drive sensor
Work/transport Batteries
mode sensor
Tilt sensor
Horn
REAR Base console
Main
contactor
4
CHECKING THE OPERATION OF THE
VARIABLE SPEED DRIVES
78 XE
80-8-04-M.69 EN
80-8-04-M.69
07 / 2004
80-8-04-M.69
INDEX

SEVCON VARIABLE SPEED DRIVE .................................................................P 2

CURTIS VARIABLE SPEED DRIVE ...................................................................P 4
80-8-04-M.69
1
SEVCON VARIABLE SPEED DRIVE
Presentation of the variable speed drive A1

- The SEVCON variable speed drive (Fig. A1) enables the electric
2
pump's speed of rotation to be modulated and adapts the hydraulic
flow separately for each movement.
B
+
B
-
M
2
1
Electrical connections for the variable speed drive

A2
Variable speed drive
REAR B+ B-
Fuse
M-
Main
contactor
B
+
B
-
M
2
Circuit
breaker
Electric pump
Main console A1
cable loom
-
D1 +
80-8-04-M.69
Batteries
Charger FRONT
Connecting the variable speed drive
- The control logic signals are sent via the DEUTSCH connector 1
(Fig. A1) to 8 points as per Fig. A3.
2
TERMINAL ASSIGNED TO A3
1 : Variable speed drive power supply.
2 : Speed selection.
3 : Maximum speed.
4 : Validation trigger.
5 : Transport/work position sensor information: 5 6 7 8
- +24V High speed. 4 3 2 1
- 0V Slow speed.
6 : Motor contactor coil.
7 : Electric lifting valve coil:
- Negative when the battery voltage ≥ 18V (Lifting cut-out).
8 : Manipulator analogue voltage input:
- 3,7/3,8V on Neutral on output from manipulator.
- 0V in both directions.
- The connection block's 8 terminals are powered as per the following

table as part of the platform's normal operation depending on the
movement instructed:
CONNECTION BLOCK TERMINAL

MOVEMENT 1 2 3 4 5 6 7 8
Neutral +24V +24V
Dead Man's
+24V +24V +24V +24V
pedal engaged
Proportional basket signal: 3.6V to 0V
Lifting +24V +24V +24V +24V 0V 0V
0V from base
Activated below 2m
Steering +24V +24V +24V +24V 0V Not activated above 2m
Forward/Reverse
Transport position +24V +24V +24V +24V 0V Proportional basket signal: 3.6V to 0V
Forward/Reverse
+24V +24V +24V +24V 0V Proportional basket signal: 3.6V to 0V
Transport position
80-8-04-M.69
Diagnosing faults from the LEDs
- While the SEVCON variable speed drive is operating in normal

mode, the troubleshooting light 2 (Fig. A1) is permanently lit.
- If the variable speed drive detects an operating error, the LED either
goes out or flashes and remains in this status until the problem has
been resolved: please refer to the TROUBLESHOOTING section,
paragraph TROUBLESHOOTING GUIDE FOR THE SEVCON
VARIABLE SPEED DRIVE.
3
CURTIS VARIABLE SPEED DRIVE
Presentation of the variable speed drive B1

- The CURTIS variable speed drive (Fig. B1) enables the electric pum- 4
p's speed of rotation to be modulated and adapts the hydraulic flow
separately for each movement.
US
AT
S1
ST
S2
B-
M- 3
B+
Electrical connections for the variable speed drive

B2
Main
contactor
REAR
Variable
B+ speed drive Circuit
breaker
M-
B-
B+
US
STAT
M-
S2
B-
S1
Electric pump
Fuse
A1
-
Timer cable
D1 +
loom
80-8-04-M.69 4-way connector
Variable speed
drive cable loom
16-way connector
Batteries
Charger FRONT
Connecting the variable speed drive
- The control logic signals are sent via the MOLEX connector 3 (Fig.
B1) to 16 points as per Fig. B3.
4
TERMINAL ASSIGNED TO B3
1 : Spare
2 : Spare
3 : Battery 80% discharged
4 : Main contactor control
5 : Spare 16 15 14 13 12 11 10 9
6 : 0-5V input (manipulator) 8 7 6 5 4 3 2 1
7 : Spare
8 : Spare
9 : Spare
10 : Spare
11 : Spare
12 : Variable speed drive operating instructions
13 : Spare
14 : Spare
15 : + After Emergency Stop
16 : + After Emergency Stop
Machines up to No. 506098 B4

- MOLEX 4-way connection block 5 (Fig. B1) provides connections for
the timer:
1 : Spare
2 : Earth (0V) 4 3
3 : Data transmitted (incrementation)
2 1
4 : Power supply (+ 15V)
Diagnosing faults from the LEDs

80-8-04-M.69
- While the CURTIS variable speed drive is operating in normal mode,

the yellow troubleshooting light 4 (Fig. B1) flashes regularly (1 flash
approximately every second).
- If the variable speed drive detects an operating error, the LED flas-
hes differently and remains in this status until the problem has been
resolved: please refer to the TROUBLESHOOTING section, para-
graph TROUBLESHOOTING GUIDE FOR THE CURTIS VARIABLE
SPEED DRIVE.
5
BATTERY CHARGERS
78 XE
80-8-05-M.69 EN
80-8-05-M.69
07 / 2004
80-8-05-M.69
INDEX
A - MACHINES UP TO NO. 505189: SEVCON CHARGER ...........................P 2
B - MACHINES FROM NO. 505190: ZIVAN CHARGER ...............................P 2
80-8-05-M.69
1
A - MACHINES UP TO NO. 505189: SEVCON CHARGER
Presentation of the charger (Fig. A1) A1
Indicator LEDs
- There are two LEDs 1 (Fig. A1) on each charger. According to their
status, they provide the following information:
Yellow LED Green LED Meaning

Unlit Unlit No main power
Lit Unlit Charging in progress
Lit Lit Charging complete
B - MACHINES FROM NO. 505190: ZIVAN CHARGER
Presentation of the charger (Fig. B1) B1
80-8-05-M.69
4 & 2-pin connectors (Fig. B2) B2 B3

- 4-pin connector 1
Internal to
1 - Red LED - Anode the charger
2
2 - Not connected
3 - Common LED - Cathode 4 3 2
2
4 - Green LED - Anode
2 1 1
External to 1
- 2-pin connector
the charger 3
1 - Common main contactor
2 - Contactor closed 4
2
LED indicator B4
- There are two LEDs on each machine: one on the charger 2 (Fig. B1)
and the other fixed on the base console in the middle of the adhesi-
ve section (Fig. B4). Depending on the colour displayed, they provi- 100%
de the following information:
- Red LED: this indicates the initial charging phase.
- Yellow LED: this indicates that the battery is 80% charged.
80% 80%
- Green LED: this indicates that the battery is 100% charged.
START
- If the LED flashes, this warns of an alarm situation: please refer to the
TROUBLESHOOTING section, paragraph TROUBLESHOOTING
THE ZIVAN CHARGER
80-8-05-M.69
3
ELECTRONIC MODULES
78 XE
80-8-10-M.69 EN
80-8-10-M.69
07 / 2004
80-8-10-M.69
INDEX
A - LOCATION OF THE MODULES ...........................................................P 2
B - PRESENTATION OF THE ELECTRONIC MODULES ..................................P 2
C - LOADING THE MASTER MODULE'S PROGRAM .....................................P 3
D - DIAGNOSTIC AND ADJUSTMENT TOOLS .............................................P 4
E - USING THE POCKET KIT AND THE DISPLAY ........................................P 6
F - SUMMARY OF HOW TO USE THE POCKET KIT AND THE DISPLAY ..........P 8
G - INPUT/OUTPUT TABLES - W517700.048 PROGRAM .........................P 11
80-8-10-M.69
1
A - LOCATION OF THE MODULES
- See the LOCATION OF THE ELECTRICAL COMPONENTS section.
B - PRESENTATION OF THE ELECTRONIC MODULES
1 - MACHINES UP TO NO. 505557, EXCEPT FOR NO. 505556:

TIME DELAY CARD
Presentation of the card (Fig. B1)
B1
8 6 14
17
9
D17
D19
D7 D5
R1 13
K2 K1 D15 D14 D13
R2
7 D9 D10
12
D8 4
D1 D2
5 sec.
Tempo
3
R3
D11 D12 1
10
18
596434 R4
D4 D3
15 16 5 11 2
Allocation of the card's terminals
Connection
block's terminal Allocated to
1 Steer right (+)
80-8-10-M.69 2 Variable speed drive B2
3 Translation electro-valve (X2)
4 Forward translation (+)
5 - Battery
6 Lifting info
7 High speed electro-valve
8 Basket control info
9 Descent electro-valve
10 Steer left (+)
11 Variable speed drive B3
12 Reverse translation (+)
13 Revolving light
14 Descent info
15 Spare
16 Variable speed drive B5
17 LS1 Info
18 Spare
2
2 - MACHINES FROM NO. 505558, PLUS NO. 505556:
ELECTRONIC MODULES
Slave modules 1 & 2 (Fig. B2) each contain an address 4 that must be
configured during their replacement: see the following table.
Module Adress
S10 (Distributor) 3
E12/S3 (Basket console) 10
B2
LED RUN
MODULE
E12/S3
1
E10/E4
8
E10/E11
E10/E5 6
4 E10/E12 3
E10/E6
E10/S2
E10/E7
E10/S3 LED RUN
4 5 6 E10/E8a
3
2
7
8 MODULE S10 + BATT
1 0 9 E10/E9a
Ro-11
- BATT J2 J4
E3/S10 E10/E10a
Ro-10
E3/S9
7
Ro-9 J1 J3 J5
J4 14
E3/S8
Ro-8 CAN high 1
E3/S7
Ro-7 CAN low 2 - BATT
E3/S6
MODULE E18/S6
1
Ro-6 - BATT 3 + BATT

E3/S5
4
Ro-5 COMMUN + 4 CAN low

E3/S4
Ro-4 LED
E3/S3
Ro-3 RUN
E3/S2 CAN high
Ro-2 CAN high 1
E3/S1
3
Ro-12 CAN low 2

6
3
J2
Ro-1 - BATT
COMMUN + 4
5
1
5
+ BATT
E10/E1
E10/S1
E10/E2
1 E10/E3 10
4
8
2
J3
C - LOADING THE MASTER MODULE'S PROGRAM
The master module ensures that the operating logic is supplied free of
any programming. It is therefore advisable to load the appropriate
program. Consult your After-Sales Service to discover the version
you need. 80-8-10-M.69
- Switch the platform off.
- Obtain the memory and insert it in its slot 5 (Fig. B2) with the indexing
slot facing towards the outside of the module.
- The memory loads automatically: the red LED 6 (Fig. B2) is lit throu-
ghout this operation.
- Once loading is complete, the red LED 6 (Fig. B2) starts to flash once
a second.
- Switch the platform off and remove the memory.
3
If the memory stays in place, the machine will refuse to make any
movements.
D - DIAGNOSTIC AND ADJUSTMENT TOOLS
1 - MACHINES UP TO NO. 505557, EXCEPT NO. 505556:

NO DIAGNOSTIC TOOL
2 - MACHINES FROM NO. 505558, PLUS NO. 505556, UP TO

NO. 506098: DIAGNOSTIC POCKET KIT
- The pocket kit, Ref. 597438 (Fig. D1) is used to adjust the platform's D1
various electronic modules
- The kit is also used as a diagnostic tool showing the value for the dif-
ferent parameters and the statuses of all the modules' inputs and out-
puts according to the action instructed
- To use it in this way, refer to paragraph E - USING THE POCKET KIT

AND THE DISPLAY and F - SUMMARY OF HOW TO USE THE
POCKET KIT AND THE DISPLAY in the main menu for viewing the
inputs/outputs.
8
Installation
D2
- Switch off the electricity supply.
- Open the left-hand cowl 7 (Fig. D2).
- Locate the S10 module situated next to the electric pump
- Connect the pocket kit's plug 8 (Fig. D1) to the free socket on the
S10 module at the bottom of the module.
- Switch the machine on. 7

80-8-10-M.69
REAR
Disconnecting
4
3 - FROM PLATFORM NO. 506099: MAINTENANCE DISPLAY
- The maintenance display 9 (Fig. D3), located on the base console is D3

used to adjust the platform's various electronic modules.
- The display is also used as a diagnostic tool showing the values of

the different parameters and the statuses of all the modules' inputs
and outputs according to the action instructed
OP
ST
ST O
P
- To use it in this way, refer to paragraph E - USING THE POCKET KIT
AND THE DISPLAY and F - SUMMARY OF HOW TO USE THE
POCKET KIT AND THE DISPLAY in the main menu for viewing the
inputs/outputs.
9
REAR
4 - DESCRIPTION
- There are the following keys on the front of the pocket kit and the D4
display (Fig. D4):
10 - F1 Access to the service menu and reset.
11 - F2 Navigation within the menus.
12 - - Reducing the parameters.
13 - + Increasing the parameters. F1 F2 P
14 - P Confirming and navigating in the sub-menus.
10 11 12 13 14
- ONLY on the back of the display, there is (Fig. D5): D5

15 - Microprocessor support
Never install the memory in this support. This is strictly reserved

for programming at the factory
1 2
3 4
16 - 4-way connector
80-8-10-M.69
15 16
5
E - USING THE POCKET KIT AND THE DISPLAY
1 - USING THE INPUT/OUTPUT MENUS
- Using the display as a diagnostic tool enables you to know whether

the inputs/outputs for the various modules are activated or not
(some inputs/outputs are given as analogue signals).
- Each of a module's inputs/outputs is symbolized by a number cor-

responding to a function.
Reading the pocket kit
- To access the display's menu, refer to paragraph F - SUMMARY OF

HOW TO USE THE POCKET KIT AND THE DISPLAY. It is read as
follows:
Input or output
Type of module number
M1 : Master module E18/S6
E3 : Slave module S10
E10 : Slave module E12/S3 M1 1 2 3 4 5 6 7 8 9 10
e 0 1 0 0 1 1 0 0 0 1
Input/output status
Type of input/output 0 : Inactive
e : input 1 : Active
s : output WARNING, some inputs/out-
puts are expressed in Volts or
in %
Correspondence between the inputs/outputs
- The tables below show the correspondences between the inputs and
outputs for each of the modules according to the movement selected.
M1 Base Card, Module E18/S6 (Master module)

Pocket kit Input Pocket kit Output
input abbreviation Correspondence output abbreviation Correspondence
codes codes
1 E1 Emergency Stop 1 S1 Horn
Power
2 E2 Basket control 2 S2 contactor
with 6-sec delay
3 E3 Lifting 3 S3 Variable speed drive
operating sequence
4 E4 Descent 4 S4 RAU relay/
80-8-10-M.69
power contactor
5 E5 Spare 5 S5 Flashing light
6 E6 Spare 6 S6a 0-5V for variable
speed drive
7 E7 Spare
8 E8 Spare
9 E9 Spare
10 E10 Spare
11 E11 Spare
12 E12 Work/transport mode sensor
13 E13 Anti-rollover bars sensor
14 E14 Tilt
15 E15 Spare
16 E16 Battery charger
17 E17 analogue Battery 80% discharged
18 E18 Spare
6
E10 Basket card, Module E12/S3 (Slave module)
Pocket kit Input Pocket kit Output
input abbreviation Correspondence output abbreviation Correspondence
codes codes
1 E1 Horn button 1 S1 Spare
2 E2 Torque button 2 S2 Basket fault light
3 E3 Transport selector 3 S3 Buzzer
4 E4 Spare
5 E5 Steer left button
6 E6 Steer left button
7 E7 Dead Man's trigger
8 E8 analogue Manipulator Neutral
9 E9 analogue Manipulator longitudinal signal
10 E10 analogue Spare
11 E11 Spare
12 E12 Emergency Stop
E3 S10 Module card (Slave module)

Pocket kit Output
output abbreviation Correspondence
codes
1 S1 Torque transmission mode EV
2 S2 Forward motion electro-valve
3 S3 Translations election EV
4 S4 Steer right electro-valve
5 S5 Lifting electro-valve
6 S6 Steering discharge EV
7 S7 Steer left electro-valve
8 S8 Brake electro-valve
9 S9 Reverse motion electro-valve
10 S10 Descent electro-valve
2 - USING THE MODULES REFERENCE MENUS
M1 W517700.XXX Software version. W517700XXX is the

EPROM reference containing the program for
this machine: this is available from the Spare
Parts Warehouse.
3 - USING THE SPEED PARAMETER MENUS
- This adjustment range enables adjustment of the acceleration and

deceleration times and the speeds for lifting, translation in transport
position and low position as a percentage. Refer to paragraph F -
SUMMARY OF HOW TO USE THE POCKET KIT AND THE DIS- 80-8-10-M.69
PLAY to access this menu.
TRAC UP Vmax Maximum speed

P001 37% Translation speed as a percentage
TRAC UP Tacc Acceleration time

P002 0.1s Reaction time in seconds
TRAC UP Tdec Deceleration time

P003 1.0s Reaction time in seconds
7
F - SUMMARY OF HOW TO USE THE POCKET KIT AND THE DISPLAY
Cumulative time coun- If a fault occurs, desi-

Horamètre
ter totalisateur
in tenths of an hour en BATTERY : 50 % Battery level
Niveau de in %en“If%0% charge, lifting
batterie Faults xxxxxxxx Si défaut
gnation of the fault
stops”
"Si 0 % de charge alors coupure de levage"
dixième d'heurewhen
“Incrementing SERVICE : 11.0h !Fxx! . Désignation
code (Fxx) du défaut
code de la faute (Fxx)
"incrémentation
the lorsque
pump is started” F1
la pompe est activée"
F2 2
SERVICE : 11.0h/J
P 5sec 3
F1
RESET SERVICE
- 1sec Daily
Remisetimer reset
à 0 de l'horamètre journalier
000.0h/J
P F1
Hold down the two keys
4
Main menu for viewing the
INPUTS
simultaneously and wait a
Menu principal de la visualisation
entries
des entrées few seconds
P 5
F2
M1 1 2 3 4 5 6 7 8 9 10 Status
Etat desofentrées
the entries in themaître
du module master modu-
e 111010010 0 le (E18/S6)
(E18/S6)
F2
P
6
M1 11 12 13 14 Status
Etat desofentrées
e 0 1 1 0 le (E18/S6)
(E18/S6) (continuation)
(suite)
F2
P
7
Status
Etat desofentrées
M1 15 16 17 18 le (E18/S6) (continuation) and viewing of
(E18/S6) (suite), avec visualisation de
e 0 0 7.2V 0 l'entrée
the analogiqueentry
17analogue 17 (en
(involts).
volts).
F2
P
8
Status
Etat desofentrées
the entries in the(E12/S3)
du module module(pupître),
E10 1 2 3 4 5 6 7 8 avec visualisation de l'entrée analogique
(E12/S3) (console) and viewing of the8 8
e 0 1 0 1 0 1 0 38% (en % de laentry
analogue tension).
(in % voltage)
F2
P
9
Status
Etat desofentrées
the entries in the(E12/S3)
du module module(suite),
E10 9 10 11 12 (E12/S3) (continuation)
avec visualisation and
de l'entrée viewing of
analogique 9
e 21% 00% 0 0 the 9 analogue
(en % entry (in % voltage)
de la tension).
P F2
10
Menu principal de la OUTPUTS
Main menu for viewing outputs
visualisation des sorties
P 11
F2 Status
Etat desofsorties
the outputs in the
du module master
maître modu-
(E18/S6),
M1 12345 6 le (E18/S6)
avec and viewing
visualisation of analogique
de la sortie the 6 analo-
6
s 1 1 1 0 1 5.0V (en volts).
gue output (in volts).
F2
P
12
E3 1 2 3 4 5 6 7 8 9 10 Status
Etat desofsorties
the outputs in the
du module module (S10)
(S10),
with
avec selector position
position du (E3)
sélecteur (E3).
s 000000110 0
F2
P
13
E10 123 Status of the module’s outputs (E12/S3)

Etat des sorties du module (E12/S3) (pupître)
(console)
s 010
P F2
36
Main
Menumenu forde
principal viewing
la Internal INTERNAL
80-8-10-M.69 bits
visualisation des bits internes FLAGS
P 37
F2
B1 Status
Etat desofbits
theinternes
masterdumodule’s internal
module maître
0 bits.(E18/S6)
(E18/S6).
P F1
Hold down the two keys
simultaneously and wait a
14
Main
Menumenu fordes
principal viewing the
différentes SOFTWARE
few seconds
various references
références PART NUMBERS
P 15
F2
M1 W517700-XXX Program
Numéro dunumber recorded,
programme master
enregistré,
PN: 50696445 module
référencereference
du module(E18/S6)
maître (E18/S6)
F2
P
16
8
E3
Module reference
Référence (S10)
du module (S10)
PN: 50696441
F2
P
17
E10 Module reference (E12/S3)

Référence du module (E12/S3)
PN: 50696444
F2
P
32
AF 2x16s Display module reference

Référence du module afficheur
PN: 50696438
F2
P
33
AF 2x16p
Display module
Référence reference
du module afficheur
PN: 50696439
P F2
38
Main
Menumenu for des
principal speed para-
paramètres CUSTOM
meters
vitesses PARAMETERS
P 39
F2
+ = increase
= incrémentation TRAC UP Vmax Parametering for travel in work
= =Decrease Paramètrage
- décrémentation P001 34% position at maximum speed
F2
P
40
TRAC UP Tacc Parametering for travel in work
Paramètrage
position at acceleration time
P002 0,1s
F2
P
41
TRAC UP Tdec Parametering for travel in work
Paramètrage
P003 1,0s position at deceleration time
F2
P
42
TRAC DOWN Vmax Parametering for travel in transport
Paramètrage
position at maximum speed
P004 100%
F2
P
43
TRAC DOWN Tacc Parametering for travel in transport
Paramètrage
P005 1,5s position at acceleration time
F2
P
44
TRAC DOWN Tdec Parametering for travel in transport
Paramètrage
position at deceleration time
P006 0,6s
F2
P
45
STEER RIGHT Vmax Parametering to the right at maxi-
Paramètrage
P007 80% mum speed
F2
P
46
STEER RIGHT Tacc Parametering to the right at accele-
Paramètrage
P008 0,5s ration time
F2
P
47
STEER RIGHT Tdec Parametering to the right at decele- 80-8-10-M.69
Paramètrage
ration time
P009 0,1s
F2
P
48
STEER LEFT Vmax Parametering to the left at maxi-
Paramètrage
P010 80% mum speed
F2
P
49
STEER LEFT Tacc Parametering to the left at accele-
Paramètrage
ration time
P011 0,5s
F2
P
50
STEER LEFT Tdec Parametering to the left at decele-
Paramètrage
P012 0,1s ration time
F2
P
51
LIFT Vmax Parametering for raising at maxi-
Paramètrage
mum speed
P013 100%
F2
9
P
52
LIFT Tacc Parametering for raising at accelera-
Paramètrage
P014 1,3s tion time
F2
P
53
LIFT Tdec Parametering for raising at decelera-
Paramètrage
tion time
P015 0,6s
P F2
54
Menu principal des paramètres FACTORY
Main menu for factory settings
usine. SETTINGS
P 55
F2
PRESS ' - ' (5s) Confirmation for resetting factory set-
Confirmation pour
TO CONFIRM tings.
remettre les paramètres usine.
F2
- 5 sec
Cut off the general power supply while still

RECYCLE POWER 56 Couper l'alimentation générale tout en restant
in this display. The factory settings are re-
dans cet affichage.
installed Les paramètres usine seront
during initialisation.
F2
réinsérés lors de l'initialisation.
Request
Demande for access
du code code
pour for the
accéder 18
various machine
aux différents parameters
paramètres machine (Manufacturer’s code)
KEY ? XXXX (code constructeur)
+ - The
les first 2 numbers
2 premiers chiffres P
+ - The
les last 2 numbers
2 derniers chiffres P
F2
80-8-10-M.69
10
G - INPUT/OUTPUT TABLES - W517700.048 PROGRAM
DESCENT LIFTING FORWARD REVERSE

Electro-valve Electro-valve TRANSLATION TRANSLATION
Electro-valve Electro-valve
Platform Platform
co tform
co form
speed com. speed com.
co se
co se
co se
co se
ol
ol
ol
ol
ol
ol
ntr
Ba
Ba
ntr
ntr
Ba
Ba
ntr
ntr
ntr
t
Pla
Pla
w
st
st
Slo
Slo
Fa
Fa
Emergency stop E1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Platform selector E2 0 0 0 0 1 1 1 1 0 0 1 1 1 1 1 1
Lifting E3 0 0 0 0 1 1
Descent E4 1 1 1+t 1+t 0 0
Spare E5
Spare E6
Spare E7
MASTER MODULE "M1" (E19/S6)
Spare E8
Spare E9
Spare E10
Spare E11
F.C. working / transport E12 0 0 1+t 1+t 0 0 1+t 1+t 1 0 1 0 1 0 1 0
mode sensor
F.C. anti-rollover E13 1 1 1 1
bars sensor
Tilt E14 1 1 1 1
Spare E15
Charger Info. E16 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Battery discharged 80% E17a >7.1V >7.1V >7.1V >7.1V
Spare E18
Spare
Beep on all movements OPT1
Beep on translation OPT2

Beep on descent OPT3
Add descent extension OPT4 0 1 0 1 0 1 0 1
Add translation lifting OPT5 0 0
Spare OPT6
Secure AU internal bit B1 0 0 0 0 0 0
Horn button E1
SLAVE MODULE "E10" (E12/S3)
Torque button E2
Transp/working selector E3 0 0 0 0 0 0 1 1 1 1
Spare E4
Beep on steering left E5
Beep on steering right E6
Dead man's trigger E7 1 1 1+t 1+t 1 1 1 1 1 1
Manipulator Neutral E8a >6% >6% >6% >6% >6% >6% >6% >6% >6% >6%
Manip. longitu. signal E9a 9 9 9 9 3 3 9 9 3 3
Spare E10a
F.C. extension E11 1 1 1 1
Emergency stop E12 1 1 1 1 1 1 1 1 1 1 80-8-10-M.69
E3/S2=1 and E3/S3=1 and E3/S8=1 and M1/S3=1 and M1/S5=1 and M1/S6=
E3/S3=1 and E3/S8=1 and E3/S9=1 and M1/S3=1 and M1/S5=1 and M1/S6=
E3/S1=1 and E3/S2=1 and E3/S3=1 and E3/S8=1 and M1/S3=1 and M1/S5=1 and M1/S6=
E3/S1=1 and E3/S3=1 and E3/S8=1 and E3/S9=1 and M1/S3=1 and M1/S5=1 and M1/S6=
E3/S5=1 and M1/S3=1 and M1/S5=1 and M1/S6=
E3/S5=1 and M1/S3=1 and M1/S5=1 and M1/S6=
(Vmin d 1V/Tacc 1.3s./Vmax 5V/Tdec 0.6 s./Vmin to 1V)

(Vmin d 1V/ Tacc 1.3s./Vmax 5V/Tdec 0.6s./Vmin to 1V)
(Vmin d 1.10V/ Tacc 0.1s./Vmax 1.85V/Tdec 1s./Vmin to 1.10V)
(Vmin d 1.10V/ Tacc 0.1s./Vmax 1.85V/Tdec 1s./Vmin to 1.10V)


E3/S10=1 and M1/S5=1
E3/S10=1 and M1/S5=1
11
80-8-10-M.69
1
1
1
0
1
1
1
1
Ste
<6%
E3/S4=1 and M1/S3=1 and M1/S5=1 and M1/S6 = e
(Vmin d 0V/ Tacc 0.5s/Vmax 4V/Tdec 0.1s/Vmin to 0V)
on ring
ly
1
1
1
0
1
1
1
1
Ste
>6%
E3/S4=1 and 0.5V on S6 if E12 = 0 tra erin Electro-valve
ns g +
STEER RIGHT
(Slow speed) lat

ion
L
E3/S7=1 and E3/S6=1 and M1/S3=1 and M1/S5=1 and M1/S6 =
1
1
0
1
1
1
1
1
1
Poow
(Vmin d 0V/ Tacc 0.5s/Vmax 4V/Tdec 0.1s/Vmin to 0V)
s.
Hig
E3/S7=1 and M1/S3=1 and M1/S5=1 and M1/S6 =
Steering
1
1
0
1
1
1
0
1
1 Po h
(Vmin d 0V/ Tacc 0.5s/Vmax 4V/Tdec 0.1s/Vmin to 0V) s.
L
E3/S6=1 and E3/S7=1 and 0.62V on S6 if E12=0
1
1
0
1
1
1
1
1
1
Poow
(Slow speed) s.
STEER LEFT
Electro-valve
Hig
E3/S7=1 and 0.62V on S6 if E12 = 0
1
1
0
1
1
1
0
1
1
Po h
Steering +
only position transl. pos.
(Slow speed) s.
<6% <6% >6% >6%

Ba
co se
ntr
ol
1
1
1
1
1
1
1
1
TORQUE
Pla
E3/S1=1
Electro-valve
co tform
ntr
ol
1
1
0
S1=1 D
mo esce
(0.07 second to 1 then 1.5 seconds to 0 alternately) ve
me nt
12
9
1
0
1
1
nts
>6%
1
1
Pla
S1=1 co tform
ntr
ol
0
1
0
0
1
1
1
1
1
1
9
1
0
1
1
>6%
Horn
0
0
1
0
1
1
1
1
Be
e
1
1
1
3
1
0
1
1
1
mo p on
v a
>7,1V >7,1V
S1=1 (O eme ll
(1 second to 1 then 1 second to 0 alternately) pti
o nts
1
1
1
9
1
1
1
1
=O n 1
n)
1
1
1
3
1
1
1
1
1
1
1
1
1
0
1
1
1
1
1
1
1
0
1
1
1
1
>6% >6% >6% <6% <6%

Secure internal bit
Buzzer Basket Power basket
Horn
fault light contactor emergency stop
(O sla n
(O sce on
sto ency
pti tion
co tform
o
nt
n) 2
=O ion 3
co se
tra eep
de ep
ol
ol
n
erg
Ba
Til
Til
ntr
ntr
p
o
Be
n)
Pla
B
n
pt
=O
Em
Emergency stop E1 1 1 1 1 1 1 1 1
Platform selector E2 1 1 0 1 0 1 1 1 0 1 0
Lifting E3 0 0
Descent E4 1 0
Spare E5
Spare E6
Spare E7
MASTER MODULE "M1" (E19/S6)
Spare E8
Spare E9
Spare E10
Spare E11
F.C. working / transport E12
mode sensor
F.C. anti-rollover E13
bars sensor
Tilt E14 0 0 0
Spare E15
Charger Info. E16 1 1 1 1
Battery discharged 80% E17a
Spare E18
Spare
Beep on all movements OPT1
Beep on translation OPT2 1 1

Beep on descent OPT3 1 1
Add descent extension OPT4
Add translation lifting OPT5
Spare OPT6
Secure AU internal bit B1 0 0
Horn button E1
SLAVE MODULE "E10" (E12/S3)
Torque button E2
Transp/working selector E3 1 1 0
Spare E4
Beep on steering left E5
Beep on steering right E6
Dead man's trigger E7 1 1 1
Manipulator Neutral E8a >6% >6% >6%
Manip. longitu. signal E9a 9 3 9
Spare E10a
F.C. extension E11
Emergency stop E12 1 1 1 1 0 1 80-8-10-M.69
(0.07 second to 1 then 1.5 second to 0 alternately)
(1 second to 1 then 1 second to 0 alternately)

(NB. B1s = set internal memorised bit)
(NB. B1s = set internal memorised bit)

(6 seconds after S4)
(6 seconds after S4)

S4=1 and S2=1
S4=1 and S2=1
E2/S2=1
E2/S3=1
E2/S2=
B1s=
S1=1
S1=1
B1r=
13
POSITION AND ADJUSTMENT OF THE
CONTACTORS
78 XE
80-8-81-M.69 EN
80-8-81-M.69
07 / 2004
80-8-81-M.69
INDEX
A - POSITION OF THE SENSORS .............................................................P 2
B - ADJUSTING THE TILT SENSOR .........................................................P 2
C - ADJUSTING THE WORK/TRANSPORT MODE SENSOR ............................P 3
D - ADJUSTING THE ANTI-ROLLOVER BARS EXTENDED SENSOR.................P 4
80-8-81-M.69
1
A - POSITION OF THE SENSORS
- See the LOCATION OF THE ELECTRICAL COMPONENTS section.
B - ADJUSTING THE TILT SENSOR
- Set the platform on an even horizontal surface and leave it switched B1

on. REAR
- Remove the protective plate 1 (Fig. B1) (4 screws, No. 7 spanner or

No. 5 hex spanner) from the tilt sensor and then open the right-
hand cowl 2 (Fig. B1).
1
4
2
Machines up to No. 505557, except No. 505556 B2

- Check that the buzzer is not working; if it sounds, proceed to tighten
or loosen the nuts 3 (Fig. B2) (3 nuts, No. 8 spanner) situated at the
top of the columns until the buzzer stops.
Machines from No. 505558, plus No. 505556 B3
The tilt sensors are factory pre-set. The only parameter that can be
adjusted is the sensor initialisation parameter. 6
5
BLEU
BLUE 0V 0V
80-8-81-M.69
MARRON+24V
BROWN +24V
- Take an electric wire 0.5m long, stripped at both ends and connect VERT
GREEN
one end to the "-" terminal 4 (Fig. B1) on the battery unit. 0V ≥DEVERS
0V > TILT
- Take the wire to the tilt sensor compartment 1 (Fig. B1).

24V 24V
<DEVERS
<TILT
Check that the sensor's angle recorded in 5 (Fig. B3) agrees with the
machine's manufacturer's plate.
2
- Grasp the unconnected wire 6 (Fig. B3) coming from the sensor.
- Remove the plastic cap 7 (Fig. B3) (flat screwdriver) from the end of
the wire.
- Take the wire connected to the battery and connect it to the one from
the tilt sensor:
- The green LED under the sensor flashes several times.
- It stops flashing when the sensor is initialised.
- It then lights permanently.
The green LED is lit in normal operation. It only goes out when the
angular tilt value is exceeded.
C - ADJUSTING THE WORK/TRANSPORT MODE SENSOR
- Set the basket to the low position. C1

- Locate the cam/sensor assembly 8 (Fig. C1) situated at the rear of 8
the platform on the right-hand side: this is accessed from the back,
between the running board and the scissors.
OP
ST
ST O
P
REAR
- Loosen the sensor's fixing screws 9 (Fig. C2) (2 screws, No. 7 span- C2
ner).
10
- Loosen the cam's locking screw 10 (Fig. C2) (No. 3 hex spanner).
80-8-81-M.69
3
- Position the sensor and the cam, ensuring that: C3
- The sensor's roller is centred on the width of the cam.
- The sensor's roller is in contact with the bottom of the
milling on the cam (Fig. C3) but that the cam is not opera-
ted.
- Tighten the screws.
- Instruct the basket to rise until its floor reaches a height of 2m above
the ground: stop lifting.
- Check that the sensor is no longer in contact with the cam's milled C4
section (Fig. C4).
- Instruct the basket to rise fully and then lower it. Check that when its
floor is 2m above the ground:
- Descent stops for a few seconds.
- Descent continues but the beeper sounds intermittently
until the basket reaches the low position.
D - ADJUSTING THE ANTI-ROLLOVER BARS EXTENDED

SENSOR
- Set the platform to the low position. D1

- Remove the covering plate 11 (Fig. D1) (4 screws, No. 13 spanner):
WARNING, on machines up to No. 505557, plus No. 505556, the bat- 11
tery charger is fastened to this plate.
FRONT
80-8-81-M.69
- Locate the sensor/roller assembly via the opening (Fig. D2). D2
- Loosen the sensor's fixing screws 12 (Fig. D2) (4 screws, No. 7 span- 13
ner).
- Loosen the cam's fixing screws 13 (Fig. D2) (1 screw, No. 7 spanner).
12
4
- Position the sensor with respect to the cam, ensuring that: D3
- The sensor's roller is centred on the width of the cam.
- The sensor's roller is in contact with the bottom of the
milling on the cam (Fig. D3) but that the cam is not opera-
ted.
- Tighten the screws.
- Instruct the basket to rise until its floor reaches a height of 1m above
the ground.
- Check that the roller has pivoted and that the sensor is activated (Fig. D4
D4).
- Replace the front right-hand cowl and fasten it down.
80-8-81-M.69
5
TESTING THE MANIPULATORS
78 XE
80-8-85-M.69 EN
80-8-85-M.69
07 / 2004
80-8-85-M.69
INDEX

MEC CONSOLE............................................................................................P 2

SAGELEC CONSOLE ....................................................................................P 3
80-8-85-M.69
1
A - MACHINES UP TO NO. 505557, EXCEPT NO.
505556: MEC CONSOLE
- Use the basket console (Fig. A1). A1

- Use a voltmeter.
- Select translation mode and then lifting via the switch 1 (Fig. A1).
4
Then operate the manipulator's body 2 (Fig. A1) and check the
1
values displayed on the voltmeter at the connection block's teminals
(Letters in brackets) when the manipulator s in Neutral, forward and
backward (Figs. A2 and A3).
3
- Operate the manipulator's dead man's pedal 3 (Fig. A1) and check
the values displayed on the voltmeter (Fig. A4) at the connection
block's (Letters in brackets). Then operate the manipulator's steering 2
knobs 4 (Fig. A1) and check the values displayed on the voltmeter
(Fig. A5) at the connection block's terminals (Letters in brackets).
A2
(L) 0V (L) 0V (L) 0V

(K) 0V (K) 3,75V (K) 0V
(H) (H) (H) +24V
(P) +24V (P) (P)
FORWARD
TRANSLATION NEUTRAL
NEUTRE REAR
TRANSLATION
TRANSLATION
AVANT TRANSLATION
ARRIERE
A3
(L) 0V (L) 0V (L) 0V

(K) 0V (K) 3,75V (K) 0V
(R) (R) (R) +24V
(W) +24V (W) (W)
DESCENT
DESCENTE NEUTRAL
NEUTRE LIFTING
ELEVATION
A4
80-8-85-M.69
(U) 0V (U) +24V
TRIGGER IN
GACHETTE AUNEUTRAL
NEUTRE TRIGGERACTIONNEE
GACHETTE ENGAGED
2
A5
(J) 0V (J) V (L) +24V

(B) +24V (B) V (B) +24V
(C) +24V (C) V (C) 0V
Mode Mode Mode
"DRIVE" +24V "DRIVE" +24V "DRIVE" +24V
STEER LEFT
DIRECTION GAUCHE NEUTRAL
NEUTRE STEER RIGHT
DIRECTION DROITE

SAGELEC CONSOLE
With the Pocket kit and the display
- Please refer to the CHECKING THE OPERATION OF THE ELEC-

TRONIC MODULES section, paragraphs D - DIAGNOSTIC AND
ADJUSTMENT TOOLS and F - SUMMARY OF HOW TO USE THE
POCKET KIT AND THE DISPLAY for locating and connecting the
equipment.
- Use the basket console (Fig. B1) and position yourself next to the left- B1
hand box or the base console.
7
- Select the menu you wish by following the summary.
5
- Act as follows: 6
- Pull the trigger 5 (Fig. B1).
- Push the manipulator's lever 6 (Fig. B1) forwards without
operating the trigger.
- Pull the manipulator's lever 6 (Fig. B1) backwards without
operating the trigger.
- Press the top left-hand button 7 (Fig. B1). 8
- Press the top right-hand button 7 (Fig. B1).
- For each action, check the status of the inputs and outputs in Neutral
on the display screen and then when the lever is in the maximum
position.
With a voltmeter
- Take a voltmeter into the platform's basket.
- Open the front of the basket console 8 (Fig. B1) (flat screwdriver) and
then locate the wires (Fig. B2).
B2
80-8-85-M.69
JOYSTICK OLD
ANCIENNE NEW
NOUVELLE
NORME STANDARD
STANDARD NORME
BLUE
BLEU YELLOW/BLACK
JAUNE/NOIR (STEER LEFT BUTTON)
(BP DIRECTION GAUCHE)
BLACK
NOIR GREY/BLACK
GRIS/NOIR (STEER RIGHT BUTTON)
(BP DIRECTION DROITE)
GREY
GRIS (Y)
(Y) GREY
GRIS(Y)
(Y) (LONGITUDINAL AXIS)
(AXE LONGITUDINAL)
VIOLET
VIOLET GREEN/BLACK
VERT/NOIR (DEAD MAN'SHOMME
(GACHETTE TRIGGER)
MORT)
RED
ROUGE BROWN/BLACK
MARRON/NOIR (SUPPLY TO TRIGGER)
(ALIMENTATION - GACHETTE)
PINK
ROSE WHITE/BLACK
BLANC/NOIR (SUPPLY TO STEERING
(ALIMENTATION BUTTON)
- BP DIRECTION)
Y BROWN
MARRON BROWN
MARRON (LONGITUDINAL AXIS)
(AXE LONGITUDINAL)
WHITE
BLANC WHITE
BLANC (+
( +BATTERY)
BATTERIE)
GREEN
VERT GREEN
VERT (MANIPULATOR NEUTRAL POINT)
(POINT MILIEU MANIPULATEUR)
3
- Take the measurements with the pins, placing them in contact with
the clips on the connection block.
- Testing the analogue outputs: operate on the manipulator's body 6

(Fig. B1) moving it forwards and backwards and checking the values
shown on the voltmeter (Fig. B3).
B3
G (Y)
6V G (Y) 12V GRIS
GREY(Y)
(Y) 18V G (Y)
12V G
V GREEN
0V VERT 12V GV
X X
0V B M 0V MARRON
BROWN X 0V B
M
Manipulateur
Manipulator versREAR
toTHE NEUTRAL
NEUTRE Manipulateur
Manipulatorvers L'AVANT
FORWARD
L'ARRIERE - RECUL
REAR TRANSLATION FORWARD AVANCE
TRANSLATION
- Testing the logic outputs: Operate the manipulator's dead man's

pedal 5 (Fig. B1) and check the values shown on the voltmeter (Fig.
B4). Then operate the manipulator's steering buttons 7 (Fig. B1) and
check the values displayed on the voltmeter (Fig. B5).
B4
OLD
ANCIENNE NEW
NOUVELLE OLD
ANCIENNE NEW
NOUVELLE
STANDARD
NORME STANDARD
NORME STANDARD
NORME STANDARD
NORME
V VIOLET
VIOLET GREEN/BLACK
VERT/NOIR 0V VIOLET GREEN/BLACK
VERT/NOIR
RED
ROUGE BROWN/BLACK
MARRON/NOIR RED
ROUGE BROWN/BLACK
MARRON/NOIR
0V BROWN
MARRON BROWN
MARRON 0V BROWN
MARRON BROWN
MARRON
Trigger in
Gachette au Trigger
Gachette
NEUTRAL
NEUTRE ACTIVATED
ACTIONNE
B5
OLD
ANCIENNE NEW
NOUVELLE
O N.
A. S N
N.SN. STANDARD
NORME STANDARD
NORME ON.
A. S N
N. SN.
N (D)
B(R) G/N
G/B V BLACK(R)
NOIR (D) GREY/BLACK
GRIS/NOIR 0V N
B(R)
(D) G/B
G/N
80-8-85-M.69 0V B(L)
B (G) J/N
Y/B V BLUE
BLEU(L)
(G) YELLOW/BLACK
JAUNE/NOIR B(L)
B (G) Y/B
J/N
R
P B/N
W/B PINK
ROSE WHITE/BLACK
BLANC/NOIR P
R W/B
B/N
0V B
M BM 0V BROWN
MARRON BROWN
MARRON 0V M
B BM
Direction
Steer NEUTRE
NEUTRAL Steer
Direction
GAUCHE
LEFT RIGHT
DROITE
The "Vs" show that a random voltage can be measured on

the indicated wire.
4
GROUPS 75
HYDROSTATIC
REMOVING THE MOTORS AND THE
WHEEL BRAKES
78 XE
75-2-41-M.69 EN
75-2-41-M.69
07 / 2004
75-2-41-M.69
INDEX
A - DISMANTLING THE TRACTION MOTOR ................................................P 2
B - DISMANTLING THE BRAKE ...............................................................P 4
75-2-41-M.69
1
A - DISMANTLING THE TRACTION MOTOR
- Set the wheels straight, switch off the electrical power using the bat- A1
tery cut-out. 3
- Remove the split pins from the centre of the hubs 1 (Fig. A1) (2 pins,
multi-grip pliers).
- Loosen the fixing nuts on the hubs 2 (Fig. A1) (2 nuts, No. 36 span-
1
ner) by one turn.
- Lift the front of the platform with a hoist and a sling attached to the 2
anchoring points 3 (Fig. A1) and then put chocks under the chassis.
4
FRONT
- Remove the fixing nuts from the wheels (10 nuts, No. 21 spanner)
and remove the wheels 4 (Fig. A1).
- Remove the fixing nuts from the hubs and remove the hubs 5 (Fig. A2
A2) with an extractor: WARNING, keep the clevis pins.
6
- Locate and remove the hoses supplying the wheel motors 6 (Fig. A2)
(No. 24 spanner). 8
- Remove the fixing screws from the wheel motors 7 (Fig. A2) (8
screws; No. 19 spanner) and remove the wheel motors 8 (Fig. A2): If
necessary, for better accessibility, switch the platform on and instruct
the hubs to pivot to the maximum on one side or the other.
75-2-41-M.69 7
RE-ASSEMBLY
- To refit the hubs:

- Remember the clevis pins.
- Tighten the nuts on the hubs (with the chassis on chocks):
maximum torque 7.5 daN/m then fit a split pin.
- Refit the wheels: tightening toque for the nuts: 7 daN/m.
- Remove the chocks from under the chassis.
- Proceed to test the machine.
2
MOTEUR DE ROUES
RAD MOTOR
10 DC 41 MOTOR DE RUEDA 78 XE
WHEEL MOTOR
7
PO A
DI CHE
C B
JU HT TTE
E U
SE GO NG DE C
AL D SA JO
KI E J TZ INT
T UN S D 8
TA
S E
F F
3
9
6
5
4
3
D
C 1
B
A
2
P.A.O
10 / 07 / 03
75-2-41-M.69
B - DISMANTLING THE BRAKE
- Set the machine on a horizontal surface. B1

- Put chocks under the machine's front wheels (Fig. B1).
- Set the platform to maintenance position: B2

9
stay 10 (Fig. B2) to be able to swivel and be placed verti-
cally, facing downwards.
- Instruct the basket to lower gently until the stay's fork 11
(Fig. B2) comes into contact with the bearing 12 (Fig. B2). 10
75-2-41-M.69 11
12
REAR
- Lift the rear of the platform with a hoist and a sling attached to the B3
anchoring points 13 (Fig. B3) or with the forks of a fork lift truck using
the special passageways fro the forks 14 (Fig. B3) and then put OP
ST
ST O
P
chocks under the chassis.
15
- Remove the fixing nuts from the wheels 15 (Fig. B3) (10 nuts, No. 21
spanner) and remove the wheels 16 (Fig. B3).
13
14
REAR 16
- Remove the brake control hoses and couplings 17 (Fig. B4) (span- B4
ners Nos. 17 and 19).
17
- Remove the brake fixing screws 18 (Fig. B4) (8 screws; No. 19 span-
ner) and remove the brakes 19 (Fig. B4). 19
RE-ASSEMBLY

- Tightening toque for the wheel nuts: 7daN/m. 18
- Proceed to test the machine.
4
FREIN DE ROUES
RAD BREMSE
10 DC 43 FRENO DE RUEDA 78 XE 81 XE
WHEELS BRAKE
KI
T
A
RE D E B
KI PA R R E P
T
RE D E A TU ARA C
P A R E R S T IO
I R PA A T N D
KI RA Z
T CI
K ÓN E 2
F
G
H
I
J
K
J
I
5
H
F
G
E
D
C
B
A
1
P.A.O
12 / 07 / 02
75-2-41-M.69

78 Xe SM

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REPAIR MANUAL

This document has been printed from my e doc

- Battery 4 elements, each of 6V-180 Ah

- Control system Electro-hydraulic

- Lifting system Single scissors

- Platform movement speed:

- Time to raise/lower scissors 20 seconds on lowering

- Operating height 7760 mm

- Overall basket size:

- Platform weight, empty 1380 +/- 30 Kg

- Handleadle gradient 25%

- Inclinaison, alarm activation 3,5% or 2°

- Maximum authorized wind speed 0 km/h

FRONT / REAR TYRES

14” x 4,5” Rubber tyre 332 kg 800 kg 75 cm2 10,7 daN/cm2

- Wheel nut tightening torque:

WHEAL GEARED MOTORS

DESIGNATION REFERENCE REPLACE AFTER

1 - Hydraulic oil filter cartridge 596353 900h

COMPONENTS TO LUBRICATE CAPACITY RECOMMENDATION PACK REFERENCE

1.HYDRAULIC OIL RESERVOIR 12 Litres MANITOU hydraulic oil 20 L. 582 297

2.WHEEL MOTOR MOUNTING SHELL Retinax HD Cartridge 161 589

- If there is a power failure or a translation problem, the machine can A

- Open the left-hand cowl 1 (Fig. A).

- Move the machine: WARNING, if the machine is unpowered the stee-

Warning: when the brakes are loosened and the platform is in

A - DISMANTLING THE DISTRIBUTOR ELEMENTS .......................................P 2

B - MACHINES UP TO NO. 506004 PLUS NO 506006 - EXCEPT FOR MACHINE

B1 - MAIN CIRCUIT ...........................................................................P 3

C - MACHINES FROM NO. 506005 PLUS NOS 504839, 505166, 505869,

C1 - MAIN CIRCUIT ...........................................................................P 6

D - DISTRIBUTOR DETAILS ...................................................................P 9

- Open the left-hand cowl 1 (Fig. A) and remove it.

70-2-56-M.69 - Locate the distributor 2 (Fig. B). B

- Perform the above operations in reverse order.

- Please refer to the Index to ensure you re-assemble correctly.

REAR Manual brake Return to

Hydraulic unit Right

Manual brake Return to

Hydraulic unit Right

LEFT-HAND MOTOR REVERSE 7 Steering selector No. 7

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

B - DISMANTLING THE LIFTING CYLINDER ...............................................P 4

- Cut the power to the platform using the battery cut-out.

- Remove hydraulic hoses 2 (Fig. A2) (No. 19 spanner) supplying the A2

- Test the assembly.

Course - Hub - Carrera - Stroke : 204 mm

- Set the platform to maintenance position: B1

- Remove the return hose 14 (Fig. B5) (screwdriver). B5

Course - Hub - Carrera - Stroke : 820 mm

A - PRESSURE SETTING FOR THE MAIN UNIT ...........................................P 2

B - PRESSURE SETTING FOR THE STEERING DISCHARGE UNIT: FROM NO.

A - PRESSURE SETTING FOR THE MAIN UNIT

Setting the main pressure restrictor (N° 2 on hydraulic layout): A1

- Use the battery cut-out to switch on the platform.

- Connect the manometer to the pressure port 2 (Fig. A2). A2

Adjusting the steering cylinder's pressure restrictor (N°6 on A3

- Connect the manometer to the pressure port 2 (Fig. A3).

- Check on the manometer that the steering cylinder's pressure res-

- Disconnect the manometer.

Setting the lifting pressure restrictor (N°3 on hydraulic layout):

- Place a load of 230 kg (maximum load) in the basket.

B - SETTING THE PRESSURE ON THE STEERING DISCHARGE