Manitou 120 AETJ L Repair Manual Download

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REF : 547 363 EN (05 / 04)

ACCESS

PLATFORM

120 AETJ

REPAIRS MANUAL

BP 249 Z. I.

44 158 ANCENIS CEDEX FRANCE

TEL : +33 (0)2 40 09 10 11

YOUR CONCESSIONAIRE

Summary of Contents for 120 AETJ L

Page 1: ...REF 547 363 EN 05 04 ACCESS PLATFORM 120 AETJ REPAIRS MANUAL BP 249 Z I 44 158 ANCENIS CEDEX FRANCE TEL 33 0 2 40 09 10 11 YOUR CONCESSIONAIRE R...

Page 2: ......

Page 3: ...1st EDITION 06 2002 ISSUE DATE COMMENTS 06 2002 1st edition 11 2003 Updated 12 2003 Variable speed drive unit parameters modification 05 2004 Updated 35 8 21 M 84 80 6 M 84 80 8 11 M 84 80 8 85 M 84...

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Page 5: ...ving the cylinders 120 AETJ 70 5 M 84 EN Hydraulic pressure 120 AETJ 70 6 M 84 EN Hydraulic layout 120 AETJ 80 Electricity 80 2 11 M 84 EN Removing the variable speed drive unit 120 AETJ 80 2 12 M 84...

Page 6: ...SECTIONS MACHINES 80 8 85 M 84 EN Testing the manipulator 120 AETJ 80 8 86 M 84 EN Positioning and adjusting the contactors 120 AETJ 100 Troubleshooting 100 M 84 EN Troubleshooting 120 AETJ 80 8 85 M...

Page 7: ...GENERAL POINTS GROUPS 0...

Page 8: ......

Page 9: ...0 1 M 84 TECHNICAL CHARACTERISTICS 120 AETJ 0 1 M 84 EN 11 2003...

Page 10: ...0 1 M 84...

Page 11: ...1 0 1 M 84...

Page 12: ...supply 48 V Output 3 7 KW Cubic capacity 4 8 cm3 Pressure 200 bars ELECTRIC WHEEL MOTORS Type T 17 2 KW ELECTRICAL CIRCUIT Battery 48 V 300 Ah Charger 50 Ah single phase BOARD FUSES Motherboard 10 A O...

Page 13: ...0 mm Floor height 9950 mm Max off centring 7000 mm Access platform weight Empty 6550 kg Under nominal load 6780 kg No of gears 2 Traversable gradient 25 Max permissible slope 5 or 3 TYRES Tightening t...

Page 14: ...4 0 1 M 84 DIMENSIONS A1 5477 A2 3740 B 1200 C 2163 D 1650 E 104 F 2228 G 1550 H 3250 I 3340 J 2138 120AETJ H G I J F A1 A2 D C E B...

Page 15: ...5 0 1 M 84 K1 2483 K2 3242 K3 6506 K4 4353 L1 9950 L2 8794 L3 4773 L4 595 K1 K2 L1 L2 K3 K4 L3 L4 3 2 1 4 5 6 7 8 9 10 11 12 2 2 3 4 8 1 0 1 5 6 7 2 2 3 4 8 5 6 7 120AETJ...

Page 16: ...MOTOR EACH ONE 0 8 Litre SHELL 2 L 661 998 SPIRAX OIL A90 20 L 661 950 50 L 661 950 TURRET ROTATION MOTOR 1 5 Litres GENERAL GREASING SHELL RETINAX HD cartridge 161 589 GREASE 400 Gr BEARING TURRET R...

Page 17: ...REDUCER GROUPS 30...

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Page 19: ...30 2 63 M 84 REMOVING THE WHEEL REDUCER BRAKE 120 AETJ 30 2 63 M 84 EN 11 2003...

Page 20: ...30 2 63 M 84...

Page 21: ...es Remove the electric motors 3 Fig B 8 bolts No 9 hex spanner Remove the brake control hoses 5 Fig C No 19 spanner Place a MA8S bung in each hose to prevent any oil leaks Remove the reducers 4 Fig B...

Page 22: ...3 REDUCTEUR DE ROUES RAD REDUKTION REDUCTOR DE RUEDA WHEEL REDUCING 2 3 4 5 6 7 8 9 10 11 12 17 18 19 20 13 14 15 16 21 22 19 23 24 25 26 1 JUSQU A LA MACHINE BIS DER MASCHINE HASTA LA MAQUINA UP TO M...

Page 23: ...RAD REDUKTION REDUCTOR DE RUEDA WHEEL REDUCING 36 2 3 4 5 6 7 8 9 10 11 20 13 12 14 15 16 17 18 19 21 22 23 3 24 25 22 26 27 28 29 30 35 31 29 32 1 34 33 A PARTIR DE LA MACHINE AB DER MASCHINE A PARTI...

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Page 25: ...STEERING AXLE GROUPS 35...

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Page 27: ...35 8 21 M 84 FREE WHEELING 120 AETJ 35 8 21 M 84 EN 05 2004...

Page 28: ...35 8 21 M 84...

Page 29: ...els must be able to turn freely If possible raise the platform to free the drive wheels in order to faci litate the operation Loosen bolt 1 Fig A on each wheel 22 mm from the edge up to the resistance...

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Page 31: ...ARMS PLATFORM GROUPS 55...

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Page 33: ...55 2 21 M 84 REMOVING THE WEAR PADS 120 AETJ 55 2 21 M 84 EN 11 2003...

Page 34: ...55 2 21 M 84...

Page 35: ...1 55 2 21 M 84 A REMOVING THE TELESCOPE CYLINDER WEAR PADS P 2 B REMOVING THE TELESCOPE ARM WEAR PADS P 2 C REMOVING THE MOBILE TUBE WEAR PADS P 2 INDEX...

Page 36: ...er Pay attention to the position of the adjustment plates 3 Fig B1 Remove the pads RE ASSEMBLY Same operations as above in reverse order If necessary position the adjustment plates Plates 3 Fig B1 see...

Page 37: ...attention to the position of the adjustment plates 7 Fig C2 RE ASSEMBLY Same operations as above in reverse order the base of the jib pads must be forcibly emmancher with a hammer If necessary positi...

Page 38: ...AGUILON TELESCOPICO TELESCOPIC JIB 4 24 23 19 20 3 20 21 22 45 44 1 2 12 13 12 14 16 15 18 42 24 23 5 26 25 28 6 28 27 17 9 10 7 8 8 31 32 43 33 34 35 41 40 39 36 37 38 34 11 30 29 JUSQU A LA MACHINE...

Page 39: ...HYDRAULICS GROUPS 70...

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Page 41: ...70 2 52 M 84 REMOVING THE DISTRIBUTOR ELEMENTS 120 AETJ 70 2 52 M 84 EN 11 2003...

Page 42: ...70 2 52 M 84...

Page 43: ...writing on the yellow rings on the power cable looms and then remo ve the loom connectors 2 Fig A flat screwdriver Remove the bolts 3 Fig B 4 bolts No 17 spanner Remove the element s requiring to be...

Page 44: ...3 11 10 1 17 15 12 2 70 2 52 M 84 1 Distributor 2 Plug 3 35 BAR reducer 4 150 BAR restrictor 5 Main 180 BAR restrictor 6 Electro valve 7 Plug 8 180 BAR balancing valve 9 80 BAR overload valve 10 Elect...

Page 45: ...70 2 80 M 84 REMOVING THE CYLINDERS 120 AETJ 70 2 80 M 84 EN 11 2003...

Page 46: ...70 2 80 M 84...

Page 47: ...1 70 2 80 M 84 A REMOVING THE STEERING CYLINDER P 2 B REMOVING THE TELESCOPE CYLINDER P 4 C REMOVING THE ANTI ROLLOVER BAR CYLINDERS P 6 INDEX...

Page 48: ...e REMOVING THE DISTRIBUTOR ELEMENTS section Mark and remove the hydraulic hoses No 19 spanner Remove the articulation shaft 2 Fig A2 1 bolt No 13 spanner Remove the articulation shaft 3 Fig A3 2 circl...

Page 49: ...IK Lenkungzylinder HYDRAULICO Cilindro de direcci n HYDRAULIC Steering cylinder P O C H E T T E D E J O I N T S D I C H T U N G S A T Z J U E G O D E J U N T A S S E A L K I T F E D C B A 2 G 3 4 A B...

Page 50: ...8 Fig B1 2 bolts No 10 spanner Remove the articulation shaft 7 Fig A3 2 circlips circlips clamp Remove the cylinder supply hoses 9 Fig B2 No 24 spanner Remove the articulation shaft 6 Fig A2 1 bolt N...

Page 51: ...enstroll zylinder HYDRAULICO Cilindro de telescopaje HYDRAULIC Telescope cylinder 1 3 P O C H E T T E D E J O I N T S D I C H T U N G S A T Z J U E G O D E J U N T A S S E A L K I T F E D C B A 2 G 4...

Page 52: ...batteries see the REMOVING THE TRACTION BATTERIES section Decompress the cylinder supply hoses see the REMOVING THE DISTRIBUTOR ELEMENTS section Mark and remove the hydraulic hoses 11 Fig C1 No 19 sp...

Page 53: ...K Stabilizer zylinder HYDRAULICO Cilindro de estabilizador HYDRAULIC Stabilizer cylinder 1 P O C H E T T E D E J O I N T S D I C H T U N G S A T Z J U E G O D E J U N T A S S E A L K I T F E D C B A 2...

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Page 55: ...70 5 M 84 HYDRAULIC PRESSURE 120 AETJ 70 5 M 84 EN 11 2003...

Page 56: ...70 5 M 84...

Page 57: ...to 40 bar Disconnect the manometer and re insert the bung Adjusting the pressure reducer Hydraulic layout No 7 Switch the platform on Connect the manometer to pressure port M1 Fig C Fully extend the...

Page 58: ...F No 24 spanner No 17 spanner to 180 bars Switch off the machine remove the manometer and then reconnect hose 5 in its original configuration Adjusting the compensation tilt sequencing valve Hydraulic...

Page 59: ...ng and monitor the pressure displayed on the manometer Fig J On start up a pressure spike of up to 210 bar Rapid drop in pressure to below 100 bar Slow drop and then very slow drop in pressure down to...

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Page 61: ...70 6 M 84 HYDRAULIC LAYOUT 120 AETJ 70 6 M 84 EN 11 2003...

Page 62: ...70 6 M 84...

Page 63: ...1 70 6 M 84 HYDRAULIC LAYOUT...

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Page 65: ...ELECTRICITY GROUPS 80...

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Page 67: ...80 2 11 M 84 REMOVING THE VARIABLE SPEED DRIVE UNIT 120 AETJ 80 2 11 M 84 EN 11 2003...

Page 68: ...80 2 11 M 84...

Page 69: ...Fig A 8 bolts No 13 spanner RE ASSEMBLY Perform the above mentioned operations in reverse order FROM PLATFORM NO 505491 Switch off the electrical supply and then disconnect the batteries see the REMOV...

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Page 71: ...80 2 12 M 84 REMOVING THE TRACTION BATTERIES 120 AETJ 80 2 12 M 84 EN 11 2003...

Page 72: ...80 2 12 M 84...

Page 73: ...Perform the above mentioned operations in reverse order FROM PLATFORM NO 505490 BATTERIES 599364 Raise the platform a few centimetres to release the engagement of the anti rollover bars 1 Fig A Switc...

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Page 75: ...80 2 13 M 84 REMOVING THE CABLE LOOMS 120 AETJ 80 2 13 M 84 EN 11 2003...

Page 76: ...80 2 13 M 84...

Page 77: ...1 80 2 13 M 84 INDEX A LOCATION OF THE CABLE LOOMS P 2 B BASKET CONSOLE CABLE LOOM P 3 C MAIN BOX CABLE LOOM P 6 D BASE CONSOLE CABLE LOOM P 10 E OTHER CABLE LOOMS P 12...

Page 78: ...No CABLE LOOM 1 Basket console 2 BUS CAN extension 3 Main box 4 Base console 5 Variable speed drive 6 Distributor 7 Overload cable loom 2 80 2 13 M 84 A LOCATION OF THE CABLE LOOMS 1 4 6 5 3 7 2...

Page 79: ...light H9 Arms 1 2 raising light H10 Arm 3 raising light H14 Tilt light H15 Telescope light H16 Pendular arm light H17 Buzzer S13 Travel switch S14 Raising arms 1 2 switch S15 Raising arm 3 switch S17...

Page 80: ...OUT 12 Spare 329 D OUT 13 0V card travel LED 331 D OUT 14 0V card overload alarm LED 320 D OUT 15 0V card buzzer 330 D OUT 16 0V card slope LED D OUT 17 Spare D OUT 18 Spare D OUT 19 Spare D OUT 20 S...

Page 81: ...OW 330 H7 D OUT 16 YELLOW 329 H8 D OUT 13 YELLOW 328 H9 D OUT 2 YELLOW 327 H10 D OUT 3 YELLOW 323 H14 D OUT 7 YELLOW 322 H15 D OUT 4 YELLOW 321 H16 D OUT 5 YELLOW 106 J4 106 H14 RED 121 S18 S17 YELLOW...

Page 82: ...6 80 2 13 M 84 C MAIN BOX CABLE LOOM 3...

Page 83: ...SCRIPTION J2 107 Clip pin J2 109 Clip pin J2 111 Clip pin J2 118 Clip pin J4 103 Clip pin J4 105 Clip pin J4 106 Clip pin J4 121 Clip pin J4 123 Clip pin KA3 24V relay KA4 24V relay KA5 24V relay S4 E...

Page 84: ...6 0V card steer right electro valve 101 D OUT 17 Counting info timer input 01 D OUT 18 Spare 217 D OUT 19 0V card horn 218 D OUT 20 0V card rotating light 230 D OUT 21 0V card maintenance alarm LED 23...

Page 85: ...230 D OUT 21 CI 5002001 YELLOW 231 D OUT 3 CI 5002001 YELLOW 110 S2 CHARGER YELLOW 105 J4 105 CHARGER YELLOW 107 S3 J2 107 YELLOW 105 J4 105 S3 YELLOW 228 D OUT 10 KA3 A1 YELLOW 106 KA3 A2 J4 106 RED...

Page 86: ...T J4 Clip pin PL Timer S2 Emergency Stop S3 3 position selector S5 Turret rotation switch S6 Telescope switch S7 Pendular arm switch S8 Jib rotation switch S9 Basket rotation switch S10 Arms 1 2 raisi...

Page 87: ...YELLOW 242 S5 S10 YELLOW 242 S10 S11 YELLOW 242 S11 S6 YELLOW 242 S6 S8 YELLOW 242 S8 S7 YELLOW 242 S7 S9 YELLOW 106 S3 S3 RED 102 PL 8 VARIABLE SPEED DRIVE YELLOW 122 PL 5 VARIABLE SPEED DRIVE YELLOW...

Page 88: ...12 80 2 13 M 84 Bridge Bridge E OTHER CABLE LOOMS VARIABLE SPEED DRIVE CABLE LOOM 5...

Page 89: ...13 80 2 13 M 84 DISTRIBUTOR CABLE LOOM 6...

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Page 91: ...80 6 M 84 ELECTRICAL LAYOUTS 120 AETJ 80 6 M 84 EN 05 2004...

Page 92: ...80 6 M 84...

Page 93: ...ONTROL SECTION SINGLE MANIPULATOR P 4 C BASKET CONTROL SECTION SINGLE MANIPULATOR P 6 D POWER SECTION DUAL MANIPULATOR P 8 E BASE CONTROL SECTION DUAL MANIPULATOR P 10 F BASKET CONTROL SECTION 1 DUAL...

Page 94: ...2 80 6 M 84 A POWER SECTION SINGLE MANIPULATOR...

Page 95: ...3 80 6 M 84...

Page 96: ...4 80 6 M 84 B BASE CONTROL SECTION SINGLE MANIPULATOR...

Page 97: ...5 80 6 M 84...

Page 98: ...6 80 6 M 84 C BASKET CONTROL SECTION SINGLE MANIPULATOR...

Page 99: ...7 80 6 M 84...

Page 100: ...8 80 6 M 84 D POWER SECTION DUAL MANIPULATOR...

Page 101: ...677523 1 4 Lower arm Telescope retracted 9 80 6 M 84...

Page 102: ...10 80 6 M 84 E BASE CONTROL SECTION DUAL MANIPULATOR...

Page 103: ...120 AETJ 677523 Version 1 Page 2 4 11 80 6 M 84...

Page 104: ...tion Basket rotation selection Horn Slope Overload alarm red Interface 2 axis joystick Left joystick A5 SQ5 Overload detection green yellow x grey y brown white JIB rotation Basket rotation 12 80 6 M...

Page 105: ...V supply Rotation instructions Steer left Steer right Traction instructions Dead man s Buzzer Pendular arm Telescope Compensation JIB rotation Turret rotation Basket rotation Upper arm Lower arm Trans...

Page 106: ...Pendular arm selection Telescop selection Compensation selection DEAD MAN s Right joystick A7 Translation green yellow blue black grey violet red pink brown white Traction Out of NEUTRAL 48V DEAD MAN...

Page 107: ...escope selection 120 AETJ 677523 Version 1 Page 4 4 Pendular selection Compensation selection Travel selection Out of NEUTRAL Steer left Steer right Traction instructions Lower arm selection Lower arm...

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Page 109: ...80 8 11 M 84 CHECKING THE OPERATION OF THE SEVCON VARIABLE SPEED DRIVE UNIT 120 AETJ 80 8 11 M 84 EN 05 2004...

Page 110: ...80 8 11 M 84...

Page 111: ...1 80 8 11 M 84 INDEX A VARIABLE SPEED DRIVE PARAMETERS P 2 B TESTING THE VARIABLE SPEED DRIVE P 4 C ERROR MESSAGES P 6 D DIAGNOSTIC LED STATUSES P 7 E USING THE CALIBRATOR P 8...

Page 112: ...tion Minimum Value Maximum Value Step Actual Value 1 4 2 22 BDI Battery Voltage V 24 96 2 48 1 4 3 23 BDI Reset Level V 2 00 2 50 0 01 2 15 1 4 4 24 BDI Discharge Level V 1 50 1 99 0 01 1 73 1 4 5 25...

Page 113: ...t Speed 0 100 1 32 2 3 13 98 Cage Rotate Left Speed 0 100 1 32 2 3 14 99 Cage Rotate Right Speed 0 100 1 32 2 3 15 96 Cage Level Forward Speed 0 100 1 70 2 3 16 97 Cage Level Reverse Speed 0 100 1 35...

Page 114: ...10 1 3 11 1 3 12 1 3 13 1 3 14 1 3 15 1 3 16 1 3 17 1 3 18 1 3 19 1 3 20 1 3 21 1 3 22 Accelerator Accelerator voltage Deadman Joystick Forward Joystick Reverse Steer Left Steer Right Horn switch Trac...

Page 115: ...itch Open Closed Open Closed Open Closed Open Closed Open Closed Open Closed Open Closed Open Closed Open Closed Open Closed Open Closed Open Closed Open Closed Joystick Forward Switch 2 4 6 Joystick...

Page 116: ...MP ACCEL FAULT SEQ FAULT 2 DIR FAULT BAT LOW BAT HIGH PERS ERRORF CRC ERROR COIL S C FET S C CAN FAULT P UP WELD FAIL Led YES YES YES 7 F 8 F 6 F 2 F 2 F 7 F 7 F 1 F 1 F 9 F 3 F 12 F OFF OFF Checks Ac...

Page 117: ...correct start up sequence 3 Flashing MOSFET short circuiting 4 Flashing Power contactor short circuiting or motor circuit open 5 Flashing Spare 6 Flashing Problem with accelerator slave potentiometer...

Page 118: ...p Lower Box Test Switch on DESCRIPTION The calibrator Fig D1 Ref 622813 is used to adjust and configu re the variable speed drive It is also used as a diagnostic tool displaying the variable speed dri...

Page 119: ...80 8 85 M 84 TESTING THE MANIPULATOR 120 AETJ 80 8 85 M 84 EN 05 2004...

Page 120: ...80 8 85 M 84...

Page 121: ...1 80 8 85 M 84 INDEX A SINGLE MANIPULATOR P 2 B DUAL MANIPULATOR P 4...

Page 122: ...rm s basket Open the front of the basket console 3 Fig A1 Flat screwdriver and then locate the wires Fig A2 2 80 8 85 M 84 A2 X Y 3W 63V 470 f 48V 24V 0V ALIMENTATION GACHETTE GACHETTE HOMME MORT BATT...

Page 123: ...OUGE VIOLET ANCIENNE NORME VERT NOIR MARRON NOIR MARRON NOUVELLE NORME Gachette au NEUTRE Gachette ACTIONNEE A3 J X M X Y 0V 4 5V GRIS Y MARRON JAUNE X X Y 0V 2 5V 2 5V M G Y X Y 0V 4 5V J X M X Y 0V...

Page 124: ...0V 0V 0V ANCIENNE NORME JAUNE NOIR BLANC NOIR MARRON NOUVELLE NORME A N N N M M R M N NOIR D GRIS NOIR N D G N A N N N Direction GAUCHE NEUTRE Direction DROITE Steer LEFT OLD NEW STANDART STANDART BL...

Page 125: ...3 UPPER BOX TEST on the calibrator and check That the proportional signal shows a good progression i e 0 to 100 That it shows 0 in Neutral and 100 only when the mani pulator arrives almost at the limi...

Page 126: ...ALIMENTATION GACHETTE GACHETTE HOMME MORT BATTERIE ALIMENTATION TRANSLATION COMMANDE TRANSLATION BP DIRECTION GAUCHE BP DIRECTION DROITE ALIMENTATION BP DIRECTION BLEU NOIR GRIS Y VIOLET ROUGE ROSE M...

Page 127: ...2 5V 2 5V Manipulateur vers L ARRIERE DESCENTE du bras 3 Manipulateur vers la GAUCHE Rotation de tourelle GAUCHE Manipulateur vers la DROITE Rotation de tourelle DROITE NEUTRE Manipulateur vers L AVAN...

Page 128: ...ONNE ROUGE BLANC ANCIENNE NORME MARRON NOIR BLANC VIOLET VERT NOIR ROUGE MARRON NOIR VIOLET VERT NOIR NOUVELLE NORME BLANC ANCIENNE NORME BLANC NOUVELLE NORME Trigger in NEUTRAL OLD NEW STANDART STAND...

Page 129: ...80 8 86 M 84 POSITIONING AND ADJUSTING THE CONTACTORS 120 AETJ 80 8 86 M 84 EN 11 2003...

Page 130: ...80 8 86 M 84...

Page 131: ...TION OF THE SENSORS P 2 B ADJUSTING THE ANTI ROLLOVER BARS OUTPUT SENSOR P 3 C ADJUSTING THE SLOPE SENSOR P 3 D ADJUSTING THE LOW ARM SENSOR P 4 E ADJUSTING THE RETRACTED TELESCOPE SENSOR P 4 F ADJUST...

Page 132: ...2 80 8 86 M 84 A LOCATION OF THE SENSORS Retracted telescope sensor Low arm sensor Stabiliser output sensor Stabilisers Slope sensor Overload sensor...

Page 133: ...es Unscrew the fixing screws 3 Fig B2 2 bolts No 13 spanner Trigger the sensors 4 Fig B2 one after the other by placing them in contact with the stabilising bar Re tighten the bolts Check the setting...

Page 134: ...No 505422 Locate the sensor 9 Fig D2 between the two sides of the interme diate joint Same procedure as for adjusting platforms UP TO PLATFORM No 505421 except for removing and refitting the protecti...

Page 135: ...lt is being untightened Stop at the limit for triggering the contactor Relieve the weight on the basket the platform s alarm no longer sounds Replace the weight in the basket the platform s alarm soun...

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Page 137: ...TROUBLE SHOOTING GROUPS 100...

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Page 139: ...100 M 84 TROUBLESHOOTING 120 AETJ 100 M 84 EN 11 2003...

Page 140: ...100 M 84...

Page 141: ...1 100 M 84 TROUBLE SHOOTING...

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